INDYEVO™™ RMK®® UPGRADEKIT - Polaris Inc

BEFORE YOU BEGINRead these instructions and check to be sure all parts and tools are accounted for. Please retain theseinstallation instructions for future reference and parts ordering information.

KIT CONTENTSThis Kit includes:

REF QTY PART DESCRIPTION PART NUMBER1 2 ASM-SHOCK, IFS, NARROW 1824011

2 1 ASM-LEVER,HTR,HI/LO 35.5MM 2010431

3 3 SLUG-43 GR,CVT,135-1083 2205307

4 1 EC55 CDI, INDY 3090428

5 1 SPROCKET-18T, 3/4W, 15 SPL, HV, PM 3221094

6 1 SPROCKET-42T, 3/4W, LWT, HYVO, PM 3222192

7 1 STRAP, LIMITER 5414031

8 1 SPRING-COMP, REAR TRACK 7044022

9 1 SPRING-DRIVE 7044154

Instr 9930729 Rev 01 2019-05 Page 1 of 25

P/N 2884251

INDY EVO™™ RMK®® UPGRADE KIT

Instr 9930729 Rev 01 2019-05 Page 2 of 25

REF QTY PART DESCRIPTION PART NUMBER10 1 SPRING-DRIVEN 7044155

11 2 LOCK NUT, M8 X 1.25, FLG 7547332

12 4 LOCK NUT, M10 X 1.5, HFN 7547423

1 INSTRUCTIONS 9930729

TOOLS REQUIRED• Safety Glasses• Drain Pan• E-Clip Tool• Pliers, Side Cutting• Socket Set, Metric• Tie-Down Straps (or equivalent)• Torque Wrench• Wrench Set, Metric• Vehicle Lift/Support Equipment

• Special Service Tools:– Alignment Bar (PN: 5333508)– PB50 Drive Clutch Holding Wrench (PN: PS-

51184)– Drive Clutch Puller (PN: PS-51183)– Drive Clutch Holding Fixture (PN: 2871358-1)– Universal Clutch Compressor, PN: PU-

50518–A– 29 mm Short Drive Reamer (PN: 2870576)

CONSUMABLES REQUIRED• Polaris Premium Grease (or equivalent)• Polaris Synthetic Chaincase Lubricant (orequivalent)

• LOCTITE® Threadlocker Blue 243® (or equivalent)

IMPORTANTYour Indy EVO™ RMK® Upgrade Kit is exclusively designed for your vehicle. Please read the installationinstructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For yoursafety, and to ensure a satisfactory installation, perform all installation steps correctly in the sequence shown.

ASSEMBLY TIMEApproximately 6 hours

NOTEInstallation time varies depending on experiencelevel, optional steps and accessories installed.

Instr 9930729 Rev 01 2019-05 Page 3 of 25

INSTALLATION INSTRUCTIONSIMPORTANT

The clutching and gearing components supplied with this kit are elevation specific and intended forlow elevations of 0-4000 feet (0-1200 meters).

Reference the 2020 550 144 snowmobile owner’s manual for clutching and gearing specifications forelevations above 4000 feet (1200 meters).

See your Authorized Polaris Dealer for additional parts if required.

VEHICLE PREPARATIONCAUTION

BEFORE STARTING INSTALLATION, alwaysensure vehicle is properly secured on a flat stablesurface to avoid accidental tipping, unwanted

movement and to prevent personal injury and/ordamage to equipment. Turn key to “OFF” position

and remove from vehicle.

1. REMOVE HOOD AND SIDE PANELS.

2. DISCONNECT BATTERY(If Equipped).

WARNINGALWAYS disconnect black negative (-) cable frombattery FIRST. Failure to do so will result in a highcurrent electrical arc, and may result in battery

explosion, if tool touches grounded frame. Death orserious personal injury may occur.

a. Disconnect black negative (-) cable frombattery FIRST.

b. Next, disconnect red positive (+) cable frombattery.

3. RAISE FRONT OF VEHICLE.

WARNINGALWAYS properly block and secure vehicle to avoidaccidental tipping. Failure to comply could result in

death or severe personal injury.

a. Raise front of vehicle so the skis are no longerin contact with the working surface.

