2004 polaris 700 xc sp edge snowmobile service repair manual

service repair manual

1. Model Number Identification 1.1...........................
Vehicle Identification Number (VIN) 1.2.....................
Publication Part Numbers 1.3.............................
Specifications
500 XC SP 1.4 -- 1.5..............................
600 XC SP 1.6 -- 1.7..............................
700 XC SP 1.8 -- 1.9..............................
800 XC SP 1.10 -- 1.11..............................
Glossary of Terms 1.12 -- 1.15....................................
General Precautions 1.16..................................
Standard Bolt Torque Specifications 1.17....................
Decimal Equivalents 1.18..................................
Tap Drill Size Charts 1.19..................................
Units of Measure Conversion Chart 1.20.....................

2. GENERAL INFORMATION
1.1
YEAR DESIGNATION ENGINE DESIGNATION
MODEL / CHASSIS DESIGNATION
MODEL NUMBER DESIGNATION
S02 SD 5 CSS=Snow
U= European Model
S= North American Model
MODEL LINE (4TH DIGIT) MODEL TYPE (5TH DIGIT)
S=Gen II A= Inactive
L= Lite B= Basic
N= EDGE C= Inactive
W=Mini Indy D= Deluxe
E= Feature Option M--10
F= Inactive
J= FTR/OPT 136 RMK (Edge)
K= FTR/OPT 144 RMK (Edge)
L= FTR/OPT 151 RMK (Edge)
M= FTR/OPT 159 RMK (Edge)
P=FTR/OPT Performance
R= Inactive
S= Switchbackt
T= Touring
U= Utility
X= Racer
Y=Pro X2
Z=Pro XR
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)
7D--780 4 Stroke EFI 2 cyl (Dom.)
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).

3. GENERAL INFORMATION
1.2
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.
12345678910 11121314151617
SN 1 S B 5BS022000000
Vehicle Descriptor Vehicle Identifier
Type
Engine
SizeEngine
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
BodyStyle Type EngineSize EngineModifier 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

4. GENERAL INFORMATION
1.3
Publication Part Numbers
Model Model No. Owner’s Manual
Owners Manual
Supplement
Parts
Manual
Microfiche
500 XC SP S04NP5CS(A,B) 9918199 9918202 9918861 9918862
500 XC SP M--10 S04NE5CS 9918199 9918296 9918861 9918862
600 XC SP S04NP6ES(A,B) 9918199 9918263 9918861 9918862
600 XC SP M--10 S04NE6ES 9918199 9918263 9918861 9918862
700 XC SP S04NP7CS(A,B) 9918199 9918275 9918843 9918844
700 XC SP M--10 S04NE7CS 9918199 9918275 9918843 9918844
800 XC SP S04NP8CS(A,B) 9918199 9918275 9918843 9918844
800 XC SP M--10 S04NE8CS 9918199 9918275 9918843 9918844
Owners Manual Supplements can be found on the CD that comes with this manual.
2004 Service Manuals
Service Manuals 2004
120 PRO X
120 XC SP
9918581
Trail Sport
Super Sport, 340 EDGE, 500 EDGE
9918582
Touring
Wide Trak LX, 340 Touring, Sport Touring, Trail Touring, 600/700/800 Classic Touring
9918584
Frontier
Frontier Classic, Frontier Touring
9918585
Trail Luxury
340 EDGE Classic , 500 Classic, 550 Classic, 600 Classic, 700 Classic, 800 Classic
9918583
Deep Snow
Trail RMK, 600/700/800 RMK, 600/700/800 Switchbackt
9918587
Performance
500/600/700/800 XC SP
9918586
PROX
440, 550, 600, 700, 800 PRO X
9918588
Wallcharts 9918589
Track Poster 9918459
Flat Rate Manual 9918590
Snowmobile Care and Adjusting for the Perfect Ride (DVD) 9918923
Snowmobile Care and Adjusting for the Perfect Ride (VHS) 9918908

