10653282-Polaris Download 1996 1997 1998 Snowmobile Service Manual Repair

CHAPTER 1 GENERAL INFORMATION
Publication Numbers .... .. .. . _. . . . . . . . . . . . . . .. 1.1 - 1.1b Service Bulletin Index By Bulletin Number ... .. .. 1.2 - 1.2c 1996 Service Bulletin Index By Model 1997 Service Bulletin Index By Model 1998 Service Bulletin Index By Model 1996 Model Identification I General Specifications 1997 Model Identification I General Specifications 1998 Model Identification I General Specifications 1.2d - 1.2h 1.2i - 1.2j 1.2k - 1.21
1.4 - 1.1 3
Service Videos ...... , . . ...... . . . .. . . . ...... . . 1.3 1.1 3a - 1.131 1.13m - 1.13u
Paint Codes . . , .. . , ' , .. , . .. , ... . .. .. . , . ... , .. 1.14 - 1.1 4b Torque Specifications . . . .... . .. . . .... . .. .... 1.1 5-1.1 6 Decimal Equivalents .. . ... ... . . . .. . . . . ... ..... 1.17
Conversion Table .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
Tap Drill Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.19 Glossary of Terms . ............ ...... . ...... 1.20-1 .22 Service Tips . ... . .. . .. . . , .. . . .... , . . .. _. .. 1.23 Warranty Policy .. _. . .. . , . . . . . . . . . . . . . . . . . . . . . 1.24 Special Tool Information . . ... .. ...... .. ... .. . . . 1.25
GENERAL INFORMATION Publication Numbers

1996 Publication Numbers
Model Model No. Owner's Manual Parts Manual Parts Microfiche Assembly Instructions
Indy Lite Indy Lite Deluxe Indy Lite GT Indy Sport Indy TranSport Indy Sport Touring Indy Super Sport Indy 440 LC Indy 440 XCR Indy 440 XCR SP Indy WideTrak GT Indy WideTrak LX Indy Trail Indy Trail Touring Indy 500 Indy 500 SKS Indy 500 RMK Indy Classic Indy Classic Trg. Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT SP Indy XLT Touring Indy 600 XCR Indy 600 XCR SP Indy RXL Indy Ultra SP Indy Ultra SKS Indy Ultra RMK Indy Storm Indy Storm SKS Indy Storm RMK
0963433 0963431 0963133 0960443 0960143 0960243 0960743 0962760 0961660 0961760 0962061 0962084 0962761 0962262 0962764 0962564 0962984 0963865 0963365 0963774 0962574 0962974 0966756 0960556 0960956 0966676 0963357 0961676 0965677 0966768 0960678 0960578 0960978 0965782 0965582 0965982
9913084 9913084 9913084 9913224 9913224 9913215 9913215 9913107 9913207 9913706 9913092 9913089 9913107 9913465 9913210 9913210 9913210 9913153 9913153 9913617 9913195 9913195 9913103 9913307 9913307 9913103 9913153 9913207 9913322 9913205 9913094 9913094 9913094 9913097 9913097 9913097
9913166 9913166 9913308 9913222 9913227 9913222 9913218 9913174 9913211 9913158 9913162 9913164 9913176 9913176 9913187 9913187 9913187 9913538 9913362 9913618 9913198 9913198 9913382 9913181 9913181 9913170 9913192 9913212 9913206 9913203 9913708 9913168 9913168 9913159 9913159 9913159
9913167 9913167 9913309 9913223 9913228 9913223 9913219 9913175 9913213 9913336 9913163 9913165 9913177 9913177 9913188 9913188 9913188 9913539 9913363 9913619 9913199 9913199 9913383 9913182 9913182 9913171 9913193 9913214 9913311 9913204 9913707 9913169 9913169 9913160 9913160 9913160
9913085 9913088 9913087 9913220 9913225 9913221 9913216 9913172 9913208 9913338 9913093 9913090 9913110 9913109 9913185 9913185 9913189 9913184 9913154 9913196 9913310 9913200 9913178 9913466 9913179 9913105 9913190 9913209 9913323 9913201 9913194 9913095 9913183 9913098 9913101 9913101
Polaris Industries Inc.
1 .1
11/95
GENERAL INFORMATION 1997 Publication Numbers 1997 Publication Numbers

Model Indy Lite Indy Lite Deluxe Indy Lite GT Indy Sport Indy TranSport Indy Sport Touring Indy XCF Indy Super Sport Indy 440 LC Indy 440 XC Indy 440 XC R Indy WideTrak GT Indy WideTrak LX Indy Trail Indy Trail Touring Indy Trail RMK Indy 500 Indy 500 SKS Indy 500 RMK Indy Classic Indy Classic Trg. Indy 500 EFI Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT SP Indy XLT Touring Indy XLT LTD Indy XLT SP LTD Indy 600 XC Indy 600 XCR Indy 600 XCR SE Indy RXL Indy Ullra Indy Ultra SP Indy Ullra SPX Indy Ul tra SPX SE Indy Ultra Touring Indy 700 SKS Indy 700 RMK Indy 700 XC Indy Storm Indy Storm SE Indy Storm RMK Model No. 0973433 097343 1 0973133 0970443 0970143 0970243 0971643 0970761 0972760 0971760 0971660 0972061 0972065 0972761 0972262 0970961 0972764 0972564 0972964 0973865 0973365 0973774 0976756 0970556 0970956 0976676 0973357 0973756 0973776 0971776 0975677 H975677 0976768 0976778 0970678 0975678 H975678 0975378 0970566 0970966 0971766 0975782 H975782 0975982
Owner's
Manual 9913748 9913748 9913740 9913688 9913696 9913699 9913661 9913763 9913934 9913755 9914006 9913816 9913821 9913709 9913705 9913647 9913709 9913841 9913841 9913845 9913732 9913753 9913713 9913761 9913761 9913774 9913732 9913658 9913658 9913755 9913795 9913795 9913851 9913804 9913912 9913801 9913801 9913812 9913856 9913856 9914180 9913781 9913781 9913786
Parts Manual 9913827 9913827 9913825 9913767 9913829 9913767 9913861 9913764 9913835 9913787 9913789 9913817 9913822 9913831 9913831 9913833 9913839 9913839 9913839 9913846 9913849 9913842 9913769 9913769 9913769 9913775 9913772 9913779 9914007 9913793 9913796 9913796 9913852 9913805 9913809 9913953 9913953 9913813 9913857 9913857 9914181 9913782 9913782 9913782
Parts Microfiche 9913828 9913828 9913826 9913768 9913830 9913768 9913862 9913765 9913836 9913788 9914472 9913818 9913823 9913832 9913832 9913834 9913840 9913840 9913840 9913847 9913850 9913843 9913770 9913770 9913770 9913776 9913773 9913780 9914008 9913794 9913797 9913797 9913853 9913806 9913810 9913954 9913954 9913814 9913858 9913858 9914182 9913783 9913783 9913783
Assembly
Instructions
9913749 9913750 9913742 9913687 9913697 9913702 9913662 9913766 9913837 9913754 9913791 9913819 9913824 9913710 9913704 9913648 9913735 9913735 9913844 9913848 9913737 9913751 9913714 9913762 9913771 9913777 9913733 9913659 9913659 9913758 9913798 9913798 9913854 9913807 9913811 9913802 9913802 9913815 9913859 9913859 9914183 9913784 9913784 9913784
......./
9/97
1.1a
GENERAL INFORMATION 1998 Publication Numbers 1998 Publication Numbers

Model Model No. Supplement to
Owner's Manual
Parts Book
Parts Microfiche
Assembly Manual Addendum 9914241 9914188 9914195 9914299 9914284 9914289 9914207 9914279 9914274 9914592 9914260 9914233 9914223 9914212 99 14364 99 14265 9914250 9914390 9914305 9914228 9914218 9914255 9914318 9914313 9914465 9914374 9914421 9914417 9914369 9914357 99 14342
Indy Lite Indy Lite Deluxe Indy Lite Trg. Indy Sport Indy TranSport Indy Super Sport Indy Sport Trg. Indy XCF Indy 440 Indy 440 XCR Indy Trail Indy Trail Trg. Indy Trail RMK Indy 500 Indy 500 Classic Indy 500 RMK Indy Classic Trg. Indy XLT LTD Indy XLT Classic Indy XLT SP Indy XLT Tr9. Indy 600 XCR Indy 700 XCR Indy 600 RMK Indy 700 RMK Indy 600 XC Indy 700 XC Indy Storm Indy Ultra Indy Ultra Trg.
0983433 0983431 0983133 0980443 0980143 0980761 0980243 0981643 0982760 0981660 0982761 0982362 0980961 0982764 0983865 0982964 0983365 0983756 0983857 0985776 0983357 0985677 0985678 0980958 0980966 0981758 0981766 0985782 0986778 0985378
9914185 9914185 9914185 9914281 9914281 9914281 9914281 9914281 9914257 9914371 9914257 9914257 9914281 9914257 9914257 9914257 9914247 9914387 9914302 9914302 9914215 9914302 9914339 9914339 9914371 9914371 9914414 9914414 9914339 9914354 9914339
9914186 9914186 9914193 9914205 9914282 9914287 9914205 9914277 9914272 9914590 9914258 9914231 9914221 9914210 9914362 9914263 991 4248 9914388 9914303 991 4226 9914216 9914253 9914316 9914311 9914463 9914372 9914419 991441 5 9914367 9914355 9914340
9914187 9914187 9914194 9914206 9914283 9914288 9914206 9914278 9914273 9914591 9914259 9914232 9914222 9914211 9914363 9914264 9914249 9914389 9914304 9914227 9914217 9914254 9914317 9914312 9914464 9914373 9914420 9914416 9914368 9914356 9914341
Indy WideTrak LX 0982065
1998 Snowmobile Owner's Manual (All) . PN 9914617 1998 Snowmobile Dealer Assembly Manual PN 9913911 1998 Snowmobile Dealer Assembly Manual Update PN 9914643
Polaris Industries Inc .
1.1 b
91 97
------GENERAL INFORMATION
Bulletin Index
Service Bulletins
S-94-03 S-94-04 S-94-05 1994 Storm (EC80PL01) Piston Replacement 1994 XCR 600 Piston Cracking, Fuel Pump Relocation, Carburetor Jetting 1995 XC R 600 1. Oil Delivery Line Routing for Magneto (RH) Cylinder 2. Choke Lever Breaking Due to Incorrect Inner Cable Length 1995 XCR 440 Cylinder Head a -Rings leaking 1994 XLT SP XTRA,1995 XLT SP, RXL Show Machines - IFS Shock and Rear Suspension Replacement (on all listed models); Head Gasket Replacement, Fuel Pump Relocation and Carburetor Main Jet Change on XLT Models Only. 1995 XLT Touring Circuit Breaker Wire may Contact Exhaust Outlet 1. 1995 XCR 600 Front Bolt Installed Incorrectly on Steering Drag Link 2. 1995 RXL Exhaust Manifold Flange Angle Incorrect Bottom Chalncase Sprocket Washer Replacement (See Models Listed on Bulletin) 1995 XLT Tunnel Wear Strips in Wrong Holes 1995 XCR 600 Steering Stops Incorrect 1995 XLT Touring - Circuit breaker wire may contact exhaust outlet (Additional Serial #'s) 1995 XCR 440 SP - Reinforced rear torque arm available 1995 XCR 440 SP - Steering stop kit available 1995 XC R 550 - PTa end crankshaft failure 1995 RXL, XLT SP - Durability Improvement kit 1995 Indy 500, 500 EFI, 500 EFI SKS , 500 EFI SKS PT, Classic, WideTrak LX - PTa end crankshaft failure
S-94-06 S-94-07
S-94-08 S-94-09 S-94-10 S-94-11 S-94-12 S-95-01 S-95-02 S-95-03 S-95-04 S-95-05 S-95-06
Information Bulletins
1-94-03 1-94-04 1995 440 and 440 SKS, Helix In Driven Clutch 1. 1995 RXL and XLT SP Reverse Gear Base Kit Information 2 . All Models using Reverse Gear Base Kit PN 2871154 or PN 2870861 - Pinion Shaft Diameter XLTand XCR Models with EC58PL02, 03 and E04 Eng ines - Coolant Leak at Spark Plug Cavity 1995 XC R 600 Coolant Line may Contact Brake Disc 1995 RXL and RXL Touring - Coolant Line may Contact Brake Disc 1995 XCR 440 SP XTRA-1 0 Scissor Stop Alignment 1995 RXL and XLT SP - XTRA 12 Suspension Adjustments and General Information 1995 RXL and RXL Touring - Hesitation or Bog when Accelerating All 1995 Models - Loose Rear Suspension Bolts. All 1995 Models Except XCRs - Seat Stain Removal 1995 Storm/Storm SKS - Oil Supply Line May Kink Near Steering Post 1996 XLT SP - Wrong Fuel Octane Called Out On Specification Decal 1996 XLT - Front Muffler Damper Location
1-94-05 1-94-06 1-94-07 1-94-08 1-94-09 1 -94-10 1-94-11 1-95-01 1-95-02 1 -95-03 1 -95-04
11/95
1.2
GENERAL INFORMATION Bulletin Index - By Number

Service Bu lletins
S-94-03 S-94-04 S-94-05 1994 Storm (EC80PL01) Piston Replacement 1994 XCR 600 Piston Cracking , Fuel Pump Relocation, Carburetor Jetting 1995 XCR 600 1_ Oil Delivery Line Routing for Magneto (RH) Cylinder 2_ Choke Lever Breaking Due to Incorrect Inner Cable Length 1995 XCR 440 Cylinder Head O-Rings leaking 1994 XLT SP XTRA, 1995 XLT SP, RXL Show Machines - IFS Shock and Rear Suspension Replacement (on all listed models); Head Gasket Replacement, Fuel Pump Relocation and Carburetor Main Jet Change on XLT Models Only_ 1995 XLT Touring Circuit Breaker Wire may Contact Exhaust Outlet
1. 1995 XCR 600 Front Bolt Installed Incorrectly on Steering Drag Link 2_ 1995 RXL Exhaust Manifold Flange Angle Incorrect
S-94-06 S-94-07
S-94-08 S-94-09 S-94-10 S-94-11 S-94-12 S-95-01 S-95-02 S-95-03 S-95-04 S-95-05 S-95-06 S-95-07 S-95-08 S-95-09 S-95-10 S-95-11 S-95-12 S-95-13 S-95-14 S-95-15 S-95-16 S-95-17 S-95-18 S-96-01 S-96-02 S-96-03 S-96-04 S-96-05 S-96-06 S-96-07
Bottom Chaincase Sprocket Washer Replacement (See Models Listed on Bulletin) 1995 XLT Tunnel Wear Strips in Wrong Holes 1995 XCR 600 Steering Stops Incorrect 1995 XLT Touring - Circuit breaker wire may contact exhaust outlet (Additional Serial #'s) 1995 XCR 440 SP - Reinforced rear torque arm available 1995 XCR 440 SP - Steering stop kit available 1995 XCR 550 - PTO end crankshaft failure 1995 RXL, XLT SP - Durability improvement kit 1995 Indy 500, 500 EFI , 500 EFI SKS, 500 EFI SKS PT, Classic, WideTrak LX - PTO end crankshaft failure 1996 Ultra - Recoil Hub Cracking on EC68PL-Ol Engines Trail Touring - Wrong Pinion Gear Installed in some Trail Touri ng Chaincases 1996 Trail Touring - Throttle Cable Ends May be Reversed on Some Trail Touring Models 1996 Ultra - Kinked Oil Lines 1996 XLT RMKlSKS and Sport Touring - Snow Skirts Cracking Around Mounting Boss 1996 WideTrak GT/LX-Handleba r Damage When Opening and Closing the Hood 1994 Storm/Storm SKS - Cooling System Update Kit 1995 Storm/Storm SKS - Cooling System Update KiVEng ine Update Kit 1995 XLT SP (48" Stance)_ Trail, XLT SKS - Safety Alert - Fuel Tank Cracks 1996 Storm RMK - Head Gasket Change to Prevent Piston Damage 1996 Ultra SP - Low Oil Level in Water Pump Drive Gearcase 1996 Ultra SP, Ultra SKS, Ultra RMK - Exhaust Thermal Sensing System Testing 1996 XLT Touring, Classic Touring - Front Torque Arm Shaft Retention Kit 1996 Storm, Storm SKS , Storm RMK, 600 XCR SP - Sharp Edge on Engine Mount Plate May Damage Water Trap 1996 Storm (Euro) , Sto rm SKS, Storm RMK - Revised Ignition Timing Specification and Carbu retor Adjustment 1996 Storm , Storm SKS , Storm RMK - Mag (RH) Exhaust Pipe Support Bracket May Crack and Separate from Pipe 1996 XLT Tou ring , Classic, Classic Touring, 500 , 500 SKS , 500 RMK, 500 EFI , 500 EFI SKS , 500 EFI RMK, Trail , Trail Touring , 440 - Handlebar Welds Missing or Incomplete 1994 Storm , Storm SKS. 1995 Storm, Storm SKS - Coolant Tank Expansion May Impair Brake Operation 1995 Trail, XLT SP (48" Stance), XLT SKS - Cracked Fuel Tanks; Reminder to perform Safety Alert S-95-15
1.2a
9/97
GENERAL INFORMATION Bulletin Index - By Number

Service Bulletins, Cont.
S-96-08 S-96-09 -5-96-10 S-9611 S-96-12 S-96-13 S-96-14 S-96-15 S-96-16 S-96-17 S-96-18 S-96-19 S-96-20 S-96-21 S-96-22 S-96-23 S-97-01 S-97-02 S-97-03 S-97-04 S-97-05 S-97-05R S-97-06 S-97-07 1996 XLT Touring , Classic Touring - Increased Rear Handwarmer Heat 1996 Ultra RMK - Improved Running Quality and Snowmobility 1996 Ultra SP, Ultra SKS, Ultra RMK, 600 XCR, Storm, Storm SKS, Storm RMK - Improved Clutch Alignment 1997 440 XC - Front Track Shock Reservoir Clamps Installed Incorrectly 1997500 RMK - Incorrect Throttle Lever 1996 RMK Models - Ski Replacement Program 1997 Lite Dlx .; Trail Trng. ; Classic Trng .; XLT Trng. ; Ultra Trng. ; WideTrak LX - Loose Starter Ring Gear Screws 1997 Ultra Touring - Aluminum Tape On Speedometer Cable May Contact Battery 1997 XLT LTD SP - Incorrect Main Jets Installed In Carburetors 1997 Ultra; Ultra SP (and Euro Models) - Oil Supply Line May Kink Below Oil Filter 1997 Sorm, Storm SE, Storm RMK - Coolant Check Valve I Filter Assembly Installed Incorrectly 1997 Ultra Touring - Hood Interference With Reverse Cable 1997 700 RMK - Insufficient Clearance Between Exhaust Pipe And Hood 1997 XLT RMK - Rich Condition I Poor Fuel Economy 1997 440 XCR - Fuel Line And Water Trap Abrasion 1997 WideTrak GT/ LX (Including European) - Transmission Oil Leaks I Transmission Hard To Shift 1997 440 XCR - Cracked Or Broken CDI Wires 1997 700 SKS, RMK - Coolant Hose May Contact Recoil Housing 1997 WideTrak LX, GT - Transmission Not Engaging Or Sticking In Gear
Safety Alert - 1997 440 XC, XCF - Pitman Ann Weld Failure Safety Alert - REVISED - Refer to S-97 -05R Below Safety Alert - 1997 CRC Models and 1998 Show Machines (Refer to Bulletin For Specific Models) Pitman Arm Weld Failure
1997 440 XCR - Engine Update Options 1997700 XC, SKS, RMK - Durability Improvement Kit For Oil Pump and CDI Mod ule
Information Bulletins
1-93-10 1-93-11 1-93-12 1-94-01 1 -94-02 1 -94-03 1-94-04 1-94-05 1-94-06 1-94-07 1-94-08 1-94-09 1-94-10 1-94-11 1-95-01 1. Oil Tank Fittings Leaking on: 1994 Indy Lite, Lite GT, Lite Deluxe , StarLite, StarLite GT 2. Indicator Lights that Pop out of Console on 1994 500 EFI Rear Torsion Springs may Rub Against Track Carrier Wheel Carburetor Jetting Recommendations for Kit PN 2200509 Water Traps on 1994 600 XCR, 400 XCR SP, StarLite, StarLite GT 1. 1994 Storm, Storm SKS may Encounter a Rich Condition on Rough Terrain 2. 1994600 XCR Carburetor May Rub Against Torque Stop Mounting Bracket 1995 440 and 440 SKS, Helix In Driven Clutch 1. 1995 RXL and XLT SP Reverse Gear Base Kit Information 2. All Models using Reverse Gear Base Kit PN 28711 54 or PN 2870861 - Pinion Shaft Diameter XLT and XCR Mode ls with EC58PL02, 03 and E04 Engines - Coolant Leak at Spark Plug Cavity 1995 XCR 600 Coolant Line may Contact Brake Disc 1995 RXL and RXL Touring - Coolant Line may Contact Brake Disc 1995 XCR 440 SP XTRA-1 0 Scissor Stop Alignment 1995 RXL and XLT SP - XTRA 12 Suspension Adjustments and General Information 1995 RXL and RXL Touring - Hesitation or Bog when Accelerating All 1995 Models - Loose Rear Suspension Bolts. All 1995 Models Except XCRs - Seat Stain Removal
9/97
1.2b
GENERAL INFORMATION Bu lletin Index - By Number Information Bulletins, Cont.

195-02 1995 Storm/Storm SKS - Oi l Supply Line May Kink Near Steering Post 1996 XLT SP - Wrong Fuel Octane Called Out On Specification Decal 1996 XLT - Front Muffler Damper Location 1995 XLT Touring - Revised Carburetor Jetting for Low Elevation 1995 Indy 500 and 1995 Classic - Revised Carburetor Jetting for Low Elevation 1996 XLT RMK , 500 RMK, 500 EFI RMK - 19 Tooth Top Sprocket Required for Reverse Kit Installation 1996 Ultra RMK - Carburetor Jetting and Fuel Recommendation for Operation Below 6000 ft. (1800 meters) . 1996 Ultra RMK - Kinked Coolant Hose 1996 XLT Touring/Classic Touring - Nut Serts " Missing from Back Rest Brackets 1996 Storm (Euro), Storm SKS, Storm RMK - Main Wire Harness/Brake Light Wire Harness Position 1996 600 XCR SP, Ultra, Ultra SKS , Ultra RMK - Sharp Edge on Hardware Mounting Bracket 1996 XLT, XLT SP, XLT SKS, XLT RMK, XLT Touring, 600 XCR, and European Models Restricted Coolant Filter 1996 All Models with P-85 Driven Clutch - Bogging or Belt Slippage 1996 XLT RMK, Ultra RMK, 500 RMK , 500 EF I RMK - Optional Setup for Deep Snow Perlormance 1996 Storm, Ultra SP, 600 XCR SP, 600 XCR , 500 Carb, Trail, 440 XCR SP, 440 XCR, 440 , Super Sport - Loose Front Torque Arm Bolts 1996500,500 SKS (Euro), 500 RMK, ClaSSiC, Classic Touring (Euro) - Hose Clamp Tabs May Damage Coolant Line 1996 600 XCR SP, Ultra RMK - Improved High Elevation Perlormance 1996600 XCR SP - Improved Low End Pertormance at Low Elevations (0-3000 ft . /0-900 m) 1996 All Models with XTRA-10 Rear Suspension - Loose Track Carrier Wheel Lock Collar 1996 Ultra SP, SKS, RMK - Cracked Exhaust Pipes 1996 XLT (All) and 600 XCR - Extended Warranty On 1996 EC58PL Engines 1996 XLT Touring, Classic Touring - Slide Rail Beam Repair Kit 1996 440 and 500cc Liquid Twins (Except 440 XCR and 440 XCR SP) - Oil In Fuel Pump Impulse Line 1997 XLT RMK - Incorrect Information On Specification Decal All Models With CRC Front Suspension - Steering Alignment During Setup 1997600 XC, XCR, SE; Ultra SPX , SPX SE - Incorrect IFS Shock Spring Pre-load 1997 Super Sport; 600 XC - Nose Cone Decal Placement 1997 600 XCR SE; Ultras (All) - Pinched Fuel Line 1997 XLT LTD, LTD SP; RXL; Storm, SE, RMK - 15 Wide Reverse Gear Kit Installation 1997 Classic Touri ng - Incorrect Torsion Bar 1997 Storm (All Including European Models) - Tight Belt-To-Sheave Clearance 1997600 XCR, SE ; Ultra SPX, SPX SE; (And All Euro Models) - Poor PTO Exhaust Pipe Fit 1997 700 RMK ; SKS - Revised Oil Injection Pump Bleeding Procedure 1996 600 XCR SP; Ultras; Storms - Recommendations For 1996 High Perlormance Models 1997 WideTrak LX - Coolant Hose And CDI Wire Routing 1997 Ultra SPX (Including SE and Euro Models) - PTO Oil Line Guide Clamp Position 1997 600 XCR, XCR SE; Ultra SPX, SPX SE ; (Including Euro Models) - Oil Line Damage At Fitting 1997 700 XC, SKS , RMK - Carburetor Calibration Changes
'-
1-95-03 1-95-04 1-95-05 1-95-06 1-95-07 1-95-08 1-95-09 1-95-10
'-
1-96-01 1-96-02 1-96-03 1-96-04 1-96-05 1-96-06 1-96-07
'--
1-96-08 1-96-09 - 1-96-10 1-96-11 - 1-96- 12 1-96-13 1 -96-14 1-96-15 1-96-16 1-96-17 1-96-18 1-96-19 1-96-20 1-96-21 1-96-22 1 -96-23 1-96-24 1-96-25 1-96-26 1-96-27 1-96-28 1-96-29
"--'
1.2c
9/97
GENERAL INFORMATION Bulletin Index - 1996 By Model

1996 Model
1996 Indy 8 torm
Bulletin #
8 -96-10 8 -96-06 8-96-04 8-96-03 8-96-02 8-95-22 8-95-1 9 1-96-10 1-96-06 1-96-04 1-96-01 1 -95-13
Type
Service
8afety
Notes
Improved Clutch Alignment Coolant Tank Expansion Exhaust Pipe support Bracket May Crack Revised Timing and Carburetor 8pecs. 8harp Edge On Engine Mount False Oil Level Piston Failure At Partial Throttle Loose Whee l Lock Collars Loose Front Torque Arm Bolts Bogging or Belt slippage Main Harness/Brake Light Harness Position Heavy 8teering Improved Clutch Alignment Coolant Tank Expansion Exhaust Pipe support Bracket May Crack Revised Timing and Carburetor 8pecs. 8harp Edge On Engine Mount False Oil Level Piston Failure At Partial Throttle Loose Wheel Lock Collars Bogging or Belt slippage
Main Harness/Brake Light Harness Position
Service Service Service

Service
Service
Info Info Info Info Info
1996 Indy 8torm 8K8
8-96-10 8 -96-06 8-96-04 8-96-03 8-96-02 8-95-22 8-95-19 1-96-10 1-96-04 1-96-01 1-95-13
Service
8afety
Service
Service
Service
Service
Service
Info Info Info Info
Heavy 8teering
Aluminum Ski Replacement Program
1996 Indy 8torm RMK
8-96-13 8-96-10 8-96-06 5-96-04 5-96-03 8-96-02 5-95-22 8 -95-16 1-96-10 1-96-04 1-96-01 1-95-13
Service Service
Safety
Improved Clutch Alignment Coolant Tank Expansion Exhaust Pipe support Bracket May Crack
Revised Timing and Carburetor Specs.

Service
Sharp Edge On Engine Mount False Oil Level Head Gasket Replacement Loose Wheel Lock Collars Bogging or Belt slippage Main Harness/Brake Light Harness Position Heavy Steering Improved Clutch Alignment Coolant Tank ExpanSion False Oil Level Exhaust Thermal Sensing 8ystem Low Oil Level In Water Pump Drive Gearcase Kinked Oil Lines Cracked Exhaust Pipes Loose Whee l Lock Collars
Service
Info Info Info Info
Service
1996 Indy Ultra 8P
5 -96-10 8-96-06 8-95-22 8 -95-18 5-95-1 7 5-95- 10 1-96-11 1-96- 10
Safety
Service
Service
Service Service
Info Info
91 97
1.2d

1996 Model
1996 Indy Ultra SP, (cant.)
Bulletin #
1-96-06 1-96-04 1-96-02 1-95-13
Type
Into Info Info Info
Notes
Loose Front Torque Arm Bolts Bogging or Bell s lippage Sharp Edge on Mounting Brackel Heavy Steering Improved C lutch Alignmenl Coolant Tank Expansion False Oil Level Exhaust Thermal Sensing Syslem Kinked Oil Lines Cracked Exhaust Pipes Loose Wheel Lock Collars Bogging or Bell slippage Sharp Edge on Mounting Bracket Heavy Steering Aluminum Ski Replacement Prog ram Improved C lutch Alignment Improved Running Quality & Snowmobility Coolant Tank Expansion False Oil Level Exhaust Th ermal Sensing System Kinked Oil Lines Recoil Hub Cracking Cracked Exhaust Pipes Loose Wheel Lock Collars Improved High Elevation Pertormance Optional Setup tor Deep Snow Pertormance Bogging or Bell s lippage Sharp Edge on Mounting Bracket Improved Snowmobility In Deep Snow Heavy Steering Kinked Coolant Hose Carb & Fue l Recomm endations for High Alt. Bogging or Belt Slippage Heavy Steering Improved Clutch Alignment Coolant Tank Exp ans ion Sharp Edge On Engine Mount False Oil Level Loose Wheel Lock Collars Improved Low End Performance-Low Alt. Improved High Alt. Performance Loose Front Torque Arm Bolts Bogging or Belt slippage
1996 Indy Ultra SKS
S-96-10 S-96-06 S-95-22 S-95-1 8 S-95-10 1-96-11 1-96-10 1-96-04 1-96-02 1-95-13
Service
Safety

Info Info Into Inlo Info
1996 Indy Ultra RMK
S-96-13 S-96-10 S-96-09 S-96-06 S-95-22 S-95-1 8 S-95-10 S-95-07 1-96-11 1-96- 10 1-96-08 1-96-05 1-96-04 1-96-02 1-95-15 1-95-13 1-95-09 1-95 -08

Satety
Service Service Service Service

Into Into Info Info Into Into Info Into Into Into Info Into
Service
1996 RXL
1-96-04 1-95-13
1996600 XCR SP
S-96-10 S-96-06 S-96-02 S-95-22 1-96-10 1-96-09 1 -96-08 1-96-06 1-96-04
Satety
Service Service
Into Into Into Into Into
1.2e
9/97
GENERAL INFORMATION Bulletin Index -1996 By Model

1996 Model
1996600 XCR SP (cant.)
Bulletin #
1-96-02 1-95-13 1-95-1 1
Type
Info Info Info Info Info Info Info Info Info
Notes
Sharp Edge on Mounting Bracket Heavy Steering Setup Recommendations Extended Warranty on 1996 EC5BPL Engines Loose Wheel Lock Collars Loose Front Torque Arm Bolts Bogging or Belt slippage Restricted Coolant Filter Heavy Steering Aluminum Ski Replacement Program Snow Skirts Cracking Around Mounting Boss Extended Warranty on 1996 EC5BPL Engines Loose Wheel Lock Collars Optional Setup for Deep Snow Performance Bogging or Belt slippage Restricted Coolant Filter Heavy Steering 19 Tooth Top Sprocket For Reverse Kit Extended Warranty on 1996 EC5BPL Engines Bogging or Belt slippage Restricted Coolant Filter Heavy Steering Wrong Octane Callout on Specification Decal Snow Skirts Cracking Around Mounting Boss Extended Warranty on 1996 EC5BPL Engines Loose Wheel Lock Collars Bogging or Bell slippage Restricted Cool ani Filter Heavy Steering Extended Warranty on 1996 EC5BPL Engines Bogging or Bell slippage Restricted Coolant Filter Heavy Steering Front Muffler Damper Installation Location
1996600 XCR
1-96-12 1-96-10 1-96-06 1-96-04 1-96-03 1 -95-13
1996 Indy XLT RMK
S-96-13 S-95-11 1-96- 12 1-96 -10 1-96-05 1-96-04 1-96-03 1-95-13 1-95-07
Service
Service
Info Info Info Info Info Info Info Info Info Info Info Info
1996 XLT SP
1-96-12 1-96-04 1 -96-03 1-95-13 1-95-03
1996 XLT SKS
S-95- 11 1-96-12 1 -96-10 1-96-04 1-96-03 1-95-13
Service
Info Info Info Info Info Info Info Info Info Info
1996 XLT
1-96-12 1-96-04 1-96-03 1-95-13 1-95-04
1996 XLT Touring
S-96-0B S-96;05 S-96-01 1-96- 13 1 -96-12 1-96-04 1 -96-03 1 -95-13 1-95- 10
Service
Safety
Increased Rear Handwarmer Heat

Handle Bar Welds Missing or Incomplete Front Torque Arm Shaft Retention Kit Slide Rai l Beam Repair Kit Extended Warranty on 1996 EC5BPL Engines Bogging or Belt slippage Restricted Coolant Filter
Heavy Steering Nut Sert MissIng From Back Rest Bracket
Service
Info Info Info Info Info Info
9/9 7
1.21
Po/arts Industrtes In c.

1996 Model
1996 Indy Classic
Bu lletin #
S-96-05 1 -96-14 1-96-07 1-96-04 1-95-13
Type
Safety Info Info Info Info
Notes
Handle Bar Welds Missing or Incomplete Oil In Fuel Pump Impulse Line Hose Clamp Tab May Damage Coolant Line Bogging or Belt slippage Heavy Steering
Increased Rear Handwarmer Heat
1996 Classic Touring
S-96-08 S-96-05 S-96-01 1-96-14 1-96-13 1-96-07 1-96-04 1-95-13 1-95-10
Service
Safety
Handle Bar We lds Missing or Incomplete Front Torque Arm Shaft Retention Kit Oil In Fuel Pump Impulse Line Slide Rail Beam Repair Kit Hose Clamp Tab May Damage Coolant Line Bogging or Belt slippage Heavy Steering Nut Sert'" Missing From Back Rest Bracket Aluminum Ski Rep lacement Program Handle Bar Welds Missing or Incomplete Oil In Fuel Pump Impulse Line Loose Wheel Lock Collars Hose Clamp Tab May Damage Coolant Line Optional Setup for Deep Snow Performance Bogging or Belt slippage Heavy Steering 19 Tooth Top Sprocket Required For Reverse Kit Aluminum Ski Replacement Program Handle Bar Welds Missing or Incomplete Loose Wheel Lock Collars Optional Setup for Deep Snow Performance Bogging or Belt slippage Heavy Steering 19 Tooth Top Sprocket Required For Reverse Kit Handle Bar Welds Missing or Incomplete Loose Wheel Lock Collars Bogging or Belt slippage Heavy Steering Handle Bar Welds Missing or Incomplete Oil In Fuel Pump Impulse Line Loose Wheel Lock Collars Hose Clamp Tab May Damage Coolant Line Loose Fronl Torque Arm Bolts Bogging or Belt slippage Heavy Steering Handle Bar Welds Missing or Incomplete 0,1 In Fuel Pump Impulse Line
Service
1996 Indy 500 RMK
S-96-13 S-96-05 1-96-14 1-96-10 1-96-07 1-96-05 1-96-04 1-95-13 1-95-07
Service
Safety Info Info Info Info Info Info Info
1996 Indy 500 EFI RMK
S-96-13 S-96-05 1-96-10 1-96-05 1-96-04 1 -95-13 1-95-07
Service
Safety Info Info Info Info Info Safety Info Info Info Safety Info Info Info Info Info Info Safety Info
1996 Indy 500 EFIISKS (SKS Only)
S-96-05 1-96-10 1-96-04 1-95-13
1996 Indy 500
S-96-05 1-96-14 1-96-10 1-96-07 1-96-06 1-96-04 1-95-13
1996 Indy 500 SKS
S-96-05 1-96-14
1.2g
9;97

1996 Model
1996 Indy 500 SKS (cont.)
Bu lletin #
1-96-10 1 -96-07 1-96-04 1 -95-13
Type
Info Info Info Info Info Info Info Info
Notes
Loose Wheel Lock Collars Hose Clamp Tab May Damage Coolant Line Bogging or Belt slippage Heavy Steering Loose Wheel Lock Collars Loose Front Torque Arm Bolts Bogging or Belt slippage Heavy Steering Loose Shock Eyelet On Fox Shocks Loose Whee l Lock Collars Loose Front Torque Arm Bolts Bogging or Belt slippage Jetting and Clutching For Improved Perf. Heavy Steering Exhaust Pipe May Contact Hood Handle Bar Welds Missing or Incomplete Loose Wheel Lock Collars Oil In Fuel Pump Impulse Line Loose Front Torque Arm Bolts Bogging or Belt slippage Heavy Steering Handlebar Damage When Opening Hood Bogging or Belt slippage Oil In Fuel Pump Impulse Line Handle Bar Welds Missing or Inco mplete Loose Wheel Lock Collars Loose Front Torque Arm Bolts Bogging or Belt slippage Heavy Steering Handle Bar Welds Missing or Incomplete Throttle Cable Ends May Be Reversed
1996 Indy 440 XCR
1-96-10 1-96-06 1 -96-04 1-95-13
1996 Indy 440 XCR SP
S-95-20 1-96-10 1-96-06 1-96-04 1-95-14 1-95-13 1-95-12
Service
Info Info Info Info Info Info Safety Info Info Info Info Info
1996 Indy 440
S-96-05 1-96-10 1-96-14 1 -96-06 1-96-04 1-95-1 3
1996 Indy Widetrak GTILX
S-95-12 1-96-04
Service
Info Info Safety Info Info Info Info Safety Service
(LX Only) 1996 Indy Trail
1 -96-14 S-96-05 1-96-10 1-96-06 1-96-04 1 -95- 13
1996 Indy Trail Touring
S-96-05 S-95-09 S-95-08 1-96-10 1-96-04 1-95-13
Service
Wrong Pinion Gear In Chaincase

Loose Wheel Lock Collars Bogging or Belt slippage Heavy Steering Loose Wheel Lock Collars Loose Fronl Torque Arm Bolts Heavy Steering Snow Skirts Cracking Around Mounling Boss Loose Whee l Lock Collars Heavy Steering Heavy Sleering
1996 Indy Super Sport
1-96-10 1-96-06 1-95- 13
1996 Indy Sport Touring
S-95-11 1 -96- 10 1-95-13
Service
Info Info Info
1996 Sport and Liles
1-95-13
91 97
1.2h

1997 Model
1997 Storm I SE 1997 Storm RMK 1997700 (SKS and RMK)
Bulletin #
S-96-1 8 S-96-18 S-97-0SR S-97-0S S-97-02 1-96-24
Type
Service Service
5ilf.t~
Safet~
Notes
Coolant Check Valve I Filter Assembly Installed Incorrectly Coolant Check Valve I Filter Assembly Installed Incorrectly
,J!hld
Pitman Arm We ld Failure and Pitman Arm to Steering Rack Bolt Replacement
Alert - Refer to 5-97-05B

Coolant Hose May Contact Recoi l Housing Revised Oil Pump Bleeding Procedure Insufficient Clearance Between Exhaust Pipe and Hood Carburetor Calibration Changes Durability Improvement Kit for Oil Pump and COl
Service Info
Servjce
(RMK Only) All 700s (XCISKSIRMK)
5-96-20 1-96-29 S-97-07
Info
Service
Safet~
Safet~
1997 Ultra SPx/SE
S-97-0SR S-97-0S
Alert
Pitman Arm Weld Failure and Pitman Arm to Steering Rack Bolt Replacement
,J!lert - Refer to 5-97-05B

1997 Ultra SP (Euro)
S-97-0SR S-97-0S S-96-17
Service
5afet~
,J!ler1 -
Bef~(
to S-IH-QliR
Service
Service
Oil Supply Line May Kink Below Filter Hood Interference With Reverse Cable Aluminum Tape On Speedometer Cable May Contact Battery Electric Start - Loose Starter Ring Gear Screws Oil Supply Line May Kink Below Filter
1997 Ultra Touring
S-96-19 S-96-1 S S-96-14
1997 Ultra (Euro) 1997 RXL 1997 600 XCR I SE
S-96-17
S-97-0SR S-97-0S
5afflt~
A/fld
Safetll. Alfl rt - Refer to 5-97-05R

Safet~
1997600 XC
S-97-0SR S-97-0S
Alert -
B~f~r
Safet~ AI~rt
to S-97-05R
1997 XLT RMK 1997 XLT LTD I LTD SP 1997 XLT Touring 1997 XLT SP 1997 XLT SKS 1997 XLT 1997500 EFI 1997500 UC 1997500 RMK
S-96-21 S-96-16 S-96-14
Rich Condition I Poor Fuel Economy Incorrect Main Jets Installed In Carburetors Electric Start - Loose Starter Ring Gear Screws
S-96-13 S-96-12
Service Service
Aluminum Ski Replacement Program

Inco rrect Throttle Leve r
1997500 SKS
1.2 i
9197
GENERAL INFORMATION Bulletin Index -1997 By Model

1997 Model
1997 Classic 1997 Classic Touring 1997 Widetrak GT
Bulletin #
S-96-1 4 S-96- 14 S-97-03 S-96-23
Type
Service Service Service Service Service Service Service Service Service Service
S.af~t~ ~l8.d
Notes
Electric Start - Loose Starter Ring Gear Screws Electric Start - Loose Starter Ring Gear Screws Transmission Not Engaging or Sticking In Gear Transmission Oil Leaks I Hard To ShiH Transmission Not Engaging or Sticking In Gear Transmission Oil Leaks I Hard To ShiH Electric Start - Loose Starter Ring Gear Screw Engine Kit options Cracked or Broken CO l Wires Fuel Line And Water Trap Abrasion Pitman Arm Weld Failure Front Track Shock Reservoir Clamps Installed Incorrectl y
1997 Widetrak LX
S-97-03 S-96-23 S-96-14
1997440 XCR
S-97-06 S-97-01 S-96-22
1997440 XC
S-97-04 S-96-1 1
Service
1997 440 UC
1997 XCF 1997 Trail Touring 1997 Trail 1997 Sport 1997 Super Sport 1997 Sport Touring 1997 Transport 1997 lite 1997 lite Deluxe 1997 Lite GT S-96-14 Service
Electric - Loose Starter Ring Gear Screws
S-97-04 S-96-14
Safetk'. ~/~11
Service
Pitman Arm Weld Failure Electric Start - Loose Starter Ring Gear Screws
9/97
1.2j

1998 Model
Storm 700 XC 700 XCR S-97-0SR S-97-0S 700 RMK S-97-0SR S-97-0S Ultra Ultra Touring 600 XC 600 XCR S-97-0SR S-97-0S 600 RMK S-97-0SR S-97-0S XLT SP S-97-0SR S-97-0S XLT Ltd XLT Classic XLTTou ring SOO SOO RMK Classic Classic Touring Widetrak LX
Safg t ~ ~i!tg t~ ~afe! ~
Bulletin #
Type
Notes
Alert
Pitman Arm Weld Failure And Pitman Arm to Steeri ng Rack Bolt Replacement
~i!t~ (~ t.lgd - Refer To S-97-05R

Safet~ A/~rt ~i! tgt~
Pitman Arm Weld Failure And Pitman Arm to Steeri ng Rack Bolt Replacement
Aled - Refer To S-97-05.R
t. /ert
Pitman Arm Weld Failure And Pitman Arm to Steering Rack Bolt Replacement
t. lgd - Refer To S-97-Q5R

Satet~ Aled
Safet~
Algrt - Rgfer To fi.-fl7-Q5B

Sat~(~ ll&.d Satl1!~ t. led
- Refer [0 S-fl7-Q5B
Trail
Trail Touring Trail RMK 440 440 XCR XCF Sport Super Sport Sport Touring Transport Lite Lite Deluxe Lite Touring
1.2k
9[97
GENERAL INFORMATION Service Videos

Service Videos
P",d NumQer Description Advanced Carburetion Fuel System Diagnostics Polaris Variable Transmissions Customer Service Magnum 4 Stroke Introduction Charging System Diagnostics Ignition System Diagnostics Snowmobile Suspension Service
9914394 9912776 9913987 9914171 9912996 9913278 9913533 9913684
1.3
9/97
GENERAL INFORMATION 1996 Model Identification SERIAL NUMBER IDENTIFICATION

The machineserial number may be used as an aid In identifying machine model year. Refertothe first digits in the serial number for proper Identification: EIRST DIGITS MODEL YEAR 1996 26
1996 MODEL DESIGNATION

YEAR DESIGNATlm'i-l- - - - - - - - - - - , MODEL DESIGNATION
O~
, - - - - ENGINE DESIGNATION
Refer to Engine Section for more detailed information
1996 MODEL DESIGNATION NUMBERS (Chassis) 01 - Indy TranSport 02 - Indy Sport Touring 04 - Indy Sport 05 - Indy XLT SKS, Ultra SKS 06 - Indy Ultra SP 07 - Indy Super Sport, XLT, Storm 09 - Indy XLT RMK, Ultra RMK 16 - Indy 440 XCR, 600 XCR 20 -Indy WideTrak GT/LX 22 - Indy Trail Touring 25 - Indy 500 EEl SKS, 500 SKS 27 - Indy 440, Trail, 500 29 - Indy 500 RMK, 500 EEl RMK 31 - Indy Lite GT 33 -Indy Classic Touring, XLT Touring 34 -Indy Lite, Lite Deluxe 37 - Indy 500 EEl 38 - Indy Classic 55 - Indy Storm SKS 56 - Indy 600 XCR SP 57 - Indy Storm 59 - Indy Storm RMK 66 -Indy XLT SP 67 - Indy XLT, RXL
1996 ENGINE DESIGNATION NUMBERS 33 - EC34-2PM02 43 - EC44-3PM01 , PM02 60 - EC45PL07, PL08, PL06 61 - EC50PM03, PM04 62 - EC50PM04 56 - EC58PL03, PL07 57 - EC58PLE05 64 - EC50PL11, PL15, PLE12 65 - EC50PLE11, PL14 68 - EC65PL05 74 - EC50PL13 76 - EC58PL02 77 - EC59PL01 78 - EC68PL01 , PL04 82 - EC80PL05, PL04 31 - EC34-2PME02
MODEL NO.
MADE IN U.S.A.
POLRRIS
PATENT NOTICE
V.l. N. NO.
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.
MFO. DATE:
MId. by Polaris Indu8U'le, Inc: .. In ROMtU, MN under one or mol1l of the following patents: PatenWC! canada U.S. Patents 882,491nl 3,805,511 3,613,810 5,050,5&9 883,894(71 3,1580,&47 3,867,i91 5,048,503 884.394n1 3,483,785 4,n3,i50 5,0515,482 Caned Ian Rd. 3,1533,1582 11,038,881 5,0i9,813 34,573171 3,1545,821 5, 172,6711 5,074,211 ~ .512171 3,105,510 5,OiO,38e 5,1tl,531 1,227,823187 3,525,412 5,050,584 3,813,811 7072133
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).
11/95
1.4
GENERAL INFORMATION 1996 Model Identification

Indy Lite
0963433 Engine Type Engine Model Number Fan Twin EC34-2PM02 339 62.3 x 55.6 2 Mlkuni VM30SS Slide Standard CDI 12V 150W 1051266.7 42.5/ 108 44/ 111.8
Indy Lite Deluxe

0963431
Indy Lite GT
0963133
Indy Sport
0960443
Fan Twin
EC34-2PM02 339 62.3 x 55.6
Fan Twin
EC34-2PM02 339 62.3 x 55.6
Fan Twin
EC44-3PM01 432 67.72 x 60
Displacement (ee)
Bore x Stroke (mm) CarouretionfThrotlle Body Oil Injected
2 Mikuni
VM30SSSIIde Standard CDI 12V 150W 105/266.7 42.51108 44/111.8
2 Mikuni
VM30SS Slide Standard CDI 12V 150W 1151292.1 42.51108 481121.9 37/94 15138.1 133.5/339.1 8/6.7/30.3 87 Octane Min. Parallel Link Trailing Arm IFS Standard Mechanical Disc Rear 01 Seat Top 01 Hood Standard N/A N/A Oil/Ace
2 Mikuni
VM34SS Slide Standard CDI 12V200W 106.251269.9 43.51110.5 44/ 111.8 38196.5 15/38.1 121/307.3 10.7/8.9/40.5
Ignition
Alternator Output Length (in.lcm.) Width (in1cm.) Height (in1cm.) Ski Stance (in.icm.) Track Width (in1cm.) Track Length Overall (in.icm.) Fuel Capacity (U.S. gas l imp. gal./liters)
37194
15/38.1 121/307.3 816.7/30.3 87 Octane Min. Parallel Link Trailing Arm IFS Standard
37194
15/38.1 121/307.3 8/6.7/30.3 87 Octane Min. Parallel Link
Recommended Fuel
Front Suspension Rear Suspension
Brake Type Storage
87 Octane Min.
Trailing Arm IFS

Standard
Parallel Link Trailing Arm IFS

Standard
Mechanical Disc Rear of Seat

Topol Hood

Topol Hood Standard N/A NlA Oil/Ace
Hydraulic Disc Rear of Seat Toolbox Footrest

Standard Option Option OiliBrake Ace High Beam
Speedometer Tachometer
Electric Fuel Gauge Aceessory Lights
Standard
N/A N/A N/A
Electric Start
Option OptiOn/Option Standard Lite Option Option
Standard
Single HeaUStd Standard Lite Option
Option Single Heat/Std 2 Up Lite Standard
Option
Single HeaUStd Standard Option
HandwarmersfThumbwarmer
Seat Storage Rack
Tow Hitch
Option
Standard
Option
1.5
111 95
Indy TranSport
0960143 Engine Type
Super Sport
0960743 Fan Twin EC44-3PM02 432 67.72 x 60
Indy
Indy Sport Touring

0960243 Fan Twin EC44-3PMOI 432 67.72 x 60
Indy 440 LC
0962760
Fan Twin
EC44-3PMOI 432 67.72 x 60
LC Twin
EC45PL09 432 67.72 x 60
Engine Model Number Displacement (cc)

Bore x Stroke (mm) CarburetionfThrottie Body Oil Injected
2 Mikuni
VM34SS Slide Standard COl 12V 200W I I 3/287 43.51110.5 45/114.3 38/96.5 15/38. I 141/358. I 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS Standard
2 Mikuni VM34SS Slide Standard

COl 12V200W 106.251269.9 45.5/115.6 38.5/97.8 411104.14 15/38. I 121/307.3 10.7/8 .9/40.5
2 Mikunl VM34SS Slide

Standard COl 12V 200W 1131287 43.51110.5 50/127 38/96.5 15138. I 133.5/339. I 10.7/8.9/40.5 87 Octane Min.
2 Mikuni
VM34SS Slide Standard COl 12V 200W 1081274.3 46.5/118. I 46/1 18.1 41 1104.14 15/38. I 121 /307.3 10.7/8.9/40.5 87 Octane Min. Parallel Link
Ignition
Alternator Output Length (in.lcm.) Width (inJcm.) Height (in.lcm.) Ski Stance (in.lcm.) Track Width (i nJcm.) Track Length Overall (in.lcm.) Fuel Capacity (U.S. gas.llmp. gal.llite",) Recommendec Fuel
88 Octane Min.
Parallel Link Trailing Arm IFS XTRA 10
Front Suspension
Parallel Link
Trailing Arrn IFS XTRA 10 Hydraulic Disc
Trailing Arm IFS

XTRA 10 Hydraulic Disc Rear of Seat
Rear Suspension
Brake Type Storage
Hydraulic Disc
Rear of Seat Toolbox Footrest
Standard Option Option OiVBrake Acc High Beam Option Single HeaVAce 2 Up
Hydraulic Disc
Rear 01 Seat Toolbox Footrest

Standard Standard Option OiVBrake

Standard Option Option Oil/Brake Ace High Beam
Toolbox
Standard
Standard Option OiVBrake Temp High Beam
Electric Fuel Gauge
Accessory lights
Ace
High Beam Option Single HeaVStd Standard
Electric Start
Option
Single HeaVAcc 2 Up
Option
Hi-Lo/Std Short
Seat Storage Rack Tow Hitch
Option
Option
Option
Option
Option
Option
Option Option
11/95
1.6

Indy 440 XCR
0961660 Engine Type Engine Model Number Displacement (ee) Bore x Stroke (mm) CarburetlonfThrottJe Body Oil Injected Ignition LCTwln EC45PL07 439 68.25 x 60
Indy 440XCRSP
0961760
LCTwin EC45PL08
Indy Trail
0962761 Fan Twin EC50PM04 488 72 x 60
Indy Trail Touring

0962262 Fan Twin EC50PME04 488 72 x 60
439 68.25 x 60
2 Mikuni
2 Mikuni VM34SS Slide

Standard COl 12V200W
1091276 .8
VM34SS Slide Standard COl 12V200W

109/276.8 46.5/11 8.1

COl 12V 200W
114/289 .5
2 Mikuni
VM34SS Slide Standard COl 12V 200W 1221309.8
46.5/118/1
Alternator Output
Length (in.lcm.) Width (inJcm.) Height (in.lcm.) Ski Stance (in.lcm.) Track Width (inJcm.) Track Length Overall (inJcm.) Fuel Capacity (U.S. gas.llmp. gal.niters) Recommended Fuel
46.51118.1 38.5197.8 41/104.14

15/38.1 121/307.3 9.5/8 .9/40.5
46.51118.1
46/116.8 41 /1 04 .14
TBA
41 / 104.1 4 15/38.1
481121 .9 41/104.14 15/38.1

133.5/339.1 10.7/8.9/40.5
15/38.1
121/307.3 10.718.9/40.5
121/307.3
9.5/8.9/40.5
91 Octane Min. CRC XTRA 10 liquid Cooled
91 Octane Min. CRC XTRA 10 TBA

Rear of Seat
87 Octane Min.
Parallel Link Trailing Arm IFS XTRA 10 Hydraulic Disc
87 Octane Min. Parallel Link Trailing Arm IFS XTRA10
Front Suspension
Rear Suspension
Brake Type
Hydraulic Disc
Rear of Seat Toolbox
Standard Option Option
Hydraulic Disc
Storage Speedometer Rear of Seat
Standard Standard N/A
Rear of Seat Toolbox Standard

Standard Option
Option Standard N/A OiVBrake Temp/Ace High Beam Option Hi-Lo/Std 2 pc I Knee Pad
Tachometer
Electric Fuel Gauge
Accessory Lights
OiV8rake Temp/Acc High Beam Option

Hi-Lo/Std 2 pc I Knee Pad
OiVBrake High Beam

Option Hi-Lo/Std Long Option Option
OiV8rake High Beam

Standard Hi-Lo/Std 2 Up Option Option
Electric Start
Option
Option
Option
Option
1.7
11/95
Indy Classic
0963865 Engine Type LC Twin EC50PLE11 488 72 x 60 2 Mlkuni VM38SS Slide Standard COl 12V 200W
108/121.9 48/121.9 49.51125.7 42.5/107.9 15/38.1 121/307.3 10.7/8.9/40.5
Indy Classic Touring

0963365 LC Twin EC50PL14 488 72 x60
Indy 500
0962764 LC Twin EC50PL11 488 72x60
Indy 500 SKS
Indy 500 RMK

0962564 0962964 LCTwin EC50PL 11 EC50PL 15 RMK 488 72 x 60
Engine Model Number

Displacement (ee) Bore x Stroke (mm)
CarburetionfThrottle Body
Oil Injected
2 Mikuni
VM34SS Slide Standard COl 12V 200W
115/292.1 481121.9 51.5/130.8 42.5/107.9 15/38.1 133.5/339.1 10.7/8.9/40.5
2 Mikuni
VM38SS Slide
2 Mikuni
VM38SS Slide
Standard
COl 12V 200W
1081274.3 46.5/118.1 46/116.8
Standard
COl 12V200W
108/274.3 46.5/118.1 48/121.9 41/104.14 15/38.1 133.5/339.1 10.7/8.9/40.5
Ignition Alternator Output

Length (in.tern.) Width (in.tem.) Height (in.tem.) Ski Stance (in.tem.) Track Width (in.tem.) Track Length Overall (in.tem.) Fuel Capacity (U.S. gas.tlmp. gal.lliters)
41/104.14
15/38.1 121/307.3 10.7/8.9/40.5
Recommended Fuel Frant Suspension Rear Suspension

Brake Type
87 Octane Min. IFS XTRA12
87 Octane Min.
Parallel Link Trailing Arm IFS XTRA12
87 Octane Min.
Parallel Link
87 Octane Min.
Parallel Link
Trailing Arm IFS XTRA 10
Trailing Arm IFS

XTRA 10
Hydraulic Disc
Standard Standard
Hydraulic Disc
Standard Standard Standard Oil/Brake
Hydraulic Disc Rear of Seat Toolbox

Standard Standard Option
Hydraulic Disc
HD Pads RMK
Storage Speedometer Tachometer

Electric Fuel Gauge

Standard
Standard
Option Oil/Brake Temp High Beam
Standard
OillBrake Temp High Beam Standard HI-Lo/Std Long
Accessory Lights
OiVBrake
Temp High Beam
Temp
High Beam
Electric Start
Standard
HI-Lo/Std 2 UplTour
Option
Hi-La/Std Short
Option
Hi-Lo/Std Long Option Option
Seat
Storage Rack
Tow Hitch
Option Option
Option
Option
Option
Option
11/95
1_8

Indy 500 EFI
0963774
Indy 500 EFI SKS Indy 500 EFI RMK

0962574 0962974 LCTwin EC50PL 13 488 72 x 60 2 Throttle Body
Indy WideTrakLX
0962064
Indy WideTrakGT
0962061
Engine Type Engine Model Number

Displacement (ce)
LC Twin EC50Pl13 488 72 x60 2 Throttle Bocy 46mm Standard COl 12V 250W 108/274.3 48/1 21.9 49.5/125.7 42.5/107.9 15/38.1 1211307.3 10.7/8.9/40.5
LC Twin EC50PLE12
488 72 x 60
Fan Twin EC50PM03

488 72 x 60
Bore x Stroke (mm)
Oil Injected
46 mm
Standard
COl 12V 250W 108/274.3 46.5/1 18.1 48/121.9 41/104.1 4 15/38.1 133.6/339.1 10.7/8.9/40.5

CO l 12V200W 128/325.1 43.5/110.5 49/124.5 38/96.5 20/50.8 156/396.2 10/8.3/38

COl 12V 200W 121 .5/308.6 43.5/ 110.5 49/ 124.5 38/96.5 20/50.8 141 /358.1 10/8.3137.8
Ignition
Alternator Output Length (in.lcm.) Wid1h (i n.lcm.) Height (in.lcm.) Ski Stance (in.lcm.) Track Wid1h (in.lcm.) Track Length Overall (in.lcm) Fuel Capacity (U.S. gas.llmp. gal.lllters)
Recommended Fuel
87 Octane Min.
87 Octane Min.
87 Octane Min.
Parallel Link Trailing Arm IFS Standard
88 Octane Min.
Front Suspension
Rear Suspension
Brake Type

Standard
Hydraulic Disc Rear of Seat Toolbox Standard

Standard Option
Hydraulic Disc HD Pads RMK Rear of Seat Toolbox

Standard
Standard
Mechanical Under Seat Storage Rack

Standard
Mechanical
Under Seat Standard Option N/A Rev/Ace Oil High Beam Option Single HeaVStd 2 Up w/Riser Standard Standard
Storage Speedometer
Tachometer
Electric Fuel Gauge
Standard
N/A
Option
Oil/BrakefTemp Batt High Beam
Accessory Lights
Oil/BrakefTemp Batt High Beam

Option Hi-Lo/Std Long
Oilffemp Rev High Beam

Standard Single HeaVStd 2 Up w/ Rlser Standard Standard
Electric Start
Option
Hi-Lo/Std Short
Option
Option
Option Option
1.9
11/95

Indy XLT
0966756
Engine Type Engine Model Number Displacement (ce) Bore x Stroke (mm) Carburetionffhrottle Body Oil Injected LC Triple EC58PL03 597 65 x 60 3 Mlkunl VM34SS Standard COl 12V 170W
Indy XLT SP
0966676
LC Triple EC58PL02 597 65 x 60
Indy XLTSKS
0960556
LC Triple EC58PL03 597 65 x 60
Indy XLT RMK

0960956
LCTripie EC58PL07 597 65 x 60
3 Mikuni VM38SS
Standard COl 12V 170W 106.25/269.9

Standard COl 12V170W

Standard COl 12V 170W 1131287
Ignition
Alternator Output Length (inJcm.) Width (in.lcm.) Height (inJcm.) Ski Stance (in.lcm.) Track Width (in.lcm.)
1081274 .3
48/121.9 48.5/123. I
1131287
46.51118.1 44/1 11.8 41/104.14 15138.1 133.5/339. I
481121.9
48.5'1 23. I
43.5/110A
44/1 I 1.8 38/96.5 15138. I 133.51339.1
42 .5/1 07.9
15138.1 1211307.3 10.7/8.9/40.5 88 Octane Min. 42.51FS XTRA12
42.5/107.9
15138.1 1211307.3 10.7/8.9/40.5 91 Octane Min.
Track Length Overall (inJcm.)