Instr 9930729 Rev 01 2019-05 Page 4 of 25

FRONT SUSPENSION1. REMOVE EXISTING IFS SHOCK ASSEMBLIES.

a. Remove locking nutB from lower shock boltA. Remove bolt, being sure to keep track oflower shock spacersC for later reinstallation.

CAUTIONPINCH POINT DANGER!

Removing lower shock bolt may allow the IFSassembly to fall, creating a pinch points between theupper an lower control arms and the underlying

components. It is recommended to hold the spindleup with one hand while removing the bolt with theother. Keep ALL body parts away from all pinchpoint areas. Failure to comply may cause serious

personal injury.

b. Next, remove the rubber plugA in the fenderto allow upper shock bolt removal.

c. Remove upper locking nutB and slide upperboltA out through the access hole in thefender while firmly holding shock.

d. Repeat step 1a-1c for opposite side.2. INSTALL PROVIDED IFS SHOCK ASSEMBLIES.

a. Place upper end of new shockq into positionand reinstall previously removed uppermounting bolt. Secure with supplied locking nutd. Torque to specification.

TORQUE37 ft. lbs. (50 Nm)

Instr 9930729 Rev 01 2019-05 Page 5 of 25

b. Place lower end of shock into position usingpreviously removed spacersB and boltA.Secure with provided locking nutd and torqueto specification.


c. Reinstall rubber plugA into fender.

d. Repeat steps 2a-2c for opposite side.

SKI ALIGNMENT/TOE ADJUSTMENTWARNING

Improper ski alignment or adjustment may causeloss of steering control, resulting in serious injury or

death.

IMPORTANTTrack alignment must be correct prior to starting thisprocedure. Ski alignment is measured with skis off

the ground.

1. Rock the front end of the snowmobile up and downand then set it down gently.

2. Place the handlebars in a straight-ahead position.Measure from each endB of the handlebar to acommon center point at the rear of the snowmobileto verify.

3. Measure 10 inches (25.4 cm) forward from thecenter of the ski mounting bolt on both skis,preferably on the center line of the skags asindicated by measurementA. The measurementbetween these two points will be measurement X.

4. Perform the same measurement rearward fromthe center of the ski mounting bolt as indicated bymeasurementC. The measurement betweenthese two points will be measurement Y.

5. Place a straight edge along side the one side ofthe track. Make sure that the straight edge istouching along the length of the track.

6. Record the measurements from the edge of thestraight edge to the X and Y marks. Adjust the tierods so both measurements are the same.

7. Repeat steps 5 and 6 on the opposite side.8. These steps will align the skis with the track. At

this point, verify the handlebars are still centeredwith the skis.

9. To set ski toe, raise the front of the snowmobileuntil the skis are off the ground.

10.Turn both steering tie rods equally to set ski toe.When finished, the overall measurement (X)should be 0 - 1/8 inches (0 - 3 mm) wider than theoverall measurement (Y).

Instr 9930729 Rev 01 2019-05 Page 6 of 25

11. Once the proper measurement is obtained ensurethe tie rod ends have equal thread engagement.Both inner and outer rod ends should also beparallel to allow the steering to be turned fully inboth directions with no binding on the tie rod ends.Once you have verified there is no binding andthere is equal thread engagement torque bothinner and outer jam nuts on each tie rod tospecification.


12.Verify all steering fasteners have been torqued toproper specification.

WARNINGYou MUST VERIFY all steering fasteners have beentorqued to proper specification. Failure to complymay result in death or serious personal injury.

REAR SUSPENSION1. REMOVE REAR SUSPENSION ASSEMBLY.

a. Support the rear of the machine so that thetrack is off the floor.

b. Loosen the rear idler boltsA. Loosen the rearidler adjuster jam nutsB, and then retract theadjuster boltsC. Repeat for opposite side.

c. Once the adjuster bolts are fully retracted, pushthe rear idler assemblyD forward.

d. Remove the support from the tunnel letting thesuspension carry the weight of the machine.

e. Remove the fastenersE, along with washerand lock washer on each bolt from each sidesecuring the skid to the tunnel.

f. Place a protective mat on the floor and slowlyroll the unit over on the left side, supporting thesled on the end of the handlebar.

g. Remove the suspension from the tunnel.2. REMOVE REAR LIMITER ASSEMBLY.

a. Remove locking nutC, boltB and rear limiterblockA.