5. GENERAL INFORMATION
1.4
MODEL: 500 XC SP..............
MODEL NUMBER: S04NP5CS(A,B) S04NE5CS.....
ENGINE MODEL: S2650--5044--PR5C......
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 38
Engine Displacement cc’s 500 Main Jet 410
Bore in / mm 2.78” / 70.5mm Pilot Jet 45
Stroke in / mm 2.52” / 64mm Jet Needle 9DFH6--57 / 2
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence in / mm .00018 -- .0023” .0045 -- .0059mmThrottle Gap UnderCutaway in / mm 0.079” 2.0 mm
Piston Ring End Gap in / mm .0006-- .0008” .014 -- .020mm
Cutaway 1.5
Piston Marking 3021316 Valve Seat 1.5
Piston Ring Marking N/A Starter Jet 145
Operating RPM±200 8250--8500 Fuel Screw 3.0 Turns
Idle RPM±200 1500 Pilot Air Jet N/A
Engagement RPM±300 4200 Air Screw 1.25 Turns
Exhaust Valve Spring Pink/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy / 89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_to --10_F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_FAltitude Below-30F
Below -34°C
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
440
#3
430
#3
410
#2
390
#2
380
#2
360
#2
600--1200
(2000--4000)
420
#3
400
#2
390
#2
370
#2
350
#2
340
#1
1200--1800 390 380 360 340 330 310
Mt
1200--1800
(4000--6000)
390
#2
380
#2
360
#2
340
#2
330
#1
310
#1
Meters
(Feet)
1800--2400
(60008000)
370 350 340 320 300 290(Feet)
(6000--8000)
370
#2
350
#2
340
#2
320
#1
300
#1
290
#1
2400--3000
(800010000)
340 330 310 300 280 260
(8000--10000)
340
#2
330
#2
310
#1
300
#1
280
#1
260
#1
3000--3700
(1000012000)
320 300 290 270 250 240
(10000--12000)
320
#2
300
#1
290
#1
270
#1
250
#1
240
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1056 Black/Green Red/Black 564236 2240:74P
0-900
(0-3000)
10-56 Black / Green Red / Black 56--42--.36 22--40: 74P
Mt
900-1800
1054 Black/Green Red/Black 564236 2240:74PMeters
(Feet)
900-1800
(3000-6000)
10-54 Black / Green Red / Black 56--42--.36 22--40 : 74P
(Feet)
1800-2700
10 Black/Green Red/Black 564036 2140:74P
1800-2700
(6000-9000)
10 Black / Green Red / Black 56--40--.36 21--40 : 74P
2700-3700
10MB Black/Green Red/Black 564036 2140:74P
2700-3700
(9000-12000)
10MB Black / Green Red / Black 56--40--.36 21--40 : 74P

6. GENERAL INFORMATION
1.5
MODEL: 500 XC SP..............
MODEL NUMBER: S04NP5CS(A,B) S04NE5CS.....
ENGINE MODEL: S2650--5044--PR5C......
DRIVE CLUTCH CHAINCASE
Type P--85 Center DIstance 7.92” / 20.12cm
Shift Weights 10--56 Gearing : Chain 22--40 : 74 P
Drive Spring Black / Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring Red / Black
BrakeType LiquidCooled
Helix Angle 56--42--.36 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 5.9 Qts / 5.6 Liters
Side Angle (Overall) 28_ Chan Case Oil 9 fl. oz. / 266 cc
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
113” / 48” / 48” 287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks (F/O) Alum. IFP / PN 7041950 Alum. IFP / PN 7042195
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M--10 FTS (ACE) Fox IFP / PN 7042224
IFS Spring Pre--Load (F/O) 3.25” / 8.26cm (.625” / 16 mm)
M--10 FTS Spring Rate160#/in
Front Vertical Travel10.28” / 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
Lug Height (F/O and M--10) .91” / 2.3 cm (1.25” / 3.175 cm) M--10 RTS (M--10 ACE) Fox IFP Res PN 7042216 (Fox IFP Res PN 7042149)
M--10 RTS Spring Rate (M--10 ACE Spring Rate)210/278 #/in. (220/1140)
Track Tension See Page 2.11 Torsion Springs .375(Sq.) 77_g
Optional Torsion Springs see page 7.9 Optional M--10 Springs see page 7.22
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010829 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see conver-
25_@2500RPM±15_ ElectricStart Accessory
IgnitionTiming(seeconver
sion chart on page 9.4 )
25_@2500RPM±1.5_ ElectricStart Accessory