Fuel Capacity (U.S. gas.llmp. gal.iliters)
10.7/8.9/40.5
88 Octane Min. Parallel Link Trailing Arm IFS
XTRA10
10.7/8.9/40.5
87 Octane Min.
Recommended Fuel Front Suspension
Non-Parallel Link Trailing Arm IFS

XTRA12

XTRA 10
Rear Suspension
Brake Type Storage

Standard Standard Option Oil/Brake Temp/Ace High Beam

Standard Standard Option Oil/Brake Temp/Acc High Beam Option HI-Lo/Std Long
Hydraulic Disc


Standard Standard Option OiVBrake Temp/Acc High Beam Option HI-Lo/Std Long Option Option
Electric Fuel Gauge Aceessory Lights
Electric Start
Handwarrne~humbwarrner
Option
Hi-Lo/Std Standard Option Option
Option
Hi-Lo/Std Long Option Option
Seat Storage Rack
Option Option
Tow Hitch
11/95
1.10
GENERAL INFORMATION
1996 Model Identification
Indy XLTTourlng
0963357 Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected LCTripie EC58PLE05 597 65 x 60 3 Mikuni VM34SS Slide Standard COl 12V 200W 115/292.1 48/1 21.9 51.5/130.8
Indy 600 XCR

0961676 LC Triple EC56PL02 597 65 x 60
Indy 600XCR SP
0965677 LCTripie EC59PL01 598 62.5 x 65
Indy RXL
0966768 LC Triple EC65PL05 648 67.72 x 60 3 Throttle Body
3 Mikuni
VM38ALSiide Standard COl 12V 170W
3 Mikuni
VM38AL Slide Standard Digital COl 12V200W
46mm
Standard
COl 12V 180W 106.25/269.9
Ignition
Alternator Output Length (in.lcm.) Width (inJcm.) Height (In.lcm.) Ski Stance (in .lcm.) Track Width (inJcm.) Track Length Overall (InJcm.) Fuel Capacity (U.S. gas.llmp. gal./liters)
109/276.8
46/116.8 38.5/97.7 41 / 104.1 4 15/38.1 121/307.3 9.5/8.9/40.5
1091276.8
46/116.8 44/11 1.7 41/104.1 4 15/38.1 121/307.3 10.7/8.9/40.5 91 Octane Min. Parallel link Trailing Anm IFS XTRA 10 liquid Cooled Hydraulic Disc
481121.9
48.5/123.1 42.5/107.9 15/38.1 121/307.3 10.7/8.9/40.5
42.5/ 107.9
15/38.1 133.5/339.1 10.7/8.9/40.5 87 Octane Min. Parallel link Trailing Arm IFS XTRA 12
Recommended Fuel Front Suspension Rear Suspension

Brake Type
91 Octane Min. Parallel Link

Trailing Anm IFS XTRA 10 liquid Cooled
87 Octane Min. NonParallel Link

Trailing Arm IFS XTRA 12 liquid Cooled
Hydraulic Disc Rear of Seat

Toolbox Under Hood Standard Standard Standard Oil/Brake Temp High Beam Standard HI-Lo/Std 2 Up Touring Option Option
Hydraulic Disc Storage Speedometer Rear of Seat

Standard Standard NlA OiVBrake Temp/Acc High Beam Option HI-La/SId 2 pc Knee Pad Option Option

Standard Standard Standard OiVBrake Temp/Acc High Beam Option
Rear of
Se~t
Toolbox Standard Standard
Tachometer
Electric Fuel Gauge Accessory lights
Option
Oil/Brake Temp/Ace High Beam N/A Hi-Lo/Std Mid, 1 pc, 121 N/A Option
Electric Start
HandwarmersIThumbwarmer
HiLo/Option
Long Option Option
Seat
Storage Rack Tow Hitch
1-11
11/95

Indy Ultra SP
0960678 Engine Type
Indy Ultra SKS

0960578 LC Triple EC68PLOl 679 66.6 x 65
Indy Ultra RMK

0960978 LC Triple EC68PL04 679 66.6 x 65
Indy Storm
0965782 LC Triple EC80PL05 794 72 x65
Engine Model Number

Displacement (ce)
LCTripie EC68PLOl 679 66.6 x 65
Bore x Stroke (mm)

CarburetionfTh ronle Body Oil Injected Ignition Mernator Output Length (inJcm.) Width (inJcm.) Height (in.lcm.) Ski Stance (in.lcm.) Track Width (inJcm.) Track Length Overall (in.lcm) Fuel Capacity (U.S. gas.llmp. gal.lltters)
3 Mikuni
VM38 Slide Standard Digital COl 12V200W 1081274.3 46.51118.1 38.5197.7 41/104.14 15138.1 121 1 307.3 10.718.9140.5
87 Octane Min.
3 Mikuni
VM38 Slide Standard DigttalCDI 12V200W 114/289.5 41/104.14 461116.8 411104.14 15138.1 133.51339.1 10.718.9140.5 87 Octane Min. Parallel Link XTRA1 0
3 Mikuni
VM38 Slide Standard Digital COl 12V 200W 1141289.5 43.51110.4 461116.8 38196.5 15138.1 133.51339.1 10.718.9140.5
3 Mikuni
VM38SS Sl ide Standard Digital COl 12V 200W 1081274.3 46.51118.1 441111.7 41/104.14 15138.1 1211 307.3 10.718.91 40.5

Srake Type
87 Octane Min.
Parallel Link XTRA 10 Liquid Cooled Hydraulic Disc
91 Octane Min.
4 1" IFS XTRA 10 HP Liquid Cooled
Parallel Link XTRA 10 Liquid Cooled
Hydraulic Rear of Seat Toolbox Footrest

Standard Standard Option Oil/Brake TemplAce High Beam NlA Hi-La/Std Long
Hydraulic Disc
Storage Speedometer Tachometer
Electric Fuel Gauge
Hydraulic Disc
Rear of Seat
Toolbox Standard

Standard Standard
Rear of Seat
Toolbox Footrest Standard Standard Option Oil/Brake TempiAce High Beam NIA Hi-La/Std Long
Standard
Option Oil/Brake TempiAcc High Seam NIA Hi-LolStd Hi-La Sculpt, Mid 121 NIA
Optian
Oil/Brake TemplAcc High Seam NlA Hi-Lol Std Standard
Accessory LIghts
Electric Start
Handwarrne~humbwanner
Seat
Storage Rack
Tow Hitch
Option
Option
Option
Option
Option Option
Option
11/95
1.12
Indy Storm SKS

0965582
Indy Storm RMK

0965982 LC Triple EC80PL04 794 72 x 65

Displacement (cc) Bore x Stroke (mm) CarouretionlThrottle Body Oil Injected
LC Triple ECSOPL05 794 72 x65
3 Mikuni
VM38SS Slide
3 Mikuni
VM38SS Slide Standard Digital COl 12V 200W 114/289.5 46.5/118.1 44/111.8 38/96.5 15/38.1 133.5/339.1 10.7/8.9/40.5 91 Octane Min. 38" IFS XTRA 10 Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard
Standard
Dig"al CDI 12V200W 1141289.5 46.5/118.1 44/111.8 41 /104.14 15/38.1 133.5/339.1 10.7/8.9/40.5 91 Octane Min. 41" IFS XTRA 10HP Liquid Cooled Hydraulic Disc
Ignition
Alternator Output Length (inlcm.) Width (in.lcm.) Height (in.lcm.) Ski Stance (In.lcm.) Track Width (inlcm.) Track Length Overall (inlcm.) Fuel Capacity (U.S. gasllmp. gal.ll"ers)

Brake Type
Storage Speedometer Tachometer Electric Fuel Gauge

Accessory Lights

Standard Standard
Option
OiVBrake Temp/Ace High Beam N/A Hi-Lo/Std HI-Lo Sculpt, Mid, 133 N/A Option
Option
OiVBrake Temp/Ace
High Beam
N/A Hi-Lo/Std Hi-Lo Sculpt, Mid, 133 N/A
Electric Start
HandwarmersIThumbwarmer
Seat
Storage Rack
Tow Hitch
Option
1.13
11/95

The machine serial number may be used as an aid in identifying machine model year. Refer to the first digits in the serial number for proper identification: F[RST D[G[TS MODEL YEAR 31 1997
1997 MODEL DESIGNATION

YEAR DES[GNAT[ON- - - - - - - - - , MODEL DES[GNAT[ON
O~
ENG[NE DES[GNAT[ON
1997 MODEL DES[GNAT[ON N UMBERS (Chassis) 01 - Indy TranSport 02 - Indy Sport Touring 04 - Indy Sport 05 - Indy XLT SKS, 700 SKS 06 - Indy Ultra SP 07 - Indy Super Sport, XLT, 09 - Indy Trai[ RMK, XLT RMK, 700 RMK 16 - Indy XCF, 440 XCR 17 - Indy 440 XC, 600 XC 20 -Indy WideTrak GT/LX 22 - Indy Trai[ Touring 25 - Indy 500 SKS 27 - Indy 440, Trail, 500 29 - Indy 500 RMK 31 - Indy Lite GT 33 - Indy Classic Touring, XLT Touring 34 - Indy Lite, Lite De[uxe 37 - Indy 500 EFI, XLT LTD 38 - Indy Classic 53 - Ultra Touring 56 - Indy 600 XCR, 600 XCR SE 57 - Indy Storm, Storm SE 59 - Indy Storm RMK 66 -Indy XLT SP 67 - Indy RXL, Ultra
1997 ENG[NE DES[GNAT[ON NUMBERS 31 - EC34-2PME02 33 - EC34-2PM02 43 - EC44-3PM02 56 - EC58PL03, PL05, PL07 57 - EC58PL09 60 - EC45PL08, PL09 61 - EC50PM03, PM04, PMOS, PM06 64 - EC50PL 16, PL 17 65 - EC50PL 19, PL20 66 - SN70LCDCSP-Ol, SP-02 68 - EC65PL05 73 - EC50PL 18 76 - EC58PL08, PL 12 77 - EC59PL01 78 - EC68PL01, PL03 82 - EC80PL04, PL05
MODEL NO .
V.I.N.NO.
MADE IN U.S.A.
PDLRRIS
PATENT NOTICE
THIS VEHICLE CONFORMS TO ALL APPUC.ABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANAOA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE, MFD. DATE:
Mfd. b:t Polaris Industtlas Inc .. In Roseau, MN under one or more of the following patents: Palented Canada U.S. Patents 882,491nl 3,605,511 3,613,810 5,050,559 883,694171 5,048,603 3,5S0.647 3,867,991 864,394(71 5,056,482 3,483,766 4,793,950 Canadian Rd. 5,038,881 3,533,662 5,099,813 34,573/71 3,545,821 5,014,271 5,172,675 34,572171 5,191,531 5,090,386 3,605,510 1,227,823187 3,613,811 3,525,412 5,050,564
70721 33
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).
9/96
1.13a

Indy Lite
0973433
Indy Lite Deluxe

0973431
Indy Lite GT
0973133
Indy Sport
0970443
Engine Type Engine Model Number Displacement (ee) Bore x Stroke (mrn) CarburetionfThrottle Body
Oil Injected
Fan Twin
EC34-2PM02 339 62 .3 x 55.6
Fan Twin
EC34-2PM02 339 62.3 x 55.6
Fan Twin EC34-2PM02

339 62.3 x 55.6
Fan Twin
EC44-3PM01 432 67.72 x 60
2 Mikuni
VM30SS Slide
2 Mikuni
VM30SSSiide
2 Mikuni
VM30SS Slide
2 Mikuni
VM34SS Slide
Standard
CDI 12V 150W 1051266.7 42.51108 44/111.8 37/94 15/38.1 121/307.3 8/6.7130.3
Standard
CDI 12V 150W 105/266.7 42.5/108 44/111.8 37194 15/38.1 121/307.3 8/6.7130 .3
Standard
CDI 12V 150W 1151292.1 42.5/ 108 481121.9 37/94 15138.1 133.5/339.1
Standard
CDI 12V 200W 1081274.3 43.51110.5 44/111.8 38196.5 15/38.1 1211307.3 10.718.9/40.5
87 Octane

Length (in.!cm.) Width (in./cm.) Height (in./cm.)
Ski Center Distance (in./cm.)

Track Width (in.!cm.)
Track Length Overall (in.lcm.)

Fuel Capacity (U.S. gas'/Imp. gal.lliters)
81 6.7130.3
87 Octane Non-Oxygenated or a9 Octane Oxygenated
Recommended Fuel
87 Octane
Non~Oxygenated
or 89 Octane Oxygenated Front Suspension Parallel Link Trailing Arm IFS

X-Lite
87 Octane Non-Oxygenated or 89 Octane Oxygenated

Parallel Link Trai li ng Arm IFS
Xd-Lite
Non-Oxygenated or 89 Octane Oxygenated
Parallel Link Trailing Arm IFS X-Ute Hydraulic Disc Rear of Seat Toolbox Footrest
Standard Option
Rear Suspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights
Standard Mechanical Disc Rear of Seat

Top 01 Hood Standard NI A N/ A

Top of Hood

Top of Hood Standard NIA NIA
Standard
N/A N/A NIA
Option Oil/Brake
Acc
Oil/Ace
Oil/Ace
High Beam Electric Start HandwarmersfThumbwarmer

Seat
Option Option/Option Standard Lite Option Option
Standard
Single HeaVStd
Option
Single HeaVStd 2 Up Lite
Option
Single HeaVStd
Standard Lite Option

Option
Standard Standard
1. 13b
9/96
Indy TranSport
0970143
Indy Super Sport

0970761
Indy Sport Touring

0970243
Indy 440 LC
0972760
..-'

Displacement (cc) Bore x Stroke (mm)
Fan Twin EC44-3PM02

432 67.72 x 60
Fan Twin EC50PM06

488 72 x 60
Fan Twin EC44-3PM02

432 67.72 x 60 2 Mikuni VM34SS Slide
LC Twin EC45PL09
432 67.72 x 60
Oil Injected

CDI 12V 200W 117/297.2 43.5/110.5 48/121.9 38/96.5 15/38.1 1411358.1 10.7/8.9140.5 87 Octane Non-Oxygenated or 89 Octane Oxygenated

Standard CDI 12V 200W 108/274.3 46.5/118.1 38.5/97.8 41 / 104.14 15/38.1 1211307.3 10.7/8.9140.5 87 Octane Non-Oxygenated or 89 Octane Oxygenated Parallel Link Trailing Arm IFS XTRA 10
2 Mlkuni VM34SS Slide Standard

CDI 12V 200W 2P 108/274.3 46.5/118.1 47.5/120.7 41/104.14 15/38.1 121/307.3 10.7/8.9140.5
Standard
CDI 12V 200W 117/297.2 43.5/110.5 48/121.9 38/96.5 15/38.1 133.51339.1 10.718.9140.5 87 Octane NonOxygenated or 89 Octane Oxygenated

Length (in./cm.) Width (in./cm.) Height (in./cm.)
Ski Center Distance (inJcm.)

Track Width (in./cm.) Track Lenglh Overall (infcm.) Fuel Capacity (U.S. gas'/Imp. gal.nlters)
Recommended Fuel
87 Octane Non-Oxygenated or 89 Octane Oxygenaled

IFS XTRA10

Brake Type Slorage
ParaUelUnk Trailing Arm IFS

Standard

XTRA10

Slandard

Slandard Standard
Hydraulic Disc
Slandard
Hydraulic Disc Rear of Seat Toolbox Under Hood

Slandard
Speedometer Tachometer Electric Fuel Gauge Accessory Lights
Option
Option Oil/Brake Acc High Beam
Option
Oplion Oil/Brake Acc High Beam Option Single HeaVAcc 2 Up Option Option
Standard Option OiVBrake Temp High Beam Option

Hi-LolStd Short
Option
OiVBrake Acc High Beam Option Single HeaVStd
Electric Start HandwarmersiThumbwarmer

Seat Slorage Rack Tow Hitch
Option
Single HeaVStd 2 Up
Option
Std
Option Option
9/96
1.13c

Indy XCF
0971643 Engine Type Engine Model Number Displacement (ee)
Bore x Stroke (mm) Fan Twin EC44-CPM02
Indy 440 XC
0971760
LCTwin
Indy Trail
0972761
Fan Twin EC50PM04
Indy Trail Touring

0972262
Fan Twin EC50PME04
EC45PL08 438 68.19x60

2 Mikuni
432 67.72x60
2 Mikunl VM34SS Slide
488 72 x 60
2 Mikunl
488 72 x 60
Carburetion/Throttle Body Oil Injected Ignition Alternator Output Length (in./cm.) Width (in./cm.) Height (in./cm.)
Ski Center Distance (in.lcm.)
VM34SS Slide
Standard
VM34SS Slide
Standard
Standard CDI 12V 200W 1081274.3

46.5/118.1
Standard CDI 12V 200W 2P 1141289.6

46.5/118/1 48/1 21.9
CDI 12V 200W 2P 1081274.3

46.5/1 18.1 38.5/97.8 41 /1 04.14
CDI 12V 200W 2P 1081274.3 46.51118.1

47.5/120.7 41 /1 04.14 15/38.1
38.5/97.8 411104.1 15138.1 12t1307.3 9.518.9140.5 870dane Non-Oxygenated or 89 Octane Oxygenated CRC XTRA 10 Vented Hydraulic Disc
4111 04.14
15/38.1
Track Width (in.lcm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gas'/Imp. gaUliters)
Recommended Fuel
15138.1
1211307.3
1211307.3
10.7/8.9140.5
133.51339.1 10.71 40.5 8.91 87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA 10
Hydraulic Disc
9.518.9140.5
87 Octane
87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA 10 Hydraulic Disc
Frant Suspension Rear Suspension Brake Type
CRC XTRA 10
Liquid CooledHydraulic Disc Rearaf Seat
Storage
Rear Seat
Rear of Seat Toolbox Under Hood

Standard
Rear of Seat Toolbox Under Hood Standard Option Option
Standard Standard
Option
Standard Standard NIA OillBrake Temp/Ace High Beam

Option
Standard
Option
OiliBrake Acc High Beam

Option
Oill Brake High Beam

Option
Oil/Brake High Beam

Standard
Electric Start HandwarmersfThumbwarmer
Single HeaVStd 2 Pc Option

Option
Hi-La/Std 2 pc I Knee Pad

Option
Hi-LalStd Long Option

Option
Hi-LalStd 2 Up
Option
Seat
Storage Rack Tow Hiteh
Option
Option
Polaris Industries inc.
1.13d
9/96

Indy Trail RMK
0970961 Engine Type Engine Model Number
Indy Classic
0973865 LCTwin EC50PL17 488 72 x 60

0973365 LCTwin EC50PL19 488 72 x 60
Indy 500
0972764
LCTwin EC50PL17
Fan Twin EC50PM05

488 72x60 2Mikuni/ACCS VM34SS Slide Standard COl 12V 200W 2P 114/289.6
43.5/110.5 461116.8
Displacement (ee)
Bore x Stroke (mm)
488 72 x 60
Carbu retionffhrottle Body

Oil Injected
2 Mikuni VM38SSSiide
Standard COl 12V200W2P 108/121.9
48/121.9

Standard COl 12V 200W 2P 11 5/292.1 48/121.9
51.5/130.8 42.5/107.9 15/38.1

Standard COl 12V 200W 2P 108/274.3
46.5/118.1
Ignition
Alternator Output
Length (inlcm.) Width (in.lcm.) Height (in.lcm.)
49.5/125.7
42.5/107.9 15/38.1
411104.14
41/104.14 15/38.1
Ski Center Distance (in.lcm. )

Track Width (inJcm.)
38/96.5
15/38.1

Fuel Capacity (U.S. ga,Jlmp. gaUliters)
133.5/339.1
10.7/8.9/40.5
1211307.3
10.7/8.9/40.5
133.5/339.1
10.7/8.9/40.5
87 Octane
1211307.3
10.7/8 .9/40.5
87 Octane
Recommended Fuel
87 Octane

IFS XTRA12
Non-Oxygenated or a9 Octane Oxygenated

IFS XTRA 10
Front Suspension

XTRA 10
IFS XTRA1 2
Rear Suspension
Brake Type
Hydraulic Disc
Hydraulic Disc Rear of Seat Toolbox Standard Standard

Standard Oil/Brake Temp High Beam Standard Hi-Lo/Std Long
Hydraulic Disc
Rear of Seat Toolbox Standard
Hydraulic Disc Rear of Seat Toolbox Standard Standard Option OilJBrake Temp High Beam Option
Hi-La/Std Shart Option
Storage Speedometer Tachometer Electric Fuel Gauge Accessory Ughts
Rear Seat/Toolbox
Standard Standard
Standard
Standard Oil/Brake Temp High Beam
Option
Oil/Brake Ace High Beam
Electric Start HandwarmerslThumbwarmer Seat Storage Rack Tow Hitch
Option
Single HeaVStd Long/RMK
Standard
Hi-Lo/Std 2 UplTour Option
Option Option
Option Option
Option
Option
91 96
1.13e

Indy 500 SKS Indy 500 RMK
0972564 0972964
Indy 500 EFI

0973774 LCTwin EC50PL 18 488 72 x60 2 Th rotlle Body 46mm
Indy WideTrak LX
0972065
Indy WideTrakGT
0972061
Engine Type Engine Model Number Displacement (ee)

Bore x Stroke (mm)
LC Twin
EC50PL 17 EC50PL 16 RMK 488 72 x 60
LCTwin EC50PLE12
488 72 x 60
Fan Twin EC50PM03

488 72 x 60
2 Mikuni
VM38SSSIIde 2 Mikuni/ACCS/RMK VM34SS Slide/ RMK
2 Mikuni
VM34SS Slide
2 Mikuni
VM34SS Slide
Oil Injected
Standard CDI 12V 200W 2P 114/289.6 46.5/1 18.1 43.5/ 110.5/RMK 481121.9 38/96.5 15/38.1 133.5/339.1 10.7/B.9/40.5
87 Octane Non-Oxygenated
Standard CDI 130 AC/ 125 DC 2P 108/274 .3 48/121 .9 49.5/ 125.7 42.5/ 107.9 15/38. 1 121 /307.3 10.7/8.9/40.5
Standard CDI 12V 200W 1281325.1 43.5/ 110.5 49/1 24.5 38/96.5 20/50.8 156/396.2 10/8.3/38 87 Octane NonOxygenated
Standard
CDI 12V 200W 122/309.9 43.5/110.5 49/124.5 38/96 .5 20/50.8 141 /35B.l 10/8.3/37.8 87 Octane Non-Oxygenated
or89 Octane Oxygenated
Ignition
Alternator Output
Length (i n.fcm.) Width (in.lcm.) Height (in.lcm.)
Ski Center Distance (in./ern .)

Track Width (in.lcm.)
Track Length Overall (i n.fern)

Fuel Capacity (U.S. gas.llmp. gal./liters)
Recommended Fuel
87 Octane
Non-Oxygenated
or 89 Octane
Oxygenated
or 89 Octane
Oxygenated IFS XTAA12
or 89 Octane
Oxygenated

Brake Type
IFS XTAA 10
Parallel Link
Trailing Arm IFS
Parallel Link
Trailing Arm IFS
WideTrak Single
Slide Aail
Wide Trak Single Slide Rail

Mechanical Under Seat
Hydraulic Disc
HD Pads AMK
Hydraulic Disc
Mechanical Under Seat

Standard
Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights
Rear of Seat
Toolbox Standard
Standard
Standard
Standard Option
N/A Aev/Acc Oil
Standard Option
Oil/Brake
Standard
N/A Oi liTemp Aev High Beam
Option
Oil/BrakeiTemp Batl High Beam
Temp High 8eam Electric Start HandwarmersfThumbwarmer Seat Storage Rack

Tow Hitch
High Beam Option

Single HeaVStd 2 Up w/Aiser
Option
Hi-La/SId Long
Option
Hi-Lo/Std Long
Standard
Single HeaVStd
2 Up w/Riser Standard Standard
Option Option
Option Option
Standard Standard
1_ 13f
9/96
Indy XLT
0976756 Engine Type
Indy XLTSP
0976676 LC Triple EC58PL12 597 65 x 60
Indy XLT SKS

0970556 LC Triple EC58PL03 597 65 x 60 3 Mlkuni VM34SSSIIde Standard COl 12V 170W 114/289.6 46.5/118. I 46/116.8 41/104.14 15/38. I 133.5/339. I 10.7/8.9/40.5 87 Octane NonOxygenated
Indy XLT RMK

0970956 LC Triple EC58PL07 597 65 x 60
Engine Model Number Displacement (eel

Bore x Stroke (mm) CarburetionfThrottie Body
LCTripie EC58PL03 597 65 x 60 3 Mlkuni VM34SS
3 Mikuni
VM38SS
Standard
3 Mikuni
VM34SS Slide/ACCS
011 Injected
Ignition
Alternator Output
Length (Inlcm.) Width (in.lcm.) Height (in.lcm.)
Standard
COl 12V HOW
1081274 .3
Standard
COl 12V 170W 114/289.6
43.5/110.4
COl 12V 200W 108/274.3 481121.9 48.5/ 123. I 42.5/t07.9 15138. I

121/307.3
46.5/11 8.1 I 461116.8 41 11 04.14 15138.1 121 /307 .3 to.7/8.91 40.5 87 Octane
41116.8 381 96.5 15/38.1 133.5/339.1 to.7/8.9/40.5 87 Octane NonOxygenated


Fuel Capacity (U.S. gas.llmp. gail liters)
10.718.91 40.5
87 Octane
Non~Oxygenated
Recommended Fuel
Non..()xygenated or 89 Octane
Oxygenated
or 89 Octane Oxygenated Non-Parallel Link

Trailing Arm IFS XTRA12
or 89 Octane
Oxygenated Parallel Link Trailing Arm IFS XTRA 10
or 89 Octane Oxygenated
Parallel link Trailing Arm IFS
Front Suspension
42.51FS XTRA 10
Rear Suspension
Brake Type
XTRA 10
Hydraulic Disc
Hydraulic Disc
Hydraulic Disc
Hydraulic Disc

Accessory Lights

OilfBrake Temp/Acc High Beam Option Hi-LolStd Long Option Option

OilfBrake Temp/Acc

OilfBrake TemplAcc High Beam Option HI-Lo/Std
Standard
Standard
Option
OilfBrake
High Beam Electric Start HandwarmerslThumbwarmer

Seat Storage Rack Option Hi-Lo/Std Standard Option Option
Temp/Acc High Beam Option

Hi-Lo/Std
Long Option Option
Long
Option
Tow Hitch
Option
9/96
1.13g

Indy XLT Touring
0973357 Engine Type LCTriple EC58PL09 597 65 x 60 3 Mikuni VM34SS Slide Standard CO l 12V 200W 6P 115/292.1
Indy XLT LTD

0973756 LC Triple EC58PL09 597 65x60
Indy XLT LTD SP

0973776 LC Triple EC58PL1 2 597 65x60
Indy 600 XC
0971776 LC Triple EC58PL08 597 65 x 60 3 Mlkuni VM38SS Slide
Engine Model Number

Displacement (ce) Bore x Stroke (mm)
CarburetionfThrottte Body
Oil Injected
3 Mikuni
VM34CS Slide
Standard
3 Mikuni
VM38SS Standard COl 12V 200W6P 108/274.3
Standard
COl 12V 170W 6P 108/274.3
Ignition
COl 12V200W6P 108/274.3
Alternator Output
Length (inJcm.) Width (in.!cm.) Height (in.!cm.)
481121.9
51.5/ 130.8 42.51107.9 15/38. I 133.5/339.1 10.7/8.9/40.5
481121.9
49.5/125.7
481121.9 49 .51125.7
42.51108 15/38.1 1211307.3 10.7/8.9/40.5
87 Octane
46.51118.11
38.5/97.7 411104.14 15/38.1 1211307.3 9.5/8.9/40.5 87 Octane Non-Oxygenated

--
42.511 08
15/38.1 1211307.3 10.7/8.9/40.5
Track Length Overall

(in.!cm.) Fuel Capacity (U.S. gas.!lmp. gal./liters) Recommended Fuel
87 Octane
Non-Oxygenated
IFS XTRA12

IFS XTRA12
or 89 Octane
Oxygenated CRC XTRA 10 Liquid Cooled
Front Suspension
Rear Suspension
Brake Type
IFS XTRA 12
Hydraulic Disc Rear of Seat

Toolbox Under Hood Standard Standard
Hydraulic Disc Rear SeatfToolbox

Hydraulic Disc Rear SeatfToolbox Standard Standard Option OiV8rake

Acc High Beam
Hydraulic Disc
Storage
Rear of Seat
Standard
Standard
N/A Oil/Brake Temp/Acc High Beam Option Hi-Lo/Std 2 pc Knee Pad Option Option
Standard
OiVBrake Temp High Beam Standard Hi-Lo/Std 2 Up Touring Option
Oil/Brake
Acc High Beam
Electric Start HandwarmersIThumbwarmer

Seat Storage Rack
Option
Hi-Lo/Std Long
Option
Hi-Lo/Std Long
Option
Option
Option Option
Tow Hitch
Option
1.13h
9/96
Indy 600XCR
0975677 Engine Type Engine Model Number LC Triple EC59PLOI 597 62.5 x 65
Indy 600 XCR SE

H975677 LC Triple EC59PLOI 597 62.5 x 65
Indy RXL
0976768 LC Triple EC65PL05 648 67.72 x 60 3 Throttle Body
Indy Ultra
0976778 LC Triple EC68PLOI 679 66.6 x 65 3 Mikuni VM38ALSIIde
Displacement (cc)
Bore x Stroke (mm)
3 Mikuni
VM38AL Slide
3 Mikuni VM38ALSIIde
Standard Digital COl 12V 200W 109/276.8 46.51118.11 44/1 11.7 411104.14 15/38.1 121/307.3 10.7/8.9/40.5
46mm
Standard COl 12V 180W 106.25/269.9
481121.9
Oil Injected
Standard
Digital COl 12V 200W 109/276.8 46.5/11 8.11 44/111.7
41 1104.1'. 15/38.1
Standard
Digital COl 12V 200W
1081274.3
Ignition
Alternator Output
Length (in./cm.) Width (inlcm.) Height (in./cm.)
48/ 121.9 48.51123.2 42.5/108

15/38.1
48.5/123.1 42.5/ 107.9 15/38.1

121 /307.3

Track Width (in./cm.) Track Length Overall (inJcm) Fuel Capacity (U.S. gas'/Imp. gaL/liters)
1211307.3 10.7/8.9/40.5
121/307.3 10.7/8.9/40.5
10.7/8.9/40.5 87 Octane Non-Oxygenated
Recommended Fuel
91 Octane Min,
91 Octane Min.
or 89 Octane
Oxygenated

Parallel Link IFS XTRA12
Front Suspension
Rear Suspension
Brake Type
Parallel Link IFS XTRA10
Parallel Link IFS XTRA 10
Non-Parallel Link Trailing Arm IFS

XTRA 12
Liquid Cooled Hydraulic Disc Rear of Seat Toolbox

Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Standard

Standard
Liquid Cooled Hydraulic Disc


Accessory Lights

Standard
Standard

OillBrake Temp/Ace High Beam
Option
OillBrake Temp/Acc High Beam
Standard
Oil/Brake Temp/Ace High Beam
Electric Start HandwarmerslThumbwarmer Seat Storage Rack

Tow Hitch
N/A Hi-Lo/Std Mid. I pc, 121 N/A Option
N/A Hi-Lo/Std Mid, I PC. 121 N/A
Option
Hi-Lo/Std
N/A HI-Lo/Std
Long Option Option
Option
9196
1.13i

Indy Ultra SP
0970678
Indy Ultra SPX

0975678 LC Triple EC68PL03 679 65x60
Indy Ultra SPXSE

H975678 LC Triple EC68PL03 679 65x60
Indy Ultra Tou ring

0975378 LC Triple EC68PL01 679 66.6 x 65
LC Triple EC68PL01 679 66.6 x 65
Displacement (ee) Bore x Stroke (mm) CarburetionfThrottle Body
3 Mikuni
VM38AL Slide
3 Mikunl
VM38AL Slide
3 Mikuni
VM38AL SIIde
3 Mikuni
VM38AL Slide
011 Injected
Ignition
Alternator Output
Length (in.lcm.)
Width (in1cm.) Height (in1cm.)
Standard
Digital COl 12V 200W 108/274.3 46.5/118.1 47.5/120.7 41/104.14 15/38.1 121 /307.3 10.7/8.9/40.5
Standard
Digital COl 12V 170W 1091276.9 46.5/118.1 44/111.8 41 / 104.14 15/38.1 121/307.3 10.7/8.9/40.5
Standard
Digital COl 12V 170W 109/276.9 46.51118.1 44/ 111 .8 41 / 104.1 4 15/38.1 121/307.3 10.7/8.9/40.5
Standard
Digital COl 12V 200W 115/292.1 48/121.9 47/ 119.4 42.5/ 108 15138.1 133.5/339.1 10.7/8.9/40.5
Ski Center Distance (inlcm.)


Fuel Capacity (U.S. gas.llmp. gal./liters)
Recommended Fuel

Parallel Link IFS. CRC XTRA10
91 Octane Min.
91 Octane Min.
87 Octane Non-Oxygenated or 89 Octane Oxygenated Parallel Link IFS

XTRA 12

Brake Type
CRC XTRA10
CRC XTRA 10
Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard
Option Oil/Brake Temp/Ace High Beam
liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard
N/A Oil/Brake Temp/Ace High Beam
Liquid Cooled Hydraulic Disc Rear ot Seat Toolbox Footrest

Standard Standard N/A Oil/Brake Temp/Ace High Beam
Liquid Cooled Hydraulic Disc Rear of Seat Standard

Standard Option Oil/B rake
Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights
Temp/Acc
High Beam
Electric Start
N/A Hi-Lo/Std Standard Option
Option Hi-Lo/Std 2-Pc/Knee Pad Option Option
Option Hi-Lo/Std 2-Pc/Knee Pad
N/A Hi-Lo/Std
Seat
Option Option
Option
1.13j
9/96

Indy 700 XC
0971766 Engine Type
Indy 700 SKS

0970566 LC Twin SN70LCDCSPOl 700 81x68 2 Keihin 238MM D Slide Standard Digital CDI 12V 280W
Indy 700 RMK

0970966 LC Twin SN70LCDCSp02 700 81x68 2 Keihin 238MM D Slide Standard Digital CDI 12V 280W 1161294.6 43.5/110.5
Engine Model Number

Displacement (ee) Bore x Stroke (mm) CarburetionIThrottie Body
LC Twin SN70LCDCSpOl 700 8 1x68 2 Keihin 238M M D Slide
Oillnjecled
Standard
Digital CDI 12V 280W 109/276.9
Ignition
Alternator Output Length (in.lcm.) Width (in.lcm .) Height (in.lcm.) Ski Center Distance (in.lcm.) Track Width (in.lcm.) Track Length Overall (InJcm.) Fuel Capacity (U.S. gas.llmp. gal.lliters) Recommended Fuel
116/294.6 46 .51118 .1 46/116 .8

41110414
46.5/118. 1 38.5/97.8
41 1104.1 4
46/116.8
38/96.5
15138.1 1211307.3 9.517.9/35.9
15/3 8.1 136/345.4

10.7/8.9/40.5 87 Octane Non-Oxygenated
15/38.1 136/345.4 10.7/8.9/40.5

87 Octane Non-Oxygenated or 89 Octane Oxygenated Parallel Link CRG I FS XTRA 10 Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Standard Standard Option Oil/Brake TemplAce High Beam Option HiLo/Std Long Option

XC to CRC IFS XTRA 10 Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Standard Standard Option OiVBrake TemplAcc High Beam Option HiLo/Std Long Option Option
or 89 Octane
Oxygenated
Parallel Link CRC IFS XTRA 10 LiqUid Cooled Hydraulic Disc Rear of Seat Toolbox Standard Standard Option Oil/Brake Templ Ace High Beam Option HiLo/Std Long Option Option
Front Suspension Rear Suspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory Ughts
Electric Start HandwarmersfThumbwarmer Seat Storage Rack Tow Hitch
Option
9[97
1.13k

Indy Storm
0975782 Engine Type
Indy Storm SE
H975782 LC Triple EC80PL05 794 72 x 65 3 Mikuni VM38SS Slide Standa rd Digital COl 12V 200W t 09/276.9 46.51118 .1 441111.7
4 11104 .14
Indy Storm RMK

0975982 LC Triple EC80PL04 794 72 x 65 3 Mikuni VM38SS Slide
Standard
Indy 440 XCR

0971660 LC Twin SN44LCDCSP-01 439 68.25 x 60
Engine Model Number

Displacement (ee) Bore x Si roke (mm)
LC Triple EC80PL05 794 72 x 65 3 Mikuni VM38SS Slide Standard Digital CDI 12V 200W 109/276.9 46.51118.1 44/111 .7 41 /104. 14 15/38. 1 1211307.3 10.7/8.9/40.5
91 Octane Min .
CarburetionfTh rottl e Body Oil Injected

Length (in.lcm.) Width (in.lcm.) Height (in.lcm.)
Standard
Digilal COl 12V 200W 2P 109/276.9 46.51118.1 38.5/97.8 41 /104_ 14 15/38.1 1211307.3
Digital CDI 12V 200W 115/292.1 46.51118.1 49/ 124.5 38/96.5 15/38.1 133.5/339.1 10.7/8.9/40.5 91 Octane Minimum 38" IFS XTRA 10 LWT Liquid Cooled
Ski Center DIstance (in .lcm.)

Track Width (i n.lcm.) Track Length Overall (in.fcm.) Fuel Capacity (U .S. gas.llmp. gal.lIlters) Recommend ed Fuel
15/38 .1 12 11307.3 10.7/8.9/40.5

91 Octane Min.
9.5n .9/35.9
91 Octane Minimum XC-10 CRC XTRA10
Front Suspension
Rear Suspension
41 " IFS XTRA 10 HP Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Standard Standard Option Oil/Brake Temp/Acc High Beam N/A HiLo/Sld Hi-La Sculpt, Mid 121 NIA Option
41" IFS XTRA 10 HP
Brake Type
Liquid Cooled Hydrauli c Disc

Rear of Seal Toolbox Standard Standard Option Oil/Brake Temp/Acc High Beam NiA Hi-Lo/Std HI-Lo Sculpt, Mid 121 N/A Option
Hydraulic Disc
Rear of Seal Toolbox Standard Standard Option OillBrake Tem p/Acc High Bea m N/A HiLa/Sld HiLo Sculpl. Mid, 133 N/A Option
Liquid CooledH ydra ulic Disc 5/8 Piston (Mast Cyl)

Rear of Seal Standard Standard N/A OilfBrake Temp/Ace High Beam Option Hi-Lo/Std 2 pc / Knee Pad N/A N/A
Storage
Polans Industries Inc.
1.131
9/97

The machine serial number may be used as an aid in identifying machine model year. Refer to the first digits in Ihe serial number for proper identification: FIRST DIGITS MODEL YEAR 33 1998 1998 MODEL DESIGNATION YEAR DESIGNATION- - - -- - - - - - - , E;European Model
~
O~
ENGINE DES IGNATION

MODEL I CHASSIS DESIGNATION _ _ _ _ _ _ _-'I
1998 MODEL DESIGNATION NUMBERS (Chassis) 01 - Indy TranSport 02 - Indy Sport Touring 04 - Indy Sport 07 - Indy Super Sport 09 - Indy Trail RMK, 600 RMK, 700 RMK 16 - Indy XCF, 440 XCR 17 - Indy 600 XC, 700 XC 20 - Indy WideTrak LX 23 - Indy Trail Touring 27 - Indy 440, Trail, 500 29 - Indy 500 RMK 31 - Indy Lite Touring 33 - Indy Classic Touring, XLT Touring 34 - Indy Lite, Lite Deluxe 37 - XLT LTD 38 - Indy 500 Classic, XLT Classic, 53 - Ultra Touring 56 - Indy 600 XCR, 700 XCR 57 - Indy Storm, XLT SP 67 - Indy Ultra
1998 ENG INE DESIGNATION NUMBERS 31 - EC34-2PM02A 33 - EC34-2PM02A 43 - EC44-3PM024 56 - ECS8PL 130 57 - ECS8PL130, EC58Pl150 58 - SN60-70LCDCSP-01 1 02 60 - SN44-44LCDCSP-01 I EC45PL091 61 - ECSOPM043, ECSOPM051, EC50PM061 62 - ECSOPM043 (-S) 64 - ECSOPL 161 , EC50Pl171 65 - ECSOPL 171, EC50PL 191 , EC50PL201 66 - SN70-70LCDCSP-01 I SN70-70LCDCSp02 68- SN60-70LCDCSp01 76 - ECS8PL 140 77 - ECS9PL020 78 - EC68PL050, EC68PL060 82 - EC80PLOS2
MODEL NO. V.I N. NO
MADE IN U.S.A
PDLRRIS
U.S. Patents
PATENT NOTICE
Patented Canada
3,613,810 3,867,991 4,793,950 5,038,881 5, 172,675 5,090,386 5,050,564 5,050,559 5,048,503 5,056,482 5,099,8 13 5,074,271 5,191,531 3,613,811
Mid. by Polaris Industries Inc, In Roseau , MN under one Ot more or Ihe l oHowing patenls :
"D-llS VEHICLE CONFORMS TO ALL APPLICABLE

US FEDERAL AND STATE REQUIREMENTS AND
CANADA MOTOR VEHICLE SAFETY STANDARD S IN EFFECT ON THE DATE OF MANUFACTURE MFD. DATE
3,605,5 1t 3,560,647 3.483,766 3,533,662 3,545,821

3,605,510
882,491nl
883.694{71 8M.394m Canadian Rd . 34.573/7 1
34,572/71
3,525,412
1.227.823187
7072133
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 seria! 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).
9197
1.13m

1998 Model Indy Lite
0983433
Indy Lite Deluxe

0983431
Indy Lite Touring

0983133
Indy Sport
0980443
Engine Type
Engine Model Number
Fan Twin
EC342PM02A 339 62.3 x 55.6 2 Mlkuni VM30SS Slide Standard CDI 12V 150W
Fan Twin
EC34-2PMQ2A 339 62.3 x 55.6 2 Mikuni VM30SS Slide Standard CDI 12V 150W
Fan Twin
EC342PM02A 339 62.3 x 55 .6 2 Mikuni VM30SS Slide Standard CD I 12V 150W
Fan Twin
EC443PM024 432 67.72 x 60 2 Mikuni VM34SS Slide Standard CDI 12V 200W
Displacement (ee)
Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output Length (in Jcm.) Width (in.!cm.) Height (in.!cm .) Ski Center Distance (in .lcm.) Track Width (in .icm.) T(ack Length Overall (in .lcm.) Fuel Capacity (U.S. gas'/Imp. gaL/liters) Recommended Fuel
105/266.7 42.5/108
44/111.8
105/266.7 42.5/108 44/111.8 37/94 15/38.1 121 /307.3 8 .817.3/33 .3 87 Octane Non-Oxygenated
11 51292.1 42 .5/108 48/121.9 37/94 15/38.1 133.5/339.1 8.817.3/33.3

87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS38 XTRA-Lite Mechanical Disc Rear of Seat Top of Hood Standard N/A Accessory N/A OillAcc
108/274.3 43.5/110.5 44/111.8 38/9 6.5 15/38. 1 121 /307.3 10 .7/8.9/40.5

87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS38 XTRALite Hydraulic Disc Rear of Seat Toolbox Footrest Standard Option Accessory Option OiliBrake Acc High Beam Option Single Heat/Std Standard Option Option
37194 15/38.1 121/307.3 8.817.3/33.3

87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS38 XTRALite Mechanical Disc Rear of Seat Top of Hood Standard N/A Accessory N/A N/A
or 89 Octane
Oxygenated
IFS38 XTRALi1e Mechanical Disc Rear of Seat Top of Hood Standard N/ A Accessory N/A Oil/Ace
Front Suspension Rear Suspension Brake Type Storage Speedometer Tachometer Reverse Electric Fuel Gauge Accessory Lights
Electric Start Handwarmersffhumbwarmer Seat Storage Rack Tow Hitch
Option Option/Option Standard Ute Option Option
Standard Single HeaVStd Standard Ule Option Option
Option Sing le Heat/SId 2 Up Lite Standard Standard
1.13n
9/97

1998 Model Indy TranSport
0980143 Engine Type Engine Model Number Displacement (ee) Bore x Stroke (mm) Carburelionrrhrottle Body
Oil InJected
Indy Sport Touring

0980243
Indy XCF
0981643
Indy 440 LC
0982760
Fan Twin
EC44-3 PM024 432 67.72 x 60
Fan Twin
EC44-3PM024 432 67.72 x 60 2 Mikuni VM34SS Slide
Fan Twin EC44-3PM024

432 67.72x60 2 Mikun i VM34S S Slide
LCTwin EC45PL091
432 67.72 x 60
2 Mikuni
VM34SS Slide
2 Mikuni
VM34SS Slide
Standard
CO l 12V 200W 117/ 297.2 43.5111 0.5 48/ 121 .9 38/96.5 151 38.1 1411358. 1 11.819.8144.7
Standard
COl 12V 200W 11 7/297.2 43.51110_5 481121.9 38196 .5 15138.1 133.51339. 1 11.819.8144.7
Standard
CO l 12V 200W 108/274.3 46 .51118. 1 38.5197.8 411104.1 15138.1 121/307.3 10.518.7139.7 87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA-10 CRC XTRA1 0 Vented Hydraulic Disc Rear Seat
Standard
COl 12V 200W 2P 1081274 .3 46.5/ 118_ 1 47 .5/120.7 41 1104.14 15138.1 121 /307.3 11.8/9. 8/44.7 87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA- l 0 XTRA 10 Hydraulic Disc Rear of Seal Toolbox Under Hood S tandard Standa rd Option Option Oil/B rake Temp High Beam Option fii-Lol Std Std Length Option Option
Ignition Alternator Output Length (in.lem.) Width (in.lem.)
Height (infern.)
Ski Center Distance (in.lcm.) Track Width (in.lcm.) Track Length Overall (in.lcm.) Fuel Capacity (U.S. gas.llmp. gal.fhters)
Recommended Fuel
87 Octane NonOxygenaled or 89 Octane Oxygenated

IFS-38 Standard Hydraulic Disc Rear of Seat Toolbox Footrest Standa rd Opti on Option Option OU/Brake Aee High Beam Option Single HeallStd 2 Up Option Std
870cIane Non-Oxygenated or 89 Octane Oxygenated

IFS-38 XTRA lite Hydraulic Djsc Rear of Seat Toolbox Footrest Standard Option Option Option Oil/Brake Aee High Beam Option Single HeaVAcc 2 Up Option Option
Front Suspension Rear Suspension Brake Type Storage
Speedometer Tachometer Reverse Electric Fuel Gauge Accessory lights
Standard Standard Option Option Oil/Brake Aee High Beam Option Sin gle HeaVStd Racing w/O pads Option Option
9/97
1.130

Indy Trail
0982761
1998 Model
Indy Trail Touring

0982362
Indy Trail RMK

0980961
Indy Super Sport

0980761
Engine Type
Engine Model Number

Displacement
Fan Twin EC50PM043

488 72 x 60
Fan Twin
EC50PM043 488 72 x 60
2 Mikuni
Fan Twin EC50PM051

488 72x60 2Mikuni/ACCS VM34SS Slide
Fan Twin
EC50PM061 488 72 x 60
(eel
Bore x Stroke (mm) Carburetlon/Throttle Body

Oil Injected

COl 12V 200W 2P
108/274 .3 46.5/118.1 47.5/120 .7 41/104 .14 15/38. 1
VM34SS Slide
2 Mikunl VM34SS Slide Standard

COl 12V 200W
108/274.3 46.5/118.1 38.5/97.8 41/104.14
Standard
COl
12V 200W 2P 114/289.6 46. 5/118/1 48/121.9 41/104 .14
Standard
COl
12V 200W 2P 114/289.6 43.5/11 0.5 46/116.8 38196.5 15/38. t 133.5/339.1 11.8/9.8144.7
Ignition
AUernator Output
Length (in.lem .) Width (in./cm.) Hei9ht (in.lem.)
Ski Center Distance (inJcm.) Track Width (inkm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gas.llmp. gaLliiters) Recommended Fue l
15/38.1
133.5/339. 1 11.8/9.8/44.7
87 Octane Non-Oxygenated or 89 Octane
15138.1 121 /307.3

11 .8/9.8/44.7
1211307.3
11.8/9.8/44.7
Oxygenated Front Suspension Rear Suspension Brake Type Sto rage

IFS XTRA-10 XTRA 10
Oxygena ted
IFS XTRA10 XTRA10
Oxygenated
IFS XTRA10 XTRA10
XTRA10 IFS XTRA 10
Hydraulic Disc Rear of Seat Toolbox Under Hood Standard Standard Option Option Oil/Brake High Beam Option
Hi-Lo/Std
Standard
Hydraulic Disc Rear of Seat Toolbox Under Hood Standard Standard Option Standard Oil/Brake High Beam Standard
HiLolSld
Hydraulic Disc Rear SeatfToolbox
Hydraulic Disc Rear of Seal Toolbox Footrest Standard Standard
Speedometer Tachometer Electric Fuel Gauge Reverse Accessory Lights
Standard Standard Option Option Oil/Brake Ace High Beam Option

Single HeaVSld
Option Oil/Brake Ace High Beam Option

Single HeaVS td
Dlx 2 Up Touri ng Option Option
Long Option Option
Option OptJon
1.13p
9/97
GENERA L INFORMATION 1998 Model Identification

1998 Model Indy 440 XCR
0981660
Indy 500
0982764 (0982764A) (0982764B)
Indy 500 RMK

0982964
Indy Classic
0983865

Displacement (ee)
LCTwin
SN44-44LCDCSP01 438 66 x 64 2 Mikuni VM34SS Slide Standard Digital COl 12V 280W 109/276.86 46 .5/1 18.1 44.0/111.76 41/104 .14 15/38.1 121/307.3 10.5/8.7/39. 7 87 Octane Non-Oxygenated or 89 Octane Oxygenated XC -1 0 CRC XTRA 10 liqUId Cooled Hydraulic Disc Rear of Seat Toolbox Under Hood Standard Standard Option Option Oil/Brake Temp High Beam N/A Hi-LoIStd Racing wI pads Option Option
l CTwin
EC50PL171 488 72 x 60 2 Mikuni VM38SS Slide Standard C Ol 12V 200W 2 P 108/274.3 46.51118.1 411104.14 41/104.14 15/38. 1 121/307.3 11.8/9 .8/44.7
LCTwin
EC50PL161 488 72x 60 2 Mikuni VM34SS / ACCS Standard COl 12V 200W 2P 114/289.6 43.51110.5/RMK
LC Twin EC50PL171 488 72 x 60 2 Mlkuni VM38SS Slide Standard CO l 12V 200W 2P 108/121.9 48/1 2 1.9 49.5/125.7 42 .51107.9 15/38.1 121/307.3 11 .8/9.8/44 .7 87 Octane
Bore x Stroke (mm)
Carbu retionffhrottle Body Oillnjecled

Ignition
Alternator Output
Length (i nlem.) Width (in.lem .) Height (in.lem.)
481121.9
38/96.5 15/38. 1 133.5/339. 1 11 .8/9 .8144 .7

Track Width (in.lem.) Track Length Overall (in.lem.) Fuel Capacity (U.S. gas.llmp. gal Jllters)
Recommend ed Fuel
87 Octane
Non-Oxygenated
87 Octane
Non-Oxygenated
or 89 Octane
Oxygenated IFS XTRA-10 CRC XTRA 10 Hydraulic Disc Rea r of Seat Toolbox Standard Standard Option Option Oil/Brake Temp High Beam Option Hi-La/Std Standard (Long Opt.A&B) Option Option
or 89 Octane
Oxygenated IFS 38 RMK XTRA 10 Hydraulic Disc HD Pads Rear of Seat Toolbox Standard Standard Option Option Oil/Brake Temp High Beam Option Hi -LoIStd Long Option Option
Non-Oxygenated or 89 Octane
Oxygenated IFS XTRA-12 XTRA 12 Hydraulic Disc Rear of Seat Toolbox Standard Standard Standard Standard OiVBrake Temp High Beam Standard Hi-LalSld Long Option Option
Front Suspension Rear Suspension Brake Type Storage
Speedometer Tachometer Reverse Electric Fuel Gauge Accessory lights
9/97
1.13q
1998 Model

0983365
Indy WideTrak LX
0982065 LCTwln EC50PL201 488 72 x 60 2 Mikuni VM34SS Slide Standard CDI 12V200W
Indy XLT Touring

0983357 LC Triple EC58PL 130 597 65 x 60
Indy XLT LTD

0983756 LC Triple EC58PL130 597 65x60 3 Mlkuni VM34SS Slid e
Engine Type Engine Model Number Displacement (cc)

Bore x Stroke (mm)
LCTwin
EC50PL191 488 72x 60 2 Mlkuni VM34SS Slide
Carburetion/ThrotUe Body
Oil Injected Ignition

Standard CDI 12V280W
Standard
CDI 12V 200W 2P 115/292.1 48/121.9 51.5/130.8 42.5/107.9 15/38. 1 133.5/339. 1 11.8/9.8/44.7 87 Octane NonOxygenated or 89 Octane Oxygenated IFS XTRA-12 XTRA 12 Hydraulic Disc Rear of Seat Toolbox Standard Standard Standard Standard Oil/Brake Temp High Beam Standard Hi-Lo/Std Deluxe 2 Up/Tour Option Option
Standard
CDI 12V 280W 108/274.3 48/121.9 49.5/125.7 42.5/107.9 15/38.1 1211307.3
Alternator Output
Length (in.lcm .) Width (in./cm.) Height (in.lcm.) Ski Center Distance (in.lcm .) Track Wid1h (in./cm.) Track Length Overall (in.!cm) Fuel Capacity (U.S. gas l imp. gal.Aiters) Recommended Fuel
1281325.1
43.5/110.5 49/ 124.5 38/96.5 20/50.8 156/396.2 11.0/9.114 1.6
1151292.1
48/121.9 51.5/130.8 42.5/107 .9 15/38 .1 133.5/339.1 11 .8/9.8/44.7 87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA-12 XTRA 12 Hydraulic DISC Rear of Seat Toolbox Under Hood Standard Standard Standard Standard Oil/Brake Temp High Beam Standard Hi-La/SId Deluxe 2 Up Touring Option Option
11 .819.8/44.7
87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA12 XTRA12 Hydraulic Disc Rear SeaVToolbox Standard Standard Option Option Oil/Brake Acc High Beam Option Hi-Lo/Std Standa rd Length Option Option
87 Octane
Non-Oxygenated or 89 Octane Oxygenated IFS 38
Front Suspension
Rear Suspension
Brake Type Storage Speedometer Tachometer Reverse Electric Fuel Gauge Accessory Ughts
WideTrak Single Slide Rail

Mechanical Under Seat Standard Standard Standard N/A Oilrremp Rev High Beam Standard Single Heat/SId WideTrak 2 Up Standard Standard
1.13r
9/97
GENERAL INFORMATION 1998 Model Identif ication

199B Model Indy XLT SP
0985776
Indy XLT Classic

0983857 LC Trip le EC58PL150 597 65 x 60 3 Mikun i VM38SS
Indy 600 XC
0981758
Indy 600 RMK

0980958
Engine Type
Engine Model Number

Displacement (ee)
Bore x Stroke (rnm)
LC Triple EC58PL 140 597 65 x 60
LCTwin
SN60-70LCDCSP-Ol 593 74_5 x 68
LCTwin
SN60-70LCDCSP-02 593 74_5 x 68 2 Keihin 39mm D-Slide Standard Digllal COl 12V 280W 116/294 .64 43.5/110.5 46/116.84 38/96.52
CarburetionfThrottJe Body
Oilln/ecled
3 Mikuni
VM38SS
2 Keihin 39mm D~Slide

Standard Digital COl 12V 280W 109/276.86 46.5/118 . I 44/111.76
Standard
COl 12V 280W 1081274.3 46.5/1 I 8.1 1 46.5/118.11 41/104.14 15/38.1
Standard
COl 12V 280W 108/274.3 48/121.92 48.51123.19 42.5/107.9 15/38.1
Ignition
Alternator Output Lenglh (in.lcm.) Widlh (i n.lcm.) Heighl (inJcm.) Ski Center Distance (in.lcm.) Track Width (in.lcm.) Track Length Overall (inlcm.) Fuel Capacity (U.S. gas.llmp. gaillilers) Recommended Fuel
41 /104 .14
15/38.1 121 /307.3
15/38.1
121/307.3 1 I .8/9.79/44.66
121/307.3 11.819.8/44.7
121/307.3 11.8/9.8/44.7
11.8/9.79/44.66
87 Octane Non-Oxygenated or 89 Octane Oxygenated XC-l0 CRC XTRA 10
87 Octane
Non-Oxygenated
or a9 Octane
Oxygenated IFS XTRA-12 XTRA 12 Hydraulic Disc
or 89 Octane
Oxygenated 38 RMK CRC XTRA 10 Liquid Cooled
Oxygenated
Front Suspension IFS XTRA-lO CRC XTRA 10
Rear Suspension
Brake Type
Hydraulic Oisc Rear of Seat

Toolbox Footrest Standard Standard Option
liquid Cooled
Hydraulic Disc
Hydraulic Disc
Rear of Seal Standard
Standard Option N/A OillBrake Temp/Ace
Storage
Speedometer

Standard
Rear of Seat
Standard Standard Option N/A OillBrake Templ Ace
Tachometer
Reverse
Electric Fuel Gauge
Standard
Standard
Option
Ol1lBrake
Optioll
Oil/Brake Temp/Ace High Beam Standard Hi-La/SId
Accessory Lights
Temp/Ace
High Beam Electric Start Option Hi-La/Sid
High Beam
Option Hi -La/Sld Aggressive Mid Length Option Option
High Beam
OptIon Hi-La/SId
Handwarrnersfrhumbwarmer
Seat
Aggressive Mid
Lenglh Option Option
Long
Option Option
Long Option Option
9197
1_ 13s
1998 Model
Indy 600 XCR

0985677
Indy Ultra
0986778 LC Triple EC68PL050 679 66.6 x 65 3 Mikuni VM38AL Slide
Indy Ultra Touring

0985378 LC Triple EC68PL050 679 66.6 x 65 3 Mlkuni VM38AL Slide
Indy 700 XCR

0985678 (0985678A) LC Triple EC68PL060 679 66.6 x 65 3 Mikuni VM38AL Slide
LC Triple EC59PL020
597 62.5 x 65
Displacement (ee)
Bore x Stroke (mm) CarburelionlThroitle Body
3 Mikuni VM38AL Slide Standard

109/276.8 46 .5/118 .11 44/111.7 411104.14 15/38.1 121 /307.3 11.8/9.8/44.7
91 Octane Min.
Oil Injected Ignition Alternator Output

Leng1h (in.lcm.) Wid1h (in.lcm.) Height (in.lcm.) Ski Center Distance (in.lcm.) Track Width (in.lcm.) Track Length Overall (in.lcm) Fuel Capacity (U.S. gas.llmp. gaUliters)
Standard
108/274.3 48/121.9 48.5/123.2 42.5/108 15/38.1 121 /307.3 11.8/9.8/44.7
Standard
1151292.1 48/121.9
Standard
109/276.8 46.5/118.11 44/111.7 41/104.14 15138.1
51.51130.8
42.5/108 15/38.1
133.5/339.1
11.8/9.8/44.7
121/307.3
11 .8/9.8/44.7
Recommended Fuel
87 Octane NonOxygenated or 89 Octane Oxygenated

IFS XTRA 12 XTRA 12 Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard Oplion OptIon Oil/Brake TemplAcc High Beam
87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA 12 XTRA 12 liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Standard Standard Oil/Brake TemplAcc High Beam
91 Octane Min.
Front Suspension
Rear Suspension
XTRA 10 CRC XTRA 10
XTRA 10 CRC XTRA 10 liqUid Cooled Hydraulic Disc Rear of Seat Toolbox Standard Standard OptIon Standard Oil/Brake TemplAce High Beam
Brake Type
Storage Speedomete r Tachometer Reverse Electric Fuel Gauge Accessory Lights