Instr 9930729 Rev 01 2019-05 Page 7 of 25

3. INSTALL NEW REAR TRACK SHOCK SPRING.CAUTION

PINCH POINT DANGER!Removing upper shock bolt may allow the rear

torque arm to fall, creating a pinch points betweencomponents. It is recommended to hold the torquearm up with one hand while removing the bolt withthe other. Keep ALL body parts away from all pinchpoint areas. Failure to comply may cause serious

personal injury.

NOTEWhen removing upper shock mounting bolt, makenote of all bushings and spacers as they will need to

be reinstalled in the same order as originallyinstalled.

a. Remove upper shock mounting boltA andlocking nutB.

b. Using a spring compression tool, compressspring and remove spring retaining collarA.Remove spring compression tool and thenremove springB.

c. Install provided springi. Using the springcompression tool, compress the spring andreinstall the spring retaining collarA. Thenremove spring retaining tool.

d. Reinstall upper shock mounting boltB and nutA. Torque to specification.

TORQUE35 ft. lbs. (47.5 Nm)

4. REMOVE FRONT LIMITER STRAP.a. Remove boltsD, washersB, nutsA and

remove limiter strapC.

Instr 9930729 Rev 01 2019-05 Page 8 of 25

5. INSTALL NEW LIMITER STRAP.a. Wrap upper and lower ends of new limiter strap

2@ around upper torque arm mounting tube andlower cross shaft as shown. Secure intoposition using provided mounting hardware asshown. Torque nuts 3$ to specification.


6. REINSTALL REAR SUSPENSION ASSEMBLY.a. With the unit on its left side, place the

suspension in the tunnel and align the front andrear torque arms with the tunnel mountingholes.

b. Ensure you have the proper washersB/Cinstalled onto the mounting boltsA as shown.Apply LOCTITE® Threadlocker Blue 243® onall four mounting bolts and loosely install thetwo right side previously removed mountingfasteners.

c. Next, set the snowmobile on the opposite side.Install the two remaining rear suspensionmounting fasteners and related hardware.

d. Slowly roll the snowmobile back to the uprightposition so the skis and track on the ground.

e. Torque all four rail mounting fasteners tospecification.


7. REALIGN AND TENSION TRACK.NOTE

Refer to your vehicle’s service manual for propertrack tension and alignment procedures and

specifications.

a. Support the rear of the machine so that thetrack is off the floor.

b. Evenly tighten the adjuster boltC on each sideuntil proper tension is achieved. Once properlytensioned tighten each jam nutB then tightenthe rear idler boltsA.

c. Check to ensure proper track alignment. Adjustas necessary.

Instr 9930729 Rev 01 2019-05 Page 9 of 25

CLUTCHINGIMPORTANT

• The clutching and gearing components suppliedwith this kit are elevation specific and intended forlow elevations of 0-4000 feet (0-1200 meters).

• Reference the 2020 550 144 snowmobile owner’smanual for clutching and gearing specifications forelevations above 4000 feet (1200 meters).

• See your Authorized Polaris Dealer for additionalparts if required.

1. REMOVE DRIVE BELT.CAUTION

Verify the driven clutch is not in reverse. Damage tothe driven clutch or LWrench will occur when

attempting to open the driven clutch with the clutch inthe reverse position

a. Install the LWrench (PN: 2875911)A into thethreaded hole on the face of the clutch. Screwthe LWrench into the clutch.

NOTEDo not bottom-out the LWrench in the clutch.

b. When the clutch sheaves are opened, removethe drive belt from the driven and then driveclutch.

2. REMOVE DRIVE CLUTCH.a. Place the PB50 Drive Clutch Holding

Wrench (PN: PS-51184)A onto the driveclutch.

b. Remove the drive clutch retaining bolt, collarand star washerB.

c. Insert Drive Clutch Puller (PN: PS-51183)Cinto the retaining bolt hole.