7. GENERAL INFORMATION
1.6
MODEL: 600 XC SP..............
MODEL NUMBER: S04NP6ES(A,B) / S04NE6ES.....
ENGINE MODEL: S2652--6044--PR6E......
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
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
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence in / mm .00018 -- .0023” .0045 -- .0059mmThrottle Gap UnderCutaway in / mm 0.079” 2.0 mm
Piston Ring End Gap in / mm .0006-- .0008” .014 -- .020mm
Cutaway 2.5
Piston Marking 3021308 Valve Seat 1.5
Piston Ring Marking N/A Starter Jet 140
Operating RPM±200 8100 Fuel Screw 2.5 Turns
Idle RPM±200 1200 Pilot Air Jet N/A
Engagement RPM±300 4000 Air Screw 1.0 Turns
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy / 89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_to --10_F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_FAltitude Below-30F
Below -34°C
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
480
#4
460
#4
440
#3
420
#3
400
#3
390
#2
600--1200
(2000--4000)
450
#4
430
#4
410
#4
400
#3
380
#2
360
#2
1200--1800 420 400 390 370 350 330
Mt
1200--1800
(4000--6000)
420
#4
400
#4
390
#3
370
#2
350
#2
330
#2
Meters
(Feet)
1800--2400
(60008000)
400 380 360 340 330 310(Feet)
(6000--8000)
400
#4
380
#3
360
#2
340
#2
330
#2
310
#2
2400--3000
(800010000)
370 350 330 320 300 280
(8000--10000)
370
#3
350
#2
330
#2
320
#2
300
#2
280
#2
3000--3700
(1000012000)
340 330 310 290 270 260
(10000--12000)
340
#2
330
#2
310
#2
290
#2
270
#1
260
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1058 DarkBlue/White
Red/Dark
584236 2339:74P
0-900
(0-3000)
10-58 Dark Blue/White
Red/Dark
Blue
58--42--.36 23--39: 74P
Mt
900-1800
1056 DarkBlue/White
Red/Dark
584236 2339:74PMeters
(Feet)
900-1800
(3000-6000)
10-56 Dark Blue/White
Red/Dark
Blue
58--42--.36 23--39 : 74P
(Feet)
1800-2700
1054 DarkBlue/White
Red/Dark
584036 2239:74P
1800-2700
(6000-9000)
10--54 Dark Blue/White
Red/Dark
Blue
58--40--.36 22--39 : 74P
2700-3700
10 DarkBlue/White
Red/Dark
584036 2239:74P
2700-3700
(9000-12000)
10 Dark Blue/White
Red/Dark
Blue
58--40--.36 22--39 : 74P

8. GENERAL INFORMATION
1.7
MODEL: 600 XC SP..............
MODEL NUMBER: S04NP6ES(A,B) / S04NE6ES.....
ENGINE MODEL: S2652--6044--PR6E......
DRIVE CLUTCH CHAINCASE
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
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring Red / Blue
BrakeType LiquidCooled
Driven Helix Angle 58--42--.36 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 5.9 Qts / 5.6 Liters
Side Angle (Overall) 28_ Chan Case Oil 9 fl. oz. / 266 cc
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
113” / 48” / 48” 287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks (F/O) Alum. IFP / PN 7041976 Alum. IFP / PN 7042211
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M--10 FTS (ACE) Fox IFP / PN 7042224
IFS Spring Pre--Load (F/O) 3.25” / 8.26cm (.625” / 16 mm)
M--10 FTS Spring Rate160#/in
Front Vertical Travel10.28” / 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
Lug Height (F/O and M--10) .91” / 2.3 cm (1.25” / 3.175 cm) M--10 RTS (M--10 ACE) Fox IFP Res PN 7042216 (Fox IFP Res PN 7042149)
M--10 RTS Spring Rate (M--10 ACE Spring Rate)210/278 #/in. (220/1140)
Track Tension See Page 2.11 Torsion Springs .375(Sq.) 77_g
Optional Torsion Springs see page 7.9 Optional M--10 Springs see page 7.22
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-
24_@3500RPM±15_ ElectricStart Accessory
IgnitionTiming(seeconver
sion chart on page 9.4 )
24_@3500RPM±1.5_ ElectricStart Accessory