Rear of Seat Toolbox Standard Standard Option Standard Oil/Brake TemplAcc High Beam
N/A HiLo/Sld Aggressive Mid Length Option Option
Option HiLo/Sld Standard Option Option
Standard HiLo/S1d Deluxe 2-up TourIng Standard OptIon
N/A HiLo/S1d Aggressive Mid Lenglh Option Option
1.13t
9/97

1998 Model Indy 700 XC
0981766 Engine Type Engine Model Number LC Twin SN7070LCDCSP02 700 81 x 68 2 Keihin 39mm O-Slide Standard Digital CDI 12V 280W 109/276.86 46.5/118.1 44/111.76 41/104. 14 15/38.1 121/307.3 11.8/9.79/44.66 87 Octane Non-Oxygenated or 89 Octa ne Oxygenated XCl0 CRC XTRA 10 Liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Option Option Oil/Brake Temp/ Ace High Beam Option HiLo/Std Aggressive Mid Length Option Option
Indy 700 RMK

0980966
Indy Storm
0985782 LC Triple ECBOPL052 794 72 x 65 3 Mikuni VM38SS Slide Standard Digital CDI 12V 280W 109/276.9 46.5/1t8. 1 44/111.7 4 1/ 104. 14 t5/38.1 121/307.3 11.8/9.8/44.7 91 Octane Min.
LCTwin
SN7070LCDCSpOl 700 81 x 68 2 Keihin 39mm D-Slide Standard Digital COl 12V 280W 116/294.64 43.5/110.5 46/116.84 38196.52 15/38.1 121/307.3 11.8/9.79/44.66 B7 Octane Non-Oxygenated
Displacement (ee)
Bore x Stroke (mm) Carbu retionfThrollle Body Oil Injected Ignition
Alternator Output
Length (in .lcm .) Width (i n.!cm.) Height (in.lcm.) Ski Center Distance (in.lcm.) Track Width (inJcm.) Track Length Overall (inJcm.) Fuel Capacity (U.S. gas.llmp. gal./liters) Recommended Fuel
or 89 Octane
Oxygenated 38 RMK CRC XTRA10 Liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Option Option Oil/Brake Temp/Acc High Beam Option HiLo/Std Long Option Option XTRA 10 IFS XTRA10 Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Standard Standard Option Standard Oil/Brake Temp/Acc High Beam N/A Hi La/SId HiLo Aggressive Mid Langth Option Option
Frant Suspension
Rear Suspension Brake Type Sto(age Speedometer Tachometer Reverse Electric Fuel Gauge Accessory lights
Elecl ric Start Handwarmersrrhumbwa rmer Seat Storage Rack Tow Hitch
9/97
1.13u
GENERAL INFORMATION
Paint Codes 1996 Polaris Snowmobile Paint Codes
Model Indy Lite Indy Lite Deluxe Indy Lite GT Indy Sport Indy Sport Touring Indy TranSport Indy Super Sport Indy 440 XC R Indy 440 XC R SP Indy 600 XC R Indy 600 XC R SP Indy 440 LC Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy Classic Indy Classic Touring Indy 500 Carb Indy 500 SKS Indy 500 RMK Indy Trail Indy Trail Touring Indy XLT Indy XLT SKS Indy XLT RM K Indy XLT SP Indy XLT Touring Indy RXL Indy Ultra SP Indy Ultra SKS Indy Ultra RMK Indy WideTrak GT Indy WideTrak LX Indy Storm Indy Sto rm SKS Indy Storm RM K Color Description Black Metallic Teal Metallic Dark Sapphire Metallic Black Metallic Black Metallic Black Metallic Bright White Bright White Bright White Bright White Black Metallic Royal Plum Metall ic Porsche Red Porsche Red Porsche Red Dark Cloisonne Dark Cloisonne Black Metallic Black Metallic Black Metallic Teal Metallic Teal Metallic Black Sapphire Metallic Black Sapphire Metallic Black Sapphire Metallic Black Sapphire Metallic Black Sapphire Metallic Black Metallic Black Metallic Black Metallic Black Metallic Emerald Emerald Black Metallic Black Metallic Black Metallic Polaris up" No. PI 77 P1 68 P204 PI77 PI 77 PI 77 PI 33 PI33 P1 33 PI 33 PI 77 P203 P1 36 PI 36 P1 36 P204 P204 PI 77 PI 77 PI77 P1 68 P1 68 P1 73 P173 P1 73 P1 73 P173 PI 77 PI 77 PI 77 PI 77 P210 P2 10 PI 77 P177 PI 77 Polaris Raw Material No. 8520044 8520096 8520154 8520044 8520044 8520044 8520079 8520079 8520079 8520079 8520049 8520 141 8520066 8520066 8520066 8520154 8520154 8520044 8520044 8520044 8520096 8520096 8520098 8520098 8520098 8520098 8520098 8520044 8520044 8520044 8520044 8520 163 8520 163 8520044 8520044 8520044 PPG/Ditzler No. 9000 4300
-
9000 9000 9000 2185 2185 2185 2185 9000
72060 72060 72060

-
9000 9000 9000 4300 4300 3885 3885 3885 3885 3885 9000 9000 9000 9000
-
9000 9000 9000
Order Polaris " P" Number from Midwest Industrial Coatings (612-942-1840) (FAX 612-942-1838). Mix as directed.
1.14
9/97
GENERAL INFORMATION Paint Codes 1997 Polaris Snowmobile Paint Codes

Model Indy Lite Indy Lite GT Indy Lite Deluxe Indy Sport Indy Transport Indy Super Sport Indy Sport Touring Indy 440 XC Indy 600 XC Indy WideTrak LX Indy WideTrak GT Indy Trail RMK Indy XCF Indy Trail Indy Trail Touring Indy 440 UC Indy XLT Touring Indy 500 UC Indy 500 EFI Indy XLT LTD Indy 500 SKS Indy 500 RMK Indy Classic Indy Classic Touring Indy Storm Indy Storm RMK Indy XLT Indy XLT SP Indy XLT SKS IndyXLT RMK Indy RXL Indy 600 XCR Indy Ultra Indy Ultra SP Indy Ultra SPX Indy Ultra Touring Indy 700 SKS Color Description Black Metallic' Dark Cloisonne' Teal Metallic' Raspberry Metallic ' Emerald' Bright White Raspberry Metallic' Bright White Bright White Emerald ' Emerald' Teal Metallic' Bright White Teal Metallic' Teal Metallic' Royal Plum' Blue Spruce' Black Metallic' Dark Cloisonne' Blue Spruce' Black Metallic' Black Metallic' Royal Plum ' Royal Plum' Black Metallic' Black Metallic' Black Sapphire' Indigo Metallic ' Black Sapphire' Black Sapphire' Indigo Metallic' Bright White .. Black Metall ic' Deep Violet Metallic ' Deep Violet Metallic' Deep Vi olet Metallic' Blue Spruce ' Polaris "P" No. P177 P204 P168 P231 P210 P133 P231 P133 P133 P210 P210 P168 P133 P168 P168 P203 P228 P177 P204 P228 P177 P177 P203 P203 P177 P177 P173 P229 P173 P173 P229 P133 P177 P230 P230 P230 P228 Raw Material No. 8520197 8520154 8520199 8520225 8520163 8520201 8520225 8520201 852020 1 8520163 8520163 8520199 8520201 8520199 8520199 8520141 8520218 8520197 8520154 8520218 8520197 8520197 8520141 8520141 8520197 8520197 8520193 8520228 8520193 8520193 8520228 852020 1 8520197 8520222 8520222 8520222 8520218 Ditzler # 9000
4300
-
2185
-
2185 2185
4300 2185 4300 4300
9000
9000 9000
9000 9000 3885
3885 3885
2185 9000
-
P228 8520218 Blue Spruce ' Indy 700 RMK Order Polaris up" Number from Midwest Industrial Coatings (612-942-1840) (FAX 612-942-1 838). Mix as directed .
.. Receive clear topcoat (8520198) Receive clear topcoat with sparkle metallic powder (8520194)
9/97
1.14a
GENERAL INFORMATION
Paint Codes 1998 Polaris Snowmobile Paint Codes
1998 Model Indy lite Indy Lite Deluxe Indy Lite Touring Indy Sport Indy TranSport Indy Super Sport Indy Sport Touring Indy XCF Indy Trail Indy Trail Touring Indy Trail RMK Indy 440 Indy 440 XCR Indy 500 (Color Opt. 1) Indy 500 Classic Indy 500 RMK Indy Classic Tou ring Indy Widetrak LX Indy XLT Classic Indy XLT LTD Indy XLT SP Indy XLT Touring Indy 600 XCR Indy 700 XC Indy 700 RM K Indy 700 XCR (Color Opt. 1) Indy Ultra Indy Ultra Touring Indy Storm Indy 600 XC Indy 500 (Color Opt. 2) Indy 500 (Color Opt. 3) Indy 600 RMK Indy 700 (Color Opt. 2) Metallic Topcoat Color Description Porsche Red Metallic Teal Metallic Black Metallic Dark Cloisonne Emerald Bright White Metallic Dark Cloisonne Bright White Metallic Teal Metallic Teal Metallic Teal Metallic Bright White Metallic Bright Red Black Metallic Royal Plum Metallic Black Metallic Royal Plum Metallic Emerald Blue Spruce Metallic Rigel Blue Black Metallic Blue Spruce Metallic Bright White Metallic Bright White Metallic Dark Cloisonne Deep Violet Metallic Black Metallic Deep Violet Metallic Porsche Red Metallic Bright White Metallic Bright White Metallic Ok Cloisonne/Blue Spruce Deep Violet Metallic Bright White Metallic Clear Topcoat with Sparkle Metallic Powder Polaris "P" No. P245 P168 Pl77 P204 P210 P241 P204 P241 P1 68 P168 P168 P241 P243 Pl77 P203 PH7 P203 P210 P228 P246 PI77 P228 P241 P241 P204 P230 Pl77 P230 P245 P241 P241 Pl075 P230 P241 N/A Raw Material No. 8520066 8520199 8520197 8520154 8520163 8520201 8520154 8520201 8520199 8520199 8520199 8520201 8520247 8520197 8520141 8520197 8520141 8520163 8520218 8520254 8520197 8520218 8520201 8520201 8520154 8520222 8520197 8520222 8520066 8520201 8520201 8520154/218 8520222 852020 1 8520194 Ditzler#
4300 9000
4300 4300 4300
9000 9000
9000
9000
Order Polaris " P" Number from Midwest Industrial Coatings (612-942-1840) (FAX 612-942-1838). Mix as directed . Receive clear topcoat (8520198) Receive clear topcoat with sparkle metallic powder (8520194)
1.14b
9/97
GENERAL INFORMATION Torque Specifications

Standard Torque Specifications '---' T he following torque specifications are to be used as a general guideline . There are exceptions in the steering, suspension, and engine areas. Always consu lt the standa rd torque chart and the specific manual section for torque val ues of fasteners. Use special torque values when listed.
Bolt Size
Threadslln (MMfThread) 24 32
0
Grade 2
Grade 5
Grade 8
"-..--
Torgue in. Ibs. (kg/m) 27 (.3 1) . 31 (.36) . Torgue ft. Ibs. (kg/m) ' 20 .. .. . ... 5 (.7) ... 1/4 6 (.8) . . . . . . . . . . 1/4 28 18 11 (1.5). 5/16 5/16 24 . .. . . .. . . . 12(1.6) . . . - .. .. . - .. . 3/8 20 (2.7) . . . . . . , . . . . . . 16 ......... . 23 (3.2) .. . . . . . .. . . . 3/8 24 14 . . . . . . . . . . . . 30 (4.0) 7116 20 35 (4.8) 7/ 16 50 (6.9) .. . .. . .. 112 13 1/2 20 55 (7.6) 'To convert ft. Ibs. to kg/m multiply fool pounds by .138. ' To convert kg/m to N/m move the decimal to the right one #10 #10
43 (.50) . ............ 49 (.56) . ............ 8 (1. 1) 10 (1.4) 17 (2.3) 19 (2.6) . . . . . ... 30 (4.0) . ........ 35 (4.8) 50 (6.9) 55 (7 .6) ......... 75 (10.4) 90 (12.4) .. . .. ... position.
60 (.69) 68 (.78) 12 (1.6) 14(1.9) 25 (3.5) 29 (4.0) 45 (6.2) 50 (6.9) 70 (9.7) 80 (11.0) 110 (15.2) 120 (16.6)
"---'
Special Application Torque List Due to the special grade bolts and nuts required for specific app lications, observe the following torque values in the are as specified. Refer 10 specific manual section for torque values of fasteners not listed here. Bolt Size
7/16 . .. . 1/2 .. .. .
Area Where Used
Torque Minimum-Maximum
3/8 ... . . Oute r Radius Rod End to Trailing Arm (Top & Bottom) .. . 28-30 ft. Ibs. (3.86-4. 14 kg-m)
Inner Radius Rod End To Bulkhead (Top) ... . .. . .. 35-40 ft. Ibs. (4.83-5.52 kg-m) Inner Radius Rod End To Bulkhead (Bottom) . . . . 40-50 ft. Ibs. (5.52-6.9 kg-m) Radius Rod, Drag Link, or Tie Rod End Jam Nuts . . . .. 24-25 ft . Ibs. (3 .31 -3.45 kg-m) Bellcrank (Center Steering Arm) . . . . . 55-60 ft. Ibs. (7 .59-8.28 kg-m) 112 3/8 Drag Link to Steering Post Arm ... . . . ..... . .. . ... . . . .. 28-30 ft. Ibs. (3.86-4. 14 kg-m) 3/8 . .. . .. . .. . .. 28-30 ft. Ibs. (3.86-4.14 kg-m) Drag Link to Bellcrank . 3/8 ... ... .. .... . ..... ...... . 28-30 ft . Ibs. (3.86-4.14 kg-m) Tie Rod to Steering Arm 3/8 Tie Rod to Steering Post Arm .. . . .. . ...... . . .. .. . . ... 28-30 ft. Ibs. (3.86-4.14 kg -m) 71t 6 . .. . Trailing Arm Rear Support ..... . . . . . .. . . . . . . . .. . .. ... 40-45 ft. Ibs. (5.52-6.21 kg -m) 3/8 . .. . . . IFS Shock (Top & Bottom) . .. . .. . .. . .. . .. ... 28-30 ft. Ibs. (3.86-4.14 kg-m) 51t 6 . .. . Steering Post to Bulkhead . .. . .. . .. .. . . 15-17 ft. Ibs. (2.07-2.35 kg-m ) . .. 8-10 ft. Ibs. (1.10- 1.38 kg-m) Upper Steering Bracket to Hoop . . 1/4 114 . 8- 10ft. Ibs. (1.10- 1.38 kg-m) Handlebar Block. . . . Side Panel to Nosepan Brace , Rubber Washer .. . .. . .. . 4-6 in. Ibs. (.05 -.07 kg-m) 114 Side Panel to Nosepan, Well Nut .. ........ .... ...... _4-6 in. Ibs. (.05-.07 kg-m) 1/4 3/8 Throttle Block Set Screw _. . _. . .. .......... .. . ...... _30-35 in . Ibs (.35-.40 kg-m) 3/8 Ski Pivot Bushing Bolt .. . ............... ... .......... 25-28 ft. Ibs. (3.45-3.86 kg-m) Choke to Plastic Console . . .. . ....... .. . .... .. . . .. . .. 20-25 in. Ibs. (.23-.29 kg-m)
1.15
9197
GENERAL INFORMATION
To r que Specifications Special Application Torque List, Cont.
Bolt Size Area Where Used
1/4 ... .. . Coolant Tank to Hoop
S/16 . .. .. 7/16 .... . 7/16 ... ..
7116 .. .
10-24 . 1/4
11 4 114
3/8 ... 318 . ..
Torque Minimum-Maximum . 4-6 It. Ibs. (.SS- .83 kg/m) Driven Clutch to Shaft. IS-17 ft. Ibs. (2.07-2.35 kg/m) Drive Clutch to Engi ne ... .. ... . . .. . 4S-S0 ft. Ibs. (6.2 1-6.9 kg/m) Engine Mount to Chassis .. 4S-S0 ft. Ibs. (6.21-6.9 kg/m) Engine Mount to Engine. . . . 44-48 ft. Ibs. (6.07-6.62 kg/m) Regulator . . . . . . . . . . . . 38-43 in. Ibs. (.43-.49 kg/m) Side Panel to Nosepan Brace , Rubber Washer . 4-6 in . Ibs. (.OS-.07 kg/m) Side Panel to Nosepan, Well Nut .. . . 4-6 in. Ibs. (.OS-.07 kg/m) Air Silencer ................................ 4-6 in . Ibs. (.OS -.07 kg(m) Set Screw to Throttle Block . . 30-3S in. Ibs (.35-.40 kg/m) Shock Rod Bolt ...... . .. . ........... . .... .. . 10-12 ft. Ibs. (1.38-1.66 kg/m) Rubber Motor Mount Nuts, Low Flex .......... 15-18 ft. Ibs. (2.07-2.48 kg/m) Rubbe r Motor Mount Nuts, High Flex . . .. . .... 25-30 ft. Ibs. (3.45-4.14 kg/m) 13-17 ft. lbs. (1.79-2.35 kg/m) Manifold Nuts. . ....... ... . .............. 20-25 in . Ibs. (.23-.29 kg/m) Ignition Switch to Plastic Console . . . . . . . . . . Ignition Switch to Aluminum Console 50-55 in. Ibs. (.S7-.63 kg/m) . . . . . . . . . . . . . . 20-2S in . Ibs. (.23-.29 kg/m) Choke to Plastic Console Lock Collar Set Screws. . . . . . . . . . . . . . . . . . . . 70~80 in. Ibs. (.8 -.92 kg(m)
Reco mmended Shop Supplies/Accessories

Part Number Description Chaincase Lubricant - One Gallon ..... ... .. ....... 2870464 Chaincase Lubricant - (Quart) ... . ..... ... . . ... . ... 287 1280 Chaincase Oil Pump ..... . ... . .. . .... . ... . .. . . .... 2870465 Cable Lubricant .... . ............. .. . . .. . ... . .. .. .. 2870510 Fuel System Deicer (Isopropyl) . . . . . .. . ...... . . . ... .. 2870505 Loctite Primer T - 6 Oz. Aerosol ... . ................. 2870585 .. .. 2870584 Loctite RC 680 - 10cc Retaining Compound Loctite 515 Gasket Eliminator - 50cc Tube .... .. ..... 2870587 LoctitelChisel - Gasket Remover - 18 Oz. Metal Polish - 8 Oz ... . .......... . 2870601 2870632
DOT 3 Brake Fluid .. . ...... . .. . . . . . .............. . 2870990 Fogging Oil ..... . . .. .. .. .... . ... . .. . . ........ .... . 287079 1 Corrosion Resistant Dielectric Grease . . ... . . . . . . . .. 287 1027 Fox Shock Oil ........................... .. . . . . .... 2870995 Premium All Season Grease (14 1(2 oz) .. Premium All Season Grease (3 oz) .......... . . . Premium 60/40 Anti-Freeze/Coolant .. . ........ . Fuel Stabilizer (16 oz.) ............ . 2871423 287 1322 287 1323 2870652 287 1076
Premium Carbon Clean Fuel System Additive ......... 287 1326 Polaris Battery Tender ........... . ..... .
Carbon Clean Fuel System Additive ... .. . .. . ... . . . . . 287 1326 T-9 Metal Protectant .. . .......... ... . . . ...... . . . .. . 287 1064 Synthetic Chaincase Lubricant - Gallon ... ... . .. ... . Synthetic Chaincase Lu bricant - 12 oz ...... . Starter Drive Grease .. . . 2871477 2871478 2871460
9/97
1. 16
GENERAL INFORMATION Decimal Equivalents

1/64 ......... ......... .. . . ... 0156 1/32 .................... 0312 ................ 3/64 ......................... 0469 1/16 ...............0625 5/64 .. ........................0781 ................ 3/32 .................... 0938 7/64 ...................... .. 1094 ................ 1/8 . ........ 1250 9/64 ..... . ........ . . . ......... 1406 5/32 .................... 1563 . .. .. .. .. . .. . .. 11/64 ......................... 1719 3/16 . .......... . ... 1875 ............. ... 13/64 ........................2031 7/32 ....................2188 15/64 ....................... .2344 ................ 1/4 ...........25 17/64 .. ......... . ........... .2656 ....... . ........ 9/32 ................... .2813 19/64 ........................ 2969 5/16 ............... 3125 ...... .. . .. .. . .. 21/64 ........................3281 11/32 ................... 3438 ................ 23/64 ................. ....... 3594 3/8 ........... 375 25/64 . .. . ....... . ..... . ..... .3906 ................ 13/32 . .... .. ..... ...... .4063 27/64 ....................... .4219 ................ 7/16 .... . ......... .4375 29/64 ............... . ....... .4531 15/32 . ................. .4688 . . .. .. ... . ...... 31/64 ....................... .4844 1/2 .......... .5 ......... ........... 33/64 ....................... .5156
1 mm = .0394" 2 mm = .0787" 3 mm = .1181' 4 mm = .1575' 5 mm = .1969' 6 mm = .2362" 7 mm = .2756' 8 mm = .3150' 9 mm = .3543" 10 mm = .3937" 11 mm = .4331" 12 mm = .4724" 13 mm = .5118 14 mm = .5512' 15 mm = .5906" 16 mm = .6299" 17 mm = .6693' 18 mm = .7087" 19 mm = .7480" 20 mm = .7874' 21 mm = .8268" 22 mm = .8661' 23 mm = .9055" 24 mm = .9449" 25 mm = .9843
17/32 .................. .5313

35/64 . .. .. ..... .. . .......... .5469 .... . ........ . .. 9/16 .............. .5625 37/64 ........................5781 ......... .... .. . 19/32 ...................5938 39/64 ................... . .... 6094 5/8 . .. . .. . ... .625 .. .. .. ........... 41/64 ........................6406 21/32 .... .. ........ ..... 6563 ................ 43/64 ........................6719 11/16 ............. .6875 45/64 ........................7031 ...... . .. . .. . .. . 23/32 ............ ..... . . 7188 47/64 .......... . ....... . .. . . . 7344 ................ 3/4 ........... 75 49/64 . ... .. .................. 7656 25/32 .. . ............. . . . 7813 ... . ............ 51/64 ................. . .... . .7969 13/16 ............. .8125 ................ 53/64 ................. ..... . . 8281 27/32 . ..................8438 55/64 ........................8594 ... . ..... .. . .... 7/8 ........... 875 57/64 ............... . .. . ..... 8906 ................ 29/32 ... . .. .. . . ......... 9063 59/64 ........................9219 15/16 . .. .. .. .. . ... .9375 . ........ ....... 61/64 .................... .. . .9531 31132 .................. .9688 .... . ........... 63/64 ............ . ...........9844
1 ........... 1.0
1.17
111 95
GENERAL INFORMATION
Conversion Table
Unit of Measure
ft. lbs. in.lbs. ft.lbs. in.lbs. kg-m kg-m kg-m in. mm in. mile (mi.) km Ounces (oz) Grams (g) cc lb. kg Cubic inches (cu in) Cubic centimeters (cc) Imperial pints (Imp pt) Liters (I) Imperial quarts (I mp qt) Liters (I) Imperial quarts (imp qt) US quarts (US qt) US quarts (US qt) Liters (I) US gallons (US gal) Liters (I) Pounds - force per square inch (psi) Kilopascals (kPa) Kilopascals (kPa) Kilograms - force per square cm C to of: 9 (OC + 40) + 5 - 40 = of of to C: 5 (OF + 40) + 9 - 40 = C x12 x .0833 x.1383 x .0115 x 7.233 x 86.796 x10 x 25.4 x.03937 x 2.54 x 1.6 x.6214 x 28.35 x 0.035 x.03381 x .454 x 2.2046 x 16.387 x 0.061 x 0.568 x 1.76 x 1.137 x 0.88 x 1.201 x 0.833 x 0.946 x 1.057 x 3.785 x 0.264 x 6.895 x 0.145 x 0.01 x 98.1
Multiplied by
= in. Ibs. = ft. Ibs. = kg-m = kg-m = ft. Ibs. = in.lbs. =Nm =mm = in. = cm = km = mile (mi.) = Grams (g)
Converts to
= Ounces (oz) = Fluid Ounces (oz) = kg
= lb. = Cubic centimeters (cc) = Cubic inches (cu in)

= Liters (I) = Imperial pints (Imp pt)
= Liters
(I)
= Imperial quarts (Imp qt) = US quarts (US qt) = Imperial quarts (Imp qt) = Liters (I)
= US quarts
=Liters (I)
(US qt)
= US gallons (US gal)

= Kilopascals (kPa) = Pounds - force per square inch (psi)
Kilograms - force per square cm
= Kilopascals (kPa)
11/95
1.18
GENERAL INFORMATION Tap Drill Charts
SAE Tap Drill Sizes

Thread Size
#0-80 #1-64 #1-72 #2-56 #2-64 #3-48 #3-56 #4-40 #4-48 #5-40 #5-44 #6-32 #6-40 #8-32 #8-36 #10-24 #10-32 #12-24 #12-28
Drill Size
3/64 53 53 51 50
Thread Size
Drill Size
27/64
1/2-13
1/2-20
5/64
45 43 42 38 37 36 33 29 29 24 21 17 4.6mm 7 3
9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14

1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 1/2-6 1 1/2-12 1 3/4-5 1 3/4-12
29/64 31/64 33/64 17/32 37/64 21/32 11 /16 49/64 13/16 7/8 59/64
63/64 1 3/64 1 7/64 1 11 /64 1 11 /32 1 27/64 1 9/16 1 43/64 1 25/32 1 59/64 21/32 2 1/4 2 1/2
11 4-20 11 4-28 5/16-18 5116-24

3/8-16
F
I
2-4 1/2
2-12
0
Q
31 8-24 7/16-14 7/16-20
U
25/64
21/4-41/2 2 1/2-4 23/4-4

3-4
23/4
Metric Tap Drill Sizes

Tap Size
3 x .50 3 x .60 4 x .70 4 x .75 5 x .80 5 x .90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1.50 12 x 1.50 12x 1.75 #39
Drill Size
Decimal Equivalent
0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406
Nearest Fraction
3/32
#30
3/32 3/32 1/8

118
1/8
#19 #20 #9
16/6 4
J
17/64 5/16 5/16 11 /32 R 3/8 13/32 13/32
11 /64 5/32 13/64 15/64 9/32 17164 5/16 5/16 11/32 11 /32 3/8 13/32 13/32
Polaris Industries inc.
1.19
11 /95
GENERAL INFORMATION Glossary of Terms

ACS: Alternator control system. The main relay for the 1993-1996 500 EFI systems. Rectifies AC alternator voltage to DC for battery charging, and triggers the ECU with DC for start up. ACV: Alternating current voltage. Air Gap Spark Test: A good check for ign ition voltage and general ignition system condition. Spark should arc 3/8" (1 cm) minimum from end 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. CDI: Capacitor Discharge Ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a capacitor or condenser (in COl box). At the proper moment a voltage generated by the stator plate pulser coil closes an electronic switch (thyristor) in the COl 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 PTa 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 stay nearly 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 cause the drive clutch to close. Coil: A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic field passes through it. Combustion Chamber: Space between cyli nder 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 COl 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 PTa. Maximum allowable run-out is .006" (.02 cm). DCV: Direct current voltage. Detonation: The spontaneous ignition of the unburned fuellair mixture after normal spark ignition. Piston looks "hammered" through, rough appearance around hole. Possible causes: 1) too high a compression ratio for the fuel octane; 2) low octane fuel; 3) over-advanced ignition timing; 4) lean fuell air mixture. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. 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:
2
Good for showing taper and
__ B_o_re__x_S_tr..,0_ke_X_3_.'_4_'_6_ = Displacement in 4 CCs
Dropping Resistor: Component in an EFI system which reduces input (battery) voltage to approximately 5 volts. ECU: Electronic Control Unit. In an EFI System, the component which monitors all data from sensors in the system, and electronically adjusts injector duration accordingly. 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-Io 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). 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. E.T. Ignition: Energy Transfer ignition. Generates primary ignition voltage through electro magnetic induction.
9/97
1.20

Flat Head Bolt: To be used where finished surfaces require a flush fastening unit. Countersunk. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. Fuel Pressure Regulator: Mechanical device in an EFI system which regulates fuel pressure in the distribution manifold by returning excess fuel to the tank. Fuel Rail: The fuel distribution manifold for the injectors in an EFI system. 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. Mounted under running boards, 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. 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, primary charge coil. Stator plate coil which generates primary ignition voltage. COl system uses one ignition generating coil. Twin cylinder E.T. ignition systems use two Ignition generating coils. Coil is mounted at the top of the stator plate. inch Pound: In. lb. 12 in. Ibs. = 1 ft. lb. Kg/cm2: Kilograms per square centimeter. Metric equivalent of PSI. Keystone Ring: A piston ring with bevel on upper inside 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. Ibs. 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 us 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 metric system. 1mm = .040". Mag End: Flywheel side of engine. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. This is how mechanical energy in our engines Is converted to electrical energy in the lighting coil, ig nition generating coils and trigger coil. Ohm: The unit 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. 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.
f}m
'-.--
"----
1.21
9/97

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) too hot a spark plug; 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. Parts of this circuit include the exciter coil, points and condenser, wires from the stator plate to the small primary winding in the ignition 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. Required in Canada. RPM: Revolutions Per Minute. Relay Coils: Electromagnetic device in an EFI system which controls circuit connection with input from another circuit. 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. ..../
.-./
Round Head Screw:The familiar head most universally used for general application. Good slot depth. ample underhead bearing surface and finished appearance are characteristic of this head. Running Time: Ignition timing when fully advanced or 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 cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Select Monitor: Diagnostic tool wh ich provides static and dynamic displays of the function of critical components in an EFI system. It also has the capability to display the contents of the ECU memory. 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 1800 of crankshaft rotation. Surge Tank: The fill tank in the liquid cooling system. TOC: Top Dead Center. Piston's most outward travel from crankshaft. Throttle Body: The air flow metering device in an EFI system. Transfer: The movement of fuel/air from the crankcase to the combustion chamber in a two stroke engine. Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI systems. Small coil mounted at the top of th e stator plate next to the ignition generating coil. V Regulator: Voltage regulator. increases. Maintains maximum lighting coil output at approx. 14.5 ACV as engine RPM
Venturi: An area of air constriction. A venturi is used in carburetors to speed up air flow which lowers pressure in venturi to below atmospheric pressure, causing fue l to be pushed through jets, etc., and into the venturi to be mixed with air and form a combustible air/fuel mixture. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the CIrcuit. Watt: Unit of electrical power. Watts = amperes x volts.
9/97
1.22
GENERAL INFORMATION Service Tips
In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this manual, thoroughly familiarizing him/herself with procedures before beginning. Pictures and illustrations have been included with the text as an aid. Notes, cautions and warnings have also been included for clarification of text and safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to perform the service work safely and satisfactorily. Use only genuine Polaris service parts .
.&. Cleanliness of parts and tools as well as the work area is of primary importance.
Dirt and foreign matter will act as an abrasive and cause damage to precision parts. Clean the snowmobile before beginning service. Clean new parts before installing . Protect hands
.&. Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel.
with gloves when working with sharp components.
'--"
.&. If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be
found . If it is necessary to tap the part into place, use a soft face hammer and tap lightly.
.&. Some of the fasteners
in the snowmobile were installed with locking agents. Use of impact drivers or wrenches will help avoid damage to fasteners . machine damage or, as in the case of steering components, can result in injury or death for the rider(s) .
.&. Always follow torque specifications as outlined throughout this manual. . Incorrect torquing may lead to serious .&. If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten.
Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value. When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before removing them .
.&. If the condition of any gasket or O-Ring is in question, replace it with a new one.
around the gasket are clean and smooth in order to avoid leaks .
Be sure the mating surfaces
.&. Some procedures will require removal of retaining rings or clips.
Because removal weakens and deforms these parts, they should always be replaced with new parts. When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation .
.&. Becau se removal damages seals, replace any oil or grease seals removed with new parts . .&. Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the
top performance and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted .
.&. Grease
should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating grease loses lubricity and may contain abrasive foreign matter.
.&. Whenever removing
or reinstalling batteries, care should be taken to avoid the possibility of explosion resulting in serious burns. Always disconnect the negative (black) cable first and reconnect it last. Battery electrolyte contains sulphuric acid and is poisonous I Serious burns can result from contact with the skin , eyes or clothing. ANTIDOTE: External - Flush with water. Internal - Drink large quantities or water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes and get prompt medical attention.
1.23
9/97
GENERAL INFORMATION Warranty Policy

LIMITED WARRANTY Polaris Industries Inc. , 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, gives a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. Details of warranty period and coverage may vary by model. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the "customer copy", please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR SNOWMOBILE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your snowmobile is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. WARRANTY COVERAGE AND EXCLUSIONS; LIMITATIONS OF WARRANTIES AND REMEDIES The warranty excludes any failures that are not caused by a defect in material or workmanship. Th is warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any snowmobile that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or snowmobile due to fire, explosions or any other cause beyond Polaris' control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the snowmobile. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above lim itations or exclusions may not apply to you if inconsistent with controlling state law. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law. HOW TO OBTAIN WARRANTY SERVICE If your snowmobile requ ires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY) . Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at Polaris. This warranty also gives you specific legal rights, and you may also have other rights which vary from state to state. If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect. Engine Oil 1. Always use Polaris 2-Cycle engine oil. 2. Never substitute or mix oil brands as serious engine damage and voiding of warranty can result.
9/97
1.24
GENERAL INFORMATION Special Tools

Special tool part numbers and usage are listed in each section of this manual as required for a specific service procedure. For complete tool information refer to the Service Tool Catalog (PN 9914681). U.S. dealers can obtain a current price list or get tool information by contacting Victor Specialty Tool Company at the address, phone or FAX number listed below. Canadian dealers can obtain this information by contacting the Winnipeg parts department at (204)-925-7125. Dealers serviced by a distributor should follow tool ordering procedures established by their respective distributor parts department.
POLARIS
SPECIAL TOOLS
VICTOR SPECIALTY TOOL CO.

66 School Street Victor, New York 14564
TO PLACE AN ORDER
Toll Free Tool Order FAX Numbers (U.S.)1-800-716-3938 (Canadian Dealers) 1-800-413-4441
Phone Orders or Information (U.S.) 1-716-742-1790 (Canadian Dealers) 1-204-925-7125
1.25
91 97
CHAPTER 2 MAINTENANCE I TUNE UP

Maintenance Inspection Forms . . ....... . ....... 2.1 - 2.2 Recommended Maintenance Products . . . ... .. .. 2.3 Lubrication . . . ............ . ...... . ............ 2.4 - 2.6 Chaincase Lubrication / Chain Adjustment .... 2.7 - 2.8 Suspension Lubrication .......... . ......... . . " 2.9 - 2.10 Cooling System .... ... . . . . .. .... . ...... . .... 2.11 Track Maintenance/Alignment .... . ............. 2.12- 2.16 Spark Plugs ..... .. ............... . .... . . ..... 2.17 Spark Plug Charts .. ... . .. . ... .. ...... ....... 2.17a - 2.17b Drive Belt Removal/Installation .. .. ... . .. . .. .... 2. 18 Backrest Adjustme nt .... . ........... . .. .. .. ... 2.19 Head light Adjustment ............... . ...... ... 2.20 - 2.22 Handlebar Adjustment .. . .... .. ...... ... .. . .... 2.23 Brakes ..... . ....... . . .... . ... ....... 2.24 - 2.25a Exhaust System ....... . .. . . .. ... . ............ 2.25 Reverse Cable Adjustment . ... .... ... . .. .. .. . .. 2.25b Off Season Storage ....... . .. . .. . ............. 2.26 - 2.28 Variable Exhaust System (V. E.S.) Main tenance Routing Diagrams . .... . . .. ... .. .. ........ . 2.28a - 2.28e 2.29 - 2.70
MAINTENANCEfTUNE UP
Maintenance Schedule 500 Mile (805 km) Initial Maintenance Inspection
Customer Name ______________________ Phone _ _ _ _ _ _ __
Machine Model _ _ _ _ _ _ _ _ Machine Serial _ _ _ _ _ _ _ _ _ Miles _ _ _ _ _ __
Torque cylinder head{s) (cold) & cylinder base nuts Only the following models need to have their cylinder
heads periodically re-torqued :
EC342PM(E)02, EC44-3PM01 & 02 (PRIOR TO 1996) EC50-PM(E) 03,04,05 &06, EC50PL(E) 17,19,19 & 20 EC65-PL(E)05 Check ignition liming observed BTDC
_ 17a.BrakesHydraulic A. Check brake fluid level. Should be 1/4" from top on large style reservoir, 1/8" from lop on older small style reservoir.
B. Check tor proper hose security and routing
C. Check lor system lIuid leaks

O. Visually inspect pads for wear damage or looseness
corrected BTDC
E. Check security and surface condition of brake disc.

17b Brake-Mechanical
_3.
_ 4.
Check clutch offset (bell removed) Check belt condition Check and adjust belt tension Inspect rubber engine mounts
A. Lubricate brake cable. NOTE: Must use Polaris Cable

lubricant. B. Check brake pad and brake disc condition and mounting C. Adjust brake to proper specifications
_5. _6.
_ 7.
Torque engine mounting plate 10 chassis fasteners Adjust engine torque stop (if equipped)
Carburetor Inspections
_ 8.
_ 9.
18. Check auxiliary shut-off switch _, 9. Perform throttle safety switch tests
_ 20. Check brake light for proper operation
_ 21. Check taillighis
A. B.
Adjust choke plungers

Adjust pilot air screw
C.
Synchronize carburetor slide valves at idle

and off idle Adjust engine idle RPM
_ 22. Check headlamp security and highlow beam ope ration. _ 23. Liquid cooled models:
A. Check coolant level and specific gravity
O.
E.
F.
10. A.
Adjust throttle lever free play

Synchronize oil pump lever Check and adjust throttle position sensor Check and adjust MR screw Check battery state of cha rge Adjust idle RPM Check charging system Adjust throttle lever free play Synchronize oil pump lever
B. Check waler pump drive bell condition & deflection

(where applicable)
Electronic Fuel Injection System Inspections
C. Check coolant hose, routing and clamps

D. Inspect heat exchangers condition and fasteners
B.
C. O. E.
E. Check cooling system for proper coolant circulation.

_ 24. Lubrica te reaf suspension pivot shafts.
_ 25. Check all suspension mounting fasteners .

Recomm endations
F.
G.
11 . 12. 13. 14 . 15 16.
Check ski toe alignment Torque and inspect all steering fasteners Torque suspension to tunnel mounting bolts Check rear suspension fasteners for tightness Adjust track tension and align track Remove chaincase cover, flush chaincase. inspect and adjust chain. refilt with new chaincase oiL
Polaris Service Technician _ _ _ _ _ _ _ __ __ _ __ Authorized Oealer _ _ _ _ _ _ _ _ _ __ _ _ _ _ __
Base Inspection Price _ _ _ _ _ __ Parts _ _ _ _ _ _ _ _ _ _ __
Date _ __ _ _ _ _ _ _ _ __
Labor ___________________________
2. 1
9/97
MAINTENANCE/TUNE UP Maintenance Schedule

1500 Mile (2400 km) Maintenance Inspection
Customer Name ___________________________________ Phone ______________ Machine Model ____________ Machine Serial _____ _ __ Miles _ _ _ __ ,
Torque cylinder head(s) & cylinder base nuts (cold) Only the following models need to have their cylinder heads & cylinder base nuts periodically re-torqued: EC34-2PM(E)02, EC44-3PM01 & 02 (PRIOR TO 1996) EC5G-PM(E) 03,04,05 &06, EC5G-PL(E) 17,18,19 & 20 EC65-PL(E)05
_19a. Brakes-Hydraulic
A. Check brake fluid level. Should be 114" from top on large style reservoir, 1/8" from top on older smaJi style reservoir. B. Check for proper hose security and routing
C. Check for system fluid leaks
_2. _3.
Check compression and record readings Check ignition timing

obseNed BTDC corrected BTDC
D. Visually inspect pads for wear damage or looseness
E. Check security and surface condition of brake disc.

F. Flush brake fluid and change every two years .
_19b. Brake-Mechanical A. Lubricate brake cable. NOTE: Must use Polaris Cable
Inspect recoil starter rope

Check drive to driven clutch offset (be~ removed)
..J
lubricant.
B. Check brake pad and brake disc condition and mounting C. Adjust brake to proper specif<:ations _20. Check auxiliary shut-off swttch & per10rm throttle safety
Remove clutches, disassemble & Inspect all wear surlaces. Clean sheaves, repair dutch as necessary. reassemble clutches and torque to specifications.
_7.
_8. _ 9.
_to. _11.
Check belt condition Check and adjust belt deflection
switch tests.
_21. Inspect brake light, taillight. oil light and all elect,.,.. accessories _22. Inspect HilLo beam operation and aim headlight _23. Uquid cooled models: A. Check ooolant level and specific gravity B. Check water pump drive belt condition & deflection (where applicable)
Inspect rubber engine mounts Torque engine mounting plate to chassis fasteners
Adjust engine torque stop (if equipped)
Carburetor Inspections
A. Adjust choke plungers
B. C.
D. E.
Adjust pilot air screw Synchronize carburetor slide valves at idle and off idle
Adjust engine idle RPM Adjust throttle lever free play
C. Check coolant hose. routing and clamps D. Inspect heat exchangers condition and fasteners E. Check. cooling system for proper coolant circulation F. Replace recovery line filter: NOTE: Must use correct filter G. Check coolant recovery line one way dleek valve (must hold
pressure)
F. Synchronize oil pump lever Electronic Fuel Injection System Inspections A. Synchronize throttle bodies B. Check and adjust throttle position sensor
C. D. Check and adjust MR screw Remove battery, check fluid level and specnic gravity of each cell. Charge necessary. Adjust idle RPM Check charging system Adjust throttle lever free play
H. Pressure test cooling system

_24. Fan Cooled: Inspect cooling fins and shrouds
_25. Remove chaincase cover, flush chaincase, inspect chain &

sprockets and adjust chain. Inspect chaincase seals.
_26. Check condition of drive shaft and jackshaft bearings. Lubricate greaseable bearings with Premium All Season grease. _27. Inspect and adjust reverse cat>e (il applicat>e) _28. Remove ski pivot bushings and lubricate
E.
F.
G. H.
_29. Inspect ski wear bars, replace if wom to 112 original diameter
_ 30. Check camber alignment and lubricate spindles
Synchronize oil pump lever I. Replace secondary fi~er @ 5,000 miles Remove chaincase cover, flush chaincase, Inspect and adjust chain, refill with new chaincase oil.
_14. _15. 16. 17. _ 18. Change primary fuel fi~er and oil fi~er
_31. Remove radius rod end bushings, lubricate and reinstall, inspect aU
radius rod ends.
_32. Reinstall skis and inspect/adjust toe alignment

_33. Check handlebar centering and lubricate steering bell crank
_34. Torque tie rod end bolts and Jam nuts _35. Inspect steering arms and torque bolts. Inspect handlebar bolt
Check. fuel and oil line condition and routing Inspect fuel and oil tank vent lines/routing Inspect airbox frtlair fitter. Clean or replace
Change shock oil (Fox) annually before storage
Polaris Service Technician: ___________________

Authorized Dealer: _________________________ Base Inspection Price: _________-,-___________ Date: Parts: _______ Labor. ________
torque _36. Lubricate rear suspension pivot shafts (1000 mile Intervals) _37. Torque suspension mounting 00lt5 and check all rear suspension fasteners and components _38. Inspect rear suspension wheels. bearings and hi-fax _39. Inspect lrack for damage. Adjust tension and alignmenl For optimum performance and reliability, repeat the above maI ntenance and Inspections annually (preferably before off-season storage) or every 1500 miles. except where noted.
RECOMMENDATION: ____________________________
9/97
2.2
MAINTENANCEfTUNE UP Recommended Maintenance Products Recommended Maintenance Products

ENGINE OIL Part # 2871721 2871722 2871723
Description Packaging (size I quantity) Quart Cans / 6
RETAINING/SEALING PRODUCTS Part #
Description
Primer N, Aerosol
Packaging (size/quanlily)
Synthetic 2-Cycle Premium Gold Synthetic 2-Cycle Premium Gold

Synthetic 2-Cycte Premium Gold Premium 2-Cycle Oil (TC-W3) Premium 2-Cycle Oil (TC-W3) Premium 2-Cycle Oil (TC-W3) Premium 2-Cycle Oil (TC-W3) Premium 2-Cyele Oil (TC-W3) Premium 2-Cyele Oil (TC-W3) Premium-4 Synthetic 4 Cycle Oil (OW-40) Prem ium-4 Synthetic 4 Cycle 011 (OW-40) MAINTENANCE PRODUCTS
2870585 2870584
2871949
25gr / l
lOee I 50ee 1 10 6ee 112 50ee 1 10 6ee 1 12
Sec 1 12
36cc 1 6
Gallon 14 16 Gallon Drum Quart Cans 112 Gallon 16 2.5 Gallon 12 16 Gallon Drum 30 Gallon Drum S5 Gallon Drum
Quart Cans 1 12
680 Retaining Compound

Threadlock 242 Threadlock 242
Thread lock 262
2871098 2871097 2871240

2871566 2871385
2871950
2871951 2871952 2871953 287 1954 2871955 2871956 2871957 2871958
Threadloek 262 Threadlock 271

Threadlock 271
2871096
2871281 2871567
Instant Adhesive : Prisim 401

Pipe Sealant 565
3ee 130 50ee 16
16 Gallon Drum
SUlcone , Black ATV Silicone. Black RTV

Ultra Blue RTV Ultra Blue RTV 518 Flange Sealanl
30z lube / 12
11
oz Cartridge/12
2871326 2871478 2871477 2871280
Carbon Clean Plus Premium Synthetic Gearcase Lube Premium Synthetic Gearcase Lube Chain Case Lubricant Chain Case Lubricant Premium AnlJfreeze 60/40 Premix Premium Antifreeze 60/40 Premix Premium Gas Shock Oil Premium Brake Fluid DOT3 Premium Fogging Oil (spray) Premium Fogging Oil (liquid wilh spout) Premium Fogging Oil (liquid) G rease Gun Kit (All Season) Premium All Season Grease Premium All Season Grease Premium Starter Grease Barrel Pump (for 16/30/55 gallon drums) Flex Spout (fits gallon and 2.5 gallon
12oz / 12 12oz / 12 Gallon 14 Quart 1 12
2871959 2871960 2871961
3.35 oz 1 12
13 oz Cartridge/12
50ee l 10
SOcc
CRANKCASE SEALANTS
2870464
2871323 2871534
Gallon 16
Gallon / 6
2870587
2871557
518 Gasket Eliminator Supercedes 515
Quart 1 12 Quart 16
120z / 12
3 Bond 1215
50z
2870995 2870990 2870791

2871517 2871518 2871312 2871322 2871423
12oz / 12
Quart I 12
Gallon / 6 3 oz 14
3 oz/24
14oz / 10
2871460
2871592 2871285 2870505 2870652 2871027 2871064
2 oz 1 12
Each
25
10oz / 24
jugs)
Isopropyl Fuel $Iabilzer Corrosion Resistant DiElectric Grease T9 Metal Protectant Metal Polish Battery Tender ,..
16oz / 12
20z
2870632
2871076
80z
2.3
91 97
MAINTENANCErrUNE UP
Lubrication
Lubricate the following fittings with Polaris Premium All Season grease annually or approximately every 1000 miles (1600 km) . Remove weight from the component being greased to permit better penetration and flushing of the joint. Spindles, left and right. Rear suspension pivot shafts. Lubricate both front ski pivots at fitting as shown using low temperature grease . Grease jackshaft and driveshaft (clutch side) bearings. Grease steering post support bra cket bushings.
Typi cal Spindle
Traiting '97+
Ski Spindles and Bushings <lireasv
Grease center steering arm (bell crank), pitman arm, and idler arm (where applicable).
NOTE: A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles.
,,-"'I~~~~~~-~~~ -_ 'f:!I _
Pitman Arm
Idler Arm
Polaris Premium All Season Grease 14 oz. PN 2871423 Grease Gun Kit PN 2871312 Jackshaft Bearing Greasing
Loosen driven clutch retaining bolt and pull clutch outward to expose bearing. Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal. Push clutch back onto shaft and replace clutch retaining bolt. Grease
Center Sleering Arm (Bell Crank)
Steering Post
Bushings
Grease Gun Adapter: 2871174 Point Type

Jackshaft Bearing
Driveshaft Bearing Greasing

Inject grease into fittin g on speedometer drive adaptor until grease purges out inside or outside bearing seal.
Driveshaft Bearing Greasing - WideTrak
WideTrak
9/97
2.4
MAINTENANCEfTUNE UP
Water Pump Gear Case 1996 Ultra Models
The water pump gear case is a sealed unit on 1996 EC68PL (Ultra) engines and required separate oil level maintenance. 1997 models are open to the crankcase and periodic maintenance is not required. The level should be inspected every 1000 miles on 1996 models, and changed annually (end of season before storage).
1996 Models Remove fill plug A to add oil r \
(1-'->"l 0'/
,'Ci'
Water Pump Oil Level Inspection (1996)

4. 5. With the machine on a level surface , check the fluid level in the sight glass. If the oil level is below the top of the sight glass (see illustration at right). remove filler plug and add Polaris Premiu m 4 OW40 synthetic oil as required to bring the level back up to the top of the sight glass. 1996 Models Oil level should be at top of sight glass
Drain Plug
CAUTION:
Failure to maintain the proper level could result in severe engine damage.
NOTE: Care should be taken when checking the oil level not to confuse the level with the water pump gear which can be seen through the glass. Be sure that what you are seeing in the window is indeed the oil level and not the gear.
Should overfilling occur, drain to proper level by removing drain plug. An atmospheric vent located on the crankcase just below the mag and center carburetors will allow a small amount of excess oil to be vented out of the case.
Water Pump Oil Change (1996)

1. To change lubricant, remove drain plug. 2. Allow oil to drain completely and re install plug . Torque to 12 ft . Ibs. 3. Add oil to top of sight glass as outlined in oil level inspection.
1997 to Current Ultra Models

Periodic maintenance is not required on 1997 to current EC68PL engine water pump gear case. The drive gears are lubricated by engine oil. Do not add oil to the gearcase on 1997 to current models.
1997 Current 600 & 700 Domestic Twins

The water pump belt on all 600 & 700 domestic twins snowmobile engines should be inspected every 1500 miles. Belts should be inspected by measuring the width at several locations around the belt. Belt width at any location should not be thinner than .250" (6.35mm). Replace the belt if you notice any loose cords, broken cracked or missing cogs, and varialIOns in width . If the water pump belt fails, serious engine damage could result. Nominal thickness of a new belt should be approximately .345" (8 .75mm) . Check belt tension by rotating crankshaft 118 turn at a time. The tension should be equal at all points of rotation.
Replace if width is less than .25" (6.35mm). Nominal new widt h is .345" (8.75 mm ).
2 .5
9/97
MAINTENANCErrUNE UP
Lubrication Water Pump Belt Tension - Fuji
1. Loosen pump mounting bolts . 2. Push on pump housing to apply tension to belt and hold in this position. Tighten pump mounting bolts. Apply light pressure at center of belt span. Check total deflection of belt span and compare to specifications. Re-adjust if necessary.
3.
Water Pump Belt Tension

1/8" - 3/16"
(3-4mm)
Throttle Cable Lubrication

With the engine off, remove the throttle cable from the throttle flipper and block. Lubricate the throttle cable with Polaris Clutch and Cable Lubricant. Turn the handlebars to the left and lubricate liberally as shown.
Polaris Cable Lube

PN 2870510
Choke Cable Lubrication

Lubricate the choke slide and cables as shown with Polaris Cable Lubricant. Operate the choke intermittently before turning the machine off. This draws moisture out of the choke plunger area and reduces the possibility of the choke becoming frozen .
9/97
2.6
MAINTENANC ErrU NE UP Chaincase

Chaincase Oil Level (All Except WideTrak Models)
Proper chaincase oil level is determined by checking the level on the dipstick with machine placed on a level su rface. The oil level should be between the "safe" marks on the dipstick. Add oil through dipstick opening as required to maintain proper level. Use Polaris Chaincase Lubricant or Polaris Synthetic Chaincase Lubricant. 00 not overfill.
Chain case Lubricant PN 2870337 Synthetic Chaincase Lubricant PN 2870337 Refer to Page 9.1-9.1b. for model type and . capacity
CAUTION:
Polaris Synthetic Chaincase Lubricant is compatible with Polaris petroleum based chaincase oil and can be mixed. However, do not mix or use other types of lubricant. Excessive wear to chain , sprockets and bearings may result.
E :--==~~~~31";[FEmF:O=:= ~
Magnetic Plug
Drive Chain Tension (All Except WideTrak Models)

To obtain correct chain tension: 1. 2.
3. 4.
Remove drain plug (F) and drain oil into a suitable container. Dispose of properly. Remove the chaincase cover. While putting a slight reverse tension on the chain by turning brake disc as indicated by the arrow (A). there should be approximately 1/4-3/8" (.6-1 cm) deflection on the chain at point (B). The chain is adjusted by loosening the adjusting bolt locknut (e) and turning adjusting bolt (D) until correct chain deflection is obtained . Reinstall the chaincase cover and drain plug. Add Polaris chaincase lubricant (PN 2870337) through the dipstick opening to the level described above.
"--'
5 . Lock the adjusting bolt locknut (C) while holding a wrench on the adjusting bolt (D) to prevent it from turning .
6.
NOTE: Clean the magnetic plug (E) every 500 miles (800 km) and whenever checking or changing lubricant.
The chain may also be tightened without removing the cover using the following procedure. Do Not over-tighten! 1. 2. 3. Rotate driven clutch counterclockwise to move all chain slack to the tensioner side . Loosen the adjuster bolt jam nut. Finger tighten the adjuster bolt until no movement or slack can be detected on the jackshalt when moving the driven clutch back & forth. Some play may be evident on driven clutch key way. and must not be confused with movement on the jackshaft. Back off the adjuster bolt by 1/4 turn. Tighten the jam nut while holding the adjuster bolt.
The chain is now tensioned. Release the brake lock lever.
4.
5. 6.
Observe jackshaft while rotating driven clutch to check for drive chain slack
2.7
9/97
MAINTENANCEfTUNE UP
Chaincase Chaincase Oil Level (WideTrak Models)
Maintain the proper oil level by removing the magnetic check plug. Remove the fill plug and add lubricant until a small amount of oil flows from ,he check plug hole. Wipe off any metal particles from the magnetic check plug. Small amounts of particles will be common on this plug. Reinstall the check plug and fill plug. Use Polaris Synthetic Chaincase Lubricant
Polaris Synthetic Chaincase Lubricant 1996 . .... .. .. 11 fl. oz. (330cc) 1997/1998 . . .. 20 fl. oz. (600cc)
CAUTION :
Drain Plug
Polaris Synthetic Chaincase Lubricant is compatible with our petroleum based chaincase oil and can be mixed. However. do not mix or use other types of lubricant. Excessive wear to chain, sprockets and bearings may result.
Drive Chain Tension (1996 and prior WideTrak Models & all models with reverse kits installed)
To obtain correct chain tension: 1. 2. 3. 4. 5. Loosen locknut and chain adjuster. Rotate driven clutch in the normal direction of rotation (top forward) to apply slight tension on drive chain. Tighten adjuster bolt to 20 In. Ibs. (,23 Kg-m) Back off adjuster bolt (counterclockwise)l 1/4 to 1 1/2 turns. Hold adjuster bolt in position and tighten locknut.
Drive Chain Tension (1997 WideTrak Models)

The 1997 model WideTrak Transmissions have self-adjusti ng chain tensioners and no adjustment is necessary.
Drive Chain Tension (1998 WideTrak Models)

Drive chain service is not required on 1998 model WideTrak Transmissions.
9197
2.8
MAI NTENANCEfTUNE UP
Suspension L ubri cati o n Suspension L ubrication '-..,. To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease, PN 2871423, at 500 miles (800 km) initially; 1000 miles (1600 km) and befo re summer storage each year. The riding characteristics of the snowmobile will be affected by lack of lubrication of these shafts. NOTE: A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles. Ord er PN 287 1312.
Polaris Premium Grease PN 2871423 Grease Gun Kit PN 2871312 Refer to the follow ing diagrams for suspension lubrication points. Sport Style and WideTrak Style
* LUBRICATION POINTS - Sport I WideTrak

Grease all fittings
Forward
*
*
* LUBRICATION POINTS - XTRA-Lite

Grease all fittings
2 .9
9/97
MAINTENANCE/TUNE UP Suspension Lubrication

Suspension Lubrication
XTRA 10 Style
Grease at fittings
* LUBRICATION POINTS
*
Forward
* *
Grease at fittings
XTRA 12 Style
* LUBRICATION POINTS
N~--*
Forward
(Both sides)
* *
2.10
11 /95
MAINTENANCEfTUNE UP
Cooling System
WARNING
Never remove the pressure cap when the engine is warm or hot. If the pressure cap is to be removed. the engine must be cool. Severe personal injury could result from steam or hot liquid. Use of a non-standard pressu re cap will not allow the recovery system to function properly. If the cap should need replacement. install the correct Polaris cap with the same pressure ratin g. Refer to the appropriate parts manual.
Coolant Level
Coolant level in the reservoir or surge tank must be maintained between the minimum and maximum levels to prevent overheating and serious engine damage.
Recommended Coolant
Use a 50/50 or 60/40 mixture of antifreeze and distilled water depending on the freeze protection required for your area. Do not use tap water in the system or reduced cooling or filter contamination may result. Replace coolant every 2 years or if contaminated. Inspect coolant filter annuallyfor contamination and replace if necessary.
COOLANT
o
0
Check Valves - tapered
,-"
~
~
\ Flow
'"'
po~.:
""ct;oo
" Check Valve Filter
Filter - Filter is located before the check valve
Bleeding the Cooling System - Pressure Caps

If the cooling system should become low in the tank and/or filler neck. the system should be bled of any trapped air using the following procedure: Lift Lock Lever To Bleed Remote Filler Neck Bleed at 600 RPM
1. Allow the system to cool completely. Fill the reservoir with coolant to the maximum indicated mark.
2. With pressure cap rem oved. add coolant and fill to the top of the filler neck. Install the pressure cap with the lever lock up in its release position and run the engine at fast idle for two to three minutes. This will purge the system of trapped air. Close the lever lock and check recovery tank fluid level. CAUTION : On models equipped with remote filler neck. low idle RPM must be used for bleeding (600 RPM 100) to allow all air to purge and prevent trapped air which can lead to overheating. Reset idle to specified RPM after bleeding.
3.
'" ~
~ ~l
Filler Neck On Cylinder Head Bleed at fast idle Caution : Increase RPM slowly when lever lock is up to avoid loss of coolant.
Remote Filler Neck Shown
Bleeding the Cooling System - Surge Tanks

If the cooling system should become low in the surge tank.
the system must be bled of any trapped air using the following procedure: 1. 2. Allow the system to cool completely. Fill the surge tank wi th coolant to the maximum indicated mark. Start the engine and loosen the bleed screw on the top of the water pump until trapped air has been purged. Tighten the bleed screw. Loosen the bleed screw at the end and top of the water outlet manifold until trapped air has been purged. Tighten the bleed screw. Recheck the su rge tank coolant level and add coolant again if necessary. Fill Surge Tank Manifold Bleed Screw
3.
I ~ <~
i
I
~"" ~
~~'
r
,
4.
"r
,
.....
2.11
9/97
MAINTENANCEITUNE UP
Track Maintenance! Alignment

it. WARNING
When performing the following checks and adjustments. stay clear of all moving parts to avoid serious personal injury.
Track Maintenance it. WARNING