CAUTIONDo not use an impact wrench to remove or install theclutch bolt or clutch puller. Damage to the clutch and/

or crankshaft can occur.

d. Tighten the puller into the clutch. If the clutchdoes not come off, strike the clutch puller headwith a hammer. If the clutch does not “pop” off,continue to tighten the clutch puller, and repeatthis step.

3. REMOVE EXISTING DRIVE CLUTCH SPRING.CAUTION

Drive clutch spring is under extreme tension. Weareye protection when servicing the driven clutch.

Instr 9930729 Rev 01 2019-05 Page 10 of 25

NOTEPrior to disassembling the drive clutch, mark the

cover, moveable sheave, and stationary sheave witha permanent marker.

a. Place the Drive Clutch Holding Fixture (PN:2871358-1) in a bench vise.

b. Place the drive clutch assembly onto the fixturetool and secure to base. Remove the nutAand flat washerB from the clutch assembly.

c. MarkC the stationary shaft and cover with apermanent marker as shown .

d. Remove cover.

e. Remove the three sliding blocksD from thesheave.

NOTENote the orientations of the sliding blocks. The

curved side should be up and the straight side down.

f. Remove moveable sheave and place into theUniversal Clutch Compressor, PN: PU-50518–A

Instr 9930729 Rev 01 2019-05 Page 11 of 25

g. Tighten clutch compressor against springcover.

h. Mark the cover and moveable sheave with apermanent marker.

i. Remove the screwsG securing the cover tothe moveable sheave. Slowly release theclutch compressor and remove the springcover.

j. Remove the old springH from the spring guideJ.

4. INSTALL PROVIDED DRIVE CLUTCH SPRING.a. Place the new springo into the spring guide

J.

Instr 9930729 Rev 01 2019-05 Page 12 of 25

b. Install the spring cover making sure thealignment marks between the cover andmoveable sheave made during disassemblyare aligned. Slowly compress the spring coverdown using the Universal Clutch Compressor.Reinstall the screwsG and torque tospecification.

TORQUE6 - 8.8 ft. lbs. (12 Nm)

c. After tightening spring cover screws, slowlyremove the clutch compressorE from thespring coverF.

5. INSTALL PROVIDED SLUGS INTO SLIDINGBLOCKS.a. Remove the caps from the blocks using a flat-

blade screwdriver.

b. Remove the shimsA from the blocks.NOTE

Note the number of shims on each block.

c. Remove the slugsB from the blocks.

d. Install the new provided slugse into eachsliding block in the same orientation as theoriginal.

Instr 9930729 Rev 01 2019-05 Page 13 of 25

e. Reinstall the shimsA along with capC intoeach block.

f. Secure the fixed sheave with Drive ClutchHolding Fixture (PN: 2871358–1).

g. Install the moveable sheave onto the fixedsheave.

h. Install the sliding blocksD into the moveablesheave. Verify the curved sides are upwardsand the straight sides are down.

NOTEVerify all three sliding blocks have the same slugs

and shims installed.

i. Install the cover making sure the alignmentmarks between the cover and stationary shaftmade during disassembly are aligned.

j. Install the flat washerB with sharp edge of flatwasher down for maximum engagement. Theninstall nutA. Torque nutA to specification.

TORQUE88.5 - 100 ft. lbs. (120 - 135 Nm)

6. REINSTALL DRIVE CLUTCH.NOTE

Always clean the clutch taper with a tapered reamerand crankshaft taper with isopropyl alcohol before

re-installing clutch on engine.

a. Place a 29 mm Short Drive Reamer (PN:2870576)A in a bench vise. Lubricate thecutting edges with cutting oil. Clean the clutchtaper by manually rotating the clutch clockwiseon the reamer one or two revolutions. Only usethe weight of the clutch and do not push downon the clutch while turning.

b. Check crankshaft taper for galling or scoring. Ifnecessary clean the taper evenly with 200 gritemery cloth.