9. GENERAL INFORMATION
1.8
MODEL: 700 XC SP..............
MODEL NUMBER: S04NP7CS(A,B) S04NE7CS.....
ENGINE MODEL: S2469--7070--PR7C......
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 40
Engine Displacement cc’s 701 Main Jet 440
Bore in / mm 3.19” / 81mm Pilot Jet 45
Stroke in / mm 2.68” / 68mm Jet Needle 9DGN--57 / 3
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence in / mm .000187-- .0023” .00454-- .0058mmThrottle Gap UnderCutaway in / mm 0.079” 2.0 mm
Piston Ring End Gap in / mm .00047-- .00071” .012 -- .018mm
Cutaway 1.5
Piston Marking 3021307 Valve Seat 1.8
Piston Ring Marking N/A Starter Jet 145
Operating RPM±200 8000 Fuel Screw 2.5 Turns
Idle RPM±200 1400 Pilot Air Jet N/A
Engagement RPM±300 3500 Air Screw 1.25 Turns
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy / 89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_to --10_F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_FAltitude Below-30F
Below -34°C
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
480
#4
460
#3
440
#3
420
#3
400
#3
390
#2
600--1200
(2000--4000)
450
#3
430
#3
410
#3
400
#3
380
#2
360
#2
1200--1800 420 400 390 370 350 330
Mt
1200--1800
(4000--6000)
420
#3
400
#3
390
#3
370
#2
350
#2
330
#2
Meters
(Feet)
1800--2400
(60008000)
400 380 360 340 330 310(Feet)
(6000--8000)
400
#3
380
#3
360
#2
340
#2
330
#2
310
#2
2400--3000
(800010000)
370 350 330 320 300 280
(8000--10000)
370
#3
350
#2
330
#2
320
#2
300
#2
280
#2
3000--3700
(1000012000)
340 330 310 290 270 260
(10000--12000)
340
#2
330
#2
310
#2
290
#2
270
#2
260
#2
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1062 Black/Green Black/Red 624246 2541:76P
0-900
(0-3000)
10-62 Black/Green Black / Red 62--42--.46 25--41: 76P
Mt
900-1800
1060 Black/Green Black/Red 624246 2541:76PMeters
(Feet)
900-1800
(3000-6000)
10-60 Black/Green Black / Red 62--42--.46 25--41: 76P
(Feet)
1800-2700
1058 Black/Green Black/Red 624046 2339:74P
1800-2700
(6000-9000)
10--58 Black/Green Black / Red 62--40--.46 23--39 : 74P
2700-3700
1056 Black/Green Black/Red 624046 2339:74P
2700-3700
(9000-12000)
10--56 Black/Green Black / Red 62--40--.46 23--39 : 74P

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11. GENERAL INFORMATION
1.9
MODEL: 700 XC SP..............
MODEL NUMBER: S04NP7CS(A,B) S04NE7CS.....
ENGINE MODEL: S2469--7070--PR7C......
DRIVE CLUTCH CHAINCASE
Type P--85 Center DIstance 7.92” / 20.12cm
Shift Weights 10--62 Gearing : Chain 25--41 : 76 P
Drive Spring Black / Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring Black / Red
BrakeType LiquidCooled
Helix Angle 62--42--.46 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 5.9 Qts / 5.6 Liters
Side Angle (Overall) 28_ Chan Case Oil 9 fl. oz. / 266 cc
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
113” / 48” / 48” 287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks (F/O) Alum. IFP / PN 7041976 Alum. IFP / PN 7042211
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M--10 FTS (ACE) Fox IFP / PN 7042224
IFS Spring Pre--Load (F/O) 3.25” / 8.26cm (.625” / 16 mm)
M--10 FTS Spring Rate160#/in
Front Vertical Travel10.28” / 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
Lug Height (F/O and M--10) .91” / 2.3 cm (1.25” / 3.175 cm) M--10 RTS (M--10 ACE) Fox IFP Res PN 7042216 (Fox IFP Res PN 7042149)
M--10 RTS Spring Rate (M--10 ACE Spring Rate)210/278 #/in. (220/1140)
Track Tension See Page 2.11 Torsion Springs .375(Sq.) 77_g
Optional Torsion Springs see page 7.9 Optional M--10 Springs see page 7.22
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010839 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see conver-
20_@2000RPM±15_ ElectricStart Accessory
IgnitionTiming(seeconver
sion chart on page 9.4 )
20_@2000RPM±1.5_ ElectricStart Accessory