Nevermake this maintenance check with the engine running as serious personal injury can result. Using a hOist. safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for any possible damage. To inspect track rods. carefully examine the track along the entire length of each rOd. bending the track and inspecting for breakage. The three most common places where breakage occurs are shown in the illustration. If any rod damage is found. the track should be replaced .
2 1
3
1 2
it. WARNING
Broken track rods are a serious hazard. since they can cause a rotating track to come off the machine. Never operate or rotate a torn or damaged track under power. Serious personal injury or death may occur.
Track window
Track Alignment
Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail. A periodic check should be made to see that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. NOTE: If excessive hi-fax wear occurs due to poor snow conditions. additional wheel kits are available. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine. 3. Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side. If the track runs to the left. loosen left locknut and tighten the left adjusting bolt. If the track runs to the right. loosen right locknut and tighten the right adjusting bolt. 4. After adjustments are complete. be sure to tighten locknuts and idler shaft bolts. Torque to specification.
Rall _ _~
Looking through track window. make sure the rails are evenly spaced on each side.
Hi-fax
Idler Shaft Bolt
11/95
2.12
MAINTENANCErrUNE UP
Track Maintenance/Adjustment Track Tension Data
Suspension
Weight
Measurement Location
Measurement
(Refer to Suspension Chapter for type) XTRA 12 121" XTRA 12 133" XTRA 10 121".133". 136" Standard 121" (Sport & Lite) Lite GT WideTrak GT I LX and Transport XTRA Ute
none
2" behind rail bumper 16" ahead of rear idler shaft 16" ahead of rear idler shaft 16" ahead of rear idler shaft 16" ahead of rear idler shaft 16" ahead of rear idler shaft 16" ahead of rear idler shaft
1/2" (1.27 em) free hanging 1-1 1/8" (2.54 - 2.86 em) free hanging 3/8 - 1/2" (1 - 1.3 em) 3/8 - 1/2" (1 - 1.3 em)
none
10 Ibs. (4.54 kg) 10 Ibs. (4.54 kg) 10 Ibs. (4.54 kg) 10 Ibs. (4.54 kg) 10 Ibs. (4.54 kg)
1 1/4 - 1 1/2" (3.2 - 3.8 em)

3/4 - 1" (1.9 - 2.5 em) 3/8 - 1/2" (1 - 1.3 em)
WARNING
When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury.
Track Tension - Sport and XTRA Lite Style

1.
2. Turn the machine off. Lift the rear of the machine and safely support it off the ground. Place a 10 lb. (4.5 kg) downward pressure on the track at a point approximately 16" (40.6 cm) ahead of the center of the rear idler wheel. Check for 3/8-1/2" (1-1.3 cm) slack between the inside of the track clip and the hi-fax (C). NOTE: Measure at the point where the weight is hanging. Traek
3.
All Models Except Lite GT 4.
Sport & XTRA Lite Style TraCk Tension 3/8 - 1/2" slack (1 - 1.3 cm) w/10 lb. (4.54 kg) weight Indy Lite GT
5.
10 lb. Weight (4.5 kg)
Check for 1 1/4- 1 1/2" (3.2-3.8 cm) slack between the inside of the track clip and the hi-fax (C). NOTE: Measure at the point where the weighl is hanging .
Indy Lite GT Track Tension 1 1/4 - 1 1/2" slack (3.2 - 3.8 cm) w/10 lb. (4.54 kg) weight
If the track needs adjustment: 6. Loosen rear idler shaft bolts (A) on both sides of the machine. 7. 8. 9. Loosen track adjusting bolt locknuts (8). Tighten or loosen the track adjusting bolts (D) evenly as necessary to obtain proper track tension. Tighten idler shaft bolts and adjuster bolt locknuts.
NOTE: Track alignmenl affects track tension. Misalignment will cause excessive wear to the track and slide rail. Excessive HI Fax wear will appear on units with track tension set too light. Refer 10 page 2.12 for alignment procedure.
2.13
9/97
MAINTENANCEITUNE UP Track Maintenance/Adjustment
WARNING
Track Tension - WideTrak LX & GT Style

Tension adjustments should be made only after the track is warmed up and limber. 1. 2. Turn the machine off. Lift the rear of the machine and safely support it off the ground. Place a 10 lb. (4.5 kg) downward pressure on the track at a point approximately 16" (40.6 cm) ahead of the center of the rear idler wheel.
3.
4. Check for 3/41" (1.92.5 cm) slack between the inside of the track clip and the plastic hifax (C).
NOTE: Measure at the point where the weight is hanging.
WideTrak LX & GT Style Track Tehsion 3/4 - 1" slack (1.9 - 2.5 cm) wl10 lb. (4.54 kg) weight
II the track needs adjustment: 5. 6. 7. Loosen rear idler shaft bolt (A) . Loosen locknuts (8). Tighten or loosen the track adjusting screws (D) as necessary to provide equal adjustment on both sides of the track .
NOTE: Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail. Excessive Hi Fax wear will appear on units with track tension set too tight. Refer to page 2.12 for alignment procedure.
9/97
2.14
MAINTENANCEITUNE UP Track Maintenance/Adjustment
WARNING
Track Tension - XTRA 10 Style

1. Turn the machine off.
2. Lift the rear of the machine and safely support it off the ground. Place a 10 lb. (4. 5 kg) downward pressure on the track at a point approximately 16" (40.6 cm) ahead of the cen ter of the rear idler wheel (D) . Check for 3/B-1 /2" (1-1 .3 cm) slack between the inside of the track clip and the hi-fax (C). NOTE: Measure at the point where the weight is hanging.
3.
'--'
4.
XTRA 10 121 " & 133/136" Style Track Tension 3/B 112" slack (1 -1.3 cm) w/l0 lb. (4.54 kg) weight
Track
If the track needs adjustment: 5. 6. 7. B. Loosen rear idler shaft bolts (A) on both sides of the machine. Loosen track adjusting bolt locknuts (S). nghten or loosen the track adjusting bolts (D) evenly as necessary to obtain proper track tension. Tighten idler shaft bolts and adjuster bolt locknuts.
Always inspect track alignment after track tension adjustment. NOTE: Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail. Excessive Hi Fax wear will appear on units with track tension set too tight. Refer to page 2.12 for alignment procedure.
2.15
9/97
MAINTENANCE/TUNE UP Track Maintenance/Adjustment A WARNING

Track Tension - XTRA 12 Style

1. 2. 3. Turn the machine off. Lift the rear of the machine and safely support it off the ground. Take measurement with track free hanging at a point 2" behind rail bumper or 16" ahead of rear idler on 133" tracks. The distance between the inside top of the track clip and the Hi-Fax should be as shown below and in the illustration at right. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new.
. XTRA 12 Styhf'l;l'ack Teqslon t

!' ~ )~:t,,, .
121" ' 1/2" (1.3 em) free hangIng 133" 1,'0 1 11S' (2.54 2.86 em) free
hanglng .
'",3;ol,;: ,, '
'
,,
'~j}J.
~ :' h
__ "
'f}:
If the track needs adjustment: 4. 5. 6. 7. Loosen rear idler shaft bolts on both sides of the machine. Loosen track adjusting bolt locknuts. Tighten or loosen the track adjusting bolts evenly as necessary to obtain proper track tension. Tighten idler shaft bolts and adjuster bolt locknuts.
Track
121 " = 1/2"
133" = 1-1 1/8"

Hi-fax
measured 16"ahead of rear idler center
Always inspecttrack alignment after track tension adjustment. NOTE: Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail. Excessive Hi Fax wear will appear on units with track tension set too tight.
11/95
2.16
MAINTENANCEITUNE UP
S pa rk Plugs Spark Plug Selection
Original equipment parts or their equivalent should always be used. However, the heat range of spark plugs is of utmost importance. A spark plug with a heat range which is too high will cause engine damage. A spark plug with a heat range which is too low will cause excessive fouling and malfunction .
In selecting a spark plug heat range for production, a manufacturer is forced to assume that the engine is going to operated under extreme heavy duty conditions. This protects the engine from internal damage in the event that the purchaser actually does operate the engine in this manner. This selection however, could cause the cus tomer who normally operates the engine under medium or light duty to have spark plug failure.
CAUTION: I
A plug with a heat range which is too high will always cause engine damage if the engine is operated in conditions more severe than that for which the spark plug was intended. A new engine can cause temporary spark plug fouling even though the heat range is correct, due to the preserva tive which has been added du ring assembly of the engine to combat rust and corrosion. Avoid prolonged idle speeds, as plug fouling and carbonization will result. Always use resistor type plugs.
NOTE: Incorrect fuel mixture can often cause a spark plug to appear to be too dark or too light in color. Before changing spark plug heat ranges, be sure the correct main jet is installed in the carburetor(s).
The spark plug and its condition is generally indicative 01 engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven under load. Immediately check the spark plug for correct color.
Normal
The insulator tip is gray, tan , or light brown . There will be a few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.
Wet Fouled
The insulator tip is black. A damp oily film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes are excessive oil, use of non recommended injec tion oil, excessive idling, idle too low or air screws adjusted too rich, or weak ignition output. 1. 2. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes . Clean with electrical contact cleaner or a glass bead spa rk plug cleaner only.
CAUTION :
A wire brush or coated abrasive should not be used. 3. 4. 5. Measure gap with a wi re gauge and adjust to specifications by bending side electrode carefully. Refer to page 2.18 for plug type and gap specification. Coat spark plug threads with a small amount of antiseize compound. Install spark plug and torque to specification.
Spark Plug Torque:

11 Ft. Lbs
2 .17
9/97
MAINTENANCE/TUNE UP Spark Plug Application Chart

1996 Models
Machine Model Indy Lite Models Indy Sport Models Indy Trail Models Indy 440 LC Indy 440 XCR Indy 440 XC R SP Indy 500/SKS/ RM KlCIassic Indy WideTrak GT Indy W ideTrak LX Indy 500 EFI Indy XLT 1 XLT SKS Indy XLT RMK Indy XLT Touring Indy XCR 600 1 XLT SP Indy 600 XC R SP Indy RXL Indy Ultra SP/SKSI (RM K) Indy Storm/SKSI (RMK) Engine Model
EC34-2PM02lE02 EC44-3PM01l02 EC50PM041 E04 EC45PL06 EC45PL07 EC45PL08 EC50PLE 1111111 4115 EC50PM03 EC50PLE12 EC50PL13 EC58PL03 EC58 PL07 EC58PLE05 EC5802 EC59PLOl EC65PL05 EC68PLOl 1 (04) EC80PL05 1 (04)
Spark Plug NGK

BABES BABES BABES BR8ES BR9ES BR9ES BR8ES BRBES BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR9ES BASES BR9 ES BR9ES
MMI nches
PIU p, Gap
Champion
AN-3C RN-3C RN-3C RN-3C RN-2C RN-2C RN-3C RN-3C RN-3C RN-3C RN-3C RN-3C RN-3C RN-2C RN-2C AN-2C RN-2C RN-2C 0.71.028 0.7/.028
--./'
0 .71.028 0. 71.028 0.71.02 8 0.71.028 0 .71.028

0.7/.028
0 .71.028
0.71.028 0.71.028 0.7/.028
0.71.028
0 .7/.028 0.7/.028 0.7/.028
0 .71.028 0.71.028
1997 Models
Machine Model Indy Lite Mod els Indy SportlTranSportiSport To uring Indy XC F Indy TraillTrail Touring Indy Trail RMK Indy Super Sport Indy WideT rak GT Indy Wide Trak LX Indy 440 LC Indy 440 XC Indy 440 XCR Indy 500 RM K Indy 500/S KS Indy Classic Indy 500 EFI Indy Classic Touring Indy XLT/SKS Indy XLT RMK Indy 600 XC Engine Model
EC34-2PM02 EC44-3PM02 EC44-3PM02 EC50PM04 EC50PM05 EC50PM06 EC50PM03 EC50PL20 EC45PL09 EC45PL08 SN44LCOCSP-Ol EC50PL16 EC50PLE 17 EC50PL11 EC50PL18 EC50PL19 EC58PL03 EC58PL07 EC58PL08
Spa rk Plug NGK

BR8ES BR8ES BR8ES BRBES BABES BABES B RBES BR8ES BR8ES BR9ES BR9ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES
Champion
RN-3C RN-3C RN-3C RN-3C RN-3C RN-3C RN-3C AN-3C RN-3C RN-2C RN-2C RN-3C RN-3C RN-3C RN-3C RN-3C RN-3C RN-3C RN-2C
Plug Gap MMllnches

0.7/.028
0.71.028 0 .7/. 028 0 .7/. 028 0.71.028 0 .71.028 0 .7/.028 0.7/. 028 0.7/.028 0 .7/. 028 0 .71.028
0.7/.028
0.7/.028 0.71.028
0.7/.028 0.7/.028 0.7/.028
0 .7/.028 0.71.028
Bold Indicates production spark plug.

9/97
2.17a
MAINTENANCE/TUNE UP
Spark Plugs 1997 Models (continued)
Machine Model Indy XLT Touringl XLT LTD Indy XLT SP 1 XLT LTD SP Indy 600 XCR/SE Indy RXL Indy UltraiSPlTouring Indy Ultra SPX/SPX SE Indy 700 XC Indy 700 SKS Indy 700 RMK Indy Storml S E Indy Storm RMK Engine Model EC58PL09 EC58PL1 2 EC59PLOl EC65PL05 EC68PLOl EC68PL03 SN70LCDCSP-Ol SN70LCDCSP-Ol SN70LCDCSP-02 EC80PL05 EC80PL04 Spark Plug BR8ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES RN-3C RN-2C RN-2C RN-2C RN -2C RN-2C RN-2C RN-2C RN-2C RN-2C RN-2C
MMI nches
0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028
PIU~ Gap
1998 Models
Mach ine Model Engine Model Spark Plug NGK Lite Models SporVTranSporVSport Touring/X CF Super Sport TraillTrail Touring Trail RMK 440 XCR 440 LC 500 RMK 500 Classic Classic Touring WideTrak LX XLT SP XLT LTD XLT Touring XLT Classic 600 XC 600XCR 600 RMK UltraiTouring 700 XC 700 XCR 700 RMK Storm Bold Indicates production spark plug. EC34-2 PM02A EC44-3PM024 EC50PM061 EC50PM043 EC50PM051 SN44-44LCDCSP-Ol EC45PL091 EC50PL161 EC50PL 171 EC50PL 171 EC50PL 191 EC50PL201 EC58PL140 EC58PL130 EC58PL130 EC58PL150 SN60-70LCDCSP-01 EC59PL020 SN60-70LCDCSP-02 EC68PL050 SN70-70LCDCSP-02 EC68PL060 SN70-70LCDCS P-01 EC80PL052 BR8ES BRSES BR8ES BR8ES BR8ES BR9ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES Champion RN-3C RN-3C RN-3C RN-3C RN-3C RN-2C RN-3C RN-3C RN-3C RN-3C RN-3C RN 3C RN-3C RN3C RN-3C RN3C RN-2C RN-2C RN2C RN -2C RN-2C RN2C RN2C RN2C
MMI nches
0.71.028 0.71.028 0.71.028 0.71.028 0 .71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028
0.71.028
PIU~ Gap
2.17b
9/97
MAINTENANCE/TUNE UP Drive Belt Removal/Installation

Drive Belt
WARNING
Inspect the condition of the drive belt. Inspect clutch sheaves for damage, wear, or belt residue. Clean with non-oil base cleaner such as isopropyl alcohol. To ensure satisfactory belt life, install belts so they operate in the same direction of rotation. Position the identification numbers so that you can read them. This will keep the belt rotating in the same direction.
Belt Removal
1. Be sure key switch is off and engine has come to a complete stop. Remove the retaining knob or pin and open the clutch guard. Apply brake (or lock parking brake if so equipped). Grasp belt firmly midway between clutches and pull upward and rearward to open the driven clutch sheaves. Remove the belt from the driven clutch and then from the drive clutch. Removal
2. 3.
Belt Installation
1. 2. Drop the drive belt over the drive clutch and pull back the slack. Turn the driven clutch moveable sheave clockwise while at the same time pushing inward and forcing the belt down between the sheaves. Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave. Once installed, be sure to work the belt to the outer edge of the sheave. Be sure to release parking brake if applied. Close the clutch guard and reinstall the retaining knob or pin . Installation
3.
4.
1.
Belt Inspection
5. 6. Refer to PVT Section for belt inspection and width measurement. Measure belt length with a tape measure around the outer circumference of the belt. Belts which measure shorter or longer than a nominal length may require driven clutch or engine adjustment to obtain proper belt deflection. Replace belt if worn past the service limit. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic operation. See Troubleshooting Chart at the back of this chapter for possible causes. NOTE: If a new belt is installed, check belt deflection. Install so part numbers are easily read.
7.
Referto pages 6.40 and 6.41 for belt specifications and measurement procedures.
Center Distance
9/96
2.18
MAINTENANCE/TUNE UP Backrest Adjustment

Backrest Adjustment
The passenger backrest on the Classic Touring and XLT Touring Models is adjustable. To move the backrest forward or backward, lift the adjustment lever on the left side. To lengthen or shorten the backrest cable, lift the cable until spring tension is felt and lock the jamb nut. When adjusting the backrest from a passenger position to a single rider position, rotate the backrest cushion adjustment knobs until the proper angle is reached. The grab bars have five height adjustments. To raise or lower the grab bar, remove the grab bar adjuster knob, position the grab bar at the desired height, and reinstall the knob. The Classic Touring and XLT Touring models are also equipped with passenger handwarmers. The handwarmer switch, located under the left hand wind deflector, has three settings: high, off, and low. Shown in "driver only" position
Backrest Cushion Adjuster Backrest Cable Adjuster Passenger Handwarmer Switch
Wind Deflector
Backrest ---PciU'IFi~L~ Adjustment Lever
Grab Bar Adjustment Knob
"--"
2.19
9/96
MAINTENANCE/TUNE UP Headlight Adjustment - Standard Indy Models

Headlight Adjustment
The headlight can be adjusted for vertical aim using the following procedure: 1. Place snowmobile on a level surface with headlight approximately 25' (7.6m) from a wall. 2. 3. Measure distance from floor to center of headlight and make a mark on the wall. Start engine and turn headlight switch to high beam. Observe headlight aim. The most intense part of the headlight beam should be aimed 2" (5.1 cm) below the mark placed on the wall in Step2. NOTE: Riderweight must be included on the seat.
25' (7.62 m)
4.
Lamp Center Height 2" (5. 1
cm~~ 5r~ lL
[@""";\
C\.~
5.
If necessary, the headlight aim can be adjusted by turning the four adjusting screws located on the front of the lens (A). Turn in or out as needed for proper aim.
\~
',llllilllllll ~,
I~
\
/ lul+
I'l
IU ~-cJ ,," l" "N.l

I I ,I
Removing the Bulb

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot which will shorten the life of the lamp. 1. Push down on left side of spring until it releases from spring retainer.
V
Halogen Bulb
Wire Harness
\
~ ...... ~
2. 3.
Lift spring carefully around wi re harness and flip to outside of housing. With the wire harness attached to the bulb, withdraw bulb from housing.
4. Grasp bulb by metal base and carefully separate bulb from harness.
Installing the Bulb

1. Hold bulb by metal base and install into wire harness. 2. 3. 4. Insert bulb into housing. Carefully flip spring back into housing placing it around wire harness. Push spring down until it is secured by spring retainer.
>r
Spring
a:rI
Bulb
5. Verify headlight aim.
I ---: W /
Spring
'"':'~';;";f
Wire Harness
9/96
2.20
MAINTENANCE/TUNE UP Headlight Adjustment - Evolved Style Models

The headlight can be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25' (7.6 m) from a wall. Measure the distance from the floor to the center of the headlight and make a mark on the wall.
Lamp Center Height
25' (7.6 m)
2.
3. Start the engine and turn the headlight switch to high beam. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 2" (5.1 cm) below the mark placed on the wall in Step 2. NOTE: Rider weight must be included on the seat.
5.
If necessary, the headlight aim can be adjusted by turning the adjustment knob located inside the hood just below the headlamp opening. Turn knob in or out as needed for proper aim.
Removing the Center Bulb

1. Push down on spring until it releases from spring retainer. 2. With wire harness attached to bulb, withdraw bulb from housing. 3. Grasp bulb by metal base and carefully separate bulb from
harness.
~ ~u
Headlight Adjustment Knob
~---
Installing the Center Bulb

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot which will shorten the life of the lamp.
1. Hold bulb by metal base only and install into wire harness. 2. 3. Insert bulb into housing. Push spring down until it is secured by spring retainer.
>r
Spring
Wire Harness
~/ ~
l%1 I
Bulb
4. Verify headlight aim.
Removing the Side Bulbs

1. 2. Disconnect terminal from back of bulb. Turn bulb assembly 1/4 turn to right and withdraw from housing.
Installing the Side Bulbs

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot which will shorten the life of the lamp.
1. Hold bulb assembly by plastic base and plug into wire terminal. 2. 3. 4. Insert bulb assembly into housing. Turn bulb assembly 1/4 turn to lett to secure in housing. Verify headlight operation.
2.21
11/95
MAINTENANCE/TUNE UP Headlight Adjustment - Aggressive Style Models

The headlight can be adjusted for vertical aim using the following procedure: 1, Place snowmobile on a level surface with headlight approximately 25' (7,6m) from a walL 2, 3, 4, Measure distance from floor to center of headlight and make a mark on the walL Start engine and turn headlight switch to high beam, Observe headlight aim, The most intense part of the headlight beam should be aimed 2" (5,1 cm) below the mark placed on the wall in Step 2, NOTE: Rider weight must be included on the seat.
25' (7,62 m)
Lamp Center Height 2" (5,1 cm)
5,
If necessary, headlight aim can be adjusted by inserting a Phillips screwdriver into the boss in the top of the console and turning the screw until correct adjustment is achieved,
Removing the Bulb

1, 2, 3, 4, Push down on left side of spring until it releases from spring retainer, Lift spring carefully around wire harness and flip to outside of housing, With the wire harness attached to the bulb, withdraw bulb from housing, Grasp bulb by metal base and carefully separate bulb from harness.
Insert screwdriver into access hole and turn screw to adjust
Installing the Bulb

1. 2, 3, 4. 5. Hold bulb by metal base and install into wire harness. Insert bulb into housing. Carefully flip spring back into housing placing it around wire harness. Push spring down until it is secured by spring retainer. Verify headlight aim.
Bulb
~ ~:~..
Spring Lens
1f~
Taillight Bulb Replacement

1. 2. 3. 4. Remove (5) Phillips screws from taillight lens. Working from front to back, carefully pry lens away from seal and remove lens. Pull bulb straight out from socket and insert new bulb. Reinstall lens,
Bulbs
t:I::IQ. ..t:lt:l/S
"""''''--
11/95
2.22
Polaris Industries Inc ,
MAINTENANCE/TUNE UP Handlebar Adjustment
Handlebar AdJustment - Standard Indy Models
1. 2.
Remove handlebar cover and foam.

Socket Screws
Using a 7/16" (11 mm) wrench, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or right for access to back nuts. Adjust handlebarto the desired height. Be sure that handlebars, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right.
3.
4. Torque the handlebar adjuster block bolts to specification . Maintain an equal gap on front and back of block. 5. Replace handlebar cover and foam.
Handlebar Adjustment - Evolved and Aggressive Style Models

1. 2. Remove two plastic fasteners holding console cover located below handlebar cover on hood side of steering post. Using a 7/16" (11 mm) wrench, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or right for access to rear nuts. Adjust handlebar to the desired height. Be sure that handlebars, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right. Torque the handlebar adjuster block bolts to specification. Maintain an equal gap on front and back of block. Replace console cover.
3.
4. 5.
,'.
'"
Bottom of Adjuster Block
Handlebar AdJustment - Indy Lite Style Models

1. Remove metal clips at front of plastic housing by prying out with screwdriver. Loosen four retainer bolts.
"--
2. Adjust handlebar to the desired height. Be sure that handlebars, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right. 3. Torque handlebar adjuster block to specification. Maintain an equal gap on front and back of block.
WARNING
Improper adjustment of the handlebars, or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in lOSS of control.
2.23
11 /95
MAINTENANCErrUNE UP
Brakes Replenishing Brake Fluid Remove brake fluid master cylinder reservoir cover. Add Polaris brake fluid as required to bring the level up to the top of the fluid level mark on the inside of the reservoir (B). The proper fluid level is 1/4-5/16" (.6-.8 cm) below the lip of the reservoir openi ng. Inspect the reservoir to be sure it contains the correct amount of fluid. Use only Polaris DOT 3 high temperature brake fluid. Change brake fluid every 2 years. Change fluid every 2 years or whenever the fluid is dark or if contamination is suspected. Polaris DOT 3 High Temp Brake Ffuid
PN 2870990
Master Cylinder Fluid Level 1/4 - 5/16" (.6 - .8 cm) below lip of reservoir opening
Brake Fluid Should Changed Every 2 Years or when fluid is dark or if contamination is suspected.
WARNING
Do not over fi ll the master cylinder. Fluid expansion could cause brakes to lock, resulting in serious injury or death. Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid . Brake fluid is hyg roscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, leading to early brake fade and the possibility of serious injury.
B leeding the Hydraulic Brake System Air in the hydraulic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to remove air from the system. 1. Remove brake fluid master cylinder reservoir cover and gasket.
2. 3. Fill the master cylinder reservoir (6) and replace gasket and cover. Keep the fluid level 114-5/ 16" (.6-.8 cm) below lip of reservoir opening. Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into a container. WARNING
Never re-use brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, leading to early brake fade and the possibility of serious injury. Squeeze brake leve r a fu ll stroke. Then unscrew bleeder valve (A) 3/4 of a turn to release air. 5. Close bleeder valve first and then release brake lever. Repeat steps 4 and 5 until fluid fl ows from bleeder valve in a solid stream free of air bubbles . Do not allow reservoir to run dry or air will be drawn into system. 6. Refill reservoir to proper level after bleeding operation. Do not overfill the master cylinder. 4. 7. Replace gasket and cover. During the bleeding procedure make sure to keep the reservoir as level as possible to minimize the possibility of air entering the system .
Bleeder Tube
91 97
2.2 4
MAINTENANCEfTUNE UP
Brakes/ Exhau st System Brake Adj ust ment - Mechanical Disc Brakes
'--' If excessive brake lever to brake block clearance is evident, the caliper adjuster should be adjusted using the following method.
WARNING
Adjust brake with caliper adjuster bolt only. Do not adjust cable or cable sleeve length. Improper brake adjustment could result in brake failure which cou ld result in severe injury or death.
r-------~----------,
Caliper Adjustment
1 . Bend locking tab (A) away from lock nut (B) and loosen lock nut.
2.
"-'
3.
Push down on actuating lever (C) and insert a .015" feeler gauge between the brake disc and outer brake pad. Turn adjusting bolt (0) in until a slight pressure is felt against the feeler gauge. While holding adjusting bolt (0), tighten locknut (B).
Ir
4.
5. Bend locking tab (A) against locknut.
WARNING
Be certain locking tab is correctly positioned in actuating lever. After locknut is tightened, check pad to disc clearance to be certain the re is .015" clearance. Be certain brake pads are not dragging on disc and brake lever travel is not excessive. Improper brake adjustment could result in brake failure which could result in severe injury or death.
B rake Pad to Disc Clearance .015" (.38 mm)

.015" Feeler Gauge
NOTE: Replace pads when worn beyond service limit. Minimum Pad Thickness .250" (6 .35mm)
Brake Pad Thickness - Type M3 shown . Service Limit .250" (6.35mm) (All brake pads)
Exhaust System
Inspect the exhaust system 1500 miles (2400 km). To inspect, allow engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or misSing retaining springs. Be sure the resonator outlet pipe exits the belly pan.
2.25
9/97
MAINTENANCE/TUNE UP Brakes
WT2 Brake Adjustment
Check to ensure floating parts move freely and that all other parts are mounted securely. Tighten hardware as required. 2. Check actuator linkage to ensure there is adequate freedom of movement for positive brake operation. Periodic adjustment of pad gap can be performed using actuating cable. 3. Loosen lock nuts. 1. Bracket Lock Nuts
Move cable up or down in bracket to adjust freeplay
4. To increase brake lever free play turn nuts counterclockwise to move cable down in bracket. To decrease lever free play move cable up in bracket. Tighten lock nuts.
5. If cable adjuster has reached maximum (used up), the lever arm can be re-indexed. Loosen lock nuts and turn counterclockwise (as viewed from top) to obtain the maximum amount of cable freeplay. Straighten tab on tab washer and loosen bolt enough to disengage actuator lever spline. Slip long leg of lever spring off caliper and rotate to the side. Rotate the lever one tooth in the direction opposite the actuation direction, and tighten bolt making sure spline teeth are properly engaged. Bend up a tab aligning with one of the bolt head flats to prevent bolt rotation. Return the spring to its original position on the caliper. Both lever and linkage must be free to return to original position. Perform steps 3. and 4. to adjust lever freeplay. Verify proper brake operation . Disc should rotate freely without drag. Check disc surface condition. Refer to Brake/Final Drive section to inspect disc and pad condition and thickness.
- 11/4-3/8" (6-10 mm) Ramp Mount Bushing
6. 7.
8. 9.
10. 11. 12.
P \
\.~'L ~~1\'\ ,
~~
Lift" ,,",
.,'
Separator Plate
Tab Washer
"
9/96
2.25a
BRAKES/FINAL DRIVE Reverse Kit Maintenance

Adjustment
'-" Due to break-in or replacement of components, the reve rse shift mechanism may require adjustment. Adjust with Ihe shifter in the forward position .
Standard Indy Style

1. 2. Loosen jam nuts on lower end of cable. Adjust cable until endplay movement of cable housing at the handlebar bracket is 1/32" (.08 cm). Do not adjust beyond this point. Tighten jam nuts and re -check adjustment.
3.
', -,
Reverse Cable End Play 1/32" (.08 em) 1/32" Adjustment (.08 cm)
Evolved and Aggressive Style

1. Lift shift lever slowly while observing shift arm on transmission. If adjustment is correct, shift will move 1 - 1 1/2" before the shift arm begins to move. If adjustment is required , proceed with step 3. Loosen jam nuts on lower end of cable. Adjust cable end at transmission until the end of the shift lever has 1 - 1 1/2" (2.5 - 3.8 cm) of freeplay before the cable starts to move the shift arm. Do not adjust beyond this point. Tighten jam nuts and re-check adjustment. Shift Arm~ 0 WhfC-'I'-,..,o/ Chaincase Cover Shift Lever
2.
1-1 1/2" (2.5-3.8 cm) free play
3. 4.
'-"
5.
Reverse Shift Lever Freeplay 1 - 1 1/2" (2.5 - 3.8 em) measured at end of shift lever
9/97
2.2Sb
MAINTENANCEfTUNE UP
Off Season Storage Cleaning And Preservation Of Hood, Chassis And Trim
Proper storage starts by cleaning, washing and waxing the hood, chassis, upholstery and plastic parts. Clean and touch up with paint any rusted or bare metal surfaces. Ensure that all corros ive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (g rease, oi l, or paint). If the machine is equi pped with a battery, disconnect the battery cables and clean the cables and battery posts. Fill battery to proper level with distilled water and charge to full capacity. Remove and store the battery in a cool dry place. The machine should be stored in a dry garage or shed out of the sun light and covered with a fabric snowmobile cover. Do not use plastic to cover the machine; moisture will be trapped inside causing rust and corrosion problems.
Controls And Linkage

All bushings, spindle shafts and tie rod ends should be coated with a light coat of oil or grease. Th rottle controls and cables should be lubricated with Polaris Cable Lubricant. Force a small amount of lubricant down cables.
Polaris'Cable Lubricant PN 2870510
Electrical Connections
Sepa rate electrical connector blocks and clean co rrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and reconnect. Replace worn or frayed electrical wire and connectors.
Dielectric G"rease PN 2871027
Clutch And Drive System

Remove drive belt and store in a cool dry location. Lubricate sheave faces, shaft and ramps of drive and driven clutches with light oil or rust inhibitor. A generous amou nt of lubrication, such as Polaris cable lubricant should be appl ied onto the roll ers and weight pins . All lubrication applied as a rust preventative measu re must be cleaned off before installing belt for service and operati ng machine.
Chaincase Lubricant
Change chaincase lubricant as outlined in this section. thoroughly. Remove the outer cove r and clean the chaincase
9/97
2.26
MAINTENANCEfTUNE UP Off Season Storage

Lubrication
Refer to page 2.5-2.10 for complete lubrication information. To prevent corrosion which wil l destroy the bearings, always grease jackshaft and drive shaft (clutch side) bearings with a high quality bearing grease. Loosen driven clutch retaining bolt and pull clutch outward to expose bearing. Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal. Push clutch back on shaft and replace clutch retaining bolt. Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal. Lubricate both front ski pivots at bushings and spind les . See 111.1 and 2. Ski Spindle andW / mgs ~ Grease
III. 1
Jackshaft Bearing Grease
Polaris Premium All Season Grease

PN 287142314112 oz.
Driveshaft Bearing
III. 2
Grease Gun Adapter: 2871174 Point Type
Located on left side of machine (clutch side)
~
0
_1)
o
Use T-9 Metal Protectant on shock absorber shafts to help prevent corrosion.
T-9 Metal Protectant

PN 2871064
Unde r normal conditions moderate track tension shou ld be maintained during summer storage. Rubber track tension should be maintained at the prescribed normal operating tension specified in this manual. The rear of the machine should be supported off the ground to allow free hanging of track.
2.27
91 97
MAINTENANCE/TUNE UP
Off Season Storage

Engine and Carburetor
Fog engine with Polaris Fogging Oil (aerosol type) according to directions on can . On models with carburetor vacuum fittings the fogging oil can be sprayed through the fitting. If you choose not to use Polaris Fogging Oil perform the following procedure: Support front of snowmobile so engine is level or tilted slightly rearward. Remove spark plug(s) . Rotate piston to BDC and pour approximately two ounces (16 ml) Polaris 2-Cycle Injector oil into the cylinder. NOTE: Allow ample time for oil to flow from top of piston down transfer ports and onto crankshaft bearings before proceeding to next cylinder. Turn engine over several times to insure coverage of piston rings, cylinder walls and crankshaft bearings. See photo at right.
----.
Treat the fuel system with Polaris fuel system additive
G .art/9!1>RIEll'!t'. fiN 287;~~~~x: & : jX;:1? ,

~ c,':' ~<.":,~",,
."
'
v'. ;".
.. "~::, , ,,_. : ~. / _' _' _
y' ,..... ,-. _
If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. To eliminate any fuel remaining in the carburetor, run the engine until it stops.
Battery
Disconnect and remove battery. Fill with distilled water. Clean terminals and cables. Apply dielectric grease. Charge until specific gravity is t least 1.270 (each cell). If machine is to be stored for one month or longer, fill and charge battery monthly using Polaris Battery Tender, or a 1 amp trickle charger to maintain at 1.270 specific gravity.
EFI Storage Considerations

Add fuel conditionerlstabilizer and fill tank as described above. Fog engine. Disconnect battery ground cable if machine will be stored for 30 days or less. If storage period will exceed 30 days, remove battery from machine and maintain as described above. Cover and store machine out of direct sunlight. If machine is to be stored more than four months , start and run engine for at least 15 minutes and re-fog with fuel stabilizer added to the fuel. Fill fuel tank and add the recommended amount of Polaris Fuel System Additive.
91 97
2.28
ENGINE Variable Exhaust System Variable Exhaust System (V.E.S.)

"--" Some snowmobiles are equipped with the Polaris (patent pending) Variable Exhaust System (V.E.S.) This unique exhaust valve management system changes the effective exhaust port height in the cylinder to provide maximum horsepower at high RPM without sacrificing fuel economy and engine torque at low to midrange throttle settings .
.-------------------------------------------------,
CYLINDER PRE!;SURE-,. ACTUATION PORT
Cover
HIGH RPM LOW RPM I I
0...""it-- - Piston Bellows Housing Exhaust Valve

EXHAUST RT PO
CYUNDER
Fig . 1
In order to understand the operation and function of the V.E.S. we must first consider the characteristics of a two stroke engine. The height of the exhaust port in a two stroke engine cylinder has an affect on the total power output of an engine . as well as the RPM at which the power occurs. Exhaust systems are "tuned" by design to match engine exhaust port configuration and desired power delivery charac teristics. Engines with relatively "high" exhaust ports (and exhaust pipe to match) produce more horsepower at high RPM. but only at the expense of low to midrange fuel economy and torque. On the other hand . "low" port engines provide good fuel economy in the midrange and make their power at relatively lower RPM. but will not produce as much peak horsepower for a given displacement range. In general. an engine designed for a racing or high pertormance snowmobile will have a relatively high exhaust port compared to an engine of the same displacement range designed for touring. Mhough the V.E.S. dees not in ITself increase horsepower. IT does allow an engine to be designed for maximum horsepower WIThout the inherent disadvantages of a high exhaust port. The main components of the V.E.S. are the exhaust valve . valve housing . bellows . piston . return spring. and cov-
"'"-""
er.
A guillotine style exhaust valve is connected to a moveable piston. This piston is attached to a flexible bellows. forming two chambers . The lower chamber is connected to the cylinder by a drilled passageway located just above the exhaust port. The upper chamber is vented to atmospheric pressure. A valve return spring is located in the upper chamber between the piston and cover. At idle and low speeds, the exhaust valve is held In the "low port" position by the return spring. When throttle IS applied (and RPM begins to increase) rising cylinder pressure Is applied to the under side of the bellows via the actuation port. This forces the exhaust valve upward against spring pressure. The valve continues to move upward toward the "High Port" position as cylinder pressure. horsepower. and RPM increase.
2.28a
9/97
ENGINE Variable Exhaust System
HOUSing~'
Housing Bolts
/'
>
~ cover Retainer _
..<@';;
O-ring~
Exhaust Valve
Gasket
?
:<>
/
/"
/
~\ Cover / \J, "" Return Spring / \J ~ '-'~ Pi ston \' ~Bellows Fastener Strap Cylinder ~//
Spring Clamp
V.E.S. Maintenance
Due to the simplicity of V. E.S. design, maintenance is limited to a periodic inspection and cleaning of system components. The V.E.S. should be disassembled, inspected, and cleaned (remove carbon deposits) every 1000 to 2000 miles , depending on operating conditions. NOTE: To ensure maximum performance and minimize required maintenance, Polaris recommends the use of Premium Gold Synthetic 2 Cycle lubricant (PN 287 172 1) only. The use of other lubricants may cause improper funct ion of the valve mechanism, and inc rease the frequency of required cleaning due to excessive buildup of carbon deposits. NOTE: Polaris Premium 2-Cycle TC-W3 Engine Lubricant (blue) is recommended for use during the break- in period.
V.E.S. Removal
1. Pull back cove r retainer c lip while holding the cover in place. 2. Remove cover and return spring. 3. If the spring stays in the cover, hold the cover with spring facing toward you. Rotate spring in a counterclockwise direction while pull ing outward on the spring. Do not distort the spring upon removal. 2. Slide Clip Down 1. Hold Cover
~1
"1
I
CAUTION : Do not attempt to remove the plastic valve piston at this time. The bellows must first be removed from the piston or damage may occur to the bellows or piston.
4. Remove two (Smm) hex screws from valve housing. 5. Lift enti re valve assembly from cylinder along with gasket. Cove r Rotate to remove
Retainer Ctz ~
'mm """ ~~
~~)
>~
9/97
2.28b
ENGINE Variable Exhaust System Disassembly, Cleaning, Inspection

1. Carefully remove the fastener strap in the area shown. Use care to avoid cutting the bellows. 2. Fold back upper edge of bellows to expose lower edge of piston.
R'~~~
Piston (do not attempt to remove piston from exhaust valve until upper clamp and bellows are removed from piston.
-\j
\ 3. Hold exhaust valve securely and remove piston by turning the 10mm hex counterclockwise. 4. Slide exhaust valve out of housing. 5. Remove O-ring from exhaust valve shaft. 6. Compress lower spring clamp and remove bellows and clamp. 7. Clean O-ring and bellows in warm water and mild detergent. Inspect bellows for holes, distortion or damage. Replace if necessary. Inspect O-ring for damage. 8. Clean all other parts with solvent. Be sure all parts are thoroughly clean. 9. Inspect the actuator port in cylinder and valve housing. Be sure it is clear and not obstructed by debris or carbon. 10.Carbon deposits can be removed from valve with a Scotch Brite ~ pad or similar soft abrasive brush. 11. Lubricate exhaust valve with Polaris Premium Gold 2-cycle engine lubricant. Install valve in cylinder and move it through the entire travel range to check for fre e movement without binding . If the valve sticks anywhere in the travel range, check the valve and valve bore in the cylinder for carbon deposits and clean if necessary.
Be II ows
Lower Clamp
, 11(\;\ ,
, "iI!f '
Housing Gas ket O-ring
~/ p
,0
"fiI:)/
10mm Hex \
~HOld exhaust valve
then remove piston
2.28c
9/97
ENGINE Variable Exhaust System V.E.S. Assembly

1. Install lower clamp over small end of bellows. 2. Assemble dry. Install bellows on housing. Be sure bellows is completely seated in groove, and install clamp. 3. Place a new o-ring and gasket on exhaust valve . 4. Insert exhaust valve in housing with TOP marks aligned. Both the valve housing and valve are marked with "TOP". 5. Apply Loctite ~ 242 to threads of exhaust valve and install the piston. Hold exhaust valve and torque piston to 25 in. Ibs. (.2S kg-m). 6. Install valve assembly in cylinder with TOP marks on valve and housing facing up. Apply Loctite 242 (blue) to housing bolt threads. Install and torque bolts to 10S in. Ibs. (1.24. kg-m) . 7. Fit upper sealing edge of bellows into groove on piston. S. Secure the bellows by installing the fastener strap. NOTE: Move the valve up and down in the full travel range and check for smooth operation. IIlhe valve binds in any spot, check the bellows to be sure it is not twisted on the piston. 9. Install spring and cover. Be sure spring is properly positioned on the piston and in the cover.
UP
A"g"r~
j!i)
\
a-ring
Housing Bolts: Appl\ Loctite ~ 242(blue) Torque: 10S in. Ibs. (1.24 kg-m)
2. Slide Clip Up
:nnrtm71k-- .7
1. Compress and Hold Cover
9/9 7
2.28d
ENGINE Variable Exhaust System V.E.S. Troubleshooting

Symptom Engine will not reach designed operating RPM Possible Cause Remedy
Valve not opening or not opening completely: 1. Exhaust valve sticking 2. Cylinder pressure feed port restricted 3. Bellows damaged or not seal ing correctly 4. Incorrect spring 5. Problem in clutch setup, drive line, engine, etc. 1. Remove carbon deposits, burrs etc. 2. Clean port 3. Inspect bellows, fastener straps, and gasket and repair as required 4. Inspect 5. Inspect
Poor acceleration; hesitation; High RPM performance is normal or near normal
Valve opening too early: 1. Valve sticking open or partially open 2. Broken , damaged, or incorrect, spring
1. Clean, Inspect
2. Inspect, Replace
2.28e
9/97
MAINTENANCE/TUNE UP Routing Diagram - Speedometer Cable

1996 to Current Indy Lite Models
Route cable down right side over post. under mounting plate. and out side of bulkhead.
2.29
9196
MAINTENANCE/TUNE UP Routing Diagram - Speedometer Cable

1996 Indy 440 LC/Classic/Classic Touring/Trail/Trail Touring/500/500 SKS/500 RMK/XLT Touring Models 1997 Indy Trail/Trail Touring/500/500 SKS/500 RMKl440 LC/500 EFI/XLT LTD/XLT Touring/ Classic/Classic Touring Models
-----.
.'
--=-- ~-----"
~ I
--- ..-
.. "
Speedometer cable should be tie strapped to wire harness at approximately this location inside hood .
9/96
2.30
MAINTENANCE/TUNE UP Routing Diagram - Wire Harness/Speedometer Cable

1996 Indy RXU440 XCR/XLT SKS/XLT RMK Models 1997 Indy XLT/XLT SKS/XLT RMKlUltra SP Models
When pulling speedometer cable through clutch guard bracket be careful not to scrape cable housing .
Clutch guard
Speedometer cable
/ Route speedometer cable between coolant hoses on right side of bulkhead .
.../ Cable tie harness only"" around hinge brace. - - -
Both wire harness and speedometer cable are cable tied to hood hinge. ~
2.31
9/96

1997 Indy 440 XC Models
Route speedometer cable through clutch guard
Clutch guard
/ ~/~
II
Speedometer Cable
. ' .,',
/
(I {(I
Wire harness _ _--t~
Cable tie wire harness only around hinge --_ __ _ brace
Both wire harness and speedometer cable are cable tied to hood ~ hinge ~
9/96
2.32

1997 Indy XLT SP Models
Clutch guard
Speedometer Cable
)
,
Wire
\
harnes~
",
//
Cable tie wire harness only around hinge brace---__
Both wire harness and speedometer cable are cable tied to hood hinge
csc _":",, >
2.33
91 96
MAINTENANCEITUNE UP
Routing Diagram - Wire Harness/Speedometer Cable
1996 Indy 440 LC/Classic/Classic Touring/XLT Touring/SOO/SOO SKS/SOO RMKlTraillTrail Touring Models
1997 Indy TraillTrail Touring/SOO/SOO SKS/SOO RMKl440 LC/SOO EFIIXLT Touring/classic/ Classic Touring/XLT LTD Models 1998 Trail/440 Indy /SOO Indy /SOO Classic / XLT Touring
Rosebud Clip 6 inches Cable Tie'-.",...

~
____________________- L_ _
Hood
p"",,";-
Wire Harness _
Nosepan Speedometer routed as shown with no other cable ties in this area.
9/97
2 .34

1997 Indy Ultra Touring Models
/\j
V""
2.35
9/96
MAINTENANCE/TUNE UP Routing Diagram - Wi re Harness/Fuel Line

1996 Indy WideTrak LX/Sport/Sport Touring/TranSport/Super Sport/Trail/Trail Touring Models
Brake line in front of steering post Fuel line behind steering post
/
/
/
'\
Recoil Mount
Rosebud clipped to bulkhead
9/96
2.36
MAINTENANCE/TUNE UP Routing Diagram - Wire Harness/Fuel Line

1996 Indy 440 LC/Classic/Classic Touring/500/500 SKS/500 RMK Models
Brake line runs in front of handlebar block.
Steering Post
Fuel line is routed behind steering post
"'/
Fuel line routed to outside of rope guide.
Temperature sending unit wire
\
/
\
,
Coolant hose runs ignition coi l wi re loop.
throu~ ~/
2.37
9[96

1997 Indy TranSport/Super Sport/Sport/Sport Touring Models
Brake line in front of steering post Fuel line beh ind steering post
...---- To Fuel Pump
/
/
/
/
\
Recoil Mount
Rosebud clipped to bulkhead
9/96
2.38
MAINTENANCE/TUNE UP Routing Diagram - Wire Harness/Fuel Line 1997 Indy Trail/Trail Touring Models
Fuel Line (Over Throttle Cable) Brake line (Over Steering Post)
Fuel line (Behind Steering Post)
2.39
9/96

1997 Indy Trail/Trail Touring/500/500 SKS/500 RMKJ440 LC/Classic Touring Models
Brake line runs in front of handlebar block.
- - - i~ ....
Steering Post
Fuel line is routed behind steering post
/'
\
\
.,
Coolant hose runs through ignition coil wire loop.
/
\
/
~ ~/
9/96
2.40
MA INTENANCE/TUNE UP Routing Diagram - Fuel Line

1996 to Curren t Indy Lite Models
Steering Post
To fuel tank Fuel Pump
Routed under carb and up to LH carb
Mounted on air box
\
To RH carb To motor
Shut off valve mounted on oil tank
2.41
9196
MAINTENANCE/TUNE UP Routing Diagram - Fuel Line

1996 Indy 600 XCR Models 1997 Indy 600 XC Models
-----=-========1 --------
Oil Line
9/96
2.42

1996 Indy XLT SKS/XLT RMKlXLT Touring Models 1997 Indy XLT SP/XLT/XLT SKS/XLT RMK/XLT Touring/XLT LTD Models
'----'
To Shut-Off Valve
-----
~:::------I
Oil Line
2.43
9/96

1997 Indy Ultra/Ultra SP Models
Fuel Valve
-::::::::::======-::; To filte rftank
Fuel Pump
PTO
Mag
Center
' 1, ,_
Impulse line on engine
- -I
I,j.u-
9/96
2.44
MAINTENANCE/TUNE UP Routing Diagram - Handlebar Harness

1996 Indy 440 LC/Classic/Classic Touring/XLT Touring/500/500 SKS/500 RMKlTailiTrai l Touring Models 1997 Indy XLT LTD/Classic Touring/XLT Touring/Ultra Tou ring/440 LC Models
Handlebar harness should be routed down through handlebar block and connect with main harness.
A tie strap loosely holds the wire harness, throttle cable and brake li ne to the steering post. 4 wi re connector plugs into throttle side .
2.45
9/96

1997 Indy Trail/Trail Touring/500/500 SKS/500 RMK Models
o
o
Reverse cable routing and cable tie.
Handlebar harness should be routed down between handlebar block and connect with main harness!
A tie strap loosely holds the wire harness, throttle cable and brake line to the steering post.
91 96
2.46

1997 Indy 500 EFI Models
Handlebar harness should be routed down between handlebar block and connect with main harness.
A cable tie loosely holds the wire harness, throttle cable and brake line to the steering post.
2.47
9/96
MAINTENANCE/TUNE UP Routing Diagram - Oil Line

1996440 XCR/XLT SKS/XLT RMK Models 1997440 XC/XLT/XLT SKS/XLT RMKlXLT SP Models
II
Oil line route Air Box
o
Oil line route
Jackshaft
9196
2.48
MAINTENANCE/TUNE UP
Routing Diagram - Oil Line 1995Indy WideTrak LXlWideTrak GT/Classic/Classic Touring/XLT Touring/500/500 SKS/500 RMKlTrailiTrall Touring/SportiSport Touring/Super SportiTranSportiLite/Lite GT/Lite Deluxe/SOO XCR/440 LC Models 1997 Lite/Lite Deluxe/Lite GTiSportiSport Touring/TranSportiSuper Sportl440 LC/Trail/Trail TouringClassic Touring/500/500 SKS/500 RMKlSOO XC/XLT Touring/XLT LTD Models
'-'
i\
Oil line route Air Box
Oil line route
Jackshaft
2.49
9/96
MAINTENANCEfTUNE UP Routing Diagram - Miscellaneous
1996 Indy 440 LC/Classic TouringlXLT Touring/SOO/SOO SKS/SOO RMKlTrail/ Trail Touring Models 1997 Indy 440 LClTraillTraii Touring/Classic/SOO/SOO SKS/SOO RMKlClassic Touring/ XLT TouringlXLT LTD/SOO EFI Models 1998 Trail/440 Indy /500 Indy /500 Classic /500 RMK / XLT LTD / XLT Touring Trail Touring / XLT Classic
1--.-;---\-10 Harness secured around ignition switch
I~~ I
~
~
Recoil rope routes between hoop and tank on XLT Classic and XLT
LTD
Oil tank ve nt line secured to steering hoop at approximately this location. Do not pinch vent line!
Torque Regulator nuts 38-43 in. Ibs .
9/97
2.50
MAINTENANCE/TUNE UP Routing Diagram - Oil Vent Line

1996 to Current Indy Classic Models
Harness secured around ignition switch
Oil vent line cable tied to steering hoop at approx. this location. Do NOT pinch vent line!
2.51
9/96
MAINTENANCEITUNE UP Routing Diagram - Vent Lines 1996 To Current Indy Lite Models
.,r--)'2., _ _ _
Push excess vent line into steering post
Torque 4-6 ft. lbs .
I\
i J~_i I
~ ~
~
\
~
\
9/97
2.52
MAINTENANCE/TUNE UP Routing Diagram - Vent Lines

1996 All Models Except Indy Lites
To Fuel Tank
Tinnerman Clip (3 total)
I
Tinnerman Clip
Steering Hoop
To Oil Tank Vent
Vent line routed around steering post and through vent line loop.
II
Tinnerman Clip
2.53
9/96
MAINTENANCEfTUNE UP
Routing Diagram - Vent Lines

1997 To Current Indy XLTIXLT SKSIXLT RMKl600 XC/440 XC Models
Tinnerman Clip To Fuel Tank
Steeri ng Hoop Tinnerman Clip
To Oil Tank Vent
Vent line routed around steering post and through vent line loop.
9/97
2.54

Steering Hoop
To Oil Tank Vent
2.55
9/96

1997 Indy Sport/Sport Touring/TranSport/Super Sport/440 LC/500/500 SKS/500 RMKl500 EFI/ Classic/Classic Touring/XLT Touring/XLT LTD Models
To Fuel Tank
Tinnerman Clip (2)

~
Steering Hoop
/
',. .,..
"'"
Steering Hoop
9/96
2.56

1997 Indy Tra il/Trail Touring/XLT SP Models
To Fuel Tank
1innerman Clip (2)
1"
Steering Hoop
1innerman Clip (1)
To Oil Tank Vent
"\
I
Steering Hoop
2.57
9/96
MAINTENANCEfTUNE UP Routing Diagram - Vent Lines

1997 Indy Sport/Sport TouringfTranSport/Super Sport/440 LC/500/500 SKS/500 RMKl500 EFI/ Classic/Classic Touring/xLT Touring/XLT LTD Models
1998 Sport / Sport Touring / TranSport / XCF / Trail/ Super Sport / Trail RMK / Trail Touring
Tinnerman Clip (4) To Fuel Tank
\
Vent Spring (3)
\
\
To Oil Tank Vent
Steering Hoop Torque nut 4-6 ft. Ibs.
((
)
\
/
Cable Tie
9/97
2.57a
MAINTENANCEfTUNE UP Routing Diagram - Vent Lines 1998 Ultra/Ultra Touring/GOO XCR1700 XCR /Storm
To Fuel Tank
Tinnerman Clip (3) \
~-.~~
Vent Spring Steering Hoop
Cable Tie
Torque nut 4-6 ft. Ibs.
Torque nut 4-6 ft. Ibs.
2.57b
9/97

1997 Indy Ultra/Ultra SP Models
To Fuel Tank ~
Tinnerman Clip
Steering Hoop
Steering post
Oil tank
Airbox
9/96
2.58
MAINTENANCEfTUNE UP Routing Diagram - Vent Lines 1998 440 Indy 1500 Classic 1 500 RMK 1 Classic Touring 1 500 Indy
To Fuel Tank
/ " Tinnerman Clip (2 )
Vent Line Routing
c::::
~~~
To Oil Tank Vent Steering Hoop
Coolant Bottle & Hose
/-;-.. - -- /
Torque 4-6 It. Ibs .
Oil Tank
2 .58a
9197
MAINTENANCEITUNE UP Routing Diagram - Vent Lines

Steenng Hoop
To Oil Tank Vent
Tinnerman Clip
9[97
2.58b
MAINTENANCE/TUNE UP Routing Diagram - Vent Lines 1998 XLT LTD I XLT SP I XLT Touring I XLT Classic
To Fuel Tank
\
Vent
./' Tinnerman Clip (2)
c::::.
~~~
Sp~g (3~)-:::::;;;::::::;;:~~~~~~~
\\
To Oil Tank Vent Steering Hoop
Coolant Bottle & Hose
/-@- ,
Torque 4-6 It. Ibs.
(o!
~ /' I
~ \ ; '1
Torque nut 4-6 It. Ibs .
I ((
)
\
/
Oil Tank
',---"
2.58c
9197
MAINTENANCEfTUNE UP Routing Diagram - Vent Lines 1998700 RMK 1700 XC 1600 XC 1600 RMK
Tinnerman Clip (3) To Fuel Tank
\
Vent Spring (2)
~
Torque 45-50 in.lbs . Steering Hoop
Cable Tie
9/97
2.58d
MAINTENANCE/TUNE UP Routing Diagram - Vent Lines 1998 WideTrak LX
Tinnerman Clip (4)
To Foo' Tack
~\: ~~1:2'h. C: :
Vent Spring (3)
~ ~~~
To Oil Tank Vent
Steering Hoop
Torque nut 48-72 in. Ibs. (.55-83 kg-m) Cable Tie
((
)
\
/
2.58e
9/97
MAINTENANCE/TUNE UP Routing Diagram - Carburetor Vent Line

1996 Indy 440 LC
Air Silencer
2.59
9/96
MAINTENANCE/TUNE UP Routing Diagram Carburetor Vent Line

1996 Indy Trail/Trail Touring
Air Silencer
9(96
2.60

1996 Indy 500/500 SKS/500 RMKlClassic/Classic Touring
~---
..- .-----
Carb
o
Y-
Carb
0='-LI~_--,I-
L------;-:-_-' _ _ _- l _
~ $
I
Air Silencer
2.61
9/96
MAINTENANCEfTUNE UP Routing Diagram - Carburetor Vent Line

1997 Indy 440 LC Models
Air Intake Silencer
1998 Trail 1 Super Sport 1440 1 Classic Touring 1 Trail Touring
Carburetor
i
Air Intake Silencer
9(97
2 .62
MAINTENANCEITUNE UP
Routing Diagram - Carburetor Vent Line
1997 Indy 500/500 SKS/500 RMKlClassic Touring Models
Air Silencer
1998 500 Indy I 500 Classic
Air Box
2.63
9/97

1997 Indy Trail/trail Touring Models
--------------
O 'l)-L_
Airbox
9/96
2.64
MAINTENANCEfTUNE UP Routing Diagram - Carburetor Vent Line

1996-Current ACCS Systems
Air Box
4 Way Manifold I Float Bowl Vent Control ACCS 4-way Man ifold mounted to air box 27S
,,
-----9L
,I II
\\
ACCS .. Valve Vent line attachment to handlebars
\!
0
,
3-way Manifold , attachment (1996 '. ACCS Only)
27L
Carb
attachment ACCS Valve
Mag Carb
Vent line attachment to handlebars EXAMPLE: 27L = 27cm Length , Large Diameter 27 = 27cm Length S Small Diameter L = Large Diameter
3 Way Manifold I Pilot Air Control (1996 ACCS Only)
NOTE: There is only one ACCS valve. The illustration above has been divided to show the separation of systems. See page 5.7a for line connections.
2.65
9/97
MAINTENANCEITUNE UP Routing Diagram - Carburetor Vent Line

1997 - Current Indy Trail RMK and 500 RMK Models
Tinn erman Clips
Air Box
if"
ACCS Valve
91 97
2 .66
MAINTENANCE/TUNE UP Routing Diagram - Miscellaneous

1996 Indy RXL Models
Cable Tie Coolant Hose to Bracket
2.67
9/96
MAINTENANCE/TUNE UP Routing Diagram Miscellaneous

1996 Indy RXL Models 1997 Indy XLT Touring/Ultra Touring Models
Small Tabs Up Position (4) Places
/'
/
1/ 16" Clearance - Bottom Tab to Tunnel (4) Places
/'
//
;/
9/96
2.68

1996 Indy Lite GT Models
Recoil rope over top of wire harness and oil line
Oil Tank
~/~~~"-<:::
________
Wire harness and oil line cable tied to bracket stand
Oil line toward - - ---/--r-T outside
Recoi l Rope
Wire Harness
2.69
9/96

1996 Indy XLT Touring Models 1997 Indy Class Touring/XLT Touring/Ultra Touring Models
Slide handle grip up to radius
Switch ----<
Cable tie holds wire to tube
Connect wiring and tuck behind taillight housing so not visible from side
Wiring to be separated at bottom one wire per slot
9/96
2.70
CHAPTER 3 ENGINES
Specifications . . . .... . .. .... .. .. .. .. . . ... . . .. . 3.1 . 3.4 Torque Specifi cations ... . . . . ..... . .... . . . .... 3.5 - 3.6 Piston/Cylinder Clearance Specifications . . . . ... . 3.7 Fuel Recommendation .... . ............... . ... 3.8 - 3.9 Engine Removal, Typical .. . . .. ....... . . ... . . 3.10- 3.13 Engine Installation, Typical . . . . . .. . .. . . . .. ..... 3.14 - 3.18 Fan Cooled Twin Service .. . . . .. .. . . . . . . " .. ,' 3.19 - 3.27 Liquid Twin Service ... . , ... .. .. .... ' ... ... . ... 3.28 - 3.34 Three Cylinder Monoblock Service ... . . . . . .. . . .. 3.35 - 3.44 RXL Service . .... . .. . .. . .. . . . . .... ....... .. .. 3.45 3.51 EC59PUEC68PL Service . . . , . , ... .. .. . ... . .. . 3.52 - 3.59 600 / 700 Case Reed Service . .. .. . . .. . . . . . .. . 3.60 - 3.71 800 Case Reed Service . . .. . , . . . . , .. , ... . , .. . , 3.72 - 3.78 440 Case Reed Service 3.78a - 3.78j General Inspection Procedures . . ........ . ... . . , 3.79 - 3.90 Cooling System - EC45/50PL " .. . ............ , 3.91 & 3.93 Cooling System - EC65PL05 .. , . . . ..... . ... . . 3.92 Cooling System - EC58PL .... , .... . . .. .. . , ... 3.94 - 3.95 Cooling System - EC 59 / 68PL . . . ........ .. , . . . 3.96 - 3.97 Cooling System - SN60 I SN70 Domestic Twins ., 3.98 - 3.99 Cooling System - EC80PL .. . .... . ... . ,., . . , .. . 3.99a Recoil Service .. . .. . .... . .. . . . . . . .. . . . .. . .. . . . 3.100 Troubleshooting . .. .. . .. . ... . .... . , . .. .... .. . 3.101 - 3.102
ENGINES Engine Specifications