Instr 9930729 Rev 01 2019-05 Page 14 of 25

c. Clean clutch and crankshaft tapers withisopropyl alcohol. Dry completely prior to clutchinstallation. Do not use harsh cleaners whichmay cause clutch taper to corrode, or damagethe crank seal.

d. Slide clutch onto crankshaft taper.e. Install the retaining bolt with all star washers

and collars that were on the bolt when it wasremoved.

f. Secure the drive clutch using the PB50 DriveClutch Holding Wrench (PN: PS-51184).

g. Torque bolt to specification.


h. Run engine then re-torque the clutch bolt tospecification.

7. REMOVE DRIVEN CLUTCH.a. Remove the driven clutch boltA, .105 washer

B, large washerC, float washersD, andclutch spacerE from the driven clutch. Notethe number of float washers installed on thebolt.

b. Remove the screwF securing the fender tothe steering hoop tube.

c. Slide the driven clutch off of the jackshaft.

NOTENote the number and location of the spacer washers

located behind the clutch.

8. REMOVE EXISTING DRIVEN CLUTCH SPRING.CAUTION

Driven clutch spring is under extreme tension. Weareye protection when servicing the driven clutch.

NOTEIt is recommended to mark the outer edge of both ofthe driven sheaves with a permanent marker to allow

for proper clutch balance after reassembly.

a. Install driven clutch into Universal ClutchCompressor (PN: PU-50518–A)A.

b. Compress driven spring enough to access andremove the snap ring.

NOTEWhen removing snap ring, note that it sits in the

recess in the spring seat.

c. Slowly release the clutch compressor.

Instr 9930729 Rev 01 2019-05 Page 15 of 25

d. Remove the snap ring, spring seat, springguide, and spring from the moveable sheaveas shown.

9. INSTALL PROVIDED DRIVEN CLUTCHSPRING.a. Install the springa, spring guide, spring seat

into the clutch.NOTE

Verify the flat (sharp) edge of the snap ring is facingup.

b. Compress the spring stack into the clutch usingthe Universal Spring Compressor. Compressstack enough to expose the snap ring groove inthe fixed sheave shaft.

c. Install the snap ringB making sure the snapring sits in the spring seat recess.

d. Slowly unscrew the compressor handle andremove driven clutch from spring compressor.

10.REINSTALL DRIVEN CLUTCH.a. Verify the same number of spacer washers are

installed on the jackshaft that were presentwhen clutch was removed.

b. Apply a light film of Polaris Premium Grease tothe jackshaft splines and shaft.

c. Install driven clutch onto jackshaft and securewith previously removed driven clutch boltA,spacerE and washersB/C/D.

d. Torque boltA to specification.


11.REINSTALL BELT.a. Place the drive belt back over the drive clutch.

Instr 9930729 Rev 01 2019-05 Page 16 of 25

b. Using the L-Wrench tool, spread the drivenclutch sheaves apart and install belt ontodriven clutch as shown.

c. Remove the L-Wrench tool and work the belt tothe top of the sheaves on the driven clutch.

GEARING1. DISCONNECT BATTERY(If not already done).

WARNINGALWAYS disconnect black negative (-) cable frombattery FIRST. Failure to do so will result in a highcurrent electrical arc, and may result in battery

explosion, if tool touches grounded frame. Death orserious personal injury may occur.

a. Disconnect black negative (-) cable frombattery FIRST.

b. Next, disconnect red positive (+) cable frombattery.

2. REMOVE BATTERYAND BATTERY MOUNTINGBRACKET. (If Equipped)a. Unhook rubber strapA and remove battery

coverB.

b. Remove battery.

c. Remove battery mounting bracket fastenersD/E and remove bracketF.

3. REMOVE BRAKE AND BRAKE DISC.a. Apply the parking brake and then remove the

brake disc mounting boltA and washerB.

Instr 9930729 Rev 01 2019-05 Page 17 of 25

b. Release the parking brake. Remove the brakecaliper mounting boltsC. Tie the caliperD tooverstructure.

CAUTIONDo not allow the brake caliper to hang by the brake

hose.

c. Remove the brake discE from the jackshaft.

4. DRAIN CHAINCASE.a. Place a drain pan under the chaincase.

Remove the plugA to drain the oil. Clean theplug threads. Verify the o-ring is not damaged.

b. Allow sufficient time for all lubricant to drain outof the chaincase then reinstall plugA. Torqueto specification.