12. GENERAL INFORMATION
1.10
MODEL: 800 XC SP..............
MODEL NUMBER: S04NP8CS(A,B) S04NE8CS.....
ENGINE MODEL: S2470--8070--PR8C......
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 40
Engine Displacement cc’s 794 Main Jet 460
Bore in / mm 3.35” / 85mm Pilot Jet 40
Stroke in / mm 2.76” / 70mm Jet Needle 9DGN5--57 / 3
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence in / mm .00023-- 00029” .0060-- .0074mm Throttle Gap UnderCutaway in / mm 0.079” 2.0 mm
Piston Ring End Gap in / mm .0006-- .0009” .016 -- .022mm
Cutaway 1.5
Piston Marking N/A Valve Seat 1.8
Piston Ring Marking 3021315 Starter Jet 135
Operating RPM±200 7900 Fuel Screw 2.5 Turns
Idle RPM±200 1500 Pilot Air Jet N/A
Engagement RPM±300 3500 Air Screw 1.5 Turns
Exhaust Valve Spring Pink/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy / 89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_to --10_F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_FAltitude Below-30F
Below -34°C
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
500
#4
480
#4
460
#3
440
#3
420
#2
400
#2
600--1200
(2000--4000)
470
#4
450
#3
430
#3
410
#2
400
#2
380
#2
1200--1800 440 420 400 390 370 350
Mt
1200--1800
(4000--6000)
440
#3
420
#3
400
#2
390
#2
370
#2
350
#2
Meters
(Feet)
1800--2400
(60008000)
410 400 380 360 340 320(Feet)
(6000--8000)
410
#3
400
#2
380
#2
360
#2
340
#2
320
#2
2400--3000
(800010000)
390 370 350 330 310 290
(8000--10000)
390
#2
370
#2
350
#2
330
#2
310
#2
290
#2
3000--3700
(1000012000)
360 340 320 300 290 270
(10000--12000)
360
#2
340
#2
320
#2
300
#2
290
#2
270
#2
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1064
Dark Blue/
Black/Red 624246 2540:76P
0-900
(0-3000)
10-64
DarkBlue/
White
Black / Red 62--42--.46 25--40: 76P
Mt
900-1800
1062
Dark Blue/
Black/Red 624246 2541:76PMeters
(Feet)
900-1800
(3000-6000)
10-62
DarkBlue/
White
Black / Red 62--42--.46 25--41: 76P
(Feet)
1800-2700
1060
Dark Blue/
Black/Red 624046 2339:74P
1800-2700
(6000-9000)
10--60
DarkBlue/
White
Black / Red 62--40--.46 23--39 : 74P
2700-3700
1058
Dark Blue/
Black/Red 624046 2339:74P
2700-3700
(9000-12000)
10--58
DarkBlue/
White
Black / Red 62--40--.46 23--39 : 74P

