Polaris Indy 500 XC EDGE, 500/600/700/800 XC SP EDGE & 800 XCR Snowmobile Service Manual 2002 Maintenance & Diagnostics
Manual Preview
Sample pages from the Polaris Indy 500 XC EDGE, 500/600/700/800 XC SP EDGE & 800 XCR Snowmobile Service Manual 2002 Maintenance & Diagnostics manual
Purchase & Download
Models Covered & Key Technical Specifications
- Polaris 500 XC EDGE (2002)
- Polaris 500 XC SP EDGE (2002)
- Polaris 600 XC SP EDGE (2002)
- Polaris 700 XC SP EDGE (2002)
- Polaris 800 XC SP EDGE (2002)
- Polaris INDY 800 XCR (2002)
- Polaris 120 XC SP (2002)
- Polaris Trail Sport (2002)
- Polaris Super Sport (2002)
- Polaris Indy 500 (2002)
- Polaris 340 Deluxe (2002)
- Polaris Wide Trak LX (2002)
- Polaris 340 Touring (2002)
- Polaris Sport Touring (2002)
- Polaris Trail Touring (2002)
- Polaris 500 Classic Touring (2002)
- Polaris 600 Classic Touring (2002)
- Polaris 500 Classic (2002)
- Polaris 550 Classic (2002)
- Polaris 600 Classic (2002)
- Polaris 700 Classic (2002)
- Polaris Trail RMK (2002)
- Polaris 500 RMK (2002)
- Polaris 500 SKS Euro (2002)
- Polaris 700 SKS (2002)
- Polaris 600 EDGE RMK (2002)
- Polaris 700 EDGE RMK (2002)
- Polaris 800 EDGE RMK (2002)
- Polaris 440 XCF SP (2002)
- Polaris 440 XC SP (2002)
Professional Workshop Service Manual & Technical Specifications
Polaris EDGE & XCR Series Snowmobile Service Manual - 2002 Edition
Engine reliability and chassis alignment for the 2002 Polaris fleet depend on adherence to factory-specified tolerances such as the precise ignition timing advance/retard curves for the CDI modules. Utilizing the correct CU code verification for the ignition box ensures optimal combustion and prevents catastrophic piston failure during high-RPM operation. This technical documentation provides the specific clearance and torque data required to maintain the structural integrity of the EDGE chassis and the high-performance XCR powerplants.
Model Identification & Technical Applicability
EDGE Chassis Configuration (Liquid Cooled)
- 500 XC EDGE / 500 XC SP EDGE
- 600 XC SP EDGE
- 700 XC SP EDGE
- 800 XC SP EDGE
High-Performance Triple/Aggressive Chassis
- 800 XCR (Indy Series)
Standard Indy & Touring Configurations
- 340, 340 Deluxe, 340 Touring
- 500 Indy, 500 Classic, 500 Classic Touring, 500 RMK, 500 SKS
- 550 Classic
- 600 Classic, 600 Classic Touring, 600 RMK (EDGE)
- 700 Classic, 700 RMK (EDGE), 700 SKS
- 800 RMK (EDGE)
- Trail Sport, Trail Touring, Trail RMK
- Super Sport, Sport Touring
- Wide Trak LX
Youth Models
- 120 XC SP
Operational Value & Service Accuracy
- Maintenance intervals for the VES (Variable Exhaust System) prevent carbon buildup and ensure linear power delivery across the RPM range.
- Detailed carburation charts for various altitudes and temperatures allow for precise jetting, protecting the engine from lean conditions in extreme cold.
- Hydraulic brake system bleeding procedures and master cylinder rebuild specs ensure consistent stopping power and operator safety.
Document Metadata
- Publication Number: 9917366
- Content Scope: Full Workshop Service Coverage
- Format: High-Resolution Digital Manual
Technical Depth & Factory Benchmarks
Precision measurement is prioritized with decimal equivalent charts and SAE tap drill size references to facilitate accurate hardware replacement and thread repair. The manual defines critical engine benchmarks, including cylinder bore taper limits, crankshaft runout tolerances, and piston-to-cylinder clearances. Ignition data charts provide the necessary voltage output and resistance values for stator coils and pickup sensors to troubleshoot electrical anomalies without unnecessary component replacement.
Diagnostic & Visual Navigation Aids
Full-color wiring diagrams for the Indy 500 XC, 600/700/800 XC SP, and 800 XCR models enable rapid tracing of electrical circuits and ground locations. Exploded views of the TEAM industries driven clutch and the EDGE rear suspension provide clear assembly sequences for complex mechanical systems.
Table of Contents
- Chapter 1: General Information (Specifications, VIN, Torque)
- Chapter 2: Maintenance
- Chapter 3: Engine
- Chapter 4: Fuel System / Carburetion
- Chapter 5: Body and Steering
- Chapter 6: Clutching (Drive/Driven Systems)
- Chapter 7: Final Drive / Brake System
- Chapter 8: Front Suspension
- Chapter 9: Rear Suspension (EDGE / RMK / Gen II)
- Chapter 10: Electrical & Wiring Diagrams
Operational Limits & Critical Specifications
- Standard Bolt Torque: Grade 5 and Grade 8 specific values for all chassis fasteners.
- Ignition Timing: Specific BTDC (Before Top Dead Center) degree settings for 500cc through 800cc variants.
- Fluid Requirements: Factory-recommended lubricant grades for the chaincase and injection systems.
- Drive Belt Tension: Precise deflection measurements required for optimal EDGE chassis performance.
FAQ
Customer Reviews
Read what our customers say about this Polaris Snowmobile manual and share your own experience.
Add a Review
This policy contains information about your privacy. By posting, you are declaring that you understand this policy:
- Your name, rating, website address, town, country, state and comment will be publicly displayed if entered.
- Aside from the data entered into these form fields, other stored data about your comment will include:
- Your IP address (not displayed)
- The time/date of your submission (displayed)
- Your email address will not be shared. It is collected for only two reasons:
- Administrative purposes, should a need to contact you arise.
- To inform you of new comments, should you subscribe to receive notifications.
- A cookie may be set on your computer. This is used to remember your inputs. It will expire by itself.
This policy is subject to change at any time and without notice.
These terms and conditions contain rules about posting comments. By submitting a comment, you are declaring that you agree with these rules:
- Although the administrator will attempt to moderate comments, it is impossible for every comment to have been moderated at any given time.
- You acknowledge that all comments express the views and opinions of the original author and not those of the administrator.
- You agree not to post any material which is knowingly false, obscene, hateful, threatening, harassing or invasive of a person's privacy.
- The administrator has the right to edit, move or remove any comment for any reason and without notice.
Failure to comply with these rules may result in being banned from submitting further comments.
These terms and conditions are subject to change at any time and without notice.
Reviews (3)