1996 Models
Machine Mod el Engine M o del EC342PM02 EC34-2PME02 EC44-3PMOI EC44-3PM02 EC50PM03 EC50PM04 EC50PM E04 EC45PL06 EC45PL07 EC45PL08 EC50PL 11 EC50PLElt EC50PLE12 EC50PL 13 EC50PL14 EC50PL 15 EC58PL02 EC58PL03 EC58PLE05 EC58PL07 EC59PLOI EC65PL05 EC68PLOI EC68PL04 EC80PL04 EC80PL05 Cyl. Disp. CC's 339 339 432 432 488 488 488 432 439 439 488 488 488 488 488 488 597 597 597 597 598 648 679 679 794 794 Bore Bore In ches 2.4528 2.4528 2.6661 2.6661 2.8346 2.8346 2.8346 2.6661 2.6870 2.6870 2.8346 2.8346 2.8346 2.8346 2.8346 2.8346 2.5590 2.5590 2.5590 2.5590 2.461 2.6661 2.622 2.622 2.8346 2.8346 Stro ke Stroke Inches 2. t889 2. t889 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.561 2.3622 2.5591 2.5591 2.5591 2.5591 No. of Cyl. 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 Type of Cooling Fan Fan Fan Fan Fan Fan Fan Fuel
MM
62.3 62.3 67.72 67.72 72 72 72 67.72 68.25 68.25 72 72 72 72 72 72 65 65 65 65 62.5 67.72 66.6 66.6 72 72
MM
55.6 55.6 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 65 60 65 65 65 65
Octane
(Minimum) 87" 87" 87" 87" 87" 87" 87" 87" 91 91 87" 87" 87" 87" 87" 87" 91 87" 87" 87" 91 87" 87" 87" 91 91
Indy LitelGT
Indy Ute Deluxe

Indy SportlTranSporti
Sport Touring
Super Sport
Indy WideTrak GT Indy Trail Indy Trail Touring Indy 440 LC Indy 440 XCR Indy 440 XCR SP Indy 500 Carbl SKS Indy Classic
Indy WldeTrak LX
Liquid
Liquid Liquid
Liquid Liquid
Liquid
Indy 500 EFII SKSIRMK Indy Classic Touring Indy 500 Carb RMK Indy 600 XCRlX LT SP Indy XLTI SKS
Liquid Liquid
Liquid Liquid
Liquid Liquid Liquid Liquid

Liquid Liquid Liquid Liquid Liquid
Indy XLT Touring

IndyXLT RMK Indy 600 XCR SP Indy RXL Indy Ultra SP, SKS Indy Ultra RMK Indy Storm I RMK Indy StormiSKS
Non-oxygenated. MInimum octane when uSing oxygenated fuel IS 89 and re-jettlng IS reqUired. See page 3.8 for fuel recommendation on 1996 models.
..
3.1
9/96

1996 Models
Engine Model Cyl. Head CC's Uninstalled Cyl. Head CC's Installed
17.3 23.0 23.0 28.6 24.1 21. 1 19.0 19.0 23.6 23.6 23.6 23.6 23.6 23.6 17.1 19.1 18.1 20.4 20.5 19.1 22.6 24.4
Piston Rings
Piston/Cylinder Bore Clearance +.05 mm -.00 mm

.08-.14 (.0031-.0055") .09-. 14 (.0035-.0055") .09 -.14 (.0035-.0055") .10-_16 (.0039-.0063") .10-.16 (.0039-.0063") .09-.14 (.0035-.0055') .06 (.0023") .06 (.0023") .09-.125 (.0035.0049") .09-. 125 (.0035-.0049") .06-.095 (_0023- .0037") .09-.125 (.0035- .0049") .06-.095 (.0023.0037') .09.125 (.0035- .0049") .09-.125 (.0035- .0049") .09-.125 (.0035- .0049") .06 -_095 (.0023- .0037") .12-_170 (.0047-.0066") .06-_095 (.0023.0037') .06-_095 (.0023-.0037') .09-. 125 (.0035-.0049") .09-. 125 (.0035-.0049")
Engine Operating RPM 200 RPM

7000 7000 6800 6500 7000 7750 8250 8250 7800 7800 7000 8000 7800 7800
Recommended Idle RPM
EC34-2PM02lE02 EC44-3PMOI EC44-3PM02 EC50PM03 EC50PM04/E04 EC45PL06 EC45PL07 EC45PL08 EC50PL1 1 EC50PLEl1 EC50PLE12 EC50PL13 EC50PL14 EC50P115 EC58PL02 EC58PL03/E05/07 EC59PLOI EC65PL05 EC68PLOI EC66PL04 EC60PL04 EC60PL05
21.1 28.6 28.6 31.2 26.7 25.8 20.0 20.0 23.6 23.6 23.6 23.6 23.6 23.6 19.8 19.8 20.2 21.4 23.8 22.5 25.6 25.6
(2) 1.5 mm (2) 1.5 mm (2) 1.5 mm (2) 1.5 mm (2) 1.5 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2mm
1600 1600 1600 1600 1600 1600 1800 2200 1600 1900 1600 1600
1600
1600 2000 1700 2000 2200 1800 1800
8500
8000 8500 8000 8200 6200 6250 8250
1600 1600
Piston Ring End Gap (Installed)

Piston ring end gap all engines (except EC80PL04/05) .20 mm - _5 1 mm (.008" - .020") Piston ring end gap EC80PL04/05 eng ines .30 mm - .45 mm (.012" - .018")
9/97
3.2
ENG INES Engine Specifications 1997 Models

Machine Model Engine Model Cyl. Oisp. CC ' s 339 339 339 432 432 432 488 488 488 488 432 432 438 488 488 488 488 488 488 488 488 597 597 597 597 597 597 597 597 598 598 648 679 679 679 679 679 701 701 794 794 794 Bore
Bore
Inches 2.4528 2.4528 2.4528 2.666 1 2.6661 2.6661 2.6661 2.8346 2.8346 2.8346 2.6661 2.6661 2.6846 2.8346 2.8346 2.8346 2.8346 2.8346 2.8346 2.8346 2.8346 2.5590 2.5590 2.5590 2.5590 2.5590 2.5590 2.5590 2.5590 2.4610 2.4610 2.666 1 2.6220 2.6220 2.6220 2.6220 2.6220 3.1889 3.1889 2.8346 2.8346 2.8346
Stroke
MM
62.3 62.3 62.3 67.72 67.72 67.72 72 72 72 72 67.72
67.72
MM
55.6 55.6 55.6 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 65 65 60 65 65 65 65 65 68 68 65 65 65
Stroke Inches 2.1889 2.1889 2.1889 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.5591 2.559 1 2.3622 2.5591 2.5591 2.5591 2.5591 2.559 1 2.6772 2.6772 2.5591 2.5591 2.5591
No. of Cyl. 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3
Type o f Cooling Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Liquid Liquid Liquid
Liquid
Fuel O c ta ne (M i n) 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 81' 81' 81' 87" 87' 87' 87" 87" 87" 87" 87" 87" 87" 87" 91 91 87" 87" 81' 87" 91 91 87" 87" 91 91 91
Indy Lite
EC342PM02 EC34-2PM02 EC342PME02 EC443PM02 EC443PM02 EC443P M02 EC50PM06 EC50PM04 EC50PM05 EC50PME04 EC443PM02 EC45PL09 EC45PL08 EC50PL17 EC50PL 17 EC50PL 16 EC50P L1 8 EC50PLE17 EC50PL19 EC50PM03 EC50PLE20 EC58PL03 EC58PL03 EC58PL07 EC58PLE09 EC58PL 12 EC58PLE09 EC58 PL 12 EC58PL08 EC59 PL01 EC59PLOl EC65PL05 EC68PLOl EC68PLOl EC68PLOl EC68PL03 EC68PL03 SN70LCDCSPOl SN70LCDCSP02 EC80PL05 EC80PL05 EC80PL04
Indy Li te GT
Indy Lile Deluxe
Indy Sport
Indy TranSport
Sport Tou ring
Super Sport
Indy Trail
Indy Trail RM K
Indy Trail Touring Indy XCF Indy 440 LC Indy 440 XC Indy 500 Indy 500 SKS Indy 500 RMK Indy 500 EFI
Indy Classic
68.19
72 72
72
72
liquid liquid liquid liquid

Fan Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid
72 72 72 72 65 65 65 65 65 65 65 65 62.51 62.51 67.72 66.6 66.6 66.6 66.6 66.6 81 81 72 72 72

Indy WldeTrak GT Indy WideTrak LX
Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT Touring Indy XLT SP Indy XLT LTD Indy XLT LTD S P Indy 600 XC Indy 600 XCR Indy 600 XCR (S E) Indy RX L Indy Ultra Indy Ultra Tou ring Indy Ultra SP Indy Ultra SPX Indy Ultra SPX SE Indy 700 SKS Indy 700 RMK Indy Storm Indy Storm SE Indy Storm RMI<"
liquid
Liquid
3
3 3 3 3 3 2 2 3 3 3
liquid
Liquid
Liquid liquid Liquid Liquid Liquid Liquid

Liquid Llquid
Liquid
Nonoxygenated . Use minimum 89 octane when usin g oxygenated fuel. Polaris Industries Inc. 3.3
9/97

1997 Models
Engine Model Cyl. Head CC 's Uninstalled Cyl. Head CC's Installed
17.3 23.0 28.7 24.1 19.0 21 .1 22.0 23.6 23.6 23.6 23.6 , 9.' 19 .1
17.1
19.1
Piston/Cylinder Bore Clearance +.05 mm - .00 mm

.08. 14 (.0031.0055") .09.14 (.0035 . 0055") .10.16 (.0039 . 0063") .10'.16 (.0039.0063") .06.095 (.0023- .0037") .09-.140 (.0035-.0055") .06-.095 (.0023-.0037") .09-.125 (.0035- .0049") .09.125 (.0035- .0049") .09- .125 (.0035-.0049") .09-.125 (.0035-.0049") .09- .125 (.0035-.0049") .09- .125 (.0035- .0049") .09-.125 (.0035-.0049") .09.125 (.0035- .0049") .09-.125 (.0035-.0049") .07-.095 (.0028-.0037") .1 2-.170 (.0047-.0066") .07-.095 (.0028-.0037") .06-.095 (.0023-.0037") .124 (.0048) .124 (.0048) .09-.125 (.0035-.0049") .09'.125 (.0035-.0049")
Piston Clearance Service Limit

.2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .15 (.0059) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .15 (.0059) .2 (.0078) .15 (.0059) .15 (.0059) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078)
Engine Operating RPM 200 RPM

7000 6800 6600 7000 8250 7750 7750 7750 7750 7750 7750 8250 8250 8500 8250 8500 8500 8000 8000 8600 8000 8000 8400 8400
Recommended Id le RPM
EC342PM02lE02 EC443PM02 EC50PM03 EC50PM04/E04/05 EC45PL08 EC45PL09 EC50PL 16 EC50PL 17 EC50PL 18 EC50P L19 EC50PL20 EC58PL03 EC58PL07 EC58PL08 EC58PL09/E09 EC58PL12 EC59PL0 1 EC65PL05 EC68PL01 EC68PL03 SN70LCDCSP-01 SN70LCDCSP-02 EC80PL04 EC80PL05
21.1 28.6 31.3 26.7 20.0 25.8 28.0 23.6 23.6 23.6 23.6 19.8 19.8 19.8 19.8 19.8 20.3 21.4 23.8 25.1 41 41 27.2 27.2
1600 1600 1600 1600 1500 1600 1600 1600 1600 1600 1600
1900
1900 1900 1900 1900 1500 2200 1500 2200 1500 1500 1600 1600
17.1 18.0 20.4 20.5 21.4 32 32 26.0 26.0

Piston ring end gap all engines (except EC80PL04/05) .20 mm - .51 mm (.008" - .020") Piston ring end gap EC80PL04105 engines .30 mm - .45 mm (.0 12" - .018")
9/97
3.4
ENGINES 1998 Engine Specifications

1998 Models
Machine Model Eng ine Model Cy l. Di sp. CC' s 339 432 432 432 432 432 438 488 488 488 488 488 488 488 488 488 597 597 597 597 593 593 598 679 679 701 701 679 794 Bore MM 62.3 67.72 67.72 67.72 67.72 67.72 66 72 72 72 72 72 72 72 72 72 65 65 65 65
74.5
Bore
Inches 2.4528 2.6661 2.6661 2.6661 2.6661 2.6661 2.5984 2.8346 2.8346 2.8346 2.6661 2.8346 2.8346 2.8346 2.8346 2.8346 2.5590 2.5590 2.5590 2.5590 2.9331 2.9331 2.4610 2.6220 2.6220 3.1889 3.1889 2.6220 2.8346
Stroke MM 55.6 60 60 60 60 60 64 60 60 60 60 60 60 60 60 60 60 60 60 60 68 68 65 65 65 68 68 65 65
Stroke Inches 2.1889 2.3622 2.3622 2.3622 2.3622 2.3622 2.5197 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.3622 2.6772 2.6772 2.5591 2.5591 2.5591 2.6772 2.6772 2.5591 2.5591
No. of Cyl. 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 2 2 3 3 3 2 2 3 3
Type of Cooling Fan Fan Fan Fan Fan Liquid Liquid Fan Fan Fan Fan
Fuel Octane (Min)
Indy Ute I Dlx I Tr9 Indy Sport

Indy TranS port
EC342PM02A EC443PM024 EC443PM024 EC443PM024 EC443PM024 EC45PL091 SN4444LCDCSP 01 EC50PM043 EC50PM 043 EC50PM051 EC5 0PM06 1 EC5 0PL201 EC50PL171 EC50PL171 EC50PL1 61 EC50PL1 91 EC58PL130 EC58PL130 EC58PL140 EC58PL150 SN6070LCDCSP -01 SN60-70LCDCSP -02 EC59PL020 EC68PL050 EC68PL050 SN70-70LCDCSP -02 SN70-70LCDCSP -01 EC68PL060 EC80PL052
81' 81' 8T
87'
Sport Touring Indy XCF Indy 440 LC Indy 440 XCR

Indy Trail
8T 81'
87"
81' 81' 81' 81' 81' 81' 81'

87" 87' 8Y" 87" 8Y"
Indy Trail Touring Indy Trail RMK
Super Sport
Indy WideTrak LX
liquid liquid
Liquid
Indy 500
Indy Classic
Indy 500 RMK

Indy Classic Tr9
Liquid Liquid liquid
Indy XLT LTD

Indy XLT Touring
liquid
Liquid
Liquid
Indy XLT SP
Indy XLT Classic
81'
87" 87" 91 87' 87"
Indy 600 XC Indy 600 RMK Indy 600 XCR

Indy Ultra Indy Ultra Touring
Liquid Liquid Liquid Liquid Liquid Liquid liquid Liquid

Liquid
74.5 62.51 66.6 66.6 81 81 66.6 72
Indy 700 XC Indy 700 RMK Indy 700 XCR

Indy Storm
81' 81'
91 91
Non-oxygenated. Use minimum 89 octane when using oxygenated fuel.
Polaris Industries In c.
3.4a
9/97
ENGINES Engine Specifications 1998 Models

Engine Model Cyl. Head CC 's Uninstalled (Bench) Cyl. Head
ee's
Installed
Piston/Cylinder Bore Clearance (Target) +.05 mm -.00 mm .06.14 (.0031.0055") .09,.14 (.0035.0055") .09'.13 (.0035.0051") .09'. 14 (.0035.0055") .10.16 (.0039.0063") .10'.16 (.0039.0063") .10'.16 (.0039.0063") .06.095 (.0023.0037") .09.125 (.0035.0049") .06.095 (.0023.0037")
.06.095 (.0023.0037")
Piston Clearance Service

Limit mm (inch) .2 (.0076) .2 (.0076) .1 9 (.0075) .2 (.0076) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .15 (.0059) .15 (.0059) .15 (.0059) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078)
Engine Operating RPM 200 RPM 7000 6600 6250 7750 7000 7000 7000 7750 7750 7750 7750 8250 8500 8500 8500 8000 8600 8000 8000 8000 8000 8400
Recommended Idle RPM
EC342PM02A EC443PM024 SN4444LCDCSPOl EC45PL091 EC50PM043 EC50PM051 EC50PM061 EC50PL161 EC50Pl171 EC50Pl191 EC50PL201 EC58Pl130 EC58PL140 EC56Pl150 EC59PL020 EC66PL050 EC66PL060 SN60 70LCDCSpOl SN60 70LCDCSpOl SN7070LCDCSpOl SN7070LCDCSp02 EC60PL052
21. 1 26.6 19.6 25.6 26.7 26.7 26.7 28.0 28.0 28.0 28.8 19.9 20.5 20.5 20.3 23.8 25.1 34.0 34.0 41 41 27.2
17.3 23.0 16.3 21 .1 24.1 24.1 24 .1 22.0 23.6 23.6 23.6 19.2 17.1 17.1 18.0 20.5 2 1.4
1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1900 1900 1900 1500 1500 1800 1500 1500 1500 1500 1600
.09. 125 (.0035.0049") .09. 125 (.0035.0049") .09. 125 (.0035.0049") .07'.095 (.0028.0037") .07'. 105 (.0028.0041") .06.095 (.0023 .0037") .11 '. 15 (.0043.0059") .11 '.15 (.0043.0059")
32 32 26.0
.11'.135 (.0043 .0053") .11 '. 135 (.0043.0053") .09'.125 (.0035.0049")

Piston ring end gap (all engines except EC80PL04/05) .20 mm - .51 mm (.008" - .020") Piston ring end gap EC80PL engines .30 mm . .45 mm (.012" - .018")
9/97
3.4b
ENG INE Torque Specifications

When tightening bolts, nuts, or screws, a torque pattern shou ld be followed to ensure uniform equal tension is applied to all fasteners. Proper torque application prevents fasteners from loosening or breaking in critical service. It also minimizes wear and eliminates premature or needless repair costs. Following uniform torque application sequence patterns ensures optimum performance from precision machined , close tolerance assemblies. On vital engine parts, torqui ng negligence is of the utmost importance. Torque is a fo rce which tends to produce rotation. The measurement of this force is expressed in units of force and length. There are at present two basic systems of units used to express torque, English and Metric. In the English system, the units of fo rce are the pound or ounce, and the length is the foot or inch . In the Metric system, the unit of force is expressed in grams (gm) or kilograms (kg). and length as centimeters (cm) or meters (m). The most common units of torque in the English system are ft. lb. and in . lb. In the Metric system, torque is commonly expressed in units of kg-m. Multiply foot pounds by .1383 to obtain kg-m.
Engine Fan Cooled Twin Cylinder EC45PL EC50PL EC58 PL' EC59PL EC65PL EC68PL EC80PL SN44 SN60" SN70"
Cylinder Head' 18-19 ft. Ibs. (2.5-2.65 kgm) 8mm 17-20 It. Ibs. (2.4-2.8 kgm) 10mm 24-26 ft. Ibs. (3.3-3.6 kgm)
Cylinder Base Nuts 24-28 ft. Ibs. (3.3-3.9 kgm) 24-28 ft. Ibs. (3.3-3.9 kgm)
Crankcase 8mm 17-18 ft. Ibs. (2.2-2.3 kgm) 17-18 ft. Ibs. (2.2-2.3 kgm)
Crankcase 10 mm 23-25 ft. Ibs. (3.2-3.5 kgm) 23-25 ft. Ibs. (3.2-3.5 kgm)
Ftywheel 60-65 ft. Ibs. (8.3-9.0 kgm) 60-65 ft. Ibs. (8.3-9.0 kgm)
20-24 fUbs. (2.8 - 3.3 kgm) 18 - 22 ft. Ibs." (2.3 - 3.04 kgm)
30-34 fUbs (4. 15-4.7 kgm) 30-34 IUbs (4.15-4.7 kgm)
20-24 fUbs. (2.8 - 3.3 kgm) 20-24 fUbs. 26-30 Ft Ibs (2.8 - 3.3 kgm) (3.6-4. 15 kgm)
90 ft. Ibs. (12.4 kgm) 55 ft. Ibs. (7.4 kgm)
, Use high end of torque range .. Torque head bolts prior to torquing cylinder base nuts. Apply Loctite All 6mm Crankcase Bolts. . .. 108 in. Ibs. (1.24 kg-m)
N
242.
All 7116-14 Engine Mount Strap Bolts ..... 44-48 ft. Ibs. (6.0-6.63 kg-m)
3 .5
9/97
ENGINE Torque Patterns
CD 0 00
CYLINDER HEAD - 5 STUD
0 CD 00@@
G)
0 8
0
CYLINDER HEAD Domestic Twins 600/700
CYLINDERHEAD - 6STUD
@@0CV8
@000 0@@@
CYLINDER HEAD - EC58PL
@ 0CDG) @ 80 0 @ 0 0 0
CYLINDER HEAD - EC45/50PL
@@
f2I
00 0
D
8 CD
o
MAG SIDE
\.!Y
f.:\ (;;\
0 0
PTO SIDE
00
CYLINDER BASE - 600/700 Twins Note: Torque Head Bolts Prior to torquing cylinder base.
G)0
0
PL TWIN BASE
Cylinder Head - SN44
o 0) CD o o
@
f11\ 00CD00~@@
G)
00
CD
@@000 0@@@@
CRANKCASE - 3 CYLINDER
CRANKCASE - TWIN CYLINDER (Except 6001700 Twins)
0
@
CRANKCASE - 600/700 TWINS
0
0)
G)
8 0 CD CD
@@
CD
@@
@
3.6
CRANKCASE - SN44-44LCDCSP-01 102
9/97
ENGINES Piston/Cylinder Clearance Specifications Piston Measure ment

"-' Whenever cylinders are honed or bore clearance is checked , it is important to measure piston diameter properly to arrive at its major dimension. Measurements should be taken with piston at room temperature, and at right angles to t he pin as shown. Determine the largest diameter within this area and refer to the chart below for clearance specifications. Cylinder bore must be straight and concentric. Refer to honing information outlined in this section for specific procedures. Refer to the specification charts at the beginning of this chapter for Target Clearance when re-boring cylinder, or Service Limit specifications (to determine if piston requires reptacement. Specifications are listed by engine model number.
--......,
0
I 90 t o p in I
-L
FUJI ENGINES - Measure 1/2" (12.7mm) up from bottom of skirt DOMESTIC ENG tNES - Measure 3/8" (10 .0mm) up from bottom of skirt Ni-Ca-Sil cylinders can be lightly honed if the proper stone is used. Ammco #3955 honing stones (for use with the Ammco 3950 cylinder hone) are suitable and can be ordered through most automotive supply stores or VST. See General Information chapter for tool ordering information.
To Oeterm ine Metric Displacement mm Bore -;2= To Determ ine Com pression Ratio
x itself. or R squared = x pi 3. 1416 = x mm stroke = + 1000 = _ _ __

displacement of one cylinder in cc
Compression Ratio
Piston Displacement +
Installed Head Volume ..;-
Installed Head Volume
: 1 Ratio
3.7
9/97
ENGINES Fuel Recommendation

Oxygenated Fuel Due to increased emphasis on reducing auto emissions, some areas are required to use oxygenated fuels. Oxygenated fuels are those which include oxygen in the molecule due to the addition of an ether or alcohol. Polaris engines are designed for use with a specific fuel octane number. If fuels with a lower octane number than that specified are used, the engine may be severely damaged. 1997 - current models are calibrated for a minimum 87 octane (no lead regular) or 89 octane (oxygenated) fuel [(R+ M)/2]. Some high performance models require a minimum of 91 octane. No change is required to 1997 models provided the minimum fuel octane requirement is met. Referto the Specification Decal on the hood, Owner's Safety and Maintenance Manual. or Engine Chapter in this manual for minimum octane recommendation. 1996 Models-Oxygenated fuel can be used in all 1996 models of Polaris snowmobiles if these guidelines are followed: NOTE: The use of fuel containing methanol is not recommended. Carbureted Models: (see following page for EFI recommendations) 1. Use fuel with a minimum pump octane of 89 or higher (R+M)/2 method and jet carbs as outlined in step 2. NOTE: Some models are calibrated to use a min imum of 91 octane fuel. On these models, only 91 octane or higher should be used. Refer to the Specification Decal. Owner's Safety and Maintenance Manual. or Engine Chapter in this manual for minimum octane recommendation. 2. When using 89 octane oxygenated fuel on 1996 models, install main jets that are one size larger than that listed on the jetting chart for a given altitude and temperature. For example, the minimum octane (non-oxygenated) fuel for the 1996 Indy Classic is 87. The main jet installed during production for use at O altitudes of 0-3000 ft. and temperatures between -20 and + 1Q F) is a 340. To use 89 octane oxygenatedfuel, install 350 main jets. 3. Turn the pilot air screws in (clockwise) 3/8 turn from the standard setting. Example: if the production airscrew setting is 1 turn out, the setting for 89 octane oxygenated fuel would be 5/8 turn out. This adjustment may vary according to model and type of fuel. NOTE: The following 1996 Indy Classic charts are provided as an example only. 1996 Indy Classic
AMBIENT TEMPERATURE
Below -20' F Below 29' C -20" 0 +10' F 2g e ,O 12 C
340
.10" 0 +40' F
12 IO+S' C
Above +40 ' F Above ~ ..C
87 Octane (Non-Oxygenated)
Altitude
()'900
360 320
320
300
(0-3000)
900- 1800
(3OQO.6000) 18QO.2700
300
Malers (Feel)
''''
24. 21.
260
220
260
260 230
(6000-9000)
27()()'3700 (9000-12000)
2<.
200
= -Shaded zone should drop Jet Needle one position (raise E-Clip) Production Setting
1996 Indy Classic
AMBIENT TEMPERATURE
Below 20"F BelOw 29' C
()'900
20" to +10' F
29 ,o-12 v C
350
.,.10"toT40' F -12 ' to +S' C

330
Above +4O ' F Above .S C
37. 33.
290
31.
270
230
(O-3000)
89 Octane (Oxygenated)
900- 1800
Altitude Meiers (Feel)
31.
27.
290
(300C)-6000)
18QO..27oo
25. 22.
(6000-9000)
2700-3700 (9000- 12000)
25.
2<.
21.
= 9/96
Shaded zone should drop Jet Needle one position (raise E-Clip)
3.8
ENGINES Fuel Recommendation - EFI

Oxygenated Fuel - 1996 EFI Models
The fuel used in the Polaris engine is as important to engine life and performance as the lubricant used.
CAUTION:
Polaris engines are designed for use with a specific fuel octane number. If fuels with a lower octane number than that specified are used, the engine can become severely damaged. Be certain the fuel used in the Polaris engine meets or exceeds the required minimum 87 octane (no lead regular) or 89 octane (oxygenated) fuel [(R+ M)/2]. NOTE: See oxygenated fuel recommendations below for 1996 EFI models . 1997 - current EFI models are calibrated for 89 octane oxygenated fuel or 87 octane non-oxygenated fuel , and do not require modifications below 5000 ft . Referto the Specification Decal, Owner's Safety and Maintenance Manual. or Engine Specifications in this manual for minimum octane recommendation . Only winter gasoline should be used in Polaris snowmobiles. The gasoline sold at the pumps and used in the summer is different than gasoline sold in the winter. "Summer" fuels used in snowmobiles can cause hard starting. To use 89 octane oxygenated fuel on 1996 EFI models: 1. At altitudes below 5000 ft. , the compression ratio must be reduced by installing .020" head gasket shims between the cylinder head gasket and cylinder head. The part numbers are shown below. No change is required if machine is operated at altitudes above 5000 feet (1500 meters).
1996 EFI Cylinder Head Shims

Model Shim Part Number
1996 500 EFI/SKS/RMK 1996 RXL
(1 ) 5211416
(3) 52114 14
Fuel System Deicers

If non-oxygenated fuel is being used, Polaris recommends the regular use of Isopropyl base fuel system deicer (Polaris PN 2870505). Add 1 to 2 ounces per gallon (8-16 mil liliters per liter) of gasoline to prevent engine damage resulting from fue l system icing and lean mixtures. Never use deicers or additives that contain methanol. Use only isopropyl fuel system deicers. If using oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives are not required and should not be used. Whenever servicing the carburetor or fuel system, it is important to heed the warnings found on page 5.1.
3.9
9/96
ENGINES Engine Removal Engine Removal , Typical

1. Open hood and remove retention cable. hood securely. Support
2.
Disconnect battery ground fuel.
H from battery.
Shut off
3.
Remove airbox.
NOTE: On some models. fuel pump and/or COl box must be removed from airbox before removing airbox.
4. Remove fuel pump from engine if applicable.
9/96
3.10
ENGINES Recoil Starter Spring Replacement

Disassembly
1. Remove recoil handle and al low rope to retract and spring to totally unwind. Remove retaining nut, ratchet friction plate and ratchet pawl from reel face. Lift reel assembly straight up , out of housing. NOTE: If the spring tension is relieved and the reel is lifted straight out, the spri ng will remain in the housing.
2.
3.
Assembly
1. 2. If the spring was removed , reinstall it by spiraling counterclockwise toward the center. Lubricate center shaft and spring with grease. Prem ium All Season Grease PN 2871423 (14 oz.) 3. 4. Wind rope In a counterclockwise direction around outside of reel, as viewed from ratchet side of reel. Pass end of rope through rope guide and slide reel down onto shaft and spring. NOTE: Make sure reel tab engages hook on end of spring.
Assembly, Cont.
5. 6. 7. 8. Install rope handle. Reinstall ratchet pawl onto reel face. Ratchet spring holds ratchet in. NOTE:
Reinstall friction plate with one end of friction spring in hole on end of ratchet pawl. Reinstall flange nut and torque to specification. Flange Nut Torque-
5 ft. Ibs . (.69 kg-m)
Assembly, Cont.
9. Pull recoil rope to fu ll extension and align notch on outside edge of reel with housing rope guide hole.
10. Usin g a needle nose pliers or hooked wire, pull a loop of rope through the notch into center of housing. 11. Holding side of rope loop attached to reel, wind reel counterclockwise until coil bind is felt. Then unwind reel between one and two turns. 12. Pu ll loop to outside of housing by pulling on rope handle. 13. Allow rope to fu lly retract and check for normal reco il and ratchet ope ration.
9/97
3.100
ENGINES Troubleshooting
PROBLEM Will not starV hard starting PROBABLE CAUSE -Check ignition switch for run position, moisture contamination -Check auxiliary shut-off switch operation -Low compression -Out of fueVfuel restriction -No spark -Spark plug(s) fouled -Disconnect engine connector to eliminate any shorts that might be in the system -If starter won't work (electric models), check wires from starter solenoid and battery or check battery and battery cables -Open or broken reed valves -Sheared flywheel key -Broken piston skirt -Excessive piston ring end gap -Improper kiston clearance -Head gas et faully -Poor ring sealing, piston damage, cylinder scored -Spark plug fouled -Secondary coil faulty or wires disconnected -Primary coil shorted or open -Exciter coil faulty -COl faulty -Trigger coil faulty -Ignition switch shorted, contaminated with moisture -Auxilial)' switch shorted or contaminated with moisture
Low cempressian
No spark
Engine idles but -Restricted fuel flow/air flow no acceleration -Restricted or plugged main jet -Incorrect ignition timing -Clutching incorrect Engine runs but fails to reach maximum RPM -Restricted or plugged fuel filter -Fuel tank inlet screen restricted or plugged -Fuel pump not operational -Impulse line restricted or plugged -Incorrect track tension -Incorrect main jet -Throttle slides not fully open -Drive chain too tight -Incorrect clutching, worn clutch components -Exhaust restriction -Excessive driveline friction (HiFax overheating) -Incorrect air mixture setting -Throttle stop screw incorrectly adjusted -Pilot jet restricted or plu~ged -Fuel pump lacks fuel to Impulse line -Air leak at carb adaptor -Incorrect carburetor synchronization -Low compression -Tight belt -Piston damage -Choke plungers not seating properly -Throttle cable incorrectly adjusted -Chokes are not seating -Fuel pump diaphragm is ruptured (can be caused by engine backfiring) -Carburetor slides are not synchronized -Too large main jet -Needle and seat not seating properly -Incorrect float level Poor reed valve condition Restricted air intake or exhaust outlet
Engine runs but fails to idle
Engine runs, but overl oads with fuel
Carburetion and -If a lot of riding is on trails, and plugs foul and get black when doing so, verify all tune up adjustments: plug fouling carb sync, oil pump adjustm ent, pilot screw settin~, spark plug type and gap, venting for carbs, proper jetting for altitude and temperature, belt tension, c utch operation. If tune up items are correct, check: float level, jet needle position, jet n~edle wear, inlet needle and seat wear, exhaust outlet clear, etc.
3.101
9/96
ENGINES Troubleshooting
PROBLEM
Engine runs but overheats
PROBABLE CAUSE -Coolant level Incorrect main jet -Incorrect timing -Incorrect spark plug -Water pump belt loose or broken -Cooling restriction -Air in cooling system (bleed properly) -Inadequate snow for cooling (ice andior marginal conditions)
-FaU I~ connections -lnsu ieient alternator output -Faulty diodes (rectifier) -Sulfated battery -Battery electrolyte overfilled or low -Faulty cell in battery -Amp draw with key oft -Excessive load on alternator
Battery will not charge (battery equiPF,ed mode s only)
Lights don't work
-Engine not runn ing -Check wiring harness connector - colo r matching Check for burned out bulbs -Check wiring for shorts or loose connections -Disconnect taillight wiring harness if headlight works, short is in taillight wiring or taillight
Unit fails to propel itself
-Check belt (center distance) -Check clutch -Check chain -Check drive sprocket assembly -Track frozen or stuck -Check tune up items
-Check -Check -Check -Riding tension for proper alignment for loose, bent, or broken suspension parts in marginal or no snow conditions
Track wears unevenly
Chaincase gets hot
-Check oil level -Check chain tension -Check track assembly -Check jackshaft and drive shaft bearings -Check brake operation
-Check lubrication on spindles -Check ski alignment -Check spindle bushings -Check steering post bushings -Check carbide skags -Front limiter strap too short (if steering is heavy) -Torsion spri ngs set too heavy
Unit hard to steer (heavy steering)
9/96
3.102
ENGINES Engine Removal

Engine Removal, Typical-Cant.
5. Free recoil rope from chassis.
6.
Loosen clamps at carburetor mounting flange. Pull carbs from adaptors and secure out of the way. Note routing of all cables and hoses for reassembly.
7.
Disconnect oil pump control cable.
8.
Disconnect and plug oil supply line. A spare water trap plug can be used to plug the oil line from the oil reservoir.
3.11
9/96
ENGINES Engine Removal Engine Removal, Typical-Cont.

9. Remove drive belt and drive clutch.
10. Remove exhaust system. NOTE: On triple pipe models, mark pipe location to simplify reassembly.
11. On liquid cooled models, drai n coolant into suitable container.
12. Disconnect coolan t supply hoses. (Liquid models)
9/96
3.12
ENGINES Engine Removal Engine Removal, Typical-Cont.

13. Disconnect electrical connections from stator and starter motor (where applicable).
14. Remo ve two front and two rear engine mounting bolts securing engine mounting plate to chassis.
15. Remove engine from chassis.
3.13
9/96
ENGINES Engine Installation Engine Installation, Typical

1. Prepare chassis for engine installation by moving hoses and wiring out of the way.
2.
With engine mounting plate con nected to engine, set eng ine on rubber mounts and loosely install mounting bolts and nuts.
3.
Install drive clutch and check clutch offset/alignmenl. Adjust torque stop (where See page 6.44. applicable) to .100" (2 .5mm).
4.
TIghten engine mounting bolts to specification.
Engine Mounting Bolt TorqueFront - 28 Ft Ibs (6.67 kgm) Rear - 28 Ft Ibs (6.67 kgm)
9/96
3.14
ENGINES Engine Insta"ation Engine Installation, Typical-Cont.

5. Connect all stator connections.
6.
Connect oil supply line to oil pump. Bleed oil pump by opening bleed screw on top until oil flows steadily. Secure bleed screw. Install throttle cable to oil pump and check adjustment. Refer to page 3.89 for oil pump adjustment procedure.
7.
Install carburetors and tighten clamps. Make su re hoses and cables are routed correctly.
8.
Install airbox.
3.15
9/96
ENGINES Engine Installation Engine Installation, Typical-Cent.

9. Secure fuel pump and CDI box.
10. Install coolant hoses where applicable. Make sure hoses are routed properly and hose clamps are positioned and tightened securely.
11. Route and install recoil rope to chassis.
12. Install starter and starter cables (electric start models).
9/96
3.16
ENGINES Engine Installation

Engine Installation, Typical-Cont.
13. Install exhaust disassembly. system in reverse orde r of
14. Secure hood cable.
15. Remove any coolant bleed screws or radiator caps and fill coolant system with coolant (liquid models).
Polaris Antifreeze Quarts PN 2871534 Gallons PN 2871323
16. Add a full tank of premix fuel (40:1) to fuel tank.
3.17
9/96
ENGINES Engine Installation

Engine Installation, Typical-Cont.
17. Start engine and check operation. system on liquid models.)
(Bleed cooling
9/96
3.18
ENGINES Fan Cooled Twin Cylinder

Engine Disassembly
The photo at right shows a complete twin cylinder engine.
1. 2.
Remove carburetors. Disconnect oil pump feed lines and remove oil pump.
3.
Remove carburetor adaptors.
4.
Remove air shrouds. NOTE: There are gaskets between shroud and cylinder.
3.19
9196

Engine Disassembly, Cant.
5. Note position of shroud retainer mounts on cyli nder heads. These must be in the same position for reassembly.
6.
Remove recoil fan housing.
7.
Remove recoil drive hub.
8.
Remove flywheel retaining nut.
9/96
3.2 0

Engine Disassembly, Cont.
9. Using flywheel pu ller, remove flywheel.
Flywheel Puller PN 2871043
10. Mark stator plate and crankcase reasse mbly. Remove stator plate.
to
ease
11 . Remove two bolts securing inne r and upper sh roud. Remove upper shroud.
12. Loosen and remove all bolts securing cylinder heads to cylinder. Remove heads.
3.21
9/96

13. Remove cylinder base nuts and remove cylinders. NOTE: Refer to cylinder inspection page 3.86.
14. Remove piston c-clip.
15. Remove piston pin and remove pistons. Refer to general inspection procedures page 3.80-3.87.
Piston Pin Puller PN 2870386
16. Remove all crankcase bolts.
9/96
3.22

17. Separate crankcase halves.
18. Measure connecting rod side clearance. See page 3.82 for measurement procedure.
Connecting Rod Side Clearance
.012" - .016 (.30 - .40 mm)
19. Refer to page 3.81 for crankshaft inspection procedu re.
3.23
9/96
ENGINES Fan Cooled Twin Cylinder Engine Assembly

1. Clean all engine components thoroughly in a solvent tank. Remove al l filings, excess sealer, and dust. Blow dry with compressed air.
2. Apply 3-Bond m sealer to top half of crankcase and lubricate labyrinth seal and oil pump drive gear.
3-Bond '" 1215 PN 2871557 120 Gram Tube
3.
Lightly grease seals and install on crankshaft on crankshaft with lip (sprin g) facing inward toward crankshaft. Place crankshaft in upper crankcase hall. Make sure seal and PTO bearing retainer fit properly into grooves.
4. Install bottom crankcase hall and insert crankcase bolts. Torque to specification in proper sequence shown on page 3.6.
Crankcase Mounting Bolt Torque: 8mm - 18 ft. Ibs. (2.48 kgm) 10mm - 26 ft. Ibs. (3.59 kgm)
5.
Install pistons with arrow (~) on piston facing flywheel. Install C-clips securely in piston groove.
6. Lubricate rings and pistons wi th two stroke oil. Install rings with letter mark or beveled side facing upward. 7. Instal l base gasket with adhesive strip facing up.
9/96
3.24
ENGINES
Fan Cooled Twin Cylinder

Engine Assembly, Cont.
8. Lubricate cylinder with two stroke oil and install onto piston while compressing piston rings by hand. Be sure ring end gap is centered over locating pin or ring damage may occur. NOTE: Use a piston support block to help hold piston and prevent piston damage during assembly.
Piston Support Block PN 2870390
9.
Torque cylinder base bolts to specification.
Cylinder Base Bolt Torque 24-28 FI Ibs (3.3-3.9 kgm)
10. Install head gasket with wide side of fire ring facing down (narrow side up).
11 . Install cylinder heads and torque head bolts to specification. NOTE: Make sure threaded head nuts are in the proper position for shroud mounting. See "x" in photo at right.
Head Boll Torque19-18 FI Ibs (2.3-2.65 kgm)
3.25
9/96

12. Install inner fan shroud.
CAUTION:
Do not tighten bolts until outer shroud is bolted in place. Outer shroud must determine placement of inner shroud, or damage may result.
13. Install stator plate aligning ignition timing mark as seen during disassembly. Tighten stator mounting baits securely.
14. Make sure key is on crankshaft and install flywheel aligning keyway. 15. Install flywheel nut and torque to specification.
Flywheel Nut Torque60-65 Ft Ibs (8.3-9.0 kgm)
9/96
3.26

16. Install recoil starter hub and recoil housing. NOTE: Tighten two inner shroud bolts.
Recoil Hub Boll Torque: 8-10 ft. lbs. (1 .1 1 - 1.38 kg-m)
17. Reassemble cooling shroud.
18. Install oil pump. If crankcase, oil pump, or pump drive components were replaced , refer to page 3.89 to inspect drive gear end play.
Oil Pump Mounting Screw Torque: 48 - 72 in. Ibs. (.55 - .83 kg-m)
3.27
9/97
ENGINES Liquid Twin Cylinder Disassembly

The photo at right shows a complete liquid twin cylinder engine.
1. 2.
Remove carburetors or throttle bodies. Remove recoil housing and exhaust manifold.
3.
Remove water pump, starter recoil cup with water pump drive pulley and flywheel nut. Note position of shim washers for pulley alignment upon reassembly.
4.
Install flywheel puller. Secure puller with a holding fixture tool, strap wrench, or chain wrench while pulling flywheel.
Flywheel Puller
PN2871043
9/96
3.28
ENGINES Liquid Twin Cylinder

Disassembly, Cont.
5. Mark stator plate and crankcase for reference when reassembling the engine.
6.
Using an impact screwdriver, remove stator screws.
7.
Remove oil pump and oil pump feed lines from cylinder banjo bolts.
8. Remove cylinder head.
3.29
ENGINES
Liquid Twin Cylinder Disassembly, Cont.
9. Remove head gasket. Note position of head gasket inlet and outlet hole sizes for reference du ring reassembly.
10. Remove cyli nder.
11 . Remove C-clip retainer clips from piston as shown.
12. Using piston pin puller, remove piston pin from piston as shown.
9/96
3.30
ENGINES Liquid Twin Cylinder Disassembly, Cont.

13. Remove crankcase bolts.
NOTE: Refer to general inspection procedures on pages 3.79-3.90 for engine component inspection (i.e. crankshaft and crankcase inspection, piston clearance, oil pump drive gear end play etc.).
3.31
91 96
ENGINES Li quid Twin Cylinder Assembly

Prior to assembly, refer to page 3.87 and check ring end gap and piston to cylinder clearance. 1. Grease crankshaft end seals, oil pump drive gear, and labyrinth seal area as shown. Seals should be installed with spring and lip facing inward toward crankshaft.
2. Turn bearing so anti-rotation pins are in the prope r groove. 3. Apply 3-Bond sealant to crankcase halves.
3-Bond 1215 PN 2871557 120 Gram Tube
4.
Torque crankcase following to rquing specs and sequence outlined on pages 3.5 and 3.6. Lubricate crankshaft main bearings through access holes.
Crankcase Mounting Bolt Torque: 8mm - 18 ft. Ibs. (2.48 kgm) 1Omm - 26 ft. Ibs. (3.59 kgm)
5.
Install pistons with "F" mark or arrow flywheel.
C toward Al
6. Install C-clip using installation tool PN 2870773. 7. Install base gasket. 8. Lubricate rings and pistons with two stroke oil. Install rings with lette r mark or beveled side faci ng upward. See page 3.87.
9/96
3.32
ENGINES
Liquid Twin Cylinder Assembly, Cont.
9. Lubricate rings and cylinder with Premium 2 Cycle Lubricant and compress rings with finge rs, aligning end gaps with locating pins. Install cylinder with a gentle frontto-back rocking motion, being careful not to damage rings. Install cylinder base nuts and tighten to 24-28 ft. Ibs. (3.33.9 kg-m) following the pattern shown on page 3.6.
10. Install head gasket. Note proper position of gasket, "V" notch forward , small intake hole on right (mag) side, large hole on left (PTO) side.
11. Install cylinder head and torque cylinder head nuts following torque specs and pattern sequence on pages 3.5 and 3.6.
12. Before installing oil pump drive gear, refer to end play adjustment, page 3.89. 13. Install oil pump in the sequence shown in photo at ri ght.
0.....,
Polar;s Industries Inc.
3.33
9/96
ENGINES Liquid Twin Cylinder Assembly, C~nt.

14. Connect oil feed lines to cylinder. 15. Align stator as previously marked on stator plate and secure with screws.
16. Install flywheel specifications.
and torque
flywheel
nut
to
Flywheel Nut Torque 60 to 65 ft. Ibs. (8.28 to 8.97 kgm)
17. Install water pump and recoil starter cup. 18. Adjust tension on water pump belt by loosening mounting bolts, applying tension , and re-tightening bolts .
Water Pump Belt Deflection 1/8 - 3/16"(.3 -.4 cm)
19. Install recoil housing, carburetors, and oil pump cable. Refer to oil pump bleeding in this section. 20. Connect COl to stator plug connector.
9/96
3.34
ENGINES Three Cylinder Monoblock Disassembly

1. Remove carburetors and secondary coils.
2.
Remove oil pump.
3.
Remove recoil housing.
4.
Remove recoil hub.
3.35
9/96
ENGINES Three Cylinder Monoblock

Disassembly, Cont. 5. Remove water pump.
6. Remove flywheel retaining nut. Position fl ywheel holder as shown.
Flywheel Holder
PN 8700229
7.
Install flywheel puller. Remove flywheel.
Flywheel Puller
PN 2871043
CAUTION:
Do not install puller bolts more than 5/16" (7.9 mm) or stator damage may result.
9/96
3.36
ENGINES Three Cylinder Monoblock Disassembly, Cont.

S. Note location of ignition timing marks.
9.
Remove stator. NOTE: Stator bolts may be loosened using an impact driver.
10. Remove cylinder head cover.
'--11. Note condition and location of spark plug seat O- rings in head cover. Also note the quantity and location of shim washers located beneath the O- rings.
3.37
9/96

Disassembly,
C~nt.
12. Remove cylinder heads. Mark PTO, Center, and Mag head to ensure correct reassembly. Shim
-R ing
13. Remove cylinder and base gasket. 14. Referto cylinder inspection procedure on page 3.86 to inspect cylinder.
CAUTION:
Use care to ensure pistons are not damaged as cylinder is removed.
15. Support pistons with piston support block and remove C-clips.
9/96
3.38
ENGINES Three Cylinder Monoblock Disassembly. Cont.

16. Remove piston pins using piston pin puller and adaptor as shown. Refer to pages 3.79 through 3.90 for general inspectio n procedures.
Piston Pin Puller PN 2870386 Adapter PN' 5130971
17. Remove all crankcase bolts.
18. Separate crankcase halves and remove crankshaft. 19. Follow procedu re on page 3.81 for crankshaft inspection.
3.39
9/96

Disassembly. Cont.
20. Clean all components in a solvent tank to remove any dust, dirt, debris, and excess sealant. Inspect mating surface of upper and lower crankcase for damage.
9/96
3.40

Assembly
1. Apply 3-Bond to upper crankcase half. Lubricate labyrinth seal and oil pump drive gear. Lightly grease seals and install on crankshaft with seal lip (spring) facing inward. 3-Bond 1215
PN 2871557
120 Gram Tube
2.
Install crankshaft in upper crankcase.
NOTE: Make sure seals and all locating (anti-rotation) pins fit correctly in grooves. 3. Some 1997 three cylinder monoblock engines have a double row PTa bearing. These models can be identified by the PTa oil check valve and wider housing. Make sure the crankshaft and crankcase mate properly. Install bottom crankcase half. Make sure anti-rotation pins are aligned properly and torque bolts to specification.
4.
Crankcase Bolt Torque: 8mm - 18 ft. Ibs. (2.48 kgm) 10mm 26 ft. Ibs. (3.59 kgm) 5. Lubricate crankshaft main bearings through oil holes in upper crankcase. Lubricate connecting rod big end bearing . Lubricate pistons, rings, connecting rod small end bearing and cylinder before assembly. Install pistons, piston pins, and C-clips with end gap up or down. NOTE: Marking on piston faces flywheel. Be sure "C" clips are fully seated in groove.
6.
7. Apply a small amount of Loctite 515 gasket eliminator to base gasket ends and install gasket noting location of transfer port reliefs. NOTE: The sealant on base gasket faces up.
3.41
9/96
ENGINES Three Cylinder Monoblock Assembly, Cont.

B. Before installing cylinder, refer to honing procedure on pages 3.793.BO of this section. Inspect piston to cylinder clearance and piston ring installed gap as shown on page 3.B7 . Install rings on pistons. Depress rings in alignment with locating pins on piston using either a ring compressor or your fingers. Carefully install the cylinder. Install pistons in the following order: Mag Center PTO
9.
Torque base bolts, starting in the middle, alternate intake to exhaust side, rnoving toward PTO end and mag end. Refer to page 3.5 and 3.6 for torque patterns and specifications.
10. Install new head gasket. Be sure cylinder and cylinder head sealing surfaces are clean. NOTE: EX stamping should be readable and facing exhaust side.
11 . Install heads in the correct position and location as marked during disassembly. Torque head bolts to specification.
Head Bolt Torque 20 ft. Ibs. (2.8 kgm)
9/96
3.42

Assembly, Cont.
12. Replace outer O-ri ng on cover. 13. Apply Loctite 515 to cover as shown. 14. Position shim and O-Ring as shown. Cover
Apply Sealant To Top Of Shim O.Ring _ _-c; O.J
Shim
15. Instal l head cover. 16. Instal l and torque head cove r mount ing bolts to specification.
Head Cover Mounting Bolt Torque 17-20 Ft Ibs (2.4-2.8 kgm)
17. Install stator in the previously marked pos ition and tighten sc rews securely. 18. Install and torque flywheel nut.
Flywheel Nut Torque 60-65 ft. Ibs. (8.28-8.97 kg-m)
19. Install water pump and belt. Apply proper tension to belt and tighten pump mou nting bo lts .
Water Pump Belt Tension 1/8" - 3/16" (3-4mm)
3.43
9/96

Assembly, Cont"
20. Install oil pump and conn"ect feed lines to rubber mount. If crankcase, oil pump. or drive components were replaced, refer to oil pump drive gear end play adjustment on page 3.89. 21 . Install recoil housing.
22. Install secondary coils and secure carbureto rs to rubber mounts.
9/96
3.44
ENGINES
RXL
Disassembly
1. Remove water pump cover.
2. 3.
Mark cylinders #1 mag side , #2 center, #3 PTO side. Remove inlet water manifold .
4. 5. 6.
Remove oil pump lines and secondary coils. Remove oil pump and drive gear. Remove water pump.
tt'
, e'_l
~,!A,.~~ !
-"" ;,
"'r .- - - -.. .
lf
" .- '1 . . 8
l-<.~
t . ,.
J
, . t~1 ':~f\\~~ ~ , T~, S tl~rt'!\'_1 _.~ : ', :9.1t.,

, I /
'f-"L~'I'
SECONDARY COILS ,OIL PUMP AND LINES
~.~~.~(~p
3.45
9/96
ENGINES
RXL
Disassembly, Cont.
7. 8. Remove outlet manifold. Remove heads eithe r as a unit or individually.
9,
Remove recoil starter cup and flywheel nut.
10. Using flywheel puller, remove flywheel.
'.
!A,,,, IJIII'. '~r _., a.' J'" . 1:/," ~ ... '_ '.~ _ r. - ,, ' " II '' , . . : ,-,~ :; ,:~
, . " - . -, f' '
,
.~
~_
. .,
~ "
-~ '\. ~ ___ i .
" . ,"I' :
t"" It)'
...... /
,-.~ .
,. '
J/-I' J '
,~
A "
11. Mark stator plate and case, screws. Remove attaching
. iI
"
12. Mark cylinders mag, center, PTO.
9/96
3.46
ENGINES
RXL
Disassembly, Cont.
13. Remove piston C-clips as shown.
14. Using piston pin puller, remove piston pin and mark pistons mag, center and PTO. Refer to pages 3.863.87 for cylinder and piston inspection. Refer to pages 3.79 - 3.80 for cylinder honing information.
15. Remove seal piate and crankcase bolts.
16. Remove crankshaft from case. Refer to pages 3.81-3.85 for crankcase and crankshaft inspection procedures. 17. Clean all parts.
3.47
9/96
ENGINES
RXL
Assembly
1. 2. Remove old crankcase sealer from case halves. Grease mag end seal lip, oil pump drive gear, and labyrinth seal area. Make sure all bearing anti-rotation pins are aligned with reliefs in crankcase.
3.
4. Apply 3-Bond H ' sealer to the bottom crankcase half.

3.Bond 1215 PN 2871557 120 Gram Tube
5.
Torque crankcase bolts as shown. Refer to torqui ng pattern and specifications page 3.5 - 3.6.
Crankcase Mounting Bolt Torque: 8mm 18 ft . Ibs. (2.48 kgm) 10mm 26 ft. Ibs. (3.59 kgm)
6.
Install pistons with arrow toward flywheel side of crankcase.
7. Install piston C-clips with C-clip installation tool.
C Clip Installation Tool PN 2870773
8. 9.
Lubricate crankshaft bearings through access holes in the case. Install keystone rings onto piston with beveled side up and flat side of ring down.
9/96
3.48
ENGINES
RXL
Assembly, Cont. 10. Before installing cylinder. refer to honing proced ure on pages 3.79-3.80 and piston/cylinder inspection on pages 3.86-3.87 of this section. Lubricate all parts with Premium 2 Cycle Lubricant. 11. Depress rings in alignment with locating pins on piston using either a ring compressor or your fingers. Carefu lly install the cylinder.
12. Install new head gasket with large diameter side of fire ring toward cyli nder.
13. Instal l cylinde r heads onto cylinder either as a unit or individually.
Cylinder Head Nut Torque :
10mm - 24-26 ft. Ibs. (3.3-3.59 kgm) 8mm - 17-18 ft. Ibs. (2.35-2.48 kgm)
3.49
9/96
ENGINES
RXL
Assembly, Cent. 14. Install exhaust manifold gaskets and water manifold. Torque nuts to specification. Use caution when torquing nuts to avoid gasket damage.
Exhaust Manifold Nul Torque: 6 ft. Ibs. (2.28 kgm)
15. Install and align stator plate with previous marks.
16. Install flywheel and flywheel nut. Using flywheel holder to hold flywheel. torque nut to specification.
Flywheel Nut Torque: 60 ft. Ibs. (8.28 kgm)
Flywheel Holder PN 8700229
17. Install water pump and pump belt. tension.
Adjust belt
Water Pump Belt Deflection
1/83/16"(.3.4 cm)
9/96
3 .50
Polaris In dustries Inc.
ENGINES
RXL
Assembly, Cont.
'--' 18. Install oil pump and connect feed lines to cylinder. 19. Install secondary coils. 20. Install carburetors, recoil housing and water pump belt guard. 21. Install exhaust manifold gaskets and exhaust manifold. 22. Refer to oil pump drive gear end play adjustment, page 3.89.
3.51
9/96
ENGINES EC59PUEC68PL
Disassembly
1. Drain lubricant from water pump drive gear case (1996 models).
2.
Remove four bolts and pull water pump straight outward.
3.
Inspect sealing O-ring on water pump manifold. Replace if worn or damaged.
9/96
3.52
Water Pump Disassembly/Inspection
'--' 1. Remove (S) impeller housing cover bolts. Replace gasket and thoroughly clean surfaces prior to reassembly.
2.
Remove impeller bolt and impeller.
3.
Remove outer gear case cover. Remove impeller sealing plate from impeller. Inspect plate and rubber seal for corrosion or damage.
4.
Use a soft faced hammer to drive gear and pump shaft assembly from pump housing.
3.53
9/9S
Water Pump Disassembly/Inspection, Cont.
5. Replace O-ring on pump shaft upon reassembly. Drive or press mechanical seal assembly from case. Always replace the seal if removed . If coolant is evident in gearcase oil, replace mechanical seal.
6.
Inspect bearings in cover and pump housing, replace if worn. The bearing seal on gear case must be in good condition to prevent oil leaks. Replace the sealed bearing if oil leakage is evident at water pump weep hole.
7.
Grease O-ring on pump shaft and install shaft in pump housing. Insta ll new mechanical seal using seal installation tool kit PN 5131135 and parts hardware shown below.
Seal Installation Tool PN 513.1135
3/8 x 31 /4" bolt ~ N 7515554
Install Bearing First
f:J
I
I~/;:-I
ffl!~lr~t "~OOI ii
QI~ jIt
Seal Installation PN 5131135 3/8" nut PN 7542401
JQ"~'@!
3/8" washers PN 7555815 9/97
I~
3.54
Wat er Pump Disassem blyllnspecti on Cont.
8. Install impeller, apply Loctite 242 T" to bolt and torque to 72 in. Ibs. (.83 kgm). Install impeller cover with new gasket and torque bolts to 72 in . Ibs. (.83 kgm).
Water Pomp Gearcase Lubricant: (96 only) Capacity: Type: Approximately 50cc' Polaris All Season OW40 Synthetic PN 2871281 Fill to top of sight glass with engine installed.
9.
10. Apply 3Bond 1215 or Loctite 518 to sealing surfaces and install gearcase cover. Torque bolts to 72 in. Ibs. (.83 kgm).
Note: 97 models - do not add lubricant to the waterpump gearcase.
1996 Models Remove filler pl ug to add oil
1996 Models Oil level shou ld be at top of sight glass
Gasket
g
~
;:
Drain Screw
Impeller
Sealing Washer /
3.55
9/96
Disassembly,
1.
C~nt.
Remove water manifold and cylinder head covers.
2.
Inspect cylinder head cover O-rings.
3. Arrow on cylinder head points to intake.
4. Remove carburetor adaptors, reed valves, and disconnect oil lines. Refer to page 3.77 for reed valve inspection.
9/96
3.56
Disassembly, Cont.
5. Remove flywheel nut and washer. Install puller and remove flywheel. Align mark on stator plate with crankcase projection upon reassembly. Remove stator plate screws (3) with a hand impact driver.
Flywheel Puller PN 2871043 Flywheel Holder PN 8700229
6.
Remove cylinde r heads, cylinder base nuts, and cylinders. Mark cylinders mag, center, PTO for reference . Replace Orings and base gaskets. Install new base gaskets with sealant toward the cylinder.
NOTE: Refer to pages 3.793.90 for general inspection procedures.
7.
Identify pistons mag, center, and PTO. The arrow must point to Mag end of engine upon reassembly.
Cylinder Head Marking (EC68PL Engines) EC68PL01 EC68PL04
"C n Marked On Head "G" Marked On Head
8.
Remove piston Cclips.
3.57
9/96
ENGINES EC59PLJEC68PL
Disassembly. Cont.
9. Remove pistons using piston pin puller.
Piston Pin Puller PN 2870386 .