13. GENERAL INFORMATION
1.11
MODEL: 800 XC SP..............
MODEL NUMBER: S04NP8CS(A,B) S04NE8CS.....
ENGINE MODEL: S2470--8070--PR8C......
DRIVE CLUTCH CHAINCASE
Type P--85 Center DIstance 7.92” / 20.12cm
Shift Weights 10--64 Gearing : Chain 25--40 : 76 P
Drive Spring Dark Blue / White Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring Black / Red
BrakeType LiquidCooled
Helix Angle 62--42--.46 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 5.9 Qts / 5.6 Liters
Side Angle (Overall) 28_ Chan Case Oil 9 fl. oz. / 266 cc
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
113” / 48” / 48” 287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks (F/O) Alum. IFP / PN 7041976 Alum. IFP / PN 7042211
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M--10 FTS (ACE) Fox IFP / PN 7042224
IFS Spring Pre--Load (F/O) 3.25” / 8.26cm (.625” / 16 mm)
M--10 FTS Spring Rate160#/in
Front Vertical Travel10.28” / 26cm FTS Pre--Load Fixed
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
Lug Height (F/O and M--10) .91” / 2.3 cm (1.25” / 3.175 cm) M--10 RTS (M--10 ACE) Fox IFP Res PN 7042216 (Fox IFP Res PN 7042149)
M--10 RTS Spring Rate (M--10 ACE Spring Rate)210/278 #/in. (220/1140)
Track Tension See Page 2.11 Torsion Springs .375(Sq.) 77_g
Optional Torsion Springs see page 7.9 Optional M--10 Springs see page 7.22
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010842 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see conver-
28_@2000RPM±15_ ElectricStart Accessory
IgnitionTiming(seeconver
sion chart on page 9.4 )
28_@2000RPM±1.5_ ElectricStart Accessory

14. GENERAL INFORMATION
1.12
Service Glossary
ACS:Alternator control switch.
ACV:Alternating current voltage.
Air Gap Spark Test:A good check for ignition voltage and generalignition system condition. Spark should
arc 3/8”(1 cm)minimum fromend 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.
CA:Compression Adjustable
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 staynearly straight as it moves
along the clutch face as the engine torques back.
Clutch Weights:Three levers in the drive clutch which relative to their weight, profile and engine RPM
causethedriveclutchtoclose.
Coil:A winding of wire around an iron core which has the ability togenerate 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. poor connections or broken
wire at hi-lo beam switch resulting in loss of headlights).
Electrical Short:Short circuit. An electrical circuit which is completed before the current reaches the
intended component. (i.e. a bare wire touching the snowmobile chassis under the seat resulting in loss of
taillights and brake lights). 4
Bore x Stroke x 3.1416
2
= Displacement in
CCs

15. GENERAL INFORMATION
1.13
End Seals:Rubber seals at each end of the crankshaft.
Engagement RPM:Engine RPM at which the drive clutch engages to make contact with the drive belt.
Flat Head Bolt:To be used where finished surfaces require a flush fastening unit. Countersunk.
F/O:Features and Options
Foot Pound:Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational
direction.
FTS:Front Track Shock
g:Gram. Unit of weight in the metric system.
Head Volume:Cylinder head capacity in cc, head removed from engine with spark plug installed.
Heat Exchanger:A device used to transfer heat. They dissipate engine heat to the atmosphere.
Hex Head Bolt:Standard type of wrench-applied hexagon head, characterized by clean, sharp
corners trimmed to close tolerances. Recommended for general commercial applications.
Hi-Fax:Trademark of Himont Advanced Materials. The special slide material which fits onto the bottom of
the suspension rails.
High Side:Sled pushes or tips up toward outside of turn.
High Tension Wire:The heavy insulated wire which carries the high secondary voltage from the coil to the
spark plug.
Hole Shot:A term used when machine starts a race from a dead stop.
Holed Piston:Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2)
pre-ignition.
Ignition Coil:A type of transformer which increases voltage in the primary windings (approx. 200V) to a
higher voltage in the secondary windings (approx. 14KV - 32KV) through inductions. Secondary voltage is
high enough to arc the air gap at the spark plug.
Ignition Generating Coil:Exciter coil or primary charge coil. Stator plate coil which generates primary
ignition voltage. CDIsystem usesone ignition generating coil.
Inch Pound:In. lb. 12 in. lbs. = 1 ft. lb.
Kg/cm2:Kilograms per square centimeter. Metric equivalent of PSI.
Keystone Ring:A piston ring with bevel on upper surface.
Kilogram/meter:A force of one kilogram at the end of a lever one meter in length, applied in a rotational
direction. Metric equivalent of ft. lbs.
L Ring:A wide face piston ring with an ”L” shaped cross section. Leg of ”L” goes up when installing on
piston.
Labyrinth Seal:A pressure type center seal identified by series of grooves and lands. Polaris engines use
this type of seal to separate the cylinders in the crankcase halves.
Left Side:Always referred to based on normal operating position of the driver.
Lighting Coil:Generates voltage for lights, battery charging, etc by electromagnetic induction.
Loose:When the rear of the vehicle slides outward in a turn. The track does not grab sufficiently.
mm:Millimeter. Unit of length in the metricsystem. 1mm= .040”.
Mag End:Flywheel side of engine.
Magnetic Induction:As a conductor (coil) is moved through a magnetic field, a voltagewill begenerated in
the windings. This is how mechanical energy in our engines is converted to electrical energy in the lighting
coil, ignition generating coils and trigger coil.
Ohm:The measurement of electrical resistance opposing current flow.
Oval Head Screw:Fully specified as ”oval countersunk”, this head is identical to the standard flat
head, but possesses a rounded upper surface for attractiveness of design.

