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08-10-2005, 10:22 AM
SB: 2002 Polaris EDGE 500/600 VES - Overheat
SAF0203
Polaris Industries Inc. has been receiving calls regarding overheat conditions o*n Polaris EDGE snowmobiles equipped with domestic 500/600 VES liquid cooled twin engines. The domestic twin engine was derived from the race proven 440 domestic twin and has proven itself to be o*ne of the most reliable and powerful engine bases in the sport of snowmobiling.
Review the check list provided below which includes inspection items that have been identified as possible causes through engineering testing and dealer feedback. Liquid cooled snowmobiles require adequate amounts of snow for cooling. Hard snow, windswept snow, icy snow, hard packed trails, or marginal overall snow may be inadequate for proper cooling.
If you are experiencing engine overheating symptoms please review the following
1) Keep Idle periods to a minimum (less than 5 minutes)
2) If the TEMP light comes o*n but the engine is not overheating, inspect the thermistor. The thermistor should read 192 +/- 30 ohms at 212 degrees F (100 degrees C) in a water bath.
3) Check to see if the coolant surge tank is distorted. Look closely at the pressure cap seat. If distorted, replace.
4) Verify that the coolant system will hold at least 12 psi of pressure. If the cap cannot hold at least 12 psi of pressure, the systemwill overheat very quickly. The coolant may boil in an otherwise normal operating temperature range disrupting thermistor readings to the CDI box.
5) Bleed the system correctly and completely. The system should be bled of any trapped air using the following procedure:
Allow the system to cool completely. Fill the reservoir with coolant to the maximum indicated mark.
Apply parking brake and install the pressure cap and run the engine at specified idle RPMuntil the thermostat opens. o*nce the thermostat opens raise the front or tilt machine slightly o*n its left side so that the coolant bottle is the highest point in the cooling system. Cycle the RPM from idle to enough RPM (4000) to get coolant to flow but not enough RPM to engage the clutch. It is important to get enough coolant flow to purge the air from the crossover hose or rear cooler and observe this air reaching the bottle.
Loosen the bleed screw at the top of the water outlet manifold until trapped air has been purged. Tighten the bleed screw. Turn off the machine and release parking brake. Allow the system to cool completely. Recheck coolant level after the cap has been removed and add coolant to fill line if necessary.
6) Check the TPS specification and make sure it is between 3.9 and 4.0 volts at wide open throttle. Use TPS
tool PN 2201519.
7) Ensure the customer is driving in adequate snow conditions for cooling. Trail riding o*n hard pack while occasionally dipping into powder may not generate enough snow o*n the heat exchangers to keep the engine cool.
8) Slower speeds may not generate enough through-hood air ventilation. Inspect the hood vents for obstruction. Removal of the hood vents may aid in ventilation.
9) Inspect the hi-fax for excessive wear, which may be an indication of snow and cooling conditions. If the hi- fax are worn, it may be due to inadequate snow conditions.
10) Make sure track tension is set to specification. Track tension specifications are: 3/8-1/2”, 16” ahead of rear idler shaft with 10 lb. weight for EDGE. 1/2-3/4”, 16” ahead of rear idler shaft free hanging for M-10.
11) Adjust the suspension settings to the specified SAG for the customer. This procedure is outlined o*n the decal located o*n the underside of the hood, any 2002 Snowmobile Owners Manual or Performance Service Manual PN 9917367.
12) Remove existing snow flap and Install new longer snow flap PN 5433521-1106, and 5 rivets PN 7621472. This longer snow flap keeps snow in the tunnel longer enhancing cooling.
IMPORTANT: The possibility exists that the new snow flap (PN 5433521-1106) may become damaged when operating unit in reverse or when backing unit off of a trailer. Use caution to ensure snow flap does not curl under the tunnel when backing up the snowmobile.
Use fail code 6227.
SAF0203
Polaris Industries Inc. has been receiving calls regarding overheat conditions o*n Polaris EDGE snowmobiles equipped with domestic 500/600 VES liquid cooled twin engines. The domestic twin engine was derived from the race proven 440 domestic twin and has proven itself to be o*ne of the most reliable and powerful engine bases in the sport of snowmobiling.
Review the check list provided below which includes inspection items that have been identified as possible causes through engineering testing and dealer feedback. Liquid cooled snowmobiles require adequate amounts of snow for cooling. Hard snow, windswept snow, icy snow, hard packed trails, or marginal overall snow may be inadequate for proper cooling.
If you are experiencing engine overheating symptoms please review the following
1) Keep Idle periods to a minimum (less than 5 minutes)
2) If the TEMP light comes o*n but the engine is not overheating, inspect the thermistor. The thermistor should read 192 +/- 30 ohms at 212 degrees F (100 degrees C) in a water bath.
3) Check to see if the coolant surge tank is distorted. Look closely at the pressure cap seat. If distorted, replace.
4) Verify that the coolant system will hold at least 12 psi of pressure. If the cap cannot hold at least 12 psi of pressure, the systemwill overheat very quickly. The coolant may boil in an otherwise normal operating temperature range disrupting thermistor readings to the CDI box.
5) Bleed the system correctly and completely. The system should be bled of any trapped air using the following procedure:
Allow the system to cool completely. Fill the reservoir with coolant to the maximum indicated mark.
Apply parking brake and install the pressure cap and run the engine at specified idle RPMuntil the thermostat opens. o*nce the thermostat opens raise the front or tilt machine slightly o*n its left side so that the coolant bottle is the highest point in the cooling system. Cycle the RPM from idle to enough RPM (4000) to get coolant to flow but not enough RPM to engage the clutch. It is important to get enough coolant flow to purge the air from the crossover hose or rear cooler and observe this air reaching the bottle.
Loosen the bleed screw at the top of the water outlet manifold until trapped air has been purged. Tighten the bleed screw. Turn off the machine and release parking brake. Allow the system to cool completely. Recheck coolant level after the cap has been removed and add coolant to fill line if necessary.
6) Check the TPS specification and make sure it is between 3.9 and 4.0 volts at wide open throttle. Use TPS
tool PN 2201519.
7) Ensure the customer is driving in adequate snow conditions for cooling. Trail riding o*n hard pack while occasionally dipping into powder may not generate enough snow o*n the heat exchangers to keep the engine cool.
8) Slower speeds may not generate enough through-hood air ventilation. Inspect the hood vents for obstruction. Removal of the hood vents may aid in ventilation.
9) Inspect the hi-fax for excessive wear, which may be an indication of snow and cooling conditions. If the hi- fax are worn, it may be due to inadequate snow conditions.
10) Make sure track tension is set to specification. Track tension specifications are: 3/8-1/2”, 16” ahead of rear idler shaft with 10 lb. weight for EDGE. 1/2-3/4”, 16” ahead of rear idler shaft free hanging for M-10.
11) Adjust the suspension settings to the specified SAG for the customer. This procedure is outlined o*n the decal located o*n the underside of the hood, any 2002 Snowmobile Owners Manual or Performance Service Manual PN 9917367.
12) Remove existing snow flap and Install new longer snow flap PN 5433521-1106, and 5 rivets PN 7621472. This longer snow flap keeps snow in the tunnel longer enhancing cooling.
IMPORTANT: The possibility exists that the new snow flap (PN 5433521-1106) may become damaged when operating unit in reverse or when backing unit off of a trailer. Use caution to ensure snow flap does not curl under the tunnel when backing up the snowmobile.
Use fail code 6227.