2000 Polaris 600, 700, 800 Snowmobile Service Manual (P/N 9915982)

This official OEM publication (P/N 9915982, published September 1999) covers the 2000 Polaris 600 XC SP, 600 XC Dlx 45th Anniversary, 600 Touring, 600 RMK, 700 XC SP, 700 XC Dlx 45th Anniversary, 700 SKS, 700 RMK, 800 RMK, and 800 XCR liquid-cooled performance snowmobiles.

Technical Content Overview

Spanning 416 pages, this first edition PDF factory reference details the exact specifications, maintenance intervals, and tear-down procedures for the liquid-cooled twin and triple engine builds. Whether you are dealing with a Fuji-manufactured triple or a domestic case reed twin powerplant, the document provides the necessary data for a proper repair and rebuild. It breaks down complex engine assemblies step-by-step. Mechanics will find precise inspection protocols alongside complete reassembly sequences, including clutch and jetting charts.

For independent technicians, factory baseline calibration data eliminates guesswork. It directly translates to faster turnaround times, guaranteeing that critical tolerances on high-RPM components are met without relying on aftermarket trial-and-error. Instead of outsourcing specialized tasks to a dealership, mechanics can utilize the step-by-step procedures for synchronizing Mikuni TM-38/TM-40 and Keihin PWK carburetors. The manual also covers completely rebuilding Fox or Polaris Position Sensitive Shocks (PSS), and setting the precise alignment for Controlled Roll Center (CRC) steering linkages.

Working on high-performance sleds involves critical mechanical systems. Always cross-reference factory torque values and observe standard workshop safety protocols when handling high-tension suspension components or fuel delivery systems. The manual thoroughly details Variable Exhaust System (V.E.S.) maintenance, outlining adjustment and troubleshooting criteria. Beyond the engine, it delivers comprehensive chassis data for the Gen II body style. This includes complete servicing procedures for XTRA-10 and XTRA-12 suspensions, track tensioning, and hydraulic brake systems.

Essential Shop Diagnostics & Diagrams

• Complete electrical wiring diagrams for rapid circuit isolation
• Detailed exploded views illustrating component stacking order
• Specific timing advance curves for accurate spark delivery
• Jackshaft speed vs. MPH charts mapped to exact gear ratios
• Comprehensive shock valving arrangement schematics
• Diagnostic fault charts for systematic error detection

Covered Components & Sub-Assemblies

• Altitude Compensating Carburetor System (ACCS) calibration
• Electronic Shock Control (ESC) module testing
• Hayes hydraulic brake master cylinder bleeding
• Primary P-85 drive and driven clutch overhaul procedures
• Silent HYVO chaincase and sprocket configurations
• XTRA-Lite, XTRA-10, and XTRA-12 rear suspension mechanics

When overhauling the driveline, professionals must be aware of specific pitfalls outlined in this reference. For example, take the P-85 primary clutch tear-down. Failing to permanently mark the spider, cover, and sheaves prior to disassembly will completely disrupt the spider indexing. If the internal shim washers are misplaced without these reference points, the entire factory balance is destroyed. This mistake leads to severe vibration and necessitates a costly replacement of the complete clutch assembly.

Specification Highlights

• Engine compression is documented at 120–140 psi, varying slightly depending on the specific model build.
• Cylinder head torque values for the 600 and 700 twins are listed as 18–24 ft. lbs (25–33 Nm).
• The trigger (pulse) coil gap requires a minimum of 0.020" (0.5 mm) and a maximum of 0.040" (1.0 mm).
• Chaincase oil capacity for most units is rated at 7 fl. oz (210 cc) or 9 fl. oz (265 cc).
• Flywheel nut torque mandates 90 ft. lbs (124 Nm) across the majority of the liquid-cooled series.