16. GENERAL INFORMATION
1.14
PTO End:Power Take Off drive (clutch side).
Pan Head Screw:Provides a low, large diameter head, but with characteristically high outer edges
along the outer edge of the head where driving action is most effective. Slightly different head contour when
supplied with Phillips Recess. See dotted line.
Piston Clearance:Total distance between piston and cylinder wall.
Piston Erosion:Piston dome melts. Usually occurs at the exhaust port area. Possible causes: 1) lean
fuel/air mixture; 2) improper spark plug heat range; 3) Poor fuel.
Pre-Ignition:A problem in combustion where the fuel/air mixture is ignited before normal spark ignition.
Piston looks melted at area of damage. Possible causes: 1)incorrect spark plug heat range; 2) spark plug
not properly torqued; 3) “glowing” piece of head gasket, metal burr or carbon in the combustion chamber; 4)
lean fuel/air mixture; 5) Incorrect ignition timing.
Primary Circuit:This circuit is responsible for the voltage build up in the primary windings of the coil. In the
CDI system the parts include the exciter coil, the trigger coil, the wires from stator plate to CDI box and to the
low resistance primary windings in the ignition coil.
Primary Clutch:Drive clutch on engine.
Primary Compression:Pressure built up in the crankcase of a two stroke engine.
psi.:Pounds per square inch.
Pushing:When the front of the vehicle does not steer as much as the driver desires. The skis do not grab
sufficiently.
R&R:Remove and replace.
RFI:Radio Frequency Interference. Caused by high voltage from the ignition system. There are special
plug caps and spark plugs to help eliminate this problem. Mandated in Canada.
RPM:Revolutions Per Minute.
PS:Position Sensitive
Resistance:In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy
conversion to heat.
Right Side:Always referred to based on normal operating position of the driver.
RTS:Rear Track Shock
Round Head Screw:The familiarhead most universally used for general application. Good slot depth,
ample underhead bearing surface and finished appearance are characteristic of this head.
Running Timing:Ignition timing at specified RPM.
Secondary Circuit:This circuit consists of the large secondary coil windings, high tension wire and ground
through the spark plug air gap.
Secondary Clutch:Driven clutch on chaincase or jackshaft.
Seized Piston:Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto
the cylinderwall. Possible causes: 1) improperlubrication; 2) excessive temperatures; 3) insufficient piston
clearance; 4) stuck piston rings.
Self Steer:Pulling the machine to the inside of the track.
Spark Plug Reach:Length of threaded portion of spark plug. Polaris uses 3/4” (2 cm) reach plugs.
Static Timing:Ignition timing when engine is at zero RPM.
Stator Plate:The plate mounted under the flywheel supporting the primary ignition components and
lighting coils.
Stroke:The maximum movement of the piston from bottom dead center to top dead center. It is
characterized by 180° of crankshaft rotation.
Surge Tank:The fill tank in the liquid cooling system.