TORQUE8 - 9.5 ft. lbs. (8 - 13 Nm)

5. REMOVE CHAINCASE COVER.a. Note the groove on the seal sleeveF. Use a

pair of flat blade screwdrivers or soft-jawedpliers to carefully pry the sleeve out of thecover.

b. Locate the o-ringG on the end of the jackshaftinside the cover. Use a pick and carefullyremove the o-ring. Inspect o-ring and discard ifdamaged or torn.

Instr 9930729 Rev 01 2019-05 Page 18 of 25

c. Remove the five cover fasteners.

d. Carefully remove the coverH. Use a flat bladescrewdriver at the pry pointsX to aid removal.

e. After removing the cover, note the two dowelsin the chaincase.

NOTEInspect the cover gasket for damage. Inspect thebearing and seal in the cover. Replace bearing if it

no longer rolls smoothly. Replace the seal ifdamaged.

6. REMOVE CHAIN AND GEARS.a. Remove the chaincase sleeveA from the

jackshaft.

b. Remove the lower gear screwB and washerC. Note the beveled washer orientation.

c. Loosen the chain adjuster screw and removethe tensioner pad.

NOTEInspect the tensioner pad for damage. Replace if

excessive wear is evident.

d. Remove upperF and lowerG gears alongwith chainH.

Instr 9930729 Rev 01 2019-05 Page 19 of 25

7. INSTALL NEW GEARS.a. Place both uppert and lowery gears into the

chainH and install the gears and chain as aset.

b. Install the chaincase sleeveA along with thepreviously removed lower gear screwB andbeveled washerC. Verify the beveled washeris installed dome side out. Torque screw tospecification.

NOTEApply LOCTITE® Threadlocker Blue 243® (orequivalent) to lower gear screw before installing.


c. Rotate the driven clutch forward to move all ofthe chain slack to the tensioner side.

d. Install the chain tensioner pad. Tighten thetensioner screw until there is 1/8" (3.175 mm)chain deflection on the backside of the drivechain.

e. Verify the tensioner screw washerF is seatedagainst the chaincase, and then torque thetensioner screw jam nutG to specification.


8. REINSTALL CHAINCASE COVER.a. Verify the gasket is installed flush in the cover

and install the cover making sure the coverengages the two locating dowels evenly.

b. Lightly tap on the cover with a soft-facedhammer to seat the cover.

Instr 9930729 Rev 01 2019-05 Page 20 of 25

c. Install the cover screws. Torque screws tospecification using the specified sequencegoing in order fromA toE.

TORQUE9.5 ft. lbs. (13 Nm)

d. Install the o-ringG on to the jackshaft. Verifythe o-ring is sitting in the groove. Install theseal sleeveF with the groove facing out.

NOTEInstall a small amount of Polaris Premium Grease (or

equivalent) to the O-ring before installing.

9. REINSTALL BRAKE DISC AND CALIPER.a. Clean the brake disc with brake cleaner and

then loosely install on to jackshaft using thepreviously removed screwA and washerB.

NOTEApply LOCTITE® Threadlocker Blue 243® (or

equivalent) to screwA before installing.

b. Install the brake caliperD.

c. Torque fastenersC to specification.


Instr 9930729 Rev 01 2019-05 Page 21 of 25

d. Set the parking brake. Torque the brake discscrewA to specification. Release the parkingbrake.


10. INSTALL NEW CHAINCASE LUBRICANT.a. Remove chaincase fill plug as shown.

b. Refill the chaincase with synthetic 80Wlubricant. Fill to specification or when lubricantreaches the fill plug bore opening.

c. Reinstall fill plug. Tighten until snug.

11.REINSTALL BATTERY BOX. (If Equipped)a. Place battery box into position and secure with

original fastenersD andE. Torque fastenersto specification.