.
~l ~. 10. Remove oil pump. Note position of shim(s), spacer, and thrust washer for reassembly. Refer to page 3.88 for oil pump drive gear end play adjustment procedure.
Ii \~i = -~
j'.
I"
.'
.
'
:\
_. -. B A'
'\'
'I'
"
11. Remove crankcase bolts.
12. Tap crankcase lightly with a soft faced hammer to separate. Remove crankshaft from case. NOTE: Refer to pages 3.79-3.90 for general inspection procedures.
9/96
3.58
Assembly
1. 2. Replace crankshaft end seals. Clean crankcase surfaces and apply a thin even layer of 3-Bond 1215 sealer to both halves.
3.Bond 1215 PN 2871557 120 Gram Tube
3. '----' 4.
Align crankshaft bearing anti- rotation pins with relief in boftom case half. Torque crankcase bolts to specification following pattern on page 3.6.
Crankcase Mounting Bolt Torque: 8mm - 18 ft. Ibs. (2.48 kgm) 10mm - 26 ft. Ibs. (3.59 kgm) 5. 6. 7. B. 9. Measure piston to cylinder clearance and piston ring instal led gap before cylinder instal lation. Install pistons with arrow to mag (flywheel) end. Be sure "C" clips are fully seated with gap up or down. Install keystone rings on pistons with beveled side up and flat side down. See page 3.B7. Lubricate all top end components with Polaris Premium 2 Cycle Lub rica nt during assembly. Install cylinder heads with new O-rings and arrows pointing to intake . Install water pump on crankcase.
Water Pump Bolt Torque: 8-10 ft.lbs. (1.11-1 .38 kgm}
10. Align mark on stato r plate with crankcase projection. Apply LocWe'" 242 to stator plate screws and tighten securely. 11. Apply Loctite 242 to flywheel nut threads . Torque nut to 60-65 ft. Ibs. (8.30 - 8.99 kg-m) . '-.,; 12. Install recoil hub and torq ue bolts to B-1 0 ft . Ibs. (1 .11 - 1.38 kg -m). 13. Install oil pump and torque screws to 4-6 ft. Ibs. (.55 - .83 kg-m). 14. Bleed oil pump and cooling system as outlined in Maintenance section after engine installation. 15. Fill and bleed cooling system as outlined on page 3.9 1. 16. Inspect ignition timing.
3.59
9/97
ENGINES
700 Case Reed Disassembly
1. Remove oil pu mp.
2.
Remove recoil housing.
3.
Remove recoil hub. Inspect waterpump drive belt for missing , cracked, or broken drive cogs. Replace if worn.
Measure the belt at 4 different points as shown . Replace
ir wid th is less than .25 u (6.35 ml11). Nomi nal new widlh is
.345" (8.7511101). Refer
Lips.
lO
engine assembly for inslatJalion
Replace if width is less than .25" (6.35mm)
9(97
3.60
ENGINES
700 Case Reed Disassembly, Cant.
4. 5. Remove drive gears and belt. Remove flywheel nut using flywheel holder.
Flywheel Holder PN , 8700229
6.
Remove flywheel using flywheel puller.
7.
Note the ignition timing strip on the flywheel.
8.
Before removing stator plate , note where ignition timing marks are located.
3.61
9/96
ENGINES 700 Case Reed Disassembly, Cont.

9. Remove four bolts holding water pump housing to crankcase. Loosen hose clamp and remove housing.
10. Inspect water pump weep hole for signs of leakage or blockage.
11. Inspect crankshaft seal and replace if necessary. Remove seal by driving from outside toward engine. Replace seal if removed.
12. Remove water pu mp cover bolts.
9/96
3.62
ENGINES
700 Case Reed Disassembly, Cont.
'-...-13. Remove impeller retaining nut, washer, impeller, and 10x14mm washer.
14. Slide shaft assembly out of cover.
15. Inspect bearings. Replace if necessary. Replace mechanical seal using the special tools listed below. Use the seal press to install a new mechanical seal in cover with spring sleeve toward impeller housing. Install seal guide over end of shaft and apply a light film of grease to seal guide. Careful ly install shaft Assemble 10x14mm and bearings in cover. washer, impeller, washer, and nut. Torque impeller nut to specification.
Seal Guide Seal Press
2871846 2871847
Impeller Nut Torque 10ft. Ibs. (1.38 kg-m)
3.63
9/97
ENGINES
16. Remove reed cover, reed stutters, and reeds .
Reed Valve Inspection

17. Measure air gap between fiber reed and reed block as shown. The air gap should not exceed .015" (.4 mm). If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap. Always replace them if damaged. Check each fiber reed for white stress marks or missing material. Replace if necessary. Reed Pedal Clearance .015" (.38 mm) max. Exaggerated for illustration
Note condition and 18. Remove cylinder head. placement of both cyl inder head a -rings . Refer to pages 3.80-3.85 for gene ral inspection procedures.
19. Loosen cylinder base nuts and remove cylinders.
9/96
3.64
ENGINES 700 Case Reed

Disassembly, Cont.
'--"' 20. Carefully rem ove C-clip holding piston pin in place.
21. Remove piston pin using piston pin puller and adaptor.
Piston Pin Puller PN 2870386 Adaptor PN 2871445
22. Remove water manifold by removing both retainer brackets.
23. Remove bottom crankcase bolts and separate crankcase halves.
3.65
9/97
ENGINES
24. Remove snap rings and crankshaft seals. For crankshaft/crankcase inspection procedure, refer to pages 3.81-3.85. 25 . Clean thoroughly to remove all grease , oil , dirt, and old sealant.
9/96
3.66
ENGINES 700 Case Reed Assembly

'--... 1. Clean all parts with solvent.
Apply 3-Bond'" 1215 sealant to upper crankcase half. NOTE: Use only 3-Bond'" 1215 sealant. Curing time and film thickness are critical for proper bearing clearance.
2.
3-Bond n, 1215
PN 2871557
120 Gram Tube
3.
Grease labyrinth seal.
4.
Set crankshaft in lower crankcase. Lubricate seal lips with Premium All Season Grease. Make sure seals are positioned properly with lip and spring facing inward toward crankshaft. Install snap rings with gap facing upward toward upper case half.
3.67
9/96

Assembly, Cont.
5. If studs were removed or new crankcase installed, apply Loctite 242 to threads of studs and screw in until bottomed. Tighten securely. Measure installed length of stud bolt. This is the length necessary to allow cylinder installation. Lower Crankcase Stud Height 121-124 m'm (4.76-4.88") from crankshaft parting line.
6.
7. Install crankcase halves together. Torque bottom crankcase bo~ to specification in the proper sequence. Crankcase Mounting Bolt Torque: 8mm - 18 ft. Ibs. (2.48 kgm) 10mm - 26 ft. Ibs. (3.59 kgm)
8.
Install new a -rings on water manifold. a -rings and install manifold.
Grease
9.
Install pistons and rings. Make sure C-clips are firmly seated in grooves. NOTE: Keystone ring bevel must be up. Marking near ring end gap faces upward. Straight Edge
~
Piston Ring Cutaway Keystone Piston Ring
9/96
3.68
ENGINES 600 I 700 Case Reed

Assembly, Cont.
'-' 10. Lubricate pistons, rings , upper rod bearing , and cylinders with two stroke oil and install cylinders. Loosely install cylinder nuts.
11. Install new cylinder head a -ring and install cylinder head. Make sure a-ring is properly seated in groove. Apply Loctite 242 to threads of head bolts and install. NOTE: Torque cylinder head bolts prior to torquing cylinder base nuts.
12. Torque head bolts in proper sequence.
Head Bolt Torque 24 Ft Ibs (3,3 kgm)
600/700 Cylinder Head
13. Torque cylinder base nuts in proper sequence.
Cylinder Base Nut Torque 30 - 34 Ft Ibs (4.15 - 4.70 kgm)
600/700 Cylinder Base
3.69
9/97

Assembly, Cont.
14. Reassemble water pump carefully installing seal.
15. Install crankcase seal to ignition/water pump housing from inside toward outside. Spring and seal lip must face inward toward crankshaft. Seal lip bottoms on housing.
16. Apply 3 Bond' " sealant to pump housing crankcase mating surface and carefully install onto crankcase. TIghten water pump to engine hose clamp and torque bolts to specification.
Ignition/Water Pump Housing Torque 22 Ft. Ibs (3.04kgm)
17. Align timing marks and install stator.
9/96
3.70

Assembly. Cont.
'-'
18. Apply Loctite 262 evenly to flywheel taper. Install flywheel key and flywheel. Apply Loctite '" 242 to crankshaft threads. Torque nut to specification.
W
Flywheel Nut Torque60-65 ft. Ibs. (8.28-8.97 kg-m)
19. Install water pump belt and recoil hub.
Recoil Hub Bolt Torque 96-108 in. Ibs. (1 .11 -1.25 kg-m)
20. To verify concentricity of the drive hub, rotate the flywheel 1/8 turn at a time while checking belt deflection. Tension should be even at all points without any tight spots. If a tight spot is found, place four 1/2" (12.7mm) lengths of 1/2" wide masking tape on outer circumference of the flywheel hub as shown at right. This will center the drive pulley on the flywheel hub and ensure even tension on the belt in all crankshaft positions.
Place tape every 90 over edge 01 hub and onto lIywheel as shown
Water Pump Belt Width Service Limit 114" (6.35 mm) Minimum Width
Do not apply tape to face of hub.
2 1. Install recoil cover and oil pump. Make su re oil pump drive slot mates properly with water pump shaft. Torque oil pump mounting bolts to specification. 22. Install reed valve , reed stuffer, and reed cover.
3.71
9/97
ENGINES 800 Case Reed Disassembly

1. Remove carbure10rs, water outlet manifold, secondary coils, oil pump and reed valve cage assemblies . NOTE: Mark each components mag, center, and PTO so they will be in the correct location when reassembling.
2.
Remove recoil housing, water pump belt guard, water pump and flywheel nut.
3.
Install flywheel puller and remove flywheel.
CAUTION:
Do not thread puller bolts more than 3/8" (0.5 mm) into flywheel or coil damage may occur.
9/96
3.72
ENGINES
"--' 4. Mark stator plate at case parting line and remove plate.
5. 6.
Remove remainder of head nuts and cylinder base nuts. Carefully remove cylinders. Measu re piston to cylinder clearance and piston ring installed gap. Refer to pages 3.BO-3 .B5 for general inspection procedures.
7.
Remove C-clip retainers.
B.
Use piston pin puller to remove piston pins.
Piston Pin Puller

PN 2870386
3 .73
9/96
ENGINES
9. Remove crankcase bolts and separate crankcase halves.
10. Inspect crankcase and crankshaft as outlined on pages 3.81-3.85. 11. Clean crankcase thoroughly to remove all grease, oil, dirt, and old sealant.
9/96
3.74

Assembly
1. Grease oil pump drive gear and labyri nth seal area.
2.
Grease end seals and oil pump drive gear.
3.
Position anti-rotation pins with relief in case.
4. Apply a light film of 3 Bond 1215 to cran kcase and reassemble halves. 3-Bond 1215 120 Gram Tube
TM
PN 2871557
3.75
9/96
ENGINES
800 Case Reed Assembly, Cent.
5. Install bolts and torque to specifications and pattern found on page 3. 5 and 3.6.
Crankcase' Mo'unting Bo,t Torque: 8mm - 18 ft. fbs. (2.48 kgm) 1 Omm - 26 ft. Ibs. ,(3.59 kgm)
6. 7. 8.
Install piston pin bearings . Install piston with arrow

(~)
toward flywheel.
Install C-clip retainers using tool. NOTE: The C-ciip opening should be in the up or down position.
C-Clip Retainer Installation Tool PN 2870773
9.
Lightly oil rings and cylinder. NOTE: Keysto ne ring bevel must be up. Marking near ring end gap faces upward. Straight Edge
------=
10. Carefully compress rings and install cylinder over piston. Torque cylinder base nuts to specification.
Cylinder Base Nut Torque: 28 ft. Ibs. (3.86 kgm)
9/96
3.76
ENGINES
800 Case Reed Assembly, Cont.
11. Install new head gasket with the rounded tab positioned directly over the left exhaust flange stud and the "UP" tab under the water outlet of head . When properly installed on the cylinder the word "UP" and "80" should be readable. All head gaskets are the same thickness.
@
,g _
"UP" T~
Tab Aligned With Notch In Head And Over Left Exhaust Stud
~_~.
~haust Side
Head Gasket Thickness .8mm
.~?:
~?
12. Install heads, positioning outlets as shown. Make sure coils are in correct position and torque head nuts to specification .
Storm coolant outlet restrictor plates must be positioned as follows for proper cooling:
11 mm PTO Center 12 mm Mag 13 mm
Cylinder Head Nut Torque: 18 ft. Ibs. (2.48 kgm)
Reed Valve Inspection

13. Measure air gap between fiber reed and reed block as shown . The air gap should not exceed .015" (.4 mm). If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap. Always replace them if damaged. Check each fiber reed for white stress marks or missing material. Replace if necessary.
Reed Pedal Clearance .015" (.38 mm) max.
Exaggerated for illustration
Reed Air Gap - Maximum .015" (.4 mm)
14. Install reed cages.
3.77
9/96

Assembly, Cont.
15. Install carburetor mounting flanges.

CAUTION:
Position oil check valve as shown.
16. Install oil pump drive gear in correct sequence. 17. Check oil pump drive gear end play. adjustment on page 3.89. 18. Install oil pump. 19. Position stator plate at previously marked position and secure in place. See
20. Torque flywhee l nut to specification. Install new O-ring on water pump and grease lightly. Install pump, recoil cup, and belt.
Flywheel Nut Torque: 65 ft. Ibs. (8.97 kgm)
21. Adjust tension on water pu mp belt by loosening mounting bolts, applying tension, and re-tightening bolts . Install recoil housing and belt guard.
Water Pump Belt Deflection
1183116"(.3 .4 cm)
9/96
3.78
ENGINES SN44 Case Reed Disassembly

1.
Remove carburetor mount adaptors, reed cages, stuffers, and oil pump. Note position of stator wire guide.
Measure air gap between fiber reed and reed block as shown . The air gap should not exceed .015" (.4 mm). If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap. Always replace them if damaged. Check each fiber reed fo r white stress marks or missing material. Replace if necessary.
Reed Pedal Clearance .015" (.38 mm) max.
Exaggerated for illustration
V.E.S. Removal
2.
3.
Pull back cover retainer clip while holding the cover in place.
Remove cover and return spring.
1. Hold Cover 2. Slide Clip Down
4.
If the spring stays in the cover, hold the cover with spring facing toward you. Rotate sp ring in a counterclockwise direction while pulling outward on the spring. Do not distort the spring upon removal.
Retainer C~ ~
Cover
CAUTION: Do not attempt to remove the plastic valve piston at this time. The bellows must first be removed from the piston or damage may occur to the bellows or piston.
fmm"'''~~
Rotate to remove
~~
5.
Remove two (5mm) hex screws from valve housing.
UP
6.
Note location of "TOP" marks on housing and exhaust valve. Lift entire valve assembly from cylinder along with gasket.
Align TOP marks
NOTE: Refer to Maintenance Chapter page 2.28a . 2.28e for cleaning and inspection procedure.
$
/
"'\ O-ring
Housing Bolts: Appl Loctite ~ 242{blue) Torque: 108 in. Ibs. (1.24 kg-m)
3.78a
9/97
ENGINES SN 44 Case Reed Disassembly, Cent.

7. Remove cylinder head cover and inspect arings (A, B) and sealing surfaces for damage.
B.
Remove cylinder head and inspect all a'ring sealing surfaces and grooves for damage or debris. Use new a rings upon reassembly. Remove cylinder base nuts. Niote location of acorn nuts on exhaust side (where applicable).
9.
10. Carefully remove cylinders while supporting pistons and connecting rods to prevent piston damage. Refer to pages 3.BO3.B5 for general inspection procedures . 11. Remove outer piston pin Cclips using a scribe through access slot in piston. 12. Place support block under piston and remove piston pins using pin puller.
Piston Pin Puller Support Block
PN 2870386 PN 2870390
13. Remove water pump cover from front of engine .
9/97
3 .78b
ENGINES SN44 Case Reed

Disassembly. Cant.
"--" 14. Remove recoil housing and drive hub.
15. Remove flywheel using heavy-duty flywheel puller. Use drive clutch puller T-handle to hold pul ler.
Flywheel Puller T-Handle
PN 2871043 PN 5020326
16. Before removing stator plate, note where ignition timing marks are located, or scribe additional marks for reference upon reassembly.
17. Mark or note location of engine mount straps and remove.
3.78c
9/97
ENGINES SN44 Case Reed Disassembly, Cont.

18. Remove bolts and separate case halves. bolts in order for assembly. Keep
19. To prevent damage to snap-ring grooves, lift crankshaft straight upward and out of lower case.
20. If pump shaft removal is necessary, remove retaining pin from crankcase using a diaganol cutter or similar tool.
21. Using a soft faced hammer, tap pump shaft out of lower case half from front (water pump side) to rear (oil pump side). Note location washers on the shaft.
9/97
3.78d

Disassembly, Cont.
"-' 22. Press front bushing, oil seal and mechanical seal out of lower crankcase using a suitable (soft) drift from the oil pump (rear) side. Be careful not to damage bushing .
'--'
Assembly
Insert bushing into case on water pump side using weep hole to align hole for retaining pin. Press in until firmly seated in case. Install retaining pin. Tap in until seated in bushing NOTE: If front bushing is replaced it may be necessary to drill a retaining pin hole in the new bushing. If there is no hole in the bushing: Install bushing in crankcase as described above. Remove the retaining pin from lower crankcase. Using the retaining pin hole as a guide, carefully drill a hole in the new bushing to the same depth and diameter as the hole in the old bushing. Be careful not to enlarge the retaining pin hole. Install new retaining pin. 1.
2.
Install oil seal with spring facing outside of crankcase (toward you) until seated against bushing. Lubricate and install washer on pump shaft (water pump end). Install shaft with washer through bushing and oil seal from the oil pump side of case. Be sure spring stays in position on seal lip. Install remaining washer on shaft. Lubricate and install rear bushing with new O-ring until seated against shaft. Install oil pump. being careful to engage pump shaft in drive shaft.
3.
"-'
4. 5. 6.
Oil Pump Mounting Screw Torque:
60 in. Ibs. (.70 kg-m)
3.78e
9/97
ENGINES SN44 Case Reed Assembly. Cont.

7. Install mechanical seal guide (special tool) on end of pump shaft. Mechanical Seal Guide Tool: PN 2871846 Mechanical Seal Press Tool: PN 2871846 8. Lubricate seal guide and drive or press a new mechanical seal into case until fully seated using the seal press tool. Washer 10.3x14x1mm /
10 ft.lbs.
~f1~kgml
Mechanical Seal Washer .325x.75x.063"
9.
Lubricate all crankshaft bearings with Premium 2-Cycle or Premium Gold Engine Lubricant.
10. Lightly grease pump shaft drive gear and sealing lip of crankshaft seals. 11. Install seals on crankshaft with spring facing inward (toward crankshaft). 12. Clean and de-grease lower crankcase and install crankshaft assembly, aligning seals and snap ring wi th grooves in case. 13. Apply a thin coaling of 3-Bond 1215 sealant to lower crankcase mating surface . 14. Install upper crankcase on lower crankcase. 15. Apply Loctite 242 to threads of bolts and install. Torque bolts in three steps to specified torque following the sequence shown at right
Crankcase Bolt Torque: 8mm 20-24 tUbs. (2.8 - 3.3 kgm) 6mm 108 in. Ibs. (1.24 kg-m)
MAG End
PTO End
(i)
G) G)
@
@
@@ @@
CRANKCASE - SN44-44LCDCSP-01 /02
9/97
3.781

Assembly, Cant.
16. Assemble engine mount straps to crankcase.
Engine Mount Strap Torque: 44-48 ft. Ibs. (6.0-6.6 kg-m)
17. Lubricate main bearing oil holes with Polaris Premium 2 Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly. 18. Install a new C-clip in both pistons (inside) with gap facing down. Be sure clip is fully seated in groove. 19. Lubricate and install new connecting rod small end bearing in rod. 20. Install piston with arrow facing exhaust (ring locating pins should be facing intake). Warming the piston may help to ease installation of pin. 21. Install remaining C-clip with gap down. Be sure both clips are fully seated on the groove. 22. Install new base gasket. Be sure gasket surface is clean and free of nicks , burrs, or scratches. 23. Lubricate and install piston rings on piston with mark on end of ring facing upward. 24. Place piston support under skirt and lubricate pistons and cylinders thoroughly. 25. Align ring end gaps with locating pins and compress rings. Install cylinder carefully with a gentle front to rear rocking motion. Install cylinder base nuts loosely. Do not tighten them at this time . Repeat Steps 2225 for other cylinder.
Straig ht Edge
'--'
CAUTION: I
Do not twist or force cylinder during installation. 26. Install new cylinder head Orings and install cylinder head. Make su re O-rings are properly seated in grooves. Apply a light film of grease to hold O-rings in place if necessary.
3. 78 9
9/97

Assembly, Cont. 27. Install new cylinder head cover Orings and install cylinder head cover. Make sure Orings are properly seated in grooves. Apply a light li lm 01 grease to hold Orings in place il necessary. 28. Loctite 242 to threads 01 head bolts and install. NOTE: Torque cylinder head bolts prior 10 torqui ng cylinder base nuts.
29. Torque head bolts in proper sequence.
Head Bolt Torque: 20-24 Ft Ibs (2.77 - 3.3 kgm)
00
@
0
@
80
Cylinder Head
00
30. Torque cylinder base nuts in proper sequence.
Cylinder Base Nut Torque: 30 - 34 Ft Ibs (4.15 - 4.70 kgm)
Cylinder Base 31. Install washers and water pump impeller as shown and torque nut to 10 It. Ibs. (1.38 kg-m).
Washer 10.3x14x 1mm /
10 IUbs.
Impeller Nut Torque: 10Ft Ibs (1.38 kgm) Mechanical Seal
@-'ir
Washer .325x.75x.063"
gm
9/97
3.78h
ENGINES SN44 Case Reed Assembly, Cent.

32. Install water pump cover with new gasket.
Water Pump Cover Bolt Torque: 9 Ft Ibs (1.25 kgm)
33. Install new exhaust manifold gaskets and manifold.
Exhaust Manifold Bolt Torque: 16 Ft Ibs (2.21 kgm)
34. Assemble V.E.S. valve as outlined Maintenance section page 2.28ae.
in
35. Install re ed valves. stuffe rs, and carbureto r adaptors. Place stator wire guide on Mag side carburetor adaptor bolt. 36. Install stator assembly, aligning timing marks or marks made upon disassembly. Seal stator wires with high temperature silicone sea lant. Install and tighten stator screws to specification. 37. Measure trigger (pu lse) coil gap and compare to specification. Stator Screw Torque 60 in. Ibs. (.69 kg-m)
Trigger (Pulse) Coil Gap Minimum: Maximum: .020" (.5mm ) .040" (1.0mm )
3.78i
9/97
ENGINES SN44 Case Reed Assembly, Cont.

38. Apply Loctite ,. 262 evenly to the flywheel mounting taper on crankshaft. Install woodruH key.
39. Install flywheel. Apply Loctite ~ 242 to crankshaft threads. Install washer and nut.
40. Use flywheel holder to hold flywhee l and torque nut to specification. Flywheel Holder: Flywheel Nut Torque: 90 ft. Ibs. (12.45 kg-m) PN 8700229
4 t . Install recoil hub and recoil housing. Torque bolts to specification. Recoil Hub and Housing Bolt Torque: 108 in. Ibs. (1.25 kg-m)
42. Install engine in chassis and align clutches. 43. Refer to Maintenance Chapter to fill and bteed cooling system and oil pump.
9/97
3.78i
ENGINES General Inspection Procedures

Cylinder Honing
The cylinder bore must be de-glazed whenever new piston rings are installed". A light honing with fine stones removes only a very smal l amount of material. A proper crosshatch pattern is important to provide a surface that will hold oil, and allow rings to seat properly. If the crosshatch is too steep. oil retention will be reduced. A crosshatch angle which is too shallow will cause ring vibration, poor sealing, and overheating of the rings due to blow-by and reduced contact with the cylinder wall. Service life of the pistons and rin gs wil l be greatly reduced. " Except Nicasil
Cylinder Hone Selection

Selecting a hone which will straighten as well as remove material from the cylinder is very important. Honing a cylinder with a spring loaded glaze breaker is never advised. Polaris recommends using a rigid type hone which also has the capability of oversizing. These hones are manufactured by such companies as Sunnen Products Company of SI. Louis , Missouri; and Ammco Tools, Inc. , of North Chicago, Illinois. Shown at right is the Ammco No. 3950 hone. This hone has roughing and finishing stone sets available to service engines with cylinder bores up to 75mm in diameter.
De-glazing
If cylinder wear or damage is minimal, hone the cylinder lightly with finish stones following the procedure outlined on page 3.80
Honing To Oversize
If cylinder wear or damage is excessive, it will be necessary to oversize the cylinder using a new oversize piston and rings. This may be accomplished by either boring the cylinder and then finish honing to the final bore size, or by rough honing followed by finish honing. For oversize honing always wet hone using honing oil and a coarse roughing stone. Measure the piston (see piston measurement) and rough hone to the size of the piston or slightly larger. Always leave .002 - .003" (.05 - .07 mm) for finish honing. Refer to pages 3.3-3.4 for piston to cylinder specifi cations before honing. Complete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearance. See procedure on page 3.80.
----
EXAMPLE OF CROSS HATCH PATTERN
3.79
9/96

Honing Procedure
1. Wash cylinder wi1h solvent. Clamp cylinder securely in a soft jawed vise by the exhaust port studs . 2. Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls (DO NOT OVERTIGHTEN). Cylinders may be wet or dry honed depending on the hone manufacturer's recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore . Using a 1/2" (13 mm) drill motor rotating at a speed of 300-500 RPM , run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered to prevent edge loading and always bring the stone approximately 1/2" (1.3 cm) beyond the bore at the end of each stroke. Release the hone at regular intervals to inspect bore size and finish. Do not "drag" the hone out of the bore.
Port Chamfering
Remove the sharp edges at the bottom and top of each port whenever boring or honing is performed. Make sure there are no sharp edges.
IMPORTANT: Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area) . Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Premium 2 Cycle Lubricant.
9196
3.80
ENGINES
General Inspection Procedures C r ankcase Inspection I Bearing Fit Any time crankshaft bearing failure occurs and the case is to be reused, Polaris recommends checking the bearing fit into the case halves using the following procedure. 1. With case halves cleaned, press a replacement bea ring into each of the main bearing journals to determine a basic amount of press fit. NOTE: Do a comparison check of all journals by manually forcing the bearing into the bearing seats noting if any are noticeably loose or tigh t. Normal hand installation will be an indication of the recommended interierence fit. If the bearing falls out of the case when the case is inverted, the case should be replaced .
Crankcase Bearing fnterference Fit: C-3 - .0006" (.015mm) - Crush C-4 - .001 " (.025mm) - Crush Crankshaft Main Bearing Inspection 1. Clean crankshaft thoroughly and oi l main and connecting rod bearings with Polaris Premium 2 engine oil. Ca refully check each main bearing on the shaft. NOTE: Due to extremely close tolerances, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and quietly. The inner race of each bearing should fit tightly on the crankshaft. The outer race should be firm wi th minimal side to side movement and no detectable up and down movement. Replace any loose or rough bearings.
'" --,,
3 .81
9/96
ENGINES General Inspection Procedures Connecting Rod (Big End) Bearing Inspection
1. Measure connecting rod big end side clearance with a feeler gauge. Clearance should be equal on all rods (within .002"). Rotate rod on crankshaft and check for rough spots. Check radial end play in rod by supporting rod against one thrust washer and alternately applying up and down pressure. Replace bearing, pin, and thrust washers if side clearance is excessive orif there is any up and down movement detectable in the big end bearing .
NOTE: Specialized equipment and a sound knowledge of crankshaft repair and straightening is required to perform crankshaft work safely and correctly. Crankshaft repair should be perform ed by trained Polaris service technicians in a properly equipped shop.
Connecting Rod Small End Inspection

1. Clean small end of connecting rod and inspect inner bore with a magnifying glass . Look for any surface irregularities including pitting, wear, or dents. 2. 3. Run your fingernail around the inside of the rod and check for rough spots, galling, or wear. Oil and install needle bearing and pin in connecting rod. Rotate pin slowly and check for rough spots or any resistance to movement. Slide pin back and forth through bearing while rotating and check for rough spots. With pin and bearing centered in rod, twist ends back and forth in all di rections to check for excessive axial play. Pull up and down evenly on both ends of pin to check for radial play. Replace pin and bearing if there is any resistance to rotation or excessive axial or radial movement. If play or rough ness is evident with a new pin and bearing, replace the connecting rod.
4.
Piston Pin I Needle Bearing Inspection

1. 2. Clean needle bearing in solvent and dry with compressed air. Inspect needle cage carefully for cracks or shiny spots which indicate wear. Replace needle bearings if worn or cracked, and always replace them if piston damage has occurred. Visually inspect piston pin fordamage, discoloration, or wear. Run your fingernail along the length of the pin and replace it if any rough spots, galling orwear is detected.
3.
9/96
3.82

Crankshaft Straightening
Lubricate the bearings and clamp the crankshaft secu rely in the holding fixture. On three cylinder crankshafts, straighten one of the ends (Magneto or PTO) and then straig hten the center section . Place the center section in the holding fixture and then straighten the remaini ng end . If tru ing the crankshaft requires striking with a hammer, always be sure to re-check previously straightened areas to verify truing . Refer to the illustrations below.
Crankshaft Alignment Fixture

PN 2870569
NOTE: The rod pin position in relation to the dial indicator position tells you what action is required to straighten the shaft. 4. To correct a situation li ke the one shown in the illustration at right , strike the shaft at point A with a brass hammer.
,,

HIGH .004 (.1 mm) A . HIGH .004 (.1 mm)
NOTE: The rod pin position in relati on to the dial indicator position te lls you what action is requi red to straighten the shaft. 5. To correct a situation like the one shown in the illustration at right, squeeze the crankshaft at point A. (Use tool from alignment kit).
SUPPORT CRANKSHAFT AT THESE TWO BEARIN GS
HIGH .002 (.05mm) .HIGH .005 (.13mm)
6.
If the crank rod pin location is 180' from the dial indicator (opposite that shown above), it will be necessary to spread the crankshaft at the A position as shown in the illustration at right. When rebuilding and straightening a crankshaft, straightness is of utmost importance. Runout must be as close to zero as possible. NOTE: Maximum allowable runout is .004" (. 1 mm).
HIGH .002 (.05mm) A l+..tAAl . HIGH .005 (. 13mm)
3.83
91 96
ENGINES General Inspection Procedures Crankshaft Indexing

Polari s crankshafts are pressed togethe r or "indexed" so the connecting rod journal center lines are 180 0 (twins) or 1200 (triples) apart from each other.
It is sometimes necessary to check multi-cylinder crankshafts to verify that one cylinder has not been forced out of position relative to the other cylinder or cylinders. Causes for out-of-index crankshafts include but are not not limited to:
Hydrolock from water or fuel; Impact to drive clutch from foreign object or accident; Abrupt piston or other mechanical failure; Engine lock-up due to drive belt failure;
Following is a method of checking:

CAUTION:
Disconnect battery ground cable and all spark pl ug high tension leads; ground high tension leads to engine. Disconnect lanyard from engine stop switch before proceeding with the following steps. 1. Securely faste n a degree wheel on the flywheel or PTO end of crankshaft. Use a large degree wheel for more accuracy, and make sure it is mounted concentrically with the crankshaft center line.
Dial Indicator
.100 ATDC
2. Sharpen a coat hanger or section of weld ing rod and anchor it to a convenient spot. Poi nt the sha rpened end at the outer perimeter of the degree wheel. 3. Install a dial indicator into the magneto end cylinde r spark plug hole (front) (#1). (The ignition timing is referenced by the magneto end.) Deg ree Wheel
4. Rotate the engine to bri ng the piston to top dead center (TDC) on the cylinder with the indicator installed . 5. Locate TDC as accurately as possible by finding the center of the poi nt where there is no piston movement. "Zero" the dial indicator at this point. Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads .100" (2.54mm) after top dead center (ATDC) .
IMPORTANT: Do not allow the crankshaft to move from this position.
9/96
3.84

Crankshaft Indexing (Continued)
6. Bend the pointer or move the degree wheel until the pointer aligns with the 180 or 120 mark on the degree wheel. With the pointer aligned, make sure the degree wheel and pointer are secured and will not move out of position. Re-check accuracy of this location by repeating steps 4. and 5. . The pointer shou ld align with the 180 or 1200 mark whe n the dial indicator reads .100" (2.54mm) ATDC.
7.
IM PORTANT: Do not move the degree wheel or pointer after the initial setting on the mag end cylinder - simply read the wheel and dial indicator.
8.
Remove the dial indicator and install in cylinder #2 or center cylinder. Repeat steps 4. and 5. Note the degree wheel indication when the dial indicator reads .100" ATDC. It should be 180 or 120' ( 2' ) from cylinder #1 . Repeat procedure on PTO cylinder (#3) where applicable. Cylinde r #3 should also be 1200 ( 2' ) from cylinder #1 .
Symptoms of an out of index crankshaft can include: Difficulty ca librating carburetor (repetitive plug fouling on one cylinder with no other cause); Unexplained piston failure on one cylinder (i. e. severe detonation , broken ring lands, piston holing); Excessive vibration of engine, backfiring, etc.; Rough idle, poor top speed.
3 .85
9/96
ENGINES General Inspection Procedures Cylinder Head Inspection

1. Inspect each cylinder head for warping. Replace cylinder head if warp exceeds service limit.
Cylinder Head Warp Service Limit: .003" (.OBmm)
Cylinder Measurement
2. Inspect each cylinder for wear, scratches, or damage. If no damage is evident, measure the cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure the bore 1/2" from the top of the cylinder; in line with the piston pin and 90 to the pin to determine if the bore is out of round. Repeat the measurements at the bottom of the cylinder to determine taper or out of round at the bottom. Record all measurements.
Cylinder Taper
Limit: .002 Max,
Cylinder Out of Round Limit: ,002 Max.
91 96
3.86
ENGINES General Inspection Procedures Piston Inspection/Measurement

1. Check piston for scoring or cracks in piston crown or pin area. Excessive carbon buildup below the ring lands is an indication of piston. ring or cylinderwear. 2. Measure piston outside diameter at a point 10 mm (3/8") up from the bottom of the skirt at a 90 angle to the direction of the piston pin. Record the measurement for each piston. NOTE: The piston must be measu red at this point to provide accurate piston-to-cylinder clearance measurement. Subtract this measurement from the minimum cylinder measurement recorded previously. If clearance exceeds the service limit. Ihe cylinder should be re-bored and new pistons and rings installed. Refer to specifications on pages 3.3-3.4 for specifications.
3.
Piston Ring Installed Gap

1. Position ring 1/2" (1.3 cm) from the top of the cylinder using the piston to push it squarely into place. Measure installed gap with a feeler gauge at both the top and bottom of the cylinder. NOTE: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round. Replace rings if the installed end gap exceeds the service limit. NOTE: Always check piston ring installed gap after reboring a cylinder or when installing new rings.
Straight Edge
1?4_________
3.87
9/96

Oil Pump Operation and Troubleshooting
Any time the engine is disassembled or repaired, it is important that the oil supply from the pump to the engine be checked.
NOTE: Banjo type or pressed in valves should open with 2 to Sibs. of pressure. CAUTION:
Use 40:1 premix in tank when troubleshooting oil delivery problems. 1. With engine in chassis, oil reservoir full , and pump bled , remove two oil feed line banjo bolts from their location on the manifold or carburetors. NOTE: Use ca re not to lose the two washers on either side of the banjo check valve. Some oil fittings are pressed into the carburetor mounting flange. Check valve is inline on 700 models. 2. 3. 4. Inspect each banjo bolt to make sure it is not plugged or restricted. Loosely thread only the banjo bolts back into the manifold or carburetors. Place oil feed lines with their check valves away from the clutch area. Start the engine and let it idle at normal idle RPM. Lift oil pump control lever up to its maximum flow position. Banjo Fitting Pressed Apply pressure with Mity Vae'" to test. Check valve should pop off between 2 and 5 psi.
5.
6.
Drops of oil should be visible from the banjo check valves after the engine is idled one to two minutes, with a drop occurring approximately every few seconds. If oil does not fl ow from one of the check valves, remove oil line from check valve and again idle engine . If oil then flows, the check valve is defective and must be replaced.
7.
8. If oil does not flow with check valves removed from their feed lines, the malfunction is one of the following: Inline filter or feed lines blocked; Kinked or restricted oil tank vent line; Feed lines leaking; Defective pump.
9/96
3.88

Oil Pump Bleeding
The oil pump must always be bled following any service to the injector system or engine which allows the loss of oil and subsequent entrapped air during reassembly. 1. 2. Fill oil reservoir with Polaris injector oil. Loosen brass hex head screw (A). After a short ti me oil should flow from beneath the screw head to indicate the pump is free of air. Tighten bleed bleed screw.
3.
Oil Pump Adjustment - All Models

After the engine RPM and carburetor adjustments have been made, the oil pump must also be adjusted. 1. With engine shut off and throttle in its idle position, the pump lever index mark (A) must align with the pump housing boss index mark (8).
2. Loosen lock nuts on cable housing sleeve and vary cable housing length as required. NOTE: Verify that pump lever is actuated upon initial throttle opening .
Oil Pump Drive Gear End Play Adjustment

If the oil pump, crankcase , or any other oil pump drive component is replaced, inspect the drive gear end play using the following procedure: 1. Measure distance from oil pump mounting surface to bushing. Call this measurement "A". NOTE : Make sure the bushing is fully seated in the crankcase.
'----'
3.89
9196

Oil Pump Drive Gear End Play Adjustment 2. Measure distance from oil pump mounting flange surface to end of seal flange as shown. Call this measu rement "9". Subtract measurement "9" from "A" to determine total bushing end play.
3.
4.
Measure thickness of existing shims and subtract from total bushing end play determined in step 3.
5. Add or subtract shims as required to provide specified end play. 6. Lightly grease a new O-ring and install it on the pump. Install pump, engaging slot in shaft with drive gear. Apply Loctite 242 to bolts and torque evenly to 78 in. Ibs. (.9 kg-m) .
Oil Pump Mounting Bolt Torque (242 Blue) 78 in. Ibs (.9 kg-m)
Optional Shims: PN 3083671 = .006"(.15mm) PN 3083672 = .012" (.3mm) PN 3083673 = .024" (.6mm)
End Play .008 - .016" (.203 - .406 mm)
9/96
3.90
COOLING SYSTEM Cooling System - EC4S/S0PL With Positive Bleed Recovery System
Filling and Bleeding Procedure
If the cooling system should become low in the tank andlor filler neck, the system should be bled of any trapped air using the following procedure: Elevate front end of machine approximately 10" (25 cm). 2. Fill coolant expansion reservoir to indicated maximum level line. 3. Remove pressure cap and slowly pour coolant into engine until the coolant level is at the pressure cap fitting neck. Install pressure cap and lift lever. 4 . Install the pressure cap with the lever lock up in its release position and run the engine at fast idle for two to three minutes. This will purge the system of trapped air. Close the lever lock and check recovery tank fluid level. CAUTION: On models equipped with remote filler neck, low idle RPM must be used for bleeding (600 RPM 100) to allow all air to purge and prevent trapped air which can lead to overheating and engine damage. Reset idle to specs after bleeding. System is properly bled when no air bubbles are visible in overflow line when RPM is increased slightly. 1. Lift Lock Lever To Bleed
~
_\
Remote Filler Neck Bleed at 600 RPM Filler Neck On Cylinder Head Bleed at fast idle Caution: Increase RPM slowly when lever lock is up to avoid loss of coolant.
"---"
~
". ,.
Remote Filler Neck Shown
r ~
.
O :
EC45/50PL ENGINES BRAKE COOLER

~-
II
NOTE: If system is difficult to bleed, inspect coolant fi lter and check valve for restriction and proper installation.
.r-"' ~OVERFLOW BODLE
1
\ FILLER NECK
FILTER GOLD BONNET
~~d~~G~'=~
./
CH ECK VALVE
'-=
F~====lJ
ENGINE ASSEMBLY
. ~, ~
RI GHT EXTRUSION
CENTER EXTRUSION
LEFT EXTRUSION
b
COOLANT FLOW SCHMATIC
3.91
9197
COOLING SYSTEM Cooling System - EC65PL05

Filling and Bleeding Procedure
1. Fill system with a 50/50 mixture of antifreeze and water. 2. With engine running, crack bleed screws on water pump and head. 3. Continue adding antifreeze mixture until system is purged of air. 4. Close bleed screws. 5. Add antifreeze mixture up to fill line.
ENGINE ASSEMBLY
WATER OUT
t~ il~~=~:=~
WATER IN
)!!.L...,
COOLANT FLOW SCHEMATIC
SURGE TANK [
BRAKE COOLER
r::0
FILLER NECK
I
In. vO
'-- C
5lL
LEFT EXTRUSION COOLER
RIGHT EXTRUSION COOLER
REAR TUNNEL COOLER
9/97
3.92
COOLING SYSTEM Typical 440 Indy /500 Indy /500 Classic /500 RMK / Classic Touring / WideTrak LX
NOTE: When leak testing cooling system , system pressure should not exceed 2 Ibs. less than cap pressure. Refer to filling and bleeding procedure on page 3.91 . Spring & Convoluted Tubing at Base of Chaincase Spring Only
Convoluted Tubing Between Hose and Engine
3.93
9/97
COOLING SYSTEM EC58 Style With Center Cooler - XLT LTD I XLT Classic I XLT SP
NOTE: When leak testing cooling system, system pressure should not exceed 2 Ibs. less than cap pressure. Refer to filling and bleeding procedure on page 3.91.
Hole , Filler Out, RH Ext.
Hose, Crossover
Hose, Engine Out, Filler ----fHf!tJ~
Hose, Center Cooler to Engine
9/97
3.94
COOLING SYSTEM EC58 Style Without Center Cooler - XLT Touring
Convoluted to go against corner of chaincase
HO~' E,gi,. OoUFill.c /
/"
Hose, Rear Cooler Inlet, 1"
Spring, Hose Retainer
3.95
9197
COOLING SYSTEM EC59/68 Style Without Center Cooler - Ultra / Ultra Touring
NOTE: When leak testing cooling system, system pressure should not exceed 2 Ibs. less than cap pressure. Refer to fill ing and bleeding procedure on page 3.9 1.
Torque 4-6 ft . Ibs.
Hose - Surge Tank! Engine In
. ,
'fW/
..... ~
l,
9/97
3.96
COOLING SYSTEM EC59/68 Style With Center Cooler -700 XCR 1600 XCR
/4
if'
fti...
Torque to 6 ft. Ibs. Hose-Rear Cooler
r:fPJ('
Hose-Autostat! Center Surge w/spring Hose-Center CoolerlTop Surge
Y/
HoseCrossover
Convoluted Tubing
3.97
9/97
COOLING SYSTEM Domestic Twins With Wear Strip Coolers - 600 XC 1700 XC
NOTE: When leak testing cooling system , system pressure should not exceed 2 Ibs. less than cap pressure. Refer to filling and bleeding procedure on page 3.91.
Hose , Cooler, Rear Wear Strip
Hose, Remote Fillerl Brake Cooler Hose, Brake Cooler Wear Strip
Hose, Engine Out Remote Filler In
""
Hose , Close Offl Wear Strip
Hose, Close Off Out Engine In
91 97
3.98
COOLING SYSTEM Domestic Twins With Center Coolers - 600 RMK /700 RMK
Hose, Brake Cooler/Rear
Hose, Coolant Hose, Close Off, Cooler/ Rear
Hose, Center Cooler/ Mid Surge
3.99
9/97
COOLING SYSTEM Storm 0985782
Hose, Autostati Brake Cooler w/Spring Hose , Autostati Engine
Hose, Surge Tank! Water Pump
Hose, Center CoolerlTop Surge
91 97
3.99a
CHAPTER 4 ELECTRONIC FUEL INJECTION (EFI)

Operation ...... . ......... . ...... .... . . . ...... 4.1-4.3 Battery Maintenance . ...... . . . . ... ............ 4.4 Battery Testing .... . .. .. . . .. . . .. .. . ... . ...... 4.5 Power Up Testing ......................... .. .. 4.6-4.7 Alternator Controlled Switch (ACS) Testing .. .. .. . 4.8 Basic Operation - System II ................... . 4.9 EFI Fuel System Maintenance and Testing ....... 4.10-4.15 System III - Electronics Operation ...... ... . . . . .. 4.16-4.17 System III - Electronics Testing . .. .... . . . . .. . .. 4.1 8-4.27 EFI Electronics .... ..... ...... ...... . ..... . ... 4.28-4.32 Wiring Diagram - 1996 / 1997 RXL ... . . ......... 4.33 Wiring Diagram - 1996 11997 500 EFI/SKS/ RMK . 4.34-4.35
Electro nic Fuel Injection (EFI) Operation
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
'--'
A A A A A A
A
Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored or used. Do not overfill the tank. Do not fi il the tank neck. If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
If you spil l gasoline on your skin or clothi ng, immediately wash it off with soap and water and change clothing .
Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.
WARNING
Battery electrolyte is poisonous. It contains acid! Serious burns can result from con tact with the skin, eyes , or clothing.
ANTIDOTE : EXTERNAL: Fl ush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia , beaten egg , or vegetable oil. Call physician immediately. EYES : Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, fla me, cigarettes, etc. away. Ventilate when charging or using in closed space. Always shield eyes when worki ng near batteries. KEEP OUT OF REACH OF CHILDREN .
ROM Identification / Charge Coil Test Specifications

Model
Sstem ype
ROM 1 0
ROMPN
Battery Charge Coli Test

POSition/Resistance
1996500 EF I/SKS/RMK 1996-1997 RXL 1997500 EFI
II
1996500 V1 1996650 V1 1997500 V1
4040061 4040065 4040073
G'NJo BmIW .2 to A ohms Bm to GryIW .2 to .4 ohms
I II
G'NJo BmIW .2 to A ohms Bm to GryIW .2 to A ohms

G'NJo BmIW .2 to A ohms Brn to Gry/W .2 to .4 ohms
4 .1
9/96
Electronic Fuel Injection (EFI) Operation

EFI Operation
Machines equipped with Polaris Electronic Fuel Injection (EFI) have many advantages over normal carburetor equipped models. The most noticeable improvements will be ease of throttle operation, better cold weather starting and improved cold engine drive away. The EFI system also compensates for temperature and altitude, and with minor adjustments will perform well over a wide range of temperatures and altitudes. To assist technicians in understanding EFI, we have divided it into three separate systems . Following is a short description of these three systems:
System I
Battery Battery charging How the EFI is "powered up" or energized Fuel handling Fuel filtering Fuel pressure regulation Electronic Control Unit (ECU) ECU inputs from various sensors Control of fuel to the cylinders by injector operation
System II
System III
The following information is a more detailed explanation of these three systems. It's very important during diagnosis that each system be checked . Failure to do so may result in a repeat failure. Basic Operation System I
Battery, Battery Charging and Powering Up

The battery is the heart of the EFI system, its condition is critical to all EFI functions. Long off-season storage periods, high vibrations, and extreme temperature variations which are encountered in snowmobile applications make periodic battery inspection and service essential. If the battery is partially shorted or in a low state of charge, or if connections offer high resistance, the result might be a lean fuel condition. NOTE: Type II systems will compensate or "fail safe" for low battery voltage or a charging problem. EFI models have two separate alternators or charging systems. One is used for lighting and accessories, the other for battery charging and EFI operation. The battery size and alternator size have been designed to provide adequate output for the EFI system. On machines equipped with electric start a larger battery will be required to provide adequate cold cranking amperage.
EFI Accessory Note
At no time should any accessories be added to the battery or battery side of the charging system. To do so may overload the system , discharge the battery and cause substandard EFI operation.
11 /95
4.2
Electronic Fuel Injection (EFI) Operation

There are two basic types of EFI systems: TYPE I (RXLs) The Type I system is used on all RXLs. Powering up requires both key and auxiliary (engine stop) switch to be in the "Run" position. At that time, a circuit is completed between the battery positive terminal and the brown relay which passes through the switches and the circuit breaker. The brown relay then connects the battery directly to the Electronic Control Unit (ECU) via the fuse link, caUSing the ECU to begin to function . The ECU connects itself to the battery via a self shut-off relay, which serves to maintain power to the ECU for approximately ten minutes after power is cut off by the key or auxiliary switches. The ECU is kept on for a short time in order to help prevent flooding of the engine during a restart. When the ECU is first powered up, the fuel pump will run for approximately five seconds in order to build pressure in the fuel rail. If the engine is stopped by the switches and then restarted within the ten minute period , the fuel pump will not repeat the five second run, since the ECU was kept powered up by the self shut-off relay. .,--, lithe engine is stopped with the switches in the "Run" position , the ECU will remain powered up until the battery is drained. TYPE II (5005) The Type II system is used on all 500 EFI models. The Type II system is similar to the Type I system in the way that it maintains power to the ECU after the engine stops, but is different in the way that it powers down. The Type I system depends on the operator to turn off at least one of the switches before the ECU will power down. The Type II system will power down regardless of the position of the switches in the event that the engine stops unexpectedly. This preserves battery power. The key switch on these models only grounds the ignition in order to stop the engine. There is no battery power connected to the switch in these models, unless electric start is used . This system uses an Alternator Controlled Switch (ACS). Mounted on the battery box, it incorporates the voltage regulator/rectifier. The ACS senses the rotation of the crankshaft by recognizing output from the engine's alternator. The alternator signal causes the ACS to connect the battery to the ECU. The operator simply pulls on the rope and the system powers up automatically.
When serviCing the fuel system on models with an ACS it is very important to first disconnect the battery. Turning the engine over without disconnecting the battery could cause the fuel pump to run and create a dangerous fuel spill.
4.3
11 /95
Electronic Fuel Injection (EFI) Battery Maintenance Battery Maintenance

Battery maintenance is of the utmost importance to ensure satisfactory EFI operation. Partially shorted batteries can cause an additional load on the charging system and in turn leave the EFI system with too little to supply the relays, ECU, fuel pump, injectors, etc. When this type of machine enters your service area, be sure to thoroughly clean, inspect and test the battery.
I'
'CAUTION:
It is extremely important that the battery condition and state-of-charge be maintained at the highest level possible or serious performance and driveability problems will arise. Battery testing procedures are covered below. Off season storage for snowmobiles, especially EFI equipped machines, requires the battery to be removed. In the summer months higher temperatures and higher levels of humidity, along with a small drain applied from the EFI system, will in a very short time discharge the battery. Once the battery is discharged, the plates will become sulfated (turn white), and the battery will no longer accept a charge. Batteries which are not disconnected, removed and kept charged will need to be replaced at the beginning of each season. Never substitute any battery of lesser quality when replacement is required. Batteries may be maintained by using the Polaris Battery Tender. The battery tender can be connected indefinitely, and will automatically maintain battery charge. The electrolyte level should be monitored monthly during periods of non-use .
Battery Tender
0.
Polaris Battery Tender

~:~:.; <~~,~"
\, PN 2871076 .
,,,<;,,,,,,,:.' .,
Battery Service
Conventional battery service techniques apply to this battery. Maintain the specific gravity of the electrolyte to between 1.270 and 1.300. The open circuit voltage must be maintained between 12.7 and 12.9 volts DC (at room temperature), at lower temperatures, slightly lower values are acceptable. Voltage readings should always be taken with a Fluke' digital volt meter. The select monitor will place a load on the battery and on Type I units the monitor will incorrectly read voltage less than 10 VDC.
Specific Gravity - 1.270-1.300

Open Clrcul(Voltllge 12.7-12. 9 v DC i'i<y'jl .c - ,t%n 'jjh.
Fluke Meter PN2870659
11/95
4.4
Electronic Fuel Injection (EFI) Battery Testing

Battery Charging System Testing
1. Set digital meter to DC volts and check battery voltage. Must be 12.4 volts or more (no load). NOTE: The select monitor on some models will not accurately read voltage below 12.0 and therefore should not be used. Does DC voltage read correctly? No-. Yes! Remove the battery. Service and test as outlined earlier in the engine electrical section. Before continuing, the battery must be in good serviceable condition and full charged. IMPORTANT: Replace battery if questiona Ie. Yes - See Block 2
Check battery charging coil. Disconnect coil leads. 2. Start engine and increase to at least 4000 RPM. Battery Refer to specifications for resistance values and voltage should increase to 13.6 to 14.6 volts. NOTE: If battery is low on charge, the reading will be low. A fully connections. NOTE: These coils are open to ground, charged battery will reach the higher number more quickly. Is between any wire and ground should show open circuit. voltage reading correct? AC amperage testing will show approximately 7 amps at 4000 to 6000 RPM. Are tests within specification? No-. Yes - See Block 3 Yes! No! 3. Charging system is testing OK. Check for any~ossible loose connections between rectifier, regulator an battery. Are there any loose connections? No! 4. Replace regulator rectifier and re-test system. Replace battery charge coil andlor flywheel. Re-test system. See Block 1.
4.5
11/95
ELECTRONIC FUE L INJECTION (E FI ) Power Up Testing

Refer to appropriate wiring diagram in Chapter 10.
Type I (RXLs)
1. Check battery voltage. Must be 12.2 or higher. Use digital volt meter. Does it read correctly? No-.
Yes~
Charge, service, test andlor replace battery.
2. Check EFI brown relay. Y/BK wire should read 12.2 volts or more with switches turned on. Does it read correctly? NoYesJ 3. Check brown relay. Rela[, should connect RIY from fuse link to RIBK (ECU) and RIB U (select monitor). Does it? No_
Yes ~
Check circuit breaker, key switch, kill switch, connections and wires. Check relay ground black wire.
Replace relay and repeat tests.
4. Check self shut-off relay and wires from relays to ECU. Are tests OK? No-< YesJ 5. Replace ECU.
Replace wires andlor relays.'
Type II (500s)
1. Check battery voltage using digital fluke meter. 12.2 or higher. Is voltage within specification? NoYesJ
MJ.lSl read
Charge, service, and test battery; or replace battery. Continue testing if needed. See battery service.
2. Check voltage to ECU R/GN Pin #106. Should be 12.2 or higher. Is voltage within specification? No_
Yes~
Check circuit from battery through circuit breaker and to ECU. Repair andlor replace faulty wiring or components. Continue to step 3. Check for an AC si?nal from batte~ charge coil to ACS Gry - GryW wires. s signal OK? epair circuit if necessary. No - See Block 4
Yes~
3. Check volta~e to ECU OIBK wire Pin #11 . Should be 12.2 volts while engine is being turned over. Is voltage within specification? No-. See Also Block 5 Yes~ 4. Check battery charge call and connecting wires. Replace coil andlor repair wires. Continue tests.
Check for battery voltage at ACS (red wire). Is voltage present? Repair circuit if needed.
Yes ~
Replace ACS. Is system now OK? No) Replace ECU and retest.' 5. Check self-shut-off relay and circuit, OK? No_ YesJ 6. Replace ECU and retest. Repair relay circuit.'
NOTE: Use only resistor spark plug caps on ignition coil high tension leads. Non-resistor caps may affect ECU operation.
9/97
4.6
Electronic Fuel Injection (EFI) Power Up Component Testing Fuse Link

The fuse link is attached to the ignition switch harness with a tie strap. It can be identified by the light green and brown wires in 2 prong white connectors. The fuse link is the ci rcuit protection device in Type I electrical systems. If a system overload (such as a dead short) occurs, the fuse wire will open the circuit preventing further damage. If this link is open, find and correct the problem and then replace the fuse link. Never attempt to replace the fuse link with a conventi onal fuse. Use only an OEM fuse link.
~fI~~ I,.ink PN 3084113
Inspection
Service of the fuse link is limited to verification of whether or not the wire is continuous. Remove fuse link from machine. Measure resistan ce on the light green wire and the brown wire. Replace the fuse link if resistance is greater than .5 n. Type II systems (500s) use a self-setting circuit breaker, located near the battery.
Relay Coils
The system relay cOils for Type I systems are mounted on the front side of the right footrest assembly. The rel ays for Type II systems are mounted on the ECU . Theirfunction is to control a major current carrying ci rcuit with a smaller, low current carrying control circuit. When the ECU or ignition switch closes the low current coil circuit within the relay, the magnetism in the coil closes the contact points, allowing cu rrent to pass through the relay and power up to the ECU , fuel pump, etc. Type I systems incorporate two blue relays (black on Type II systems), one controlling the fuel pump and the other the self shut-off time delay relay. The Type I system also uses a brown relay to control the main power input to the ECU. Relays can be tested by measuring pull-in coil resistance and volt drop across the main contacts. Coil resistance should be between 65 and 70 ohms measured between the two pins marked "coil" on relay base. When relay is energized, volt drop across relay con tacts should be less than.1 vDC, measured in parall el with relay. On the bench, the relay can be checked by hooking the marked relay coil terminals to a 12v battery and checking resistance of relay contacts . The resistance must be less than .2 ohms. Type II style EFI relays are tested by placing 12 volts to contact left side as shown in the diagram at right. Measuring volt drop across contacts .1 vDC. Measure resistance of right side contact. This should be 100 ohms 10%. Right 100 ohms 10% Type II System
BLUE
BROWN
Bottom
4 .7
9/96
Electronic Fuel Injection (EFI) Alternator Controlled Switch (ACS) - Type II Systems
Shown in the photo at right is the 500 EFI system ACS. The ACS has two functions: 1) Rectifies AC voltage from alternator to DC voltage for battery charging; 2) Connects the ECU with 12vDC battery voltage when an AC signal from the alternator indicates that the engine's crankshaft is turn ing. NOTE: Even if the key switch and kill switch are in the "off' position , the ACS will power up the system if the crankshaft is turned. (See also page 4.6, Power up testing.)
Test Procedure
With ignition in the "on" or "run" position , crank engine over slowly. You will hear the fuel pump run for approximately five seconds . This tells you the ACS is working. If the fuel pump doesn't cycle when cranking, disconnect ECU wire harness and reconnect to reset ECU. Crank engine again. If fuel pump won't start working, unplug the harness althe ECU and check Orange/Black wire PIN #11 on the ECU harness. Battery voltage should be present when cranking engine. NOTE: 500s have a five wire ACS LR36. The extra wire is for a center tap alternator. You can also use the select monitor to determine if the ECU is getting power. If the select monitor display lights up the ECU is getting power. Check the ACS wire at the ECU plug.
I. CAUTlq~i: I
Take care not to distort the pin with the tester lead. If no voltage is present, reset ECU and check Orange/Black lead at ACS unit. If no voltage is present, check for alternator output or loose connections. If alternator output is OK, replace ACS.
Cold Starting
On Type I systems, during cold starting the ECU will select a special "start-up" mode . This will occur any time the engine is being cold started, for example, any Type I system which has had the key off long enough for the self shut-off timer to power down the system will go to the start up mode. After turning on the ignition key to reset the system, the fuel pump will run from three to five seconds to pressurize the fuel rail. When the ECU sees the first ignition pulse it provides a longer than normal "prime" pulse tothe injectors to inject enough fuel into the engine for starting. On Type II systems, there is no ready light or ignition key reset. The pump mayor may not run for the 3-5 second period depending on how long the engine has been off. In all systems, the "prime" pulse only occurs if the pump runs for the 3-5 second period. Once the engine is running the ECU provides a rich mixture while the engine is warming up. It uses the engine temperature sensor(s) as an indicator of when the engine is warm, and will begin decreasing the fue l air ratio accordingly. If the key is turned off, the ECU provides power to the self shut-off relay for a period of ten seconds to ten minutes, depending upon the system type, and will not repeat the fuel system pressurizing and prime pulse during that time. Once the self shut-off sequence has expired, the engine will have had sufficient time to cool and the ECU will again repeat the cold start sequence. In Type I systems only, during times of severely hard running or in very warm weather, if the engine crankcase should approach a temperature which might result in engine damage the ECU will provide additional fuel to the engine for cooling . When the crankcase temperature sensor indicates a temperature of approximately 100C (212F), the ECU will lengthen the pulse time and cause an over-rich condition which will cool the engine. As soon as the engine temperature returns to normal, the ECU will return to the original map. In Type II systems, the engine is protected against overheating by the engine coolant sensor. If the engine coolant reaches 85 C (185F) the '1emp" light on the dash will begin to flash. If the engine coolant temperature continues to increase, the light will begin to blink faster. At this point the ECU adds fuel to enrich the mixture and help prevent engine damage. Fuel will continue to be added until the light stops blinking. If the engine should become flooded during starting, it can be cleaned out by holding the throttle wide open while turning the engine over. If the engine is not running, and the throttle is open more than 60 . no fuel will be injected. The engine will start and will begin receiving fuel from injection when the engine exceeds 800 RPM, or when the throttle position goes under 60 . The engine should then clean out and run normally.
11/95
4.8
Electronic Fuel Injection (EFI) Basic Operation - System II
The fuel system consists of all the parts responsible for storing, cleaning, delivering, pressurizing and injecting fuel into the engine. They are: fuel tank, fuel pick-up, fuel hose, primary filter, fuel pump, secondary filter, fuel rail, injectors, throttle bodies, pressure regulator and fuel return hose. Fuel is picked up from the bottom of the fuel tank by the fuel pick-up hose and filter. It then travels through a hose to the primary (75 micron) filter, located under the air box. Once leaving the primary filter, it travels to the electric fuel pump, located under the mag end throttle body. The electric fuel pump is responsible for the movement of the fuel in the entire system. Connected to the battery by a relay, the pump runs continuously whenever the engine is started. Also located at the outlet end of the pump is a check valve which holds pressure in the system when the pump has stopped.
Injector - Side View Cross Section
Screen on Injectors, inlet
t--~~~~~i!~553
Pressure Regulator
Return Line Vent Line
Electric Fuel Pump

I
" "--<
Fuel Filter 75 micron Weighted Pickup and Screen Screen on Inlet End Check Valve Outlet End
Throttle Bodies
After leaving the pump, the fuel goes through the secondary 10 micron filter for further purification. The secondary filter is located under the mag end throttle body. Cleanliness is essential to the operation of the system, and its importance cannot be overstressed. The fuel is then stored under pressure in the fuel rail, ready for discharge into the throttle bores. The pressure regulator provides consistent pressure and maintains specific pressure in the rail. The pressure regulator is pre-set to maintain rail pressure at 35-37 PSI. Any pressure greater than this is relieved or returned to the tank by a return line. The return line must be free of kinks or obstructions to prevent excess fuel rail pressure which may cause a rich condition. Refer to fuel pressure test page 4.11 .
4.9
11/95
Electronic Fuel Injection (EFI) EFI Fuel System Maintenance and Testing Tank, Hose And Filters
The fuel tank is the reservoir for the fuel. It contains a flexible hose with a weighted pickup and a course screen which drops to the lowest part of the tank regardless of machine attitude. Fuel travels through the fuel hose to the primary (75 micron) filter located under the airbox and then to the fuel pump. The fuel hose changes to a reinforced rubber hose on the pressure side of the pump, which carries fuel to the secondary (10 micron) filter located under the throttle bodies, and then to the fuel rail.
STANDARD FUEL HOSE
REINFORCED
PRIMARY FILTER
The fuel tank, hoses, and filters require little maintenance or service . Periodically inspect tank and hose condition . Ensure that the pickup is clean and properly positioned and venttube is properly routed and not kinked or pinched. Replace any hose showing signs of deterioration. Replace primary and secondary filters at 5000 mile (8000 km) intervals, every two years, or more often if contamination of any kind is present in the system. Use OEM parts only. If for any reason, at any engine RPM, the fuel system should fail to deliver a sufficient quantity of fuel to meet engine requirements and have some fuel returning to the tank, the fuel hoses must be checked for obstructions and/or the fuel filters replaced. If the problem does not rectify itself, proceed to fuel pump testing.
ItrI?:~a11l0N;: ! I ",.~,\ ' .. . " " ,,.,

Whenever inspection reveals worn, damaged or defective parts, replacement is necessary in order to avoid serious damage to the machine or injury to the operator.
Fuel Pump
The electric fuel pump is located on the bulkhead underneath the mag end throttle body. The 12v pump receives fuel from the fuel tank, then sends it through the small strainer in the pump inlet nozzle, through the roller vane type pump, through the outlet check valve and on to the injector rail. The pump is completely filled with fuel during operation. This provides cooling, corrosion protection and lubrication. Outlet
Armature
Never run the pump without a sufficient supply of fuel or pump damage will result. The pump is cooled and lubricated by fuel. The pump outlet pressure can reach as much as 70 psi. It is regulated. however, to between 35 and 37 PSI by the fuel rail pressure regulator. Located near the outlet end of the pump is a check valve. The pressure regulator also acts as a check valve. There will be high pressure fuel between these two valves. The fuel pump is a sealed unit. No internal repair of the pump components can be performed. Pump condition can be verified by an amp draw test, an output volume test and an output pressure test.
11 /95
4.10
Electronic Fuel Injection (EFI) EFI Fuel System Maintenance and Testing
Amp Draw Test
'-' Install a DC ammeter in series with the purple pump power feed wire. The draw should be 2.5 amps. A draw at or slightly less than that value indicates the pump is electrically sound. No draw indicates either no power present or an open circuit in either the pump or its ground . A draw greater than that value indicates either a stuck or defective pump. A pump which is stuck due to long periods of non-use can occasionally be freed by striking with a soft face hammer. If this does not free the pump, it must be replaced.
Output Volume Test

The output volume of the fuel pump and delivery system can be verified with an output volume test. To perform test, start machine and make sure delivery side of system is filled and pressurized to the pressure regulator. With machine turned off, disconnect fuel return hose and place it into a 200 milliliter graduated container. Activate ECU to cycle pump for approximately five seconds. The measured output during this time period should not be less than 90 to 100 milliliters . NOTE: Battery voltage less than 12.6vDC or restrictions in the fuel lines or filters will cause output to be less than recommended amount.
Fuel Pressure Test

........ Install EFI fuel System pressure tester in fuel line on PTO end of rail. NOTE: Use caution when removing hose. The rail may contain pressurized gas if engine has been recently run . Activate dealer mode using select monitor service harness plug, by connecting gray and black test loads together or by jumping gray and black wire terminals at diagnostic plug, then turning on ignition switch. With pump running, system pressure should be between 35 and 37 psi. A pressure reading of higher than normal indicates a faulty pressure regulator or an obstructed fuel return hose. A pressure reading lower than normal indicates a faulty pressure regulator, a bad pump, or a restriction in fuel hoses or filters between tank and rail. If pressure starts out normal and then gradually lowers, suspect the fuel tank vent and/or any of the fuel filters or hoses which may restrict fuel delivery to the pump. Pressure
Filter 10 micron
"T" Fitting
I~
Pressure Gauge
\.-.....'
Connect Fuel Pressure Gauge Between Rail and 10 Micron Filter
Pr1 2816ge
Fuel pressure can also be checked with the gauge in place and with the engine running. Pressure should be checked at both idle and at operating RPM . A plugged filter or restricted fuel pickup hose may show good pressure at idle but restrict flow at operating RPM.
4.11
11/95
Electronic Fuel Injection (EFI) Fuel System Maintenance and Testing

Fuel Rail The fuel rail is the fuel distribution manifold for the injectors. The injectors slip into fittings on the underside of the rail which are sealed with O-Rings around the injectors. The rail stores fuel under pressure so that simply opening the injectors will allow fuel to pass from the fuel rail through the injectors and into the throttle body. Pressure in the fuel rail is controlled by the pressure regulator. The fuel rail requires little if any service. Periodically inspect seal between rail and injectors and rail and regulator. If any leakage exists, replace O-Rings and recheck for leaks.
Return Hose
The return hose runs between the bottom of the pressure regulator and the top of the fuel tank. It provides a path for excess fuel from the fuel rail to return to the fuel tank. If this hose should become obstructed in any way, the excessive fuel pressure in the rail will cause a rich operating condition.
Pressure Regulator
The fuel pressure regulator is mounted on the fuel rail, opposite the fuel entry point. Its function is to maintain a consistent fuel pressure within the rail by allowing pressure above the desired level to bleed off the rail, through the regulator, and back to the tank by way of the return hose. When the fuel pressure on the bottom of the regulator diaphragm reaches between 35 and 37 psi, it overcomes the spring on the other side of the diaphragm and pushes it up. This opens the valve to the return hose allowing fuel to escape, maintaining the specified pressure.
11 /95
4.12
The regulator can also vary pressure consistent with engine load, atmospheric pressure, etc. A manifold pressure tube runs between the mag end throttle body and the top of the diaphragm. As the throttle is opened, the pressure in the throttle bore rises. This additional pressure enters the cavity above the diaphragm, assisting the regulator spring and raising the pressure in the rail, allowing more fuel through the injectors while they are open due to the higher pressure. The opposite is true during deceleration. High engine vacuum while the butterflies are closed is applied to the top olthe diaphragm , allowing the fuel to compress the spring and open the regulator valve at a lower pressure. These pressure changes are very small and tend only to maintain a specific pressure differential between the throttle bodies and the fuel rail, and not to vary mixture ratios while driving. In addition to checks made under fuel pump service, the pressure regulator span can also be checked. With a fuel pressure gauge on the fuel line and aMity Vac' pump installed on the regulator, activate the system as was done to check the fuel pump. The fuel pressure at atmospheric pressure should read between 35 and 37 psi; with five inches (mercury) of vacuum it should be between 33 and 35 psi ; with ten inches (mercury) of vacuum it should read between 30 and 32 psi ; and with five pounds of pressure it should be between 42 and 44 psi. Consistent readings outside the span indicate a bad regulator, bad hoses or filter, bad fuel pump, or an inaccurate test gauge. Verify the problem and correct it before any additional work is done to the system.
"-"
To Mag end throttle body
Diaphragm
Fuel
'----'"
4.13
11/95
Injector
The injector is an extremely close tolerance solenoid type valve which opens and closes electrically. It allows fuel to pass from the fuel rail through the injector body and into the throttle body. The quantity of fuel is controlled by the length of time each injector is open, and constant fuel rail pressure.
Injector Filter
Pintle!9I~~=
O-Ring
1. Check battery voltage. Must be 12.2 or Charge, service, test and/or replace higher and be capable of handling pump battery. See battery service section. load. If not, the fuel rail pressure test will be low. NoYesL
Connect fuel pressure gauge and test as earlier outlined. Must read 35 to 37 psi. Pressure reading high_ Pressure reading 10wL Inspect pump pickup lines, filters and volume test pump. Is volume OK? No YesL Replace pump. Check for pinched or kinked pressure regulator return line. Is line OK? NoYesL Replace pressure regulator. Clean or replace return line.
NOTE: It is very important to inspect fuel tank pick up screen and tank for floating plastic particles. It's possible to have particles collect around screen as pump is running and float away after pump has stopped running.
11 /95
4.14
Electronic Fuel Injection (EFI) EFI Fuel System Testing

Injectors cannot be disassembled for service or cleaning. If a cylinder is not functioning properly and fuel supply is suspected as the cause, determine if an injector problem exists and whether it is mechanical or electrical. Switch the harness leads from the injector in question with an adjacent injector. If the problem moves to the adjacent injector, it is electrical. Referto injector electrical service, page 4.29. If the problem stays with the same injector, it is a mechanical problem, and injector replacement is necessary. If one of the cylinders fills with fuel and the rail empties after shutdown, remove airbox and open throttles. Install a 1" (2.5 cm) wide strip of cardboard above butterfly and close throttles. Turn on ignition to pressurize rail. Wait two minutes and remove cardboard. Some wetting Is OK, but a soaked cardboard indicates a defective injector. Some of the mechanical problems which will necessitate injector replacement are: internal and external leakage, partial or total fuel blockage, open injector coil, and physical damage to the pintle and pintle case .
Throttle Body
The throttle body assembly replaces carburetors in a fuel injected engine. It consists of one throttle body unit for each cylinder. Air flow is controlled by a throttle plate or butterfly type throttle shutter. On top of each unit one injector is held in place by the fuel rail. The throttle position sensor is mounted on the mag end of the throttle body assembly. Engine idle RPM is controlled by the throttle stop screw mounted between the mag and center throttle bore units. To synchronize the throttle assembly, synchronize the adjuster between each pair of throttle body units.
THROTTLE STOP REGULATOR
'--""
Throttle Body Synchronization

Since each cylinder and throttle bore operates independently and the only common factor is that they all get the same quantity of fuel, it may be necessary to periodically synchronize the throttle butterflies to coordinate the fuellair quantities. This is best accomplished by removing the throttle body and visually synchronizing the butterflies on the bench.
Procedure
1. 2. 3. Loosen synchronizer jam nut between mag and center cylinder. Turn adjuster until center and PTa butterflies are farther open than mag side. While shining a flashlight into bore on engine side, view through air box side of mag throttle bore. Back out throttle stop screw until butterfly just closes at top of bore (no light shining through). Moving flashlight to center bore, adjust synchronizer jam nut until center butterfly just closes at top of bore. Once center and mag butterflies are set to a just closed position, synchronize PTa butterfly the same way by adjusting synchronizer jam nut between center and PTa throttle bores until PTa butterfly is just closed. Open and close throttle three or four times by pulling up on cable attaching pOint on throttle shaft. Recheck all three butterflies to verify synchronization and readjust if necessary. synchronizer jam nuts are tight. Make sure that all
4. 5. 6. 7. 8.
NOTE: Make sure the PTa butterfly does not hold the center open while adjusting.
Reinstall throttle body assembly on engine. The method for adjusting the throttle pOSition sensor is covered on page 4.24.
NOTE: The same procedure can be used on twin cylinder engines.
4.15
11 /95
Electronic Fuel Injection (EFI) System III - Electronics Operation

The Electronic Control System is the mixture control part of the system . It uses sensor inputs to control the fuel/air ratio. The illustration below shows the components of the basic Electronic Control System. Sensors (Inputs) (Three Cylinder System Shown) Twins have 2 injectors
Injectors (Outputs)
TPS
ECU
Drop Resistor
In From Battery
c...,O"'u::::tp-:cut,-----l
0
DO DO
Select Monitor
(Type II Systems Only)
The electronic control unit delivers a low voltage signal to each sensor. Depending on variations in air temperature , throttle position, etc., each sensor will vary the amount of that signal passing through it to ground , depending on its position and temperature. The ECU reads the information and from that determines actual air temperature, throttle position, etc. This information is then plotted on a map which is pre-programmed on the PROM (Programmable Read Only Memory) or "chip". Based on the two primary inputs; RPM (X) and throttle position (Y) , the ECU can select a specific injector open time (Z). This value is the distance between the base plane and the map at the point where X and Y cross. The value is converted to milliseconds and referred to as pulse width .
Simulated prom map
Pulse Width (in milliseconds)

(Z)
Throttle Position RPM (X)

(Y)
11 /95
4.16
Electronic Fuel Injection (EFI) System III - Electronics Operation

Input from the other sensors either adds or subtracts a percentage from the pulse width to tailor the fuel/air ratio for the specific altitude, air temperature and engine temperature. See III. 1.
Leaner for warm air tem-
peratures, high altitude etc.
[J
Richer for low altitude, cold engine, cold inlet air, etc.
.... Pulse Width Z
/'
",/'
'"
"- "Throttle Position Y
'"
III. 1
The illustrations at right depict pulse widths in milliseconds output by the ECU. III. 2 shows a situation where the air temperature is low, the machine is at low altitude with acold engine, wide open throttle and high RPM . The ECU determines the engine's fuel requirements and selects a relatively long pulse width which allows more injector open time for fuel to enter the engine.
ON , - _ - ,
OFF
I
Long Pulse Width (i.e. High RPM, Cold Temps. , Low Altitude, etc.)
III. 2
'----'
If the same engine were at high altitude on a warm day at low RPM and throttle settings, the ECU would select a pulse width closer to III. 3, indicating a shorter injector open time and less fuel entering the engine. In this way the system can ultimately vary the mixture for all temperatures, loads and altitudes by varying the amount of time the injectors are open per revolution.
0:: n
III. 3
Short Pulse Width (I.e. Idling, Warm Temps. , High Altitude, etc.)
n____- -' ..
4.17
11/95
Electronic Fuel Injection (EFI) System III - Electronics Testing

Select Monitor
The select monitor is designed to provide easy, accurate diagnostic and service information to the technician. When installed on the machine it will provide both dynamic and static displays of the function of critical fuel system control components. It also has the ability to display the contents of the ECU memory. With this tool, electrical service of the EFI system should be quick and easy.
'\fj Select Monitor
PN 2870969
Remove protective plug from diagnostic plug in machine harness next to ECU. Connect select monitor to instrument harness, to service harness, and to diagnostic plug in. Install program cartridge into select monitor. Turn on ignition switch and place handlebar kill switch into run position. Turn on select monitor switch. On most models the monitor display will now light up. Type I (RXL) models will stay powered up with switches on . On Type II (500) systems, the time will be limited unless the engine is running. The ECU will remain powered for approximately one minute at or above room temperature. There are two ways to search for information with the monitor. You can scroll through the different modes in order until the correct information is found, or you can select the specific mode letter and number and advance to the specific information that you want.
SERVICE HARNESS
11 /95
4.18

Electronic Control Unit
The Electronic Control Unit (ECU) is the brain of the EFI system. It is a digital computer which holds the memory chip forthe read out of basic injector opening duration on a three dimensional map. There are two ECU systems used, Type 1 for the RXL and Type 2 for the 500 EFI snowmobiles. Each system receives the same type of information from the sensors. The ECU incorporates a number of special features. Some of these features are: adjustable low speed mixture control automatic cold engine start up enrichment engine over temperature protection
CHIP
PRESSURE
ESS
SENSOR
flooded engine clean out mode fail safe feature LED self diagnostic system
In the event that any sensor should give inaccurate or no information, the ECU will then flash a coded light sequence to identify the affected sensor.
NOTE: It is important to note that the ECU will not identify mechanical problems. Only sensor inputs are monitored. For example, low fuel pressure or lack of fuel will not be diagnosed.
'-'
The ECU can only tell if a sensor reading is within a specific range. For example, a failure code will not be indicated if throttle position shows 3.9 " when the throttle is actually wide open. Use display of throttle position to ensure the readings reflect actual conditions. This same concept applies to the temperature sensors and the barometric sensor.
"" ECU Part Numbers
Type I wlo chip Type I wlo chip Elect. Start Type II wlo chip
!F
2410028
241QQ29
241oq~Q
Select Monitor Cartridge 3084414' "i!7H

~?C
Select Monitor Cable
3084417
4.19
11/95
Electronic Fuel Injection (EFI) System III Electronics Testing

ROM Chip Removal and Installation
The chip can be removed and replaced with the appropriate chip puller and installation tool. You will need to supply a ROM removal tool and dielectric grease. Note the location of the indicator notch when replacing the chip (see photo at right). The system will not function with the chip in backwards or with the chip See the pins not properly in their sockets. specification section in this chapter for chip information.
FSM5631
ROM Removal Toor~ DlglKey PN: ,K158-ND Phone # 1-8000344-4539 ,

''0~
The computer chip and the ECU are extremely sensitive to static electricity. The handling of either component in a static electricity environment will cause irreversible damage. Work on a metal bench or other static dissipating surface. It is very important that you ground yourself by touching the crystal inside the ECU before any internal service work begins on the ECU assembly. See III. 1 and 2. If the ECU has not been removed from the machine, be sure to unplug it before proceeding. 1. Disconnect main harness connector from ECU. Remove phillips head cover screws and cover.
Connector
White line on board Be sure notch on ROM is positioned here
2.
Touch the crystal located inside the ECU box to ground yourself before proceeding. See
Illustrations 1 and 2.
CAunON:
@\
III. 1
lLL
;7
RXL ECU Box
Crystal - touch before performing service to rself
;@
The Chip and the ECU are very sensitive to static electricity. Working inside the ECU without grounding yourself may cause irreversible damage to either or both components.
11/95
4.20

3. In the event you are removing an old chip for replacement, place ROM removal tool over ROM chip. Pull up on triggers to securely grasp chip and pull chip out.
4. 5.
Check charts on page 4.1 to be sure you are installing the correct ROM. Coat the pins of the ROM with a light coating of dielectric grease.
"'"Crystal -
___
~ II, ~=dJ'\...
\
,,@
"-
6. Carefully insert the ROM, making sure the notch on the end of the ROM matches the notch indication mark drawn in white on the circuit board. See illustrations 1 and 2.
touch before performing service to ground yourself
'\... White line on board
Be sure notch on ROM chip is positioned here
@
If the chip is installed with the notch incorrectly positioned the chip will be ruined and the machine will fail to run. 7. Align cover gasket, positioning cover rubber bumper above chip . Reinstall cover screws and reconnect wire harness. Install select monitor and check functions.
Connector
500 ECU Box
III. 2
4.21
11 /95

Troubleshooting EFI System
When key switch is turned to the on position , voltage is suppl ied to ECU and the select monitor. NOTE: Some models will require the engine to be turned over. After the ECU is powered up, it will run the fuel pump for five seconds, read the sensors and do a self diagnosis of the complete system. The ECU does not check the Air Temperature Sensor (ATS) until the engine RPM is above 1000. With a good understanding of how each component functions, the test procedures given in this manual, and the use of the select monitor, you will be able to service and diagnose the Polaris fuel injection system. All informati on and specifications are based on the latest product information available .
Select Monitor Scrolling

With the ignition on and the monitor hooked up and turned on as described earlier, the display should show the year and the mode (FOO). By pressing the A key, the display will proceed to (F01 ), which is the model. Press the A again and the (F02) will appear, which is battery voltage. By pressing the A or T keys, you can either scroll forward or backward through the modes. If you know the mode you want, simply press "F" followed by the two digit mode number, and enter. The monitor will display the mode number and the registe~ed information. The following chart shows the modes, what the readings are for, and what an approximate reading should be.
Mode
FOO FOI F02 F03 F04 F05 F06 F07 FOa F09 F14 F21 F22 FAO FAI FA2 FBO FBI FCO
Description Model Year Engine Code Battery Voltage Engine RPM Throttle Valve Angle (Whole Range) Intake Air Temp in C' Intake Air Temp in F' Crankcase Temp in C'
C ra nkcase Temp In
Normal Reading
Year of machine (not always correct) Polaris code number 30 for Triples; 20 for Twins 12.2 or above at room temperature Idle: 2000 to 2200 3 Cylinder; 1600 Twins 0' to 77' large steps Room temperature (engine cold) Room temperature (engine cold) Room temperature (engine cold) Room temperature (engine cold)
Barometric pressure in millimeters of mercury
FO
Barometric Sensor
Throttle Valve Angle (Low End) MR (Idle Mixture) Position Water Temp Sensor in C' Ignition Key Diagnostic Dealer Mode Relay Check Existing Trouble Codes Memory TrOUble COdes Memory Clear
0' to 35.9' small steps 2.5 or more than 4.0 for All. See page 4.27. Same as ATS or CTS Cold or 30' to 90' running KY + No.3 LED (with key on) DM + No. 5 LED (with DM activated) FP,SD ,SS + No.1 ,2 , and 3 LED when operating Faults presently existing
Faults that are intermittent
11195
4.22

The ECU determines the amount of fuel to be injected by accurately calculating the engine's need for fuel delivery. To do tr,is, the ECU memory chip reads the three dimensional map discussed on page 4.16. Various sensors such as air temperature sensor, coolant temperature sensor, barometric pressure sensor, battery voltage, and MR setting in the ECU are also inputs to control fuel delivery.
Select Monitor Readings

Mode
F100 F01 F02
Description Model Year Engine Code Battery Voltage
Normal Reading Year of machine Polaris code number 30 for Triples Polaris code number 20 for Twins
12.2 or above
Type I systems will indicate a high battery voltage on the select monitor if the actual voltage is below approximately 10vOC. If you suspect a low battery, use a Fluke meter to directly measure the battery voltage. This will not occur in Type II systems. The select monitor accurately reads low battery voltage.
Fluke Meter PN 2870659
RPM Sensor
The ECU receives an engine RPM signal from the COl box. This signal is one of the main inputs and is very critical to proper operation . If the ECU does not see this signal, the injectors will not open and the fuel pump will only cycle for the initial five seconds when the ECU is powered up . The ignition switch and auxiliary kill switch are connected in series with the ECU COl signal. If these switches are leaking partial voltages to ground, the ECU will not function properly. Whenever COlor intermittent running problems are occurring, the switches should be suspected. These switches will also fail more often when To troubleshoot the switches, humidity is high. disconnect or isolate them from the Circuit.
~RPM
OUTPUT
'-'

Mode
F03
Description Engine RPM
Normal Reading Cranking 300-500
Polaris Industnes Inc.
4.23
11/95
Electronic Fuel Injection (EFI) System'" - Electronics Testing

Throttle Position Sensor (TPS)
Throttle position is one of the two main inputs used to calculate fuel/air ratio. The throttle position sensor is a rheostat type variable resistor which is mounted on the end of the throttle shaft. The resistance value of the sensor is relatively low at idle. As the throttle is opened, the resistance goes up proportionately to the butterfly angle. The ECU passes a specific current through the sensor and experiences more current flow at Idle. This flow lessens as the throttle is opened. From this information, the ECU can determine butterfly angle and control fuel delivery accordingly.
The throttle position sensor can be checked on the bench with an ohmmeter. With the butterflies closed, the resistance between the black and white wire, measured at the plug, should be between 400 and 700 ohms. With the throttle wide open, the resistance should be approximately 4.5 k ohms. Some minor variations in resistance values will be experienced due to throttle position sensor location, but radical differences or failure to see a consistent progressive increase or decrease In the resistance as the throttle is opened and closed indicate a defective position sensor. The sensor can also be checked with the select monitor using mode F04. It should read between 3 - 4 when the throttle is closed and consistently, progressively increase with throttle opening to more than 74 at wide open throttle. The throttle pOSition sensor can be replaced by removing the two mounting screws and gently prying it off the end of the throttle shaft.
TPS Adjustment
During periodic inspection, or when replacing the TPS, it must be synchronized to the throttle butterflies. The sensor must be positioned to the positive side of 0 with the butterflies totally closed. To adjust the sensor, disconnect the throttle cable from the throttle flipper and back out the throttle stop screw until the butterflies are \Qla!! closed. Connect the select monitor to the system diagnostic plug. Turn on the ignition switch and the monitor on/off switch. Scroll the monitor to mode F04 or F14 and verify the sensor pOSitioning. NOTE: F14 is a low end scale for sensor adjustment. This is the desirable scale, but because of programming may not work on all models. Loosen the sensor mounting screws and rotate the sensor until the reading on the monitor is .1 on F14, or the point where the reading "breaks over" between 0 and a positive number on F04. Tighten the mounting screws, open and close the throttle a few times and recheck the reading. Readjust if necessary.

Mode
F04 F14
Description
Throttle Valve Angle-Range Throttle Valve Angle Low End Not Used on All Systems
Normal Reading
0 to 77 " Large Steps See TPS Adjustment 0 to 35 " Small Steps Depending on Position
11/95
4.24

Intake Air Temperature Sensor (ATS)
The air temperature sensor is mounted in the air box. Its function is similar to the crankcase temperature sensor in that its temperature will vary the resistance across the sensor. It has a reduced thermal capacity for quicker response. Cold air will cause high resistance and warmer air will lower the resistance. The ECU sends current to the sensor and, depending on its temperature, a certain amount will pass through to ground. By measuring how much passes through, the ECU can calculate air inlet temperature and vary fuell air ratio accordingly. The intake air temperature sensor can be tested in a manner similar to the crankcase temperature sensor. Determine the approximate temperature of the sensor, measure the resistance between the two lead ends at the plug and compare the reading to the graph shown on the bottom of page 4.28. An easier and more accurate method is to use the select monitor to indicate what air temperature reading the ECU receives from the sensor. If the air box and underhood area have not been warmed due to recent running of the engine, the air temperature sensor should read room temperature on the select monitor. Radical differences between room temperature and the indicated reading indicate a problem with the sensor, wiring, battery, or ECU . Verify and repair any problem before attempting to operate the machine.

Mode
F05 F06
Description Intake Air Temp C Intake Air Temp of
Normal Reading Room Temp "Engine Cold" Room Temp "Engine Cold"
Crankcase Temperature Sensor (CTS)

The crankcase temperature sensor is screwed into the upper crankcase half below the mag throttle bore. This thermistor type semi conductor varies in resistance depending on its temperature. The ECU delivers an electrical current to the sensor. When the sensor is cold, its resistance is high and little current passes through the sensor to the engine ground. As the sensor heats up its resistance lowers, allowing more current to pass through. The ECU measures the current flow through the sensor and knows the temperature of the engine crankcase and can vary fuel ratio according to case temperature. The CTS is used on all Type I (RXL) systems. Type II (500) systems do not use a crankcase temperature sensor.

Mode Description Crankcase Temp C Crankcase Temp F Normal Reading Room Temp "Engine Cold" Room Temp "Engine Cold"
FO? FOB
4.25
11195
Electronic Fuel Injection (EFI) System III - Electronics

Barometric Pressure Sensor (BPS)
The barometric pressure ~ensor is located inside the ECU. Its function is to read atmospheric pressure. This information is then used by the ECU to determine fuellair ratio, depending on pressure changes during a given day, or for any altitude change. The barometric pressure sensor is an integral part of the ECU and cannot be replaced separately. No service can be performed on the barometric pressure sensor. However, the barometric sensor reading can be checked with the select monitor. The monitor reads millimeters of mercury. To arrive at air pressure in inches of mercury, divide this number by 25.4. Compare the reading to an accurate barometer. NOTE: Readings reported by the radio or television are corrected to sea level. The select monitor is an actual reading. Any changes to the stock machine which affect the air pressure around the ECU will cause the barometric sensor reading to be inaccurate.
LED
CHIP
BAROMIET"'" PRESSURE SENSOR
ESS
CONTROL

Mode Description Barometric Sensor Normat Reading Barometric Pressure in Millimeters of Mercury
FOg
11195
4.26
Po/ans Indus(nes Inc .
Electronic Fuel Injection (EFI) System III - Electronics MR Adjustments

On Type I (RXL) systems, the fuell air ratio at engine RPMs below 3500 can be adjusted slightly richer or leaner than the standard program mixture by adjusting the MR control. This adjustment is made to improve idle quality and drive away. It affects the same carb area as an air screw. To adjust the MR control, remove the rubber plug. Install the select monitor, power up the system and press F-21. A correct reading on the monitor is between 2 and 3, with 2.5 being the most desirable. (The production setting is 2.5). Turning the MR screw clockwise will increase the observed number and rich en the mixture. Turning the screw counterclockwise will lower the number and lean the mixture. The leanest setting is 0 and the richest will approach 5. NOTE: At high altitudes, a higher number will result in earlier drive-away after startup. Adjusting the MR control screw on Type II (500) systems will only affect cold starts and cold drive-away. (It is designed to assistthe driver when using poor or summer grade fuels. ) If a lean condition is suspected, change the number to a higher value. If a rich condition is suspected, change to a lower number. Approximately two minutes after starting, this adjustment has little effect; after 10 minutes it has no effect.
'--'

Mode Description Mixture Enrichment Normal Reading
F21
2.5
MR Adjustments For Altitude And Temperature

The following tables list MR screw settings for various temperatures and altitudes . Whenever performing MR adjustments, take the operator's riding location and weather conditions into account before making an adjustment. Numbers anywhere within the ranges listed should provide acceptable operation.
Type I Systems - RXL Production Settings 2.5

Ambient Temperature Below +20F (-6C)
+20 to +50' F (_6 to 10' C) 3.0-3.5 3.5-4.0 4.0-4 .5 4.0-4.5
Above +50F (10C)
0-3000 Ft. or 0-900 m 3000-6000 Ft. or 900-1800 m 6000-9000 Ft. or 1800-2700 m 9000-12000 Ft. or 2700-3700 m
2.5 3.0-3.5 3.5-4.5 3.5-4.5
3.5-4.5 3.5-4.5 4.5 4.5
4.27
11195
Electronic Fuel Injection (EFI) EFI Electronics

Type II System
Type 1/ EFI systems incorporate an engine coolant temperature sensor. This sensor is positioned In the engine water jacket where it is able to receive and relay reliable engine top end temperature to the ECU . This sensor also controls the temperature light and '1ail safe" mode. The "TEMP" light will come on and begin to blink slowly when the coolant reaches an unsafe temperature. If the temperature continues to increase, the light will begin to blink faster; at this time the EFI system will increase the fuel being supplied to the engine. This increase in fuel will cause a decrease in engine performance which is designed to protect the engine in an overheat condition . The increased fuel will continue until the engine coolant reaches a safe temperature and the light goes out. Correcting this problem may be as simple as driving the machine slower and/or driving in a snow condition which allows more snow to be thrown onto the heat exchangers. If this condition continues, check the cooling system, coolant level, water pump belt tension, etc. To check sensor function, connect a select monitor and advance to mode F22. With engine cold, observe reading. It should be near the readings of the ATS and CTS in degrees centigrade. Start engine and observe temperature increase as engine warms up. If readings vary greatly or fluctuate from other sensor readings, check harness and connectors for condition and repair as necessary. If no other problems can be found, and incorrect readings continue , replace sensor.

Mode Description Water Temp C o Normal Reading
Cold Engine Room Temp
F22
To bench test a temperature sensor, measure resistance between sensor wire terminal and sensor shell; then compare reading to the graph shown below. An easier and more accurate method is to use the select monitor to indicate what temperature reading the ECU receives from the sensor. If the engine has not recently run, the sensor should read at or near room temperature. A radically different reading from room temperature could indicate a problem with sensor, wire to sensor, any of sensor connections, battery, or ECU. Verify and repair any problem before attempting to operate machine . The sensor's resistance curve is shown at right. Resistance of the sensor is high when it is cold, and lowers as its temperature increases. This creates low current flow through the sensor at low temperatures and high current flow as the temperature increases. NOTE: The formula for converting F to C is (0F ; C x 1.8 + 32) Resistance (kQ)
80 40
20
10 6 4 2 0.6
2.5kQ 120 C
0.4
0.2
-20
20
40
60
80
100
120
Temp (O C)
11 /95
4.28

Fuel InJectors
Variation in the amount of fuel delivered per stroke to suit varyi ng load and speed conditions can be obtained by controlling the discharge duration of the injector. The injector is a solenoid-actuated constant stroke plunger consisting of a solenoid, plunger, needle valve and housing. The ECU will determine the duration time the injector is energized to deliver fuel. The resistance between the two pins on the injector (isolated) should be 2 to 2.5 ohms. There should be no continuity to ground. Pintle
Since the operating voltage is approximately 5 volts DC on the injectors, never attempt to test them with any higher voltage or the injector will be destroyed.

Mode FBO-21 FBO-22 FBO-23 Description Type One System RXL Type Two System 500 EFI Type One System Type Two System Type One System Normal Reading Mag Side Injector Center of PTO Injector on Twin Cylinders PTO Injector
Dropping Resistor
The dropping resistor is mounted on the engine side of the battery box. The three cylinder system consists of four individual resistors wired in parallel with a common voltage feed (only three are used). The twin cylinder has two resistors wired parallel, also with a common voltage feed. They are used to drop or reduce the voltage going to the injectors to approximately 5 volts. Voltage from the battery travels through one of the resistors, through an injector and into the ECU . A failure of any injector or resistor will cause one cylinder to quit operating. The ECU will then flash the trouble code for that injector. NOTE: The ECU can only determine electrical failure. If an injector failure code is flashing, the problem could be anywhere in the electrical circuit for that injector. The ECU will not find a plugged or leaky injector. The dropping resistor may be tested with an ohmmeter between the white terminal and each of the black terminals at the resistor plug. The resistance is 6 ohms 10%. Replace the resistor if any of the readings are outside of the spec. Clean the terminals if they become corroded. The injector's operating power comes through these resistors. Any suspected injector electrical problem must first be traced through the dropping resistor.
'--""
4.29
11/95

ECU Diagnostics
If any of the main sensors should malfunction while the machine is being driven, the ECU will sense a problem and proceed to an over-rich '1ail safe" mode. An open or shorted circuit in any of the sensor circuits will show the ECU a reading outside what it normally sees and the ECU will determine that a problem exists. Without this feature, certain kinds of failures could cause the mixture to be leaner than the required ratio and cause engine damage. This feature is important for engine protection. Once the sensor problem is determined and corrected, the ECU will return to the original map. If any of the injectors or sensors should malfunction during operation, the ECU will record this information and start flashing a Light Emitting Diode (LE D) code informing the mechanic/ownerwhich component failed. The LED is on the right of the ECU, in front of the main plug. See ECU photo below. If the problem still exists and is ongoing, the LED will continuously flash the code. lithe problem occurred butthe machine is now operating properly (intermittent), it will be stored in the memory and can be drawn out of the ECU by connecting the gray and black wires together at the diagnostic plug. The LED will then begin blinking long followed by short light pulses; then a pause and the long and short pulses again. The long pulses are the first digit in the code and the short pulses are the second digit. Compare the code to the trouble code chart on page 4.31 to determine the problem. Rememberthat the problem can exist in the sensor, the power feed to the sensor, the sensor ground, connectors, or the part of the injector or sensor circuit inside the ECU.

Mode FBa is for existing problem diagnosis. Press buttons F, B, a and enter. If there is an existing problem, a code number and the abbreviation of the problem component will appear. See the chart on page 4.31 for an explanation of the code numbers. The LED will also display this code. For example, if the LED displays one long and two short pulses, this is a code 12. Mode FBI is for retrieving trouble codes from the ECU memory. If a problem happened sometime during the machine's operation, but everything is operating properly at the present time, the ECU memory will verify which component was at fault. This helps find Intermittent problems such as a wiring open or short. Press the F, B, 1 and enter buttons. If the display shows one of the codes, check that component and its circuit. If nothing appears, there is nothing in memory. NOTE: If the ECU power is disconnected at any time, this memory will be erased. Mode FCa is used for erasing problem codes which are stored in the ECU's memory. To erase the problem codes, certain steps must be followed in a particular order. I . Select the mode for the component which indicated a failure. 2. Press F, C, a, and enter on the monitor. 3. The display will ask "Memory clear? a-yes and I-no". By pressing a and enter the memory will be erased. Indication of the memory being cleared will be a display of "Please key off'.
11/95
4.30
ELECTRONIC FUEL INJECTION (EFI) EFI Fail Codes

Mode
FBO FB1 FCO
Description
Existing Trouble Codes Memory Trouble Codes Memory Clear
Normal Reading
Faults Presently Existing Faults Which Are Intermittent Used to Remove Stored Information
Monitor Code First Number Long DashSecond Number Short Dash-
L.E.D. CODE
System Type Type Abb. One Two Component

Throttle Position Sensor Crankcase Temperature Sensor Intake Air Temperature Sensor Barometric Pressure Sensor Water Temperatu re Sensor Barometric Pressure Sensor Mag Side Injector Center I~ector or PTa on wins PTO Injector Low Battery Voltage Low Charging System Output CDIOutput
--
--
11 12 13 14 14 15 21 22 23 31 32 33
X X X X
TH V T Case
------
X X
T Air ALT
--------
X
X X X X X X X X X
TW
ALT Inj 1 Inj 2 Inj 3 VB VB CDI
--
----
---
-------
----
4.31
9197

The FA modes are for testing the input and output functions from the ignition switch and the relays.
Type I System
With the select monitor on mode FAO, the display should show KY. Whenever the ignition switch and the handlebar kill switch are in the run position, the number 3 LED should also lighl. Cycle the switches a few times and make sure the LED goes off when the switches are turned off and comes on when the switches are returned to the run position. Advance the monitor to mode FA1. Connect the gray and black dealer mode wires together on the monitor's service harness. The monitor display should read DM (Dealer Mode), and the number 5 LED should be iiI. During dealer mode operation, the fuel pump will cycle on and off in one second intervals and any stored problem code will flash on the ECU's LED. Advance the monitor to mode FA2 and the letters FP (fuel pump), SD (self diagnostics) and SS (self shut-off) will appear on the display. When the EFI system is in the normal run mode, the number 1 LED will be lit when the fuel pump is required to run. This will be for five seconds when the key is initially turned on, and whenever the ECU senses engine ignition pulses. The number 3 LED will be lit when the key is turned on and will go out ten minutes after the switch is turned off. When the dealer mode wires are connected together at the service harness, the ignition key is cycled off and on, and the select monitor returns to mode FA2, the number 3 LED will not be IiI. The number 2 LED will flash any problem codes which are in memory in the ECU and the number 1 LED will flash off and on in one second intervals. --..-/
Type II System
With the select monitor on mode FAO, the monitor should show an ST and DM on the left, and a KY on the right of the display. The number 1 and 5 LEDs will light when the key is rotated to the start/reset position. The number 6 LED will light when the gray and black dealer mode wires are connected together on the service harness. The fuel pump relay will only cycle on and off for three one second runs each time the system is reset while in dealer mode. Due to the different operational method used in the Type Two system, there is not an FA 1 or FA2.
11/95
4.32
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Qi .:SA
WHITE R RED TWO COLOR WIRES ARE SHOWN WITH MAIN / TRACE COLORS
W
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/~
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~ BLU/W
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LU/GRN
--
BRN GRY GRN PUR LG

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BROWN GRAY GREEN PURPLE Ll GHT GREEN

ORANGE
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WHITE
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OR/BLK
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SCI
ENGINE GND
:;: RED TWO COLOR W I RES ARE SHOWN WITH MA I N/TRACE COLORS . EXAMPLE: BLU/R :;: BLUE WITH REO TRACER .
L-
GRN/Y
I
L-
L - - GRN/'(
.s
.~
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POLAR IS ELECTRON IC FUEL INJECTION CONTROL UNIT
~ .s
.~
.!!!
CHAPTER 5 FUEL SYSTEM I CARBURETION

Jet Part Numbers .. . ........... .. ... .. .... .. .. 5.1 - 5.1 a 1996 Condensed Data ... . ... . .. .. . ... . ..... 5.2 - 5.3 1997 Condensed Data .... . ..... . ..... ...... 5.3a - 5.3b 1998 Condensed Data ..... . .... . ............ 5.3c Exploded View - Keihin ..... .... . .. . .. ...... 5.3d Exploded View - VM30SS .... .. .... .. .. ... .. 5.4 Exp loded View - VM34SS ....... . ............. 5.5 Exploded View - VM38SS .......... .... . .. .. .. 5.6 Exploded View - VM34SS with ACCS .... .. . ... 5.7 1996 Jetting Compensation Charts ... ........... 5.8 - 5.15 1997 Jetting Compensation Charts .... . ......... 5.15a - 5.15j 1998 Jetting Compensation Charts .......... . .. . 5.15k - 5.15p Gasoline Volatility .......... . ....... .... .. ..... 5.16 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17 -5.23 Component Functions .. . ................ . ..... 5.24-5.27 Component Effect vs Th rottle Opening ... .. . .... 5.28 Jetting Guidelines . . .... . .............. . ..... 5.29 Oxygenated Fuel - Carbureted Models . .. .. . .... 5.30 Oxygenated Fuel - EFI Models ............ . . .. . 5.31 ACCS System . .. . ... .. . .... . .. ....... .. . . . .. 5.32-5.34 Mikuni Carburetor Service ................ . ... . 5.35-5.37 Mikuni Carburetor Float Level / Adjustment .... 5.38 Keihin Carburetor Service ... ..... . .. .... . ..... 5.38a-5.38e 1996 Synchronization Specs .... . .. . ... . . . .... 5.38f 1997 Synchronization Specs 5.39 1998 Synchronization Specs .. .. ........ ... ... 5.39a Synchronization Procedu re .. ...... . . . .. . ...... 5.39b-5.39c Choke Adjustment (All) ....................... 5.40 Fuel Pump Operation Water Trap Service . . ... ... . ............ . . 5.42-5.45 . . .. . ...... .. ... . . .. 5.46 5.47-5.48
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM/CARBURETION Jet Part Numbers

Whenever servicing the carburetor or fuel system, it is important to heed the following warnings.
WARNING
Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored or used. Do not overfill the tank. Do not fi ll the tank neck. If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately. If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.
Jet Part Numbers

The following chart lists all Mikuni main and pilot jets and the part number of each that are presently available.
Mikuni
PILQIJEHIQ
25 30 35 40 45
~BI~Q
Mikuni
EILQT JEI~Q EIlBI
50 55 60 65
~Q
Keihin EILQT JET

35 .. .. . 38 .. .. ' 40 . . . " 42 .. . . . 45 . . . .. 48 .....
EABI ~Q
Keihin EILQI.IEI
50 52 55 .. . . . 58 60 . .... 62 65
PABI ~Q
305021950 3050219-52 3050219-55 3050219-58 3050219-60 3050219-62 3050219-65
.... .... 3130064 ... ......... .3130065 ... . . .. .. .. 3130066 ... . ... 3130067 .. ........... 3130068
3130069 3130070 3130071 3130072
'-...Mikuni I:JElIl:JEIlQ
M AI~JE I ~ Q
305021935 3050219-38 3050219-40 3050219-42 3050219-45 3050219-48
~ BI~Q
Mikuni tJElI tJEIlQ MIlIt,l JEI t,lQ

250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 490 500 530 560 590 620
~BIt,lQ
'--"
80 . ........... 3130099 85 ............. 3 130100 90 ............. 3 130101 .. 3 130102 95 .... 100 ..... .. 3130103 .3130104 105 .. 11 0 ... . 3130105 115 . .3130106 120 ... ... . 3130107 . 3 130108 125 ... 130 . . ........ 3130109 135 .. .... 3130110 140 .. ........ 3130111 ..... 3 130112 145 . . ... 31301 13 150 .. .... . 31301 14 155 .. ..... 3130 115 160 ... 165 ... .. 31301 16 .. 31301 17 170 ..... 175 .. . ... 3130118 . .. 3 130119 180 ... 185 ........ . .. . 3130120 190 . . . .... ... 3130121 .. 3130122 195 .. 3 130123 200 . .. 3130124 210 .... .. 3130125 220 ..... .. 3130126 230 .. ... 3130127 240 ..
............ 3130128 .... . .. . .... 31 30129 ............ 3130130 ............ 3130131 . 3130132 .... .... . 3130133 ............ 3130134 ... . ........ 3130135 ... . ... ... . . 3130136 ..... . ..... 3130137 .. .. .. . .3130138 .... . ...... . 3130139 ...... . ... . . 3130290 ... ........ . 3130140 ........... . 3130480 ........... . 3130 141 ........ ... 3130599 .... . 3130142 ... . ... 3130143 ....... . .. . 3130 144 . ........... 3130145 .. . . . ... . . 3130146 ............ 3130147 ...... . .. 3130148 ... 3130149 . 3130150 .. .3130151 .. ......... .. . 3130152 ..... 3130153
Keihin Long Hex Head (Amal Type) MIlIt,l,IEI t,lQ ~BI~Q 140 . ........ 3050235-140 142 ... . .. 3050235-142 145 .... ... 3050235-145 148 , ... 3050235148 150 ..... 3050235-150 152 .. , " 3050235-152 155 . . . .. 3050235-1 55 158 . .. -,-.. . 3050235-158
160 162 165 168 170 172 176 178 180 182 185 188 190 192 195 198 200 205 210 215 220 3050235-160 3050235-162 3050235-165 3050235-168 3050235-170 ... . 3050235-172 .. . 3050235-1 76 . .. 3050235-178 .. . ...... 3050235-180 .. .. . 3050235-182 . ... .. . .. 3050235-185 . . . . . . . . 3050235-188 3050235-190
305023~192
.. .. .. . .. ...
.... ..
3050235-195 .. . 3050235-198 .. . 3050235-200 3050235-205 .. . 3050235-210 3050235-215 ...... . .... .... 3050235-220
5.1
9197
FUEL SYSTEM/CARBURETION Jet Part Numbers

Jet Needle Part Numbers (Mikuni)
J~I tcl~~QL~ tclQ
50P7 . . . 50T49 " ... .. .. . 50P l 0 .. . . 50Pl0 .. . .. . .... 50T2 . . . . . . . . . 5078 . " 5F81 ... .. 5078 . . ....... . 6CEY6 .. ... .. .. 6CGY3 . . .. 6CGY6. 60H3 .. .
.. ... ..
PART tclQ 3130155 3130154 3130333 3130310 3130473 3 130667 3130528 3130667 3130476 3130484 3130652 3130470
JET tclEEQLE NQ 60H4 ....... .. ... ... 60H5 . ... .. ... .. . .. . 60H7 . . . . .. . ... . . 60H8 . . . . . . .. . . 60H29 . .... . .... . . .. 60Pl . . .. .. 60P17 . . . . . . . . . . . . . . . 6EJ26 . . .. . 6EJ3 6F4 .. 6F9 . . . . . . . . . . . .. .. .
.... .
~ABI tclQ. 3130402 3130391 3130329 3 130645 3130462 3130156 3130374 3130423 3130680 3130319 3130378
Jet Needle Part Numbers (Keihin)

JET tclEEOLE tclQ R1 368G ... .... R1370G .. R- 1371 G ..... .. . R-1372J . PABI tclQ 3050244 3050220 3050256 3050247 JEI NEEDLE NQ R-1369G . . . . . . . . . . . .. R-1370J . . . ......... . R-1 371J .... .. .... . PABI tclQ 3050245 305022 1 3050246
Needle Jet Part Numbers (Mikuni)

JET NQ P-4 (159) P-2 (166) P-4( 166) .. P-4 (166) . . P-6 (166) . P-8 (166) . 0-2 (166). 0-4 (169) . . 0-4 (169) .. . 0-6 (169) . 0-6 (169) 0 -8 (169) . .. 0-8 (171) .. P-O (225) .... P-2 (255) . ... P-2 (259) . P-O (247) . P-2 (247) P-4 (247) . ..
t>!~~DLE
PARI ~Q. 3130162 3130460 3130348 3130499 3130160 3130421 3130376 3130166 3130409 3130358 3130469 3130453 3130035 3 130579 3130608 3130161 3130671 3130672 3130641
NEE OLE JET NO PART NO P-6 (247) . . .. 3130655 P-8 (247) . . .... . . 3130382 00 (247) .. .. 3130414 0-2(247) .3130165 0-4 (247) 3130603 0-8 (247) . ... . . 3130485 . . 3130477 R-O (247) P-O (286) . . 3130607 P-2 (286) . ... 3130608 04 (286) .... 3130635 0-6 (480) . ..... . . 3130429 0-8 (480) . ... . .... . . 3130683 P-2 (480) . 3130675 P-4 (480) .... . 3130639 0 6 (480) . . .. .. .. 3130618 P-8 (513) .... . .... . .. 3130510
Throttle Valve Part Numbers (Keihin)

Throttle Valve No. 3.0 ... . 4.0 ... 5.0 . .. 5.5 . 6.0 ..... . .. 6.5 7.0 . 7.5 . .. .. 8.0 9.0 PART NO. 3050234802 3050234C02 3050234002 3050234-J02 3050234E02 3050234- K02 3050234-F02 3050234-L02 3050234-G02 3050234-H02
9/97
5.1 a
FUEL SYSTEM/CARBURETION 1996 Condensed Data

Machine Model Engine
Cyl.
Disp.
Mod el
CCs Indy Ute/GT/Deluxe Indy sporVsport Tounngl TranSport Indy Super Sport Indy 440 LC Indy 440 XCR Indy 440 XCR SP Indy TrailfTouring Indy Classic EC34-2PM(E)02 EC44-3PM01 EC44-3PM02 EC45PL06 EC45PL07 EC45PLOB EC50PM(E)04 EC50PLEtl EC50PL14 EC50PM03 EC50PL12 EC50PL 11 EC50PL15 EC58PL03 EC58PLE05 EC5BPL07 EC58PL02 EC59PLOt EC6BPLOl EC6BPL04 EC80PL04 EC80PL05 339 432 432 432 439 439 4BB 4B8 488 488 488 488 488 597 597 597 597 598 679 679 794 794
Carburetor Model , Mount Type & No.
Std. Main Jet & Type
Std. Pilot Jet 35 35 35 40 50 50 35 40 40 30 35 40 45 35 35 35 35 40 50 50 45 45
Air Screw Adjust {counterclockwise from light
Fuel Octane Reqmt.
seat}
VM30SS (2)
145 Hex
1 1/2 Turn
1 1/4 Turn 1 1/4 Turn 1 1/2 Turn
BT BT BT BT 91 91 BT
Zinc
VM34SS (2) Zinc VM34SS (2) Zinc VM34SS (2) lBO Hex
180 Hex
260 Hex 260 Hex 260 Hex 220 Hex

340 Hex
240 Hex
Zinc
VM34SS (2) Aluminum VM34SS (2)
1 Turn
1 Turn 1 Turn 1 Turn 3/4 Turn 1 Turn
3/4 Turn
Aluminum
VM34SS (2) Zinc VM38SS (2) Alumi num VM34SS (2) Zinc VM34SS (2) Zinc VM34SS (2)
8T 8T 8T 81' 81' 8T 8T 81' 81'

91 9t

Indy WideTrak GT
200 Hex
190 Hex 340 Hex
240 Hex 210 Hex 250 Hex
Indy WideTrak LX Indy 500/SKS Indy 500 RMK Indy XLTlSKS

IndyXLTTouring
linc
VM38SS (2) 1 Turn 1 Turn
1 Tum 1 Tum
Aluminum
VM38SS (2) Aluminum VM34SS (3) Zinc VM34SS (3)
Zinc
Indy XLT RMK w/ACCS Indy XLT SP/600 XCA Indy 600 XCA SP Indy Ultra SP/SKS Indy Ultra AMK Indy Storm RMK Indy Storm/SKS VM34SS (3) Zinc VM38AL (3) Aluminum VM38SS (3) Aluminum VM38AL (3) Aluminum VM3BAL (3) Aluminum VM38 (3) Alummum VM38 (3) Aluminum
190 Hex N/A (see page 5.32)
260 Hex
1 Turn
400 Hex
340 Hex
1 1/2 Turn 1 Turn 1 Turn 1 Turn 1 Turn
81' 81'
91 9t
280 Hex PTO CtrMag 330330350 PTO CtrMag 400400420
Non-Oxygenated. Whe n using oxygenated fue l increase octane mi nimum to 89.
9/97
5.2

Engine Model EC34-2PM02 EC44-3PMOl EC44-3PM02 EC45PL02 EC45PL07 EC4SPL08 EC50PLEll EC50PL14 EC50PM E04 ECSOPM03 EC50PL12 EC50PL11 EC50PL15 ECS8PL03 EC58PLE05 EC58PL07 EC58PL02 EC59 PLOl EC68 PLOl EC68 PL04 EC80PL04 EC80PLOS Jet Needle No. " E" Clip Position 5DP7-2 6DH7-3 6FJ6-3 6DH7-3 6DH3-2 6DH3-3 6F9-3 6EJ26-2 6DH7-3 6DH7-3 6EJ26-2 6F9-3 6F9-2 6DP17-J 6DP17-3 6D P17-J 6DH7-3 6CEY6-3 6DH8-2 6DH8-2 6CGY6-3 6CGY6-3 Needle Jet No. 0-6 (169) P-4 (166) P-8 (166) P-2 (480) Throttle
Valve
Seat 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
Valve
Cutaway 2.5AL 2.5CH 2.0 2.0 2.0 2.0 2.5 3.0CH 3.0 3.0CH 3.0CH 2.5CH 2.0 2.0 2.5 2.0 2.5CH 2.5 2.0 1.5 3.0 3.0
Idle RPM 200 1600 1600 1600 1600 1800 2000 1900 1600 1600 1600 1600 1600 1600 1700 1700 1700 2000 2000 1800 1800 1600 1600
Fu el/Oil Mixture
Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio
Auto Injection
0-4 (286) 0-4 (286)

P-8 (247) P-4 (480) P-8 (166) P-6 (166) P-6 (166) P-8 (247) P-4 (247) 0.2 (166) 0.2 (166) -'
Variable Ratio Aulo Injection Variable Ratio Auto Injection Variable Ratio
Auto Injection
Variable Ratio Auto Injection Variable Ratio Auto Injection Variable Ratio
Auto Injection
0-6 (480) 0 -2 (247)

R-O (247) P-4 (247) P-4 (247) P-6 (247) 0.0 (247)
Variable Ratio Auto Injection

Variable Ratio
Auto Injecticn
Variable FaUo
Auto Injac1ion
Variable Ratio
Auto Injection
Variable Ratio Auto Injection
5_ 3
11195
FUEL SYSTEMICARBURETION 1997 Condensed Data

Machin e Model
Engine Model
Cyl. Disp. CCs 339 432 432 488 488 488 432 438 488 488 488 488 488 597 597 597 597 597 597 598 679 679 701 701 794 794
Carburetor Model, Mount Type & No.