12.REINSTALL BATTERY. (If Equipped)

WARNINGWhen BOTH battery cables are disconnectedALWAYS connect AND tighten red positive (+)

battery cable FIRST. Failure to comply will result in ahigh current electrical arc, and may result in batteryexplosion, if tool touches grounded frame. Death or

serious personal injury may occur.

a. Place batteryC into battery box as shown.

b. First connect the red positive (+) solenoid cableto the positive (+) battery terminal using thebattery cable connection hardware suppliedwith your battery. Torque battery connectionhardware to specification provided.

TORQUE40 in. lbs. (4.5 Nm)

Instr 9930729 Rev 01 2019-05 Page 22 of 25

c. Next, connect the black negative (-) batterycable to the negative (-) battery terminal usingthe battery cable connection hardware suppliedwith your battery. Torque battery connectionhardware to specification provided.

TORQUE40 in. lbs. (4.5 Nm)

d. Reinstall battery coverB and secure withrubber strapA. Ensure hook on rubber strap isfully seated in the groove on the mounting tabD.

THROTTLEIMPORTANT

Note the number and location of spacer washers onthe throttle pin BEFORE removing E-clip or throttlepin. These will need to be replaced with the washer

provided when installing the new throttle.

1. REMOVE EXISTING THROTTLE LEVER.a. Unseat throttle cable.b. Remove E-clipA and throttle pivot pinB.

c. Remove the four screwsD holding the throttleblock coverC on and remover cover.

d. Remove the two screws and wire retainingcover to allow the heated throttle flipper wireand throttle flipper to be removed.

e. Follow thumb warmer wire down to theelectrical bag located under the console.Unplug the thumb warmer connection andremove throttle lever.

2. INSTALL PROVIDED THROTTLE LEVER.a. Plug in the new throttle flipper heater wire into

previously unplugged heater wire connection.b. Route heater wire back to throttle flipper and

through the groove in the bottom of the throttleblock.

Instr 9930729 Rev 01 2019-05 Page 23 of 25

c. Place throttle block coverC back into positionand secure with previously removed fastenersD.

d. Reinstall the wire retaining coverE and securewith the two previously removed screwsF.

e. Install throttle pinB and secure with E-clipAbeing sure the supplied spacers are installed inthe original locations to allow free movement ofthe throttle flipper.

f. Reconnect throttle cable. Be sure cable is fullyseated into new throttle flipper.

3. CHECK THROTTLE FUNCTION.a. With the engine off, operate throttle flipper

through full range of motion and verify throttleis properly functioning.

ELECTRICAL1. REMOVE EXISTING CDI BOX.

a. If not already done so, remove clutch guard.b. Remove the upper portionA of the airbox by

rotating the two wire clipsB outward.

c. Next, remove the lower portionD of the airbox.To do so, unhook the rubber strapC from themounting tab located on the back side of theengine and rotate the lower portion of theairbox towards the rear of the machine and liftupwards.

Instr 9930729 Rev 01 2019-05 Page 24 of 25

d. Remove the two screwsF securing the CDIEto the oil bottle assembly.

e. Unplug and remove existing CDIE.2. INSTALL PROVIDED CDI BOX.

a. Secure the new CDI boxr into position usingthe previously removed screwsF. Torque tospecification.

NOTEApply LOCTITE® Threadlocker Blue 243® (orequivalent) to both screwsF before installing.


b. Reconnect previously disconnected mainelectrical harness connector to newly installedCDI box.

c. Reinstall lower portionD of airbox being sureboth rubber boots are fully seated around thecarburetors. Secure with the rubber airboxstrapC.

d. Reinstall upper portionA of airbox being surethe hinge mechanism on the far side is fullyengaged and then securing upper portion withwire retaining clipsB.

e. Reinstall clutch guard.3. REINSTALL HOOD AND SIDE PANELS.

VERIFY WORK1. Verify all steps have been completed and all tools

are accounted for.a.

Instr 9930729 Rev 01 2019-05 Page 25 of 25

FEEDBACK FORMA feedback form has been created for the installer to provide any comments, questionsor concerns about the installation instructions. The form is viewable on mobile devicesby scanning the QR code or by clicking HERE if viewing on a PC.

FEEDBACK FORM

https://form.jotform.com/61263903942153?&number=9930729&revision=R01

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INDYEVO™™ RMK®® UPGRADEKIT - Polaris Inc