VM30SS (2)Zinc VM34SS (2)Zinc VM34SS (2)Zinc VM34SS (2)Zinc VM34SS (2)Zinc VM34SS (2)Zinc (ACCS) VM34SS (2)Zinc VM34SS (2) AL VM38SS (2) AL VM34SS (2)Zinc (ACCS) VM34SS (2)Zinc VM34SS (2)Zinc VM34SS (2)Zinc VM34SS (3)Zinc VM34SS (3)Z inc (ACCS) VM34CS (3) Zlnc VM38AL (3) AL VM38AL (3) AL VM38SS (3)Zinc VM38SS (3) AL VM3BAL (3) AL VM3BAL (3) AL PWK 39-Keihin PWK 39-Keihin VM38SS (3) AL VM38SS (3) AL
Std. Main J et & Type
Std. Pilot Jet 35 35 35 45 35 45 40 50 40 40 40 30 35 35 50 35 35 35 35 40 40 50 40 55 55 50
Air Screw AdJ ust (counterclockwise from light

seat)
Fuel Octane Reqmt.
Indy liteiGT/Deluxe Indy Sporvsport Touring/ TranSport Indy XCF Indy Super Sport
EC34-2PM(E)02 EC44-3PM02 EC44-3PM02 EC50PM06 EC50PM(E)04 EC50PM05 EC45PL09 EC45PL08 EC50PL17 EC50PL16 EC50PL19 EC50PM03 EC50PL20 EC58PL03 EC58PL07 EC58PL(E)09 EC58PL12 EC58PL 12 EC58PL08 EC59PLOl EC68PLOl EC68PL03 SN70LSDCSP-01 SN70LCDCSP-02 EC80PL04 EC80PL05
150 Hex 185 Hex 185 Hex 250 Hex 230 Hex 270 Hex 270 Hex 240 Hex 350 Hex 250 Hex 250 Hex 200 Hex 195 Hex 220 Hex 240 Hex 260 Hex 270 Hex 310 Hex 270 Hex PTa Ctr Mag 360 380 380Hex 340 Hex 380 Hex 185 Long Hex 158 Long Hex PTa Ctr Mag 300290310 PTa CtrMag 410400420
1 1/2 Turn
87" 87" 87" 87"
1 Turn 1 Turn
, Turn
1 1/2 Turn
Indy TraillTouring
Indy Trail RMK Indy 440 LC Indy 440 XC Indy 500/SKSICIassic Indy 500 RMK
81' 81'
87"
1 Turn
314 Turn
3/4 Tum
81'
87" 87"
1 Turn
3/4 Tum

Indy WideTrak GT Indy WideTrak LX Indy XLT/SKS IndyXLT RMK Indy XLT Touring/LTD Indy XLT SP Indy XLT LTD SP Indy 600 XC Indy 600 XCRISE Indy UltralSprrouring Indy Ultra SPXlS E Indy 700 SKS Indy 700 RMK Indy Storm RMK Indy StormiSE
1 Turn
1 Turn
1/2 Tum
8r 81' 8r
87"
1 Turn
3/4 Turn
1 Turn 1.5 Turn 1 Turn
3/4 Tum
81'
87" 87"
81' 8T
91
1/2 Turn
1 Turn 1 Turn 1 Turn

1/2 Turn
8T
91
8r
87" 91 91
1 Turn
1 Turn
Non-Oxygenated. When using oxygenated fuel increase octane minimum to 89.
9/96
5.3a

Engine Model EC34-2PM02 EC44-3PM02 EC45PL09 EC45PL08 EC50PM03 EC50PM04 EC50PM05 EC50PM06 EC50PL16 EC50PL17 EC50P119 EC50Pl20 EC5BPL03 EC5BPL07 EC58PLOB EC5BPL09 EC58PL12 EC59PLOl EC6BPLOl EC6B PL03 SN70LCDCSP-Ol SN70LCDCSP-02 ECBOP L04 EC80PL05 Jet Needle No. "E" Clip Position 5DP7-2 6FJ6-3 6DH7-2 6DH3-3 6DH73 6DH7-3 6DH7-2 6DH7-3 6EJ26-3 6F93 6EJ26-3 6EJ26-2 6DP17-3 6EJ3-2 6D H7-3 6DP17-3 6DH7-3 6C EY6-4 6DHB-2 6CEY6-4 R1370G-3 R1370J.;J 6CGY63 6CGY6-3 Needle Jet No. 0-6 (169) P-8 (166) P-2 (480) 0-4 (286) P-6 (266) P-8 (166) P-2 (480) 0-8(480) P-2 (480) P-8 (247) P-2 (480) P-6 (166) 0-2 (166) P-2 (4BO) 0-2 (247) 0 -2 (166) 0 -2 (24 7) P-6 (247) P-4 (247) 0 -2 (247) Throttle Valve Cutaway 2.5 2.0 2.0 1.5 3.0 3.0 2.0 2.0 2.5 2.5 3.0 3.0 2.0 2.0 2.0 2.5 2.0 2.0 2.0 3.0 6.5 5.0 2.5 3. 0
Fixed Fixed
P-6 (247) 0-0 (247)
9/96
FUEL SYSTEM/CARBURETION 1998 Condensed Data Machine Model

Engine Model
Cyl.
Oisp. CCs
Carburetor Model, Mount Type & No.
Std . Main J et
Std.
Pi
Air
Screw {Turns
& Type
Fu el Octane
Je.
Needle
10'
Reqmt.
J e.
Indy lite! Lile Deluxel lite Touring Indy Sport! Sport Touring! TranSport , XCF Indy Super Sport EC34-2PM02A 339 VM30SS (2)Zinc
150 Hex
Out}
E Clip
Needle Jet 1#
Throt. Valve Cutawa y
35
1 1/2
87"
SOP7 #2 6FJ6 #3 60H7 #3 60H7 #3 6EJ3 #3 60H7 #2 60H7 #3 6F9 #3 6FJ43 #2 6EJ26 #3 6EJ26 #2 60P17 #3 60H7 #3 60H7 #3 6CEY6 #4
A'368G OJ AI368G 12
0-6 (169) P-8 (166) 0-8 (480 ) P-8 (166) 0-6 (480) P-2 (480) P-4 (286) P-6 (480) P-O (480) P-2 (480) P-6 (166) 0-4 (480) 0-0 (247) 0 -0 (247) P-6 (247) FIXED
2.5 AL
EC44-3PM024
432
VM34SS (2)Zinc
185 Hex
35
87'
2.0
EC50PM061 EC50PM043 EC50PM051 EC45PL091 SN44-44LCDCSP01 EC50PL171 EC50PL161 EC50PL191 EC50 PL201 EC58PL130 EC58 PL140 EC58PL150 EC59PL020 SN60-70LCOCSP -01 SN60-70LCOCSP -02 EC68PL050 SN70-70 LCOCSP -02 EC68PL060 SN70-70LCOCSP -01 EC80PL052
488 488 488 432 438 488 488 488 488 597 597 597 598 593 600 679 701 679 701 794
VM34SS (2)Zinc VM34SS (2)Zlnc VM34 (2)Zinc (ACCS) VM34SS (2)Zlnc VM34SS VM38SS (2) AL VM34SS (2)Zinc (ACCS) VM34SS (2)Zinc VM34SS (2)Zinc VM34SS (3)Zinc VM38SS (3)AL VM38SS (3)AL VM38SS (3) AL Keihin PWK 39 (2) AL Keihin PWK 39 (2) AL VM38 (3) AL Keihin PWK 39 (2) AL VM38 (3) AL Keihin PWK 39 (2) AL VM38 (3) AL
250 Hex
45 40 45 40 45 45 55 40 35 40 35
1 1 1 3/4 1 1/2
87' 87' 87' 87' 87' 87" 87' 87' 87' 87' 87' 87' 91 87'
2.0 3.0 2.0 2.0 2.0 2.5 2.5 3.0 3.0 2.5 2.0 2.0 2.0 6.5 6.0
Indy TrailfTouring
Indy Trail RMK Indy 440 LC Indy 440 XC R Indy 500/ 500 Classic Indy 500 RMK
230 Hex
270 Hex
270 Hex
360 Hex
350 Hex
260 Hex 250 Hex
314
1 1/4 3/4 1/2 1 1.5 1.5 1/2 1 1/2 1 1 1 1 1
Indy Classic Tmg

Indy WideTrak LX
Indy XLT LTD/ XLT Touring Indy XLT SP
195 Hex 240 Hex

330 Hex 340 Hex
PTOClr Mag 360380380 Hex
Indy XLT Classic

Indy 600 XCR Indy 600 XC Indy 600 RMK Indy Ultra! Ultra Touring Indy 700 XC Indy 700 XCR Indy 700 RMK
3S
40
185 Hex 160 Hex
4S
45 40 38 50 42 50
8T
87' 87' 91 87' 91
FIXED P-4 (247) FIXED 0-2 (247) FIXED 0-0 (247) 3 ..oCH 3.0 5.5 2.0 6.0
340 Hex 185 380 158

PTOClrMag
41() 400 420
60H8 #2
A1368G
6CEY6 #4
R1371G
"
f3
6CGY6
Indy Storm
03
Non-Oxygenated. When using oxygenated fuel increase octane minimum to 89.
9/9 7
5.3c
FUEL SYSTEM/CARBURETION Exploded View - Keihin
GaSket~
Spring
~
~
Adjuster
-~~
I /
LOCk Nut
~ ~
~ ~
(9/ ./ Retainer
Spring Seat
Jet Needle
Enricher (Choke)
1'~ /'
~
~_ ~
"E" Clip
Slide
""""--I
/""
L----/
e/
A~/
./e
~~mRl
Idle Adjustment Screw Main Jet
~~ Fuel Inlet Needle

a
Float
O- Ring
5.3d
9/97
FUEL SYSTEM/CARBURETION Exploded View - VM30SS
3.
~9.
~o.
6.----+
7 . - - -rt
.........r.T..,
/"
(
9--11 .
8.
26.-~~{}J
33. 32. 29. 28 ---:;

26.
~
25.~
23 .
"~
..........--~
~7.
24. ~
22.~::
21.
Ref. Oty. Description (Incl. Gasket) Spring, Throttle Plate, Throttle E-Ring Jet Needle Throttle Valve Needle Jet Cap Cap, Plunger Spring, Plunger Asm., Plunger Spring, Throttle Adjuster Screw, Throttle Stop Screw, Air Spring, Throttle Stop Screw Pilot Jet
"'---20.
Ref. Qty. Description Clamp, Hose Clamp, Hose Plug, Trap Line, Fuel Nipple O-Ring Main Jet Washe r Asm., Carburetor (Incl.
1. 2. 3. 4. 5. 6.
1 Asm., Mixing Chamber Top 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
7.
8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
18. 19. 20. 21. 22. 23. 24 . 25. 26. 27. 28. 29. 30. 31. 32. 33.
1 1 1 1 1 1 1 1 2
1.-17.,23.-33.) 2 Asm., Float 2 Cap

1 1 1 1 1
Gasket, Float Chamber Needle & Seat Packing, Needle Valve Arm , Float Pin, Float
4 Asm., Screw and Washer
91 97
5.4

1-_~~
9 4 5 10
11
3
16
31
30
21
22 12
29--@) 28
~ 22
~ A---....
j
27
----n
'If
23
24
4--26
25
Ref. Qty
1. 2. 3. 4. 5. 6.
Description
Ref. Qty
17. 1 18. 1 19. 1 1 20. 21. 1 22. 2 23. 4 24. 1 25. 1 26. 1 27. AR 28. 1 29 . 1 30. 1 31. 1 32. 1 33. 1
Description
Pilot Jet Plate Ring Main Jet Gasket, Float Chamber Asm., Float Asm., Screw and Washer Clamp, Hose Clamp, Hose Plug, Trap Tube, Sediment Nipple O-Ring Arm, Float Pin, Float Asm., Fuel Inlet Needle Valve Packing, Needle Valve
7.
8. 9. 10. 11. 12. 13. 14. 15. 16.
1 Asm., Mixing Chamber Top (Inci. Gasket) 1 Spring, Throttle 1 Plate, Throttle 1 E-Ring 1 Jet Needle 1 Throttle Valve 1 Needle Jet 1 Cap 1 Guide, Holder 1 Spring, Plunger 1 Asm., Plunger 2 Asm., Carburetor (Incl. 1.-17.,23.-31.) 1 Screw, Air 1 Spring, (Air Adjuster) 1 Spring, Throttle Adjuster 1 Screw, Throttle Stop
Polaris Industfles Inc.
5.5
9/97
3 . ---.rn
4. 5. ----11
~34 . 33
6.
7. - _."
8 . "'-.
~
i- . ? 32.
)
15. 3 1.
----1./ 30 .
" ___ 29. 2 7~ ~28. r';'?7-'-- 26 .
11.
25. ""'_, .; - - - 24 .
""~-- 23.
12. 13.
14.
.-----13.
) ---4.
15.
16 . - -'il'i
17.
----->;~
22.
~
-
~~ ..
19. 18.
Ref. Qly
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Description
Ref. Qly
18. 2 19. 2 20. AR 21. 2 22. 4 23. 1 24. 1 25. 1 26. 1 27. 1 28. 1 29. 1 1 30. 31 . 1 32 . 1 33. 1 34. 1
Description
Plug, Trap Clamp, Hose Line , Fuel Clamp, Hose
Asm ., Screw and Washer
1 Asm. , Mixing Chamber, Top (Inc!. Gasket) 1 Spring 1 Plate 1 E-Ring 1 Jet Needle (6F9-3) 1 Throttle Valve (2.5) 1 Needle Jet (P- 8) (2 47) 1 Cap 2 Packing 1 Asm., Needle Valve (1.5) 1 Float Pin 1 Float Arm 2 Cap 2 Asm., Float 2 Asm. , Carburetor (Incl. 1.-16.,22.-34.) 1 O-Ring 1 Nipple
Gasket, Float Chamber Main Jet (#340) Ring Plate Pilot Jet (#40) Throttle Stop Screw Spring
Air Screw
Spring Asm., Plunger Plunger Spring Plunger Cap
9197
5.6
FUEL SYSTEM/CARBURETION Exploded View - 1996-Current VM34SS with ACCS

1996-Current ACCS Systems
Air Box
4 Way Manifold I Float Bowl Vent Control ACCS 4-way Manifold mounted to air box 27S
ACCS - - . Valve Vent li ne attachment 10 handlebars
15S
,
3-way Manifold , , attachment (1996', ACCS Only) 4-way Manifold attachment ACCS Valve
Mag Carb
Vent line attachment to handlebars EXAMPLE: 27L = 27cm Length, Large Diameter 27 = 27cm Length S = Small Diameter L = Large Diameter
3 Way Manifold I Pilot Air Control (1996 ACCS Only)
NOTE: There is only one ACCS valve. The illustration above has been divided to show the separation of systems.
Do not change calibration setting or serious engine damage may result.
----n"l--f--d
5.7
9197
FUEL SYSTEM/CARBURETION 1996 Jetting Compensation Charts

Indy Lite EC34-2PM02 Carburetor Type - VM30SS Main Jet - 145 Pilot Jet - 35 Cut Away - 2.5 AL Air Screw - 1.5 Turn Jet Needle - 5DP7-2 Needle Jet - 0-6 (169)
AMBIENT TEMPERATURE
Below -20'F Below 29C
(0-3000)
900-1800 (3000-0000)
'20' 10
~IO' F
29"10 12"C
'145
.10",0,"0"F -12" 10 .5"C
Above +4O"F
AboYeS"C
"'00
155
135 125
>30
121)
All. Mel. (Ft)
14"
>30 120
135 120 110
1801).2700
(6CJOO..90(0)
,,6
).1QO ""
HO
27()(}3100
(9(XlO-12OOO)
~1Iie ~100 )l<i,
c=:::;] . Shaded zone should drop Jet Needle one posillon (raise E<llp)
ProduClion Setting
Indy Lite GT EC34-2PM02 Carburetor Type - VM30SS Main Jet - 145 Pilot Jet - 35 Cut Away - 2.5 AL Air Screw - 1.5 Turn Needle Jet - 0-6 (169) Jet Needle - 5DP7-2
AMBIENT TEMPERATURE
BeJow2QF Balow -29'C
(0-3000)
-20 to .100F -29"10 -12"C

"45
+10"10 .. CO'F
-12'10 +5' C
/l.OOV& ,"",O"F AboVeS "C
"'00
165 140 130 120
135 125
115
130 ,'0
_ Tie
Ah.
Mel.
(Ft)
9(1).1800 (300CH3000)
1800-2700 (6001).9000)
135 120 110
"0 100 .
2100-3100
(9(XlO-12OOO)
06
c=:::;] - Shaded zooe shoold drop Jet Needle one poalllon (raise E-Cllp)
'. Production Selling
Indy Lite Deluxe EC34-2PME02 Carburetor Type - VM30SS Main Jet - 145 Pilot Jet - 35 Cut Away - 2.5 AL Air Screw - 1.5 Turn Jet Needle - 5DP7-2 Needle Jet - 0-6 (169)
AMBIENT TEMPERATURE
Below 20"F Below 29C
(1).3000) 900-1800 (3000-6000)
'20' to ~10'F -29 "11;) -12 "C
.. 10"'0.40' F 1210"S"C
Above +40 "F
Above 6"C
"'00
155 140 125 110
145 i3S 120 110
135 125
130
120
AIL Mel. (Fl)
1600-2700 (6000-9000)
(9(XlO-12000)
2700-3700
".
'06
'10
100
c=:::;] - Shaded zone ~hould drop Jel Need!e one position (ra!se E-clip)
Indy Sport EC44-3PM01 Carburetor Type - VM34SS Main Jet - 180 Pilot Jet - 35 Cut Away - 2.5 CH Air Screw - 1.25 Turn Needle Jet - P-4 (166) Jet Needle - 6DH7-3
BeIow-20"F BeIoW 2QC -20 to .!O"F -2910 -12C
Above .~O F Above SoC
190
900-1800
AIL Mel. (FI)
(3000-6000)
180 165
180 160 145
1800-2700 (6000-9000) 2700-3700
(9(XlO-12OOO)
- Shaded zone $/lould drop Jet Needle one pos!tlon (raise E-cUp)
11/95
5.8
FUEL SYSTEM/CARBURETION
1996 Jetting Compensation Charts

Indy Sport Touring EC44-3PMOl Carburetor Type - VM34SS Main Jet - 180 Pilot Jet - 35 Cut Away - 2.5 Air Screw - 1.25 Turn Needle Jet - P-4 (166) Jet Needle - 6DH7-3
BeloW 2(J' F Belew -29"C
~900
-20' to +, O' F
.. 10' 10 +40' F
-29"\0 -1 2' C
180
-12' 10 .S C
170
AtKNe .40' F Above S' C 160
(Q.3000)
190 180
All.
Met.
(Ft)
1800.2700
(6000-9000)
270Q.3700 (9000-12000)
160
145
Shaded zone should drop Jet Needle one position (raise E-cJlp)
Indy TranSport EC44-3PMOl Carburetor Type - VM34SS Main Jet - 180 Pilot Jet - 35 Air Screw - 1.25 Turn Cut Away - 2.5 Needle Jet - P-4 (166) Jet Needle - 6DH7-3
Below '20~F
_20 0 to +,O" F
.'0"\0 ..40+F
12" to.S"C
Above .. 40"F
Below-29"C
~,oo
29"to-12 ' C
AooveS' C
(0-3000)
190
-t80
170
160
- Production Setting
Indy Super Sport EC44-3PM02 Carburetor Type - VM34SS Main Jet - 180 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.25 Turn Jet Needle - 6FJ6-3 Needle Jet - P-8 (166)
BeloW -20F Balow -29'C

~900
'20' to +10" F -29"10 -12"C
.10"\0 "'40' F -12' to +!i' e
Above ..40' F Above S' C
(0-3000)
ISO
180
180
All.
M~.
(Ft)
Indy Trail EC50PM04 Carburetor Type - VM34SS Main Jet - 220 Pilot Jet - 35 Air Screw - 1.5 Turn Cut Away - 3.0 Needle Jet - P-8 (166) Jet Needle - 6DH7-3
Solow -20" F Below 29' C
-20' to +, O" F ,29' 10 -12"C 220 200
<>900
(0-3000)
230 210
AIt,
Mel.
(Ft)
1800-2700
(600Q-9(00)
195 180
Shaded zoos should drop Jet Needle one poslllon (raise E-cllp)
Indy Trail Touring EC50PME04 Carburetor Type - VM34SS Main Jet - 220 Pilot Jet - 35 Air Screw - 1.5 Turn Cut Away - 3.0 Needle Jet - P-8 (166) Jet Needle - 6DH7-3
BeIo'N 20"F Below 2ij"C

260
-20' to .. 10"F 29"to-12 C

240
+10 '0 .40~ F 12" 10 .5"C

22<>
Above .40"F AbOve t)"C

210
Ale
230
210
Met.
(FI)
190
Shaded l one should drop Jet Needle one position (raise E-<:Iip)
5.9
11/95

Indy 440 LC EC45PL02 Carburetor Type - VM34SS Main Jet - 260 Pilot Jet - 40 Cut Away - 2.0 Air Screw - 1.5 Turn Jet Needle - 6DH7-2 Needle Jet - P-2 (480)
AMBIENTTEMPERATURE
Below -20"F
BeIow-29"C 20 to .'0"F 29"10 ,'2"C .. ,O'o."O"F -12" to .5"C Above .4Q"F AlxllleS"C
0-""
(""000)
~1800
280
260
24()
230
.210
230
AlL
(300CHlOOO)
1800-2700
(6001).0000) 270(}'37oo
250 230
200
240
220
220
!fo'
Met.
(Ft)
'':!t~ E roo
i1$p
(9(I(IO-.2QOO)
200
f90 i@~:
"",.
1~:'::;/Hi~' 1 _Shaded zone should drop Jet Needle one position (rals6 E-cllp)
Indy Classic EC50PLE11 Carburetor Type - VM38SS Main Jet - 340 Pilot Jet - 40 Cut Away - 2.5 Air Screw - 1.0 Turn Jet Needle - 6F9-3 Needle Jet - P-8 (247)
AMBIENT TEMPERATURE
Below 20~F
Below 29"C
(<><lOOO)
900--1800 (3000-6000) 1800-2700 (6001)..9000)
-20 to .IO"F 29"10 -' 2"C
.'0"\0 .. 40"F
-12" 10 .S"C
AlXWe .. 40 "F
Abolfa S "C
0-,'"
360
'340
300 260
320 2eo
All.
320
280
Met.
(fl)
...
220
300
.40
2'0
2700..J700 (9(I(IO-.2QOO)
240
230
20"
[=:J - Shaded zone should drq> Jet Needle one posillon (raise E-Chp)
Indy ClassIc TourIng EC50PL14 Carburetor Type - VM34SS Main Jet - 240 Pilot Jet - 40 Cut Away - 3.0 CH Air Screw - 3/4 Turn Jet Needle - 6EJ26-2 Needle Jet - P-4 (480)
AMBIENT TEMPERATURE
BeIow 2Q"F
Below-2S"C
().gOO
20 ,o.tO"F
,29"\0 -'2C
+10 'O .. 40"F 12" 10 ..li"e
Above .40F
Above S"C
,0-30(0)
900-1800 (3Q0()..6000) ,aoo.2700 (6QOO.9000) 2700-3700 (9(I(IO-'2QOO)
250
230
"240
230 "0 190
220
All
220
200
200"
180 166
Met. IF!)
210 195
')'fl';
[=:J . Stladed zone Should drop Jet Needle one poslllon (raise E-c:lip)
Indy 500 EC50PL11 Carburetor Type - VM38SS Main Jet - 340 Pilot Jet - 40 Cut Away - 2.5 CH Air Screw - 1 Turn Jet Needle - 6F9-3 Needle Jet - P-8 (247)
AMBIENT TEMPERATURE
Below -20"F Below -29"C
().gOO (D-3000)
-20" tO .. l0~ F -29'\0 -12 "C
.'0 'o.40"F -12" to .5"C
Above .40"F Abolle 5"C
360
' 340 300
320 280
300
900-1800
AH,
Me.. (Ft)
(3()(){)-6(JOO)
320
2BO
' i!;'~~"
,
1800-2700 (9000-9000)
2100-3100 (9(I(IO-'2QOO)
280
'40
210
0
;:
240
230
200
[=:J _ Shaded zone should drop Jet Needle one posItion (tahle E-c:llp)
- Production SettIng
11/95
5.10
Polaris Industries Inc,

Indy 500 SKS
EC50PL11 Carburetor Type - VM38SS Main Jet - 340 Pilot Jet - 40 Cut Away - 2.5 CH Air Screw - 1 Turn Needle Jet - P-8 (247) Jet Needle - 6F9-3
BeIow-20' F Below -29C
360
-20" to+,O'F
-29"10-12' C
' 340
9Q().1800
All. Met.
(Ft)
(3001:;6000)
320 280
240
300
1600.2700 (6000-9000)
- Shooed zone should drop Jet N8&dle one position (raise E-Cllp) - Production Setting
Indy 500 RMK

EC50PL15 Carburetor Type - VM38SS Main Jet - 240 Pilot Jet - 45 Air Screw - 1 Turn Cut Away - 2.0 Needle Jet - P-4 (247) Jet Needle - 6F9-2
BeIow-20' F Below -29'C -20' !o+IO"F
-29' to 12' C
340
0900
(0-3000) 360
All.
260
'240
Met. (Ft)
220
2\0
200
~
Indy WldeTrak GT
EC50PM03 Carburetor Type - VM34SS Main Jet - 200 Pilot Jet - 30 Air Screw - 1 Turn Cut Away - 3.0 CH Jet Needle - 60H7-3 Needle Jet - P-6 (166)
- Shaded zone should raise Jet Needle two pos1t1ons (iower E-<:lIp to 1t4)
. Production Setting
Below _20F Below -29'C
-20' 10 +to' F -2910 -12' C
AbOve 440F Above S' C
0900
(G-SOOO)
900-1600
210
200
166
All.
(300o-6000) 18QG.27QO (6000-9000)
195 180
160
Mel. (RI
L~t:.J
- Shaded zona should drop Jet Needle one position (mise E-cllp)
Indy WideTrak LX
EC50PL12 Carburetor Type - VM34SS Main Jet - 190 Pilot Jet - 35 Air Screw - 3/4 turn Cut Away - 3.0 Jet Needle - 6EJ26-2 Needle Jet - P-6 (166)
BeIow-20' F Below -29"C -20' 1O+10' F -29' 10 -12'C
osoo
(o-3000)
900-1800
200 185 170 150
'190
Met.
{Ft}
'"I.
(300G-60oo)
1800-2100
(6000-9000)
175
2700-3700
(9(XXl-12000)
- Shaded zone should drop Jel Needle one posttlon (raise - Production Setting
E~))p)
5. 11
11/95

Indy 440 XCR EC4SPL07 Carburetor Type - VM34SS Main Jet - 260 Pilot Jet - SO Air Screw - 1 Turn Cut Away - 2.0 Jet Needle - 60H3-3 Needle Jet - 0-4 (286)
Below -20' F 8elow-29"C 0-900
-20" 10 .to"F -29'10 -12' C
~10'O
.. 40 F
AbQlle .. 40F
-1 2 " 10 +5 'C
Above SC
(0-3000)
270 260
230
'260
250
230
All. Mel.
901).1600 (3000-6000) 1900-2700

(6000-9000)
1Ft)
2700-3700 (!3Il 12000)
210
- Shaded zone should drop Jet Needle one position (raise E-clip)
Indy 440 XCR SP EC4SPL08 Carburetor Type - VM34 Main Jet - 260 Cut Away - 2.0 Jet Needle - 60H3-3
'20' to .10 F -29"10 -12' C
+10"to .40"F -12' to +5' C
Above .... OF
Above S"C
Pilot Jet - 50 Air Screw - 1 Turn Needle Jet - 0-4 (286)
Q.9OO
(0-3000)
280
280
280
250
230
All.
900-1800 (3000-6000)
Mel. (Ft)
270()..3700
(9CJOO.12000)
230
200
- Shadad zone shook:! drop Jet Needle ooe position (raiSE! E-cllp)
Indy 600 XCR EC58PL02 Carburetor Type - VM38AL Slide Main Jet - 260 Pilot Jet - 35 Air Screw - 1.0 Turn Cut Away - 2.S Jet Needle - 60H7-3 Needle Jet - 0-2 (247)
Selow-20' F
SeIow29"C
0-,'"
(0-3000)
Above +40 ' F Above S' C
270 250
220
260 240 220 200
240 220
230 210
900-1600
"",. 1Ft)
Alt.
(3000-6000)
210G-3700
(9000-12000)
200
" ' - - - ' - Shaded zone should drop Jet Needle one poshk)n (ralse E-cliPl
Indy 600 XCR SP EC59PLOI Carburetor Type - VM38SS Main Jet - 400 Pilot Jet - 40 Cut Away - 2.5 Air Screw - 1.5 Turn Jet Needle - 6CEY6-3 Needle Jet - R-O (247)
,20" 10.j.jO"F '29"10 -12- C
+10"10 +40F -12" to .j.S"C
Above +40"F Above S' C
0-'00
(0-3000)
420 390 350
All.
900-1800 (3QO().BOOO)
Mel.
(Ft)
2700-3700
(9000- 12CXX1)
310
=-""W . Shaded zone ShOUld drop Jet Needle one poslUon (raise E-cllp)
Indy XLT ECS8PL03 Carburetor Type - VM34SS Main Jet - 210 Pilot Jet - 35 Air Screw - 1.0 Turn Cut Away - 2.0 Jet Needle-60PI7-3 NeedleJet-0-2
Below -20F Below -29 C 0-900
-20' to ., O F ' -29"tot2"C
.10' 10 +40 F '12 to +O"C
Above +40- F Above S+C
(0-3000)
900-1600 (3000-6000) 1600-2700 (6000-9000) 2700-3700
{9OOC> 12000)
220 200 175 160
210 190 170 160
200
185 165
All.
Met. (Ft)
lao
. Shaded zone shOUld drop Jet Needle one position (raIse E-clJp)
11 /95
5.12
Indy XLT SKS

EC58PL03 Carburetor Type - VM34SS Main Jet - 210 Pilot Jet - 35 Air Screw - 1.0 Turn Cut Away - 2.0 Jet Needle - 6DP17-3 Needle Jet - 0 -2 (166)
Below-20"F Below -29"C
~.OO
-20 to +10' F
'29"to - t2 C
... 10 \0 .. 40"F -1 2"10 ..sC
Above +40"F Above SoC
(0.-3000)
220 200
210 190 170 150
'00
180
ISS
All. Met. (Ft)
165
1800-2700 (8000.9000)
175 160
270l}3700
(9000-12000)
- Shaded zone should drop Jet Needle one positfon (raise E-cllp)
'--
Indy XLT RMK

EC58PL07 Carburetor Type - VM34SS Main Jet - 190 Pilot Jet - 35 Pilot Air Jet 1 (PAJ1) - 1.0 Pilot Air Jet 2 (PAJ2) - 1.6 Air Screw - N/A (ACCS) Cut Away - 2.0 Jet Needle- 6DP17-3 Needle Jet - 0-6 (480)
Below -20"F Solow -29"C
AMBIENT TEMPERATURE
'20" 10 +IO"F
-29"10 -12"C
... , 0"to .40"F -12" '0.5"C
Above +-40"f
Above SoC
M.,
Jel
230
210
' 190
160
- ProdUcllon Setllng
Indy XLT SP
EC58PL02 Carburetor Type - VM38AL Pilot Jet - 35 Main Jet - 260 Air Screw - 1.0 Turn Cut Away - 2.5 Needle Jet - 0-2 (247) Jet Needle - 6DH7-3
BeIow 20"F B&low-29"C
~900
+10" to +40 "F -12" to ..soC
Above .40"F
Above 5"C
(G-3000)
270 250
'60
240 220 200
'40
230 210
All.
Met. (Ft)
900-1800 (3001).6000)
'"
27()().3700
(900)-12000)
'"
200
- Shaded zone shoukl drop Jet Needle one position (raise E-cllp)
Indy XLT Touring

EC58PLE05 Carburetor Type - VM34SS Pilot Jet - 35 Main Jet - 250 Cut Away - 2.5 Air Screw - 1.0 Turn Needle Jet - 0-2 (166) Jet Needle - 6DP17-3
Below -20"F Below -29"C
-20"10 +10"F -29"\0 -12"C ... 10"to ... 40" F -12 0 to ..s C Above .40"F Above S'C
270
9()().1600
'250
''''
220
230
All. Mel. (Ft)
~--~-----+-----+-----+~ 18QO.2700
(6000(9000) 270Q-.3700
(!KXXJ-12000)
(300G-6000)
240 220 200
230 210
'"
190
Shaded zone should drop Jet Needle one positIon (raise E-cl1p)
ProductlOl'l Setting
5.13
11/95

Indy Ultra RMK EC68PL04 Carburetor Type - VM38 Main Jet - 280 Cut Away - 1.5 Jet Needle - 6DH8-2
Pilot Jet - 50 Air Screw - t .O Turn Needle Jet - P-4 (247)
(J.900
(()-.3000)
All. Mel.
(Ft)
900. 1800 (3000-8000) 1600-2700 (6000-9000) 2700-3700 (9000-12000)
290 270
2eo
260
270
260
250
240
- Shaded zone change cylinder head
c=J -Shaded zons productIon seiling

No Jet Needle Changes are Recommended
Indy Ultra SKS EC68PL01 Carburetor Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
AMBIENT T EMPERATUR E
BeIoW-2Q'F Below -29' C
-20' to .j.l0'F
-29 ' 10 -12"C
+10'10 +""O' F
Above +40"F
-12'
to
.soC
Abovo S' C
Pilot Jet - 50 Air Screw - t.O Turn Needle Jet - P-4 (247)
(J.9OIl
(0-3000) 900-1800 (300()'6000)

1800-2700 (6OQO.9000)
350 320 290 270
34<J 310 280
320 300 270
300
A~
'80 '60
"0
Mel.
(Ft)
2700-3700
(900)-12000)
'80
'50
Indy Ultra SP EC68PL01 Carburetor Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
AMBIENT TEMPERATURE
BeIow-20' F
Below -29' C
-20' to +10 ' F -29 '!O-12' C
+10' 10 .4~F -12' to .. S' C
Above .40' F
~bOYe5' C
Pilot Jet - 50 Air Screw - 1.0 Turn Needle Jet - P-4 (247)
(J.,oo (()-.3000)
350 320 290 270
340 310
3'0 300 270
300
900-1800
All Met.
(3000-6000)
'80 '60
'40
1Ft)
1800-2700 (600o-90(0)
2700-3700 (!lOOO-12000)
,eo
260
'50
Indy Storm EC80PL05 Carbu retor Type - VM38SS Main Jet - 400-400-420 Pilot Jet - 45 Air Screw - t .0 Turn Cut Away - 3.0 Needle Jet - 0-0 (247) Jet Needle - 6CGY6-3
Below -20' F Below-2Q' C

1>900
(0-3000)
-20' to +10' F -29to-12 C
+10'tO .. 40' F 12' to +S' C
Above .40' F
Aoova S' C
420 4'0 440

390
400 400 420
380 3'0 400
360 360 380
All Met.
900-1800
(3000-6000)
(Ft)
160()'2700
390 410
380 360
(6000-9000)
380 )900<).12000) 320 340
Shaded zone should drop Jet Needle one posillOn (raise E-(:lip)
Prcxlucfion Setting
?TO smaJl8SI. Mag biggest PTO..(;enler-Mag left to right
11/95
5.14
Indy Storm SKS

EC80PL05 Carburetor Type - VM38SS Main Jet - 400-400-420 Pilot Jet - 45 Air Screw - 1.0 Turn Cut Away - 3.0 Jet Needle - 6CGY6-3 Needle Jet - 0-0 (247)
Below -20"F
Below 2QC
-20\0 +'O"F -2910 _12C
... '0"\0 +4Q oF -12' 10 .. SoC
AbOVe .40 F
AOOV8 SoC
420
(ll-3000)
.. 0
All.
900-1800
'20
400 400 420
380 380
400
380 360 380
Met.
(Ft)
(3000-6000)
390 390 410 360

360
1800-2700 (6QO().9000) 2700-3700 {9OIXJ.12OOO}
3.0 320 320 340
L..,"",OD - Shaded zone should drop Jet Needle one poslHon (raise E<lip)
c:::J Indy Storm RMK

EC80PL04 Carburetor Type - VM38SS Main Jet - 330-330-350 Pilot Jet - 50 Cut Away - 3.0 Air Screw - 1.0 Turn Jet Needle - 6CGY6-3 Needle Jet - P-6 (247)
Production Setting
PTa smallest - Mag biggest, PTQ..Center-Mag left to right
Mel.
..
(AI
0.900
(0-3000)
330
350 300 310
310 310 330
280
280 300
- Shaded lone should raise Jet Needle one position (lower E<lip 10 14)
c:::J -
Production Setting
c:=::=J -Shaded zone should drop Jet Needle one positron (raise E-<::llp)
PTO smallest - Mag biggest. PTO-Center-Mag lett to right
5.15
11/95

Indy Lite EC34-2PM02 Carburetor Type - VM30SS Main Jet - 150 Pilot Jet - 35 Cut Away - 2.5 AL Air Screw - 1.5 Turn Jet Needle - 5DP7-2 Needle Jet - 0-6 (169)
AMBIENT TEMPERATURE
BeIoW-20 F
Below 2S'C
~900
-20 to . 10'F 29"0 12' e
+ 10'10 +40' F
AOOve +40' F
12" 0 +5- 0
AboVE! SC
ID-3(00)
900-1800
160 145 130 115
150 1'0
140 130
135
All. Mel.
(3001}-6000)
1R5
Ft 1)
1800-2700
(6000-9000) 2700-3700 (9000-12000)
,"
1<+'1) 5. i,i,
1:11
'hi
'liS,
);~t;i
>;; !'
n;:)~::~- I . Shaded zone snooK! drop Jel Needle OIlE! positio!1 (raise E-clip)
Indy Lite GT EC34-2PM02 Carburetor Type - VM30SS Main Jet - 150 Pilot Jet - 35 Air Screw - 1.5 Turn Cut Away - 2.5 AL Needle Jet - 0-6 (169) Jet Needle - 5DP7-2
AMBIENT TEMPERATURE
Below -20~ F BelOw 29'C
~900
-20~
",.
10
. 10~ F
-29" 0 -IZ ' C
; 10"\0 +40~ F 12' to _o' e
Above "40~ F
Above o' e
(0-3000) 900-1800 (3QOO.60oo)
160 145 \30

liS
150 140
140 130
135
All. Met. (Ft)
"& ~
)1~ i
1800-2700
(6000-9000)
125
1 1' \15
27Q(}3700
(9000-12000)
e 'N " I ",,8ili!'
. ;~r-"
IO;6L")/;~ I _ Sh'aded zone should drop Jet Needle one position (raise E-cllpJ
Indy Lite Deluxe EC34-2PM02 Carburetor Type - VM30SS Main Jet - 150 Pilot Jet - 35 Cut Away - 2.5 AL Air Screw - 1.5 Turn Jet Needle - 5DP7-2 Needle Jet - 0-6 (169)
AMBIENT TEMPERATURE
Below -20 F BelOW -29 C
-20 ' to .10 F -29 ' to '12"C
. to",o .40' F
-12 \0 .s C
Above .40"F Above 5C
0.900 (0-3000) 900-1800

(300C).f;QOO)
\60 \45 \,0 \15
150
\40
140 \30
'35
All.
Met.
1Ft)
IS00-2700 (6000-9000) 2700-3700

(9000-12000)
125
120
:!i{' . . 8+ "
\'
,.'... n'
'.5
c=J] _Shaded zone should drop Jet Needle one position (raise E~lipl
Indy Sport EC44-3PM02 Carburetor Type - VM34SS Main Jet - 185 Pilot Jet - 35 Cu t Away - 2.0 Air Screw - 1 Turn Jet Needle - 6FJ6-3 Needle Jet - P-8 (166)
8e!OW-20" F
~~t~
-20'
l()
105
+10" F
.. 10 'o.-40" F
Below W"C
~900
-29\0 .12"C
-12' to...s C
Above j.40 v F Above 5' C
(0-3000)
900-1800
AIL
(3000-6000) 1800-2700
(saDO-goOD)
MeL
(Ft)
2700-3700
(9O()I).1 2000)
Shaded zone should drop Jet Needle one position (raise E~lip)
Indy Sport Touring EC44-3PM02 Carbu retor Type - VM34SS Main Jet - 185 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.0 Turn Jet Needle - 6FJ6-3 Needle Jet - P-S (166)
Bekiw -20' F Below -29' C

~900
-20' Lo \0 ' F -29' \0 -12'C
.. 10"0 . '10' F -12 1 ..s" C 0
Above +40"F Above SoC
to-3OO0)
900-1800
Alt,
Mel..
(3000-5000) 1800-2700 (600 0-9000)
(FI)
2700-3700
(9000-12000)
Shaded zone should drop Jet Needle one positiOn (raise E~l ip)
9/96
5.15a
FUEL SYSTEM/CARBURETION 1997 Com Charts

Indy TranSport EC44-3PM02 Carbu retor Type - VM34SS Main Jet - 185 Pilot Jet - 35 Cut Away - 2.0 Air Screw -1.0 Turn Jet Needle - 6FJ6-3 Needle Jet - P-8 (166)
BeIow-20' F Below zg ~c
0-900
20' 10 ~10 ' F 29 IO12"e
(0-3000}
195
185
185
All.
Me .
(Ft)
1800-2700
(6000-9000)
2700-3700 (9000-12OOOJ
- Shaded zone ShOU ld drop Jel Needle one position (raise E<lIp)
Indy Super Sport EC50PM06 Carburetor Type - VM34SS Main Jet - 250 Pilot Jet - 45 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 6DH7-3 Needle Jet - 0-8 (480)
AMB IENT TEMPERATURE

Balow -2D"F Below -29"C
20' 10 .. 10~ F 29"10 '12~C
... 10"'0 .. 40' F -12 ~ 10 . 5 v C
Abovo 1"40~f AbovaS"C
0-900 [0-3000)
260 250
220
2.50 230 210
240 220
230
2jO~
9()O.lBDO
All, Met.
(Ft)
(300Q.OOOCI
1800-2700
(6000-9000)
,21b 200
....
~ k
2QO
2700-3700
(!IIJO[).l2000)
210
.~oii:
~
Indy Trail EC50PM04 Carburetor Type - VM34SS Main Jet - 230 Pilot Jet - 35 Cut Away - 3.0 Air Screw - 1.5 Turn Jet Needle - 6DH7-3 Needle Jet - P-8 (166)
- Shaded zone snOlild drop Jet Needle one positloll (raise E-Chp)
AMBrENTTEMPERATURE
8elow 2Q" F Below -29" C
-20' 10 .. ,O F
-29"10 - 12"C
~ 10
'0 +40"F -12 to 'S- C
Above +40 " F AboI/O S' C
0900
(0-30001
900-1600
240 220 200 190
230 21 0 <9,
220 200
210
"-'
All.
Mel. IF!)
(3000-6000)
1600-2700
(600 0-0000)
I'!
...<
.
190
180
185
2700.3700 [9000-120(0)
. 116':1;. ctl
AMBIENT TEMPERATURE
"" . 0 $
~
Indy Trail Touring EC50PM04 Carburetor Type - VM34SS Main Jet - 230 Pilot Jet - 35 Cut Away - 3.0 Air Screw - 1.5 Turn Jet Needle - 6DH7-3 Needle Jet - P-8 (166)
Shaded zone should drop Jet Needle one position (raIse
E<~p)
Above .. 40"F AboveS"C
Below 20"F Below -29C

0-900
-20~
29~ lo
to .10'F ' 12' C
.10' to
' 12~ to
~40 F
..SoC
(1).3000) 90().1800 (JQOI).6000) 1600-2700 (500{)-9000) 2700-3700 (9000-12000)
240 220 200 <90
230 210 195
220
210
All. Mel.
(Ft)
200
i:~:
. :: ;,,;;;%:1.>':
,JJ'I .
189,.; \
li;F;:r~
CJ";,
t- ,;~, "AI _ Shaded zone should drop Jel Needle One position (raise E--clip)
Indy Trail RMK EC50PM05 Carburetor Type - VM34SS Main Jet - 270 Pilot Jet - 45 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 6DH7-2 Needle Jet - P-2 (480)
AMBIENT TEMPERATIJRE
BelOw -20" F BelOw 29"C
~'OO
-20 10 ~10 F -29 -10 -12"C
; 10"10 .-40"F -12" 10 ..S-C
Above ~40 F AbovO S"C
3 10
(0-3000) 900-1800 (SQOo.60 00) 1801).2700 (600()'9000) 270()..3700 (9000-12000)

- ProdUClion Setti ng
290 290 290 290
270
#3
250
li2
" 310
#3
All.
'" ., "
270
#2
250
#2
Me ..
(Ftl
310 310
.,
.,
270 270
.,.
'"
250
#2
250
"
"
9/96
5.15b

Indy 440 LC EC45PL09 Carburetor Type - VM34SS Main Jet - 270 Pilot Jet - 40 Cut Away - 2.0 Air Screw - .75 Turn Jet Needle - 6DH7-2 Needle Jet - P-2 (480)
AMBIENT TEMPERATURE
-20' F Balow 2Q' C
8Qlow
-20~
to ... 10 F -29'10 -12"C
+10 !o ... 40 F -12 ' to ~6 ' C

ft
AbDVe .. 40 "F Above S'C
()'900
(0.300.0)
900-18CO
290
260
270
25{) 240
240
All.
M~ .
(3000-6000) 1800-2700 {600G-9DOO}
250 230 .210
230
...
1 Ft)
240 220
.. 'i~o
h, g.~p
;~
1\0
:;;.,
l~O
270(}37.oO (90(XH2000)
1..
d:~:T:...1 . Shaded lone should drop Jet Needle one position (raise E-cflp)
AMBIENT TEMPERATURE
Below 20' F
Below 29"' C
Indy 500 Classic EC50PL17 Carburetor Type - VM38SS Main Jet - 350 Pilot Jet - 40 Cut Away - 2.5CH Air Screw - 1.0 Turn Jet Needle - 6F9-3 Needle Jet - P-8 (247)
' 20' to +10"F 2.9 ~to - 12"C
,1C "tO .. 40"F
Abo~e ~40 ' F
- 12' IO"SC
AbovoS"C
0-900
(0-3000)
9OO-I80D (3000-6000) 180()'2700 (600Q-9COO)
370 330
290
350 3>0 210 240
330
3'0 210
Me,
1Ft)
All.
29.0
.,
.U :1""
27.oQ-3100 (9OIJO.12000)
2h<l
.iii~ ~
:01
l ij
",: : 1
23Qj W
'216'
c:::::J .Shaded zone should drop Jet Needle one pOSItion (r\llse E-c1ip)
. Pro::Iuctloo Seltlng
Indy Classic Touring EC50PL19 Carburetor Type - VM34SS
AMBi ENT TEMPERATURE

Beklw-20' F Below -29~C -20" 10 t-l0' F -29 "'0 -12' C tID"to t40"F -12 0 to .S C
Abo~8
+40 F
Abo\Oe 6 ' C
Main Jet - 250 Cut Away - 3.0 CH Jet Needle - 6EJ26-3
0-900 (0-3000)
8{)(}16oo (3000-6000)
260 240 220 21)0
250 230 2.0
"0 220
' 195
230
Ie
Ait Met. (Ft)
"t,.
l~l:~ii;
,m
1800-2700 (OOOo-SOOO) 2700-3700
19000-I2000)
JOO
""fh
,k
A.
'. '0'~
c:::::J _ lone should drop Jet Needle one position (raise E-<:hp) Shaded
- - PrOCluctJ SettIng on
Indy 500 EC50PL 17 Carburetor Type - VM38SS Main Jet - 350 Pilo1 Jet - 40 Air Screw - 1.0 Turn Cut Away - 2.5CH Needle Jet - P-8 (247) Je1 Needle - 6F9-3
AMBIENT TEMP ERATURE

Below -2Q' f
Beta ..... -29'C

0-900
-20' to .10' F -29'10 12- C
+10"10 ..-40+F -12" 10 .S C
Above .AO"F Above S"C
(0-3000)
900-1600 (3001)..6000)
370
-350
330
310
AIL
330 290 250
3.0
270
290
~O
Mel.
(Ft)
1800-2700
(6000-9000)
270Q-.370D
19000-12000)
"0
I",:n', ~ ,I _ Shaded zane should drop Jet Needle ane posilloo (raise E-clip)
- - Production SettIng
9196
5 .15c

Indy XCF EC44-3PM02 Carburetor Type - VM34SS Main Jet - 185 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 6FJ6-3 Needle Jet - P-8 (166)
Below -2Q"F Below -29' C
-20" 10 .,O' F 29"1 -12' C 0
0-900
{0-3000)
Alt.
Mel.
{Ft}
;95
185
185 170 155
900-1600 (3 00 0-6000)
laDO-27oo
(6000-9000)
165
27 00- 3700 (90OCH2000)
filS
- Shaded zone should drop Jet Needle one position (raise E-clip)
Indy 500 SKS EC50PL17 Carburetor Type - VM38SS Main Jet - 350 Pilot Jet - 40 Cut Away - 2.5CH Air Screw - 1.0 Turn Needle Jet - P-8 (247) Jet Needle - 6F9-3
AMB IENT TEMPERATU RE

Below -20 "F
-20 tO + l0~F
BeloW 29C 0-900
-29"\0 . 12 "C
. ,O' (0 .. 40' F -12 " to .. S"C
Above .. 40 ~ F AbOveS'C
(0-3000) 900- 1800

AI!.
370 330 290 250
'350
310
330 290
J 10
(3000-6000)
0k74
<' "
23Q-;
Mel.
(Ft)
1601).2700
(600[).9000)
27O
240
1'\1: 1: 250
2700-3700
(9000- 12(00)
I'
""0
l~tO, d}
L <L':: -~I
Indy 500 RMK EC50PL16 Carburetor Type - VM34SS Main Jet - 250 Pilot Jet - 40 Cut Away - 2.5CH Air Screw - .75 Turn Jet Needle - 6EJ26-3 Needle Jet - P-2 (480)
. Shaded ~one should drop Je~ Nedle one POSition (raise E-clip)
AMBIENT TEMPERATUR E
BelO'W 20~ f
Saklw -29 ' C 0-900 f0-30c0)
900-1800
- Producllon Setting
20' \0 "O'F
-29 ' to -12' C
+10' \0 .. 40"F -t2 ~ 1 +5 C 0
AOOVe
+40~ F
AbovsS' C
290
290 #4 290 290 #3
...
270 #4 270 #4 270 270 iI3
250 #4 250
240 #3 240 240 .3 2'0 ,_#2
All,
(3000-8000)
.,
Mel.
1Ft)
160(}2700 (6000-9000) 2700-3700 19()O(} 12000)
'4
' 250 250 #3
"
"
"
c=J -Shaded zona should raise Jel Needle one pOSition (lov.er E-(lilp 10 93) c=J -Shaded zone should raise Jet Needle two posllions {lower E-clip 10 #4)
- - Production Setting
Indy WideTrak GT EC50PM03 Carburetor Type - VM34SS Main Jel - 200 Pilot Jet - 30 Cut Aw ay - 3.0 CH Air Screw - 1 Turn Jet Needle - 60H7-3 Needle Jet - P-6 (166)
AMBIENT T EMPERATU RE
BelOW -20' F
8elow -29' C
O~OO
-20 to ..10" F -29"tO-12 "C
+10" 0 +40 F -12' 10 tS C
Above .. 40 F Aoove S"C
(a-3000)
900.1800
210 195 180 160
' 200 185 170
190 175
180
All.
(3000-6000)
1800-2700 (8000-90(0) 27Q()3700
Met.
(FI}
-'T',., 60' .
" ~
I..
c
;~ :);
j$ ilC:
13$"
(9000-12000)
15S
:1
l:e~i : : ;V" I ~ Shaded zone should drop Jet Needle one posiHon (raise E-cllp)
- Producllon Settin g
I ~!t"s
5.15d
9/96
FUEL SYSTEMICARBURETION 1997 Jetting Compensation Charts

Indy WideTrak LX EC50PL20 Carburetor Type - VM34SS Main Jet - 195 Pilot Jet - 35 Cut Away - 3.0 Air Screw - 1/2 turn Needle Jet - P-6 (166) Jet Needle - 6EJ26-2
AMBIENT TEMPERATURE
Belo..... -20'F
Be~w-29'C
20 to .10" F
-29"10
-12~C
.. '0 ' 1 .. 40 - F 0 ,12' 10 <IoS'C
Above ... 40" F
Above SoC
'900 (0-3000)
900-1600
AI!.
20' 190 17'
'195
,8<)
,'"
'70
(3001)-6000)
lt i
I I,
nof;
MB
fFI)
l BOG-2700 (6000-9000)
2700-.3700 (9000-12OOOl
I.,;...
'55
,'"
l~q W
~:::ii'55
1</0
.. .., I"
;::;"'.
IT:] _Shaded zone should drop Jet Needle one posltion (raise E~lIp)
- Productiol'l Seltlng
Indy 440 XC EC45PL08 Carburetor Type - VM34SS Main Jet - 240 Pilot Jet - 50 Cui Away - 1.5 Air Screw - .75 Turn Needle Jet - 0-4 (286) Jet Needle - 6DH3-3
AMBIENT TEMPERATURE
8(11cw-20" F Befow29"C
-20' to .IO" F -29' to .12"C
.. 10"0 .. 40 f -12+ to .. S C
Above +40" F
Abovo6 ' C
0-900
(}-3OOO)
900.1800
250 230 210
240 220 200
230 210
220
All.
Mel.
(Ft)
(3000-SOO0)
1800-2700
(6000.9000)
2~~~T
'ltl:,O
170
.'.' PAil,I,'
.""
270C>-31oo
(9COO-12ooo)
'9'
', . ,,&111
i~I~75 ?
IT:] -Shaded zone shou ld drop Jei Needle one pOSllion (raise E-cllp)
Indy 600 XCR EC59PL01 Carburetor Type - VM38SS Main Jet - P-360/C-380/M-380 Pilot Jet - 40 Cut Away - 2.0 Air Screw - .5 Turn Jet Needle - 6CEY6-4 Needle Jet - P-6 (247)
8910W -20"F Below -29'C -20 10 _I O" F .. 10 10 .<lO F
-29"10 -12 ~C
-i2" 10 -S' C
Ar.ove .<l0 F AbOve S-C
0-900 (0-3000)
All. Mel.
1-==:-I----I-----h-~--+-----_'__1
360 l~~~~-~~~-~~-l~~~~~~~~Id
400
J60
(R)
- Shaded zone should drop Jel Needle one position (raise E-cllp)
Indy 600 XCR SE EC59PL01 Carburetor Type - VM38SS Main Jet - P-360/C-380/M-380 Pilot Jet - 40 Cut Away - 2.0 Air Screw - .5 Turn Jet Needle - 6CEY6-4 Needle Jet - P-6 (247)
BOIoW -20" F
-20 ' lo.'O ' F
~IO 'IO
+40 ' F
Bolo..... -29'C
().900
-29"1 -12'C 0
- 12 1 ..SC 0
Above . 40' F Above S C
(0-3000)
All. Me!.
(Fl)
400
900-1800
(3000-600 0)
380
360
360
1801).2700
(6000-9000)
- Shaded zone should drop Jal Needle one position (raise E-cI;pJ
9196
5.15e

Indy 600 XC EC58PL08 Carburetor Type - VM38SS Main Jet - 270 Pilot Jet - 35 Air Screw - .75 Turn Cut Away - 2.0CH Needle Jet - 0-2 (247) Jet Needle - 6DH7-3
AMBIENT TEMPERATURE
Below 20' F
Below -29' c
-20' to ~ 1O'F 29"0 \2 "C
.. to' ,o ... 40'" F

12' 10 _S ' C
Above .40' F
AtxlveS' C
0-900
(D-JOOO)
900-1800
290
270 250 230 210
250 240 220

200
240 230 210 190
Al.
Moe
(30006000)
1800-2700
260
(Ft)
(6000-9000)
2700-3700
(9(00. 1200)
NO
220
c=J .Shaded zone shoulO drop Jet Needle one pGSmon (raise E-<:1ip)
Indy XLT EC58PL03 Carburetor Type - VM34SS Main Jet - 220 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.0 Turn Jet Needle - 6DP17-3 Needle Jet - 0-2 (166)
AMBIENT TEMPERATURE
Below 2Q' F
20" 0 .. 10 F
. 1 0 10~40F
BelOW 29' C
29" 0 t2 C
-12"D .fS' C
Ab0ll8 .. 40"" AOO\IO fo ' e
0-900
(0-3000)
230 210
'95
220 200
210 .90 175 170
200
900- 1800
All. Met
(3000-6000)
,.0 170 170
1800-2700
(6000-9000)
(Ft)
2700-3700 (9:0:)-120001
."
.70
180
c=J .
Indy XLT SKS EC58PL03 Carburetor Type - VM34SS Main Jet - 220 Pilot Jet - 35 Cut Away - 2.0 Air Screw 1.0 Tum Jet Needle - 6DP17-3 Needle Jet - 0-2 (166)
ShadllCllone should drop Jet Needle one POSition {raise E-ClipJ
AMBIENT TEMPERATURE
Bal ow '20 ' F BeIQw 29'C
-20" o __ 10' F !o-t2'C -29 " 220
,,'O' lo .. 40' F 12' [0 .. S C
Above .. ~ O F AbOvo 5' C
0-900
((1.30001
9CX,} 1800
230 210
'95
210
Alt. Met. (FI )
(300Q.6000)
200
'.5
18QO.2700 (6000-9000)
2700-3700 (9(XXl-. _
...
175
200 '.0 .7. 170
180
170
'70
c=J .
Indy XLT RMK EC58PL07 Carburetor Type - VM34SS (ACCS) Main Jet - 240 Pilot Jet - 50 Air Screw - .75 Cut Away - 2.0 Needle Jet - P-2 (480) Jet Needle - 6EJ3-2
Shaded zone should drop Jet Needle one position (I Olse E-cllp)
AMBIENT TEMPERATURE
, IndIcates E-cllp Location 1 10m lop 01Jet Needle
Below -20 ' F Below 29-C 20 ' to .. 1O' F 29' 10 -Il' e
. 10lo~40 F
AbOve .40' F
\2 - IO .. S 'C
Above 54 C
0-900
(0-3000)
2.0 280
280
260
<2
"0 240
'240
230 230 .2 230 230
All. Moe
900- 1800 (3000-6000) 1800-2700 (6000-9000)
" "
280
1Ft)
2100.3700 {9OOil-' _
.2 280 ,2
- Produclioo Setting
" " 280 "
280
240 .2
" " "
" " "
5 .151
9/97

Indy XLT SP
AMBIENT TEMPERATURE
BelOVo'
-20 ~ F
EC58PL12 Carburetor Type - VM38ALSS Main Jet - 270 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.5 Turn Jet Needle - 6DH7-3 Needle Jet - 0-2 (247)
-20
to ~'O ' F
",' 0 '0 .. 40F

-12 " 10 +5' C
6elow-29 ' C
29" O12"C
Above .40' F Above 5' C
0-900
(0-3OO0J 900- 1800 (3000-6000]
290 270 2'0 220
270 250 230 210
250
2'0 230
Alt.
Mel.
(Ft)
2'0 220
1800.2700 (6000-9000) 270()..370a

(9000-12000)
I i: . (
+10' lo+<!O'F 12" 10 ~5'C
2{~ '"
190 ...
,!#'i
~
Indy XLT Touring
- Shaded zone should drop Je\ Needle one position (raise E-chp)
AMBlENT TEMPERATURE
Below -20' F Below -"<!S ' C
~900
EC58PL09 Carburetor Type - VM34CS Main Jet - 260 Pilot Jet - 35 Cut Away - 2.5 Air Screw - 1.0 Turn Needle Jet - 0-2 (166) Jet Needle - 6DP17-3 Inlet Needle Seat - 1.5
-20' to +10' F -29 " 0 -12 ' C
Above +40' F At:ove 5' C
(Q.3000)
2SO 250 230
2""
240
230
NI.
Me1. (Ft)
9DO-1800 (3000-6000)
1800-2700 (6000-9000)
2700-3700 (9(XX}> 12(00)
.;;. :::,~"
21 0
@fw200,
(SO
Ir!/t:AFI . Shaded zone should drop Jet Needle one posltlon (raise E-cllp)
Prodl.lctlon Setting
Indy XLT LTD
AMBIENT TEMPERATURE
Balow -20 ' F Below -29 C
(}-900
EC58PL09 Carburetor Type - VM34CS Main Jet - 260 Pilot Jet - 35 Cut Away - 2.5 Air Screw - 1.0 Turn Jet Needle - 6DP17-3 Needle Jet - 0-2 (166) In let Needle Seat - 1.5
-20' to+l0 ' F -29' 1012 ' C
+10 ' 10 +40' F -12" IO"'S' C
Above +40 ' F AbOvaS"C
(0-3000) 900-1800 (3000-6000) 1800-2700 (flOOO-9000) 2700-3700 (9000-1200))
260 250 230 210
260'
2'0
230
AIL Me1.
(Ft)
2'0
;~dl
;210
", '~1\ "

~:~190
1 m. .1
F
200
C:=!l .Shaded zone should drop Jet Needle one position (raise E-clip)
. ProdUCtion Selling
'""if
"""!60,
Indy XLT LTD SP
AMBI ENT TEMPERATURE

BOlOw -20' F BelOw -29 C
0-900
EC58PL12 Carburetor Type - VM38ALSS Main Jet - 310 Pilot Jet - 35 Ai r Screw - 1 Turn Cut Away - 2.0 Needle Jet - 0 -2 (247) Jet Needle - 6DH7-3
-20' 10 ... 10' F -29 ' 10 -12' C
... 10'to t 40' F - ,2 to ... S"C
AbOve .. 40' F Above S C
10-3000)
900-1aOO
330 3'0 2SO 260
310 290 270 240
290 270 250 230
270 260
~~{f
Me,.
(Fl)
All.
(3000-6000)
1800-2700 (6000-9000) 2700-3700 (9OO). ,2OOCl)
rl2d~
L:::;, ,- - ',1 _Shadecll.one should drop Jet Needle one position (raise E-cllp)
9/97
5.15g

Indy Ultra EC68PLOI Carburetor Type - VM38 Main Jel - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
AMBIENT TEMPERATURE
Below 20'F BeiOw 29C
20' to .10"F _2g a la -12'C
.. 10- lo+40 F 12' to +S' C
Above +40'F
AboveS"C
0900
(0-3000) 900-\800
(3000-0000)
350 320 290 270
340 310 280 260
320 300 270 260
300 280 260 2' 0
All. Mel.
(FI)
1600-2700 (6000-9000)
2701).3700
(9QOO.12OOO)
Indy Ultra SP EC68PLOI Carburetor Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
AMBIENTTEMPERATURE
Be~w
-20"F
2 0~ 10
+10"F
Tl0"\0 ~40' F
-12 " to .. 5C
Beklw-29'C
-29' to -12'C
Ab0v6+40"F AhoveS'C
0-900
(o-3000)
3SO
320
340 310 2'" 260
320 300 270 250
300 280 260 2'0
AU. Mat.
9OG-1800 (30QO.6000)
1801).2700 (6000-9000) 270()'37DO (900() 12000)
(Ft)
290 270
Indy Ultra Touring EC68PLOI Carburetor Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6D H8-2
AMBIENT TEMPERATURE
Below-20' F Balow -29' C -20"ttHl0' F -29'\0 _12 C
+10'10 .40"F -12' to +& ' C
Above ...-IO' F Above S' C
0-900
(Q-.3000)
900-1800
350 320 290 270
340 310 280 260
320 300 270 2SO
300
All.
Met.
(3DOO-6000) 1800-2700 (600o-9000 )
280 260 240
1Ft)
2701).3700
(9OOO-121JCX))
Indy Ultra SPX EC68PL03 Carburetor Type - VM38 Main Jet - 380 Cut Away - 3.0 Jet Needle - 6C EY6-4
AMBIENTTEMPERATURE
Below 20 F Saki .... 29C
-20' to +lO' F
29' 10 '2"C
Pilot Jet - 50 Air Screw - 1.0 Needle Jet - 0-2 (247)
0-900
(0-3000)
900-1600
400 #' 370 #4 340

#3
360 350 #3 320

#3
290 #2
..
-t-l0'!o+40' F 12' to ..s C
Above ~40'F Abolla SoC
360 #3
330 #3
3'0 310
02
""
#1
AIL M,I (Ft)
(3000-6000) 1600-2700 (6000-9000) 2700-3700 (!IOCO-I2OOO)
300
1!2
280 250
310
#3
270
#2
'"
Productron Setting
Indy Ultra SPX SE EC68PL03 Carburetor Type - VM38 Main Jet - 380 Cut Away - 3.0 Jet Needle - 6CEY6-4
AMBIENT TEMPERATURE
Below-20' F BeloW 29<C -20' to ,,'0 F 29"10 -12 ' C +,O"10.40 F -12 ~ 10 ...S'C Above +40 F Abolle S C
Pilot Jet - 50 Air Screw - 1.0 Needle Jet - 0-2 (247)
0-900 {0-3000) 91)0-1800 13000-6000) 1600-2700 (8000-9000) 2700-3700

(9COO-12000)
400
#4
'380 #' 350 320 #3 290 #2
360
330 #3
340 310
#2
All.
Met. (Ft)
370 #. 340 #3 310

#3
""
#2
""
#I
"
300 #2
'80
112
270
'SO
ProdUClion Setting
5.15h
9/96

Indy 700 SKS SN70LCDCSP-01 Carburetor Type - Keihin PWK 39 Main Jet - 185 Long Hex Pilot Jet - 40 Cut Away - 6.5 Air Screw - 1 Turn Jet Needle - R1370G-3 Needle Jet - Fixed
AMBIENT TEMPERATURE
Beiow-20"F
-20" 10 +IO F
.10 ,o.40"F
-12 " 10 tS"C
BeIow-29' C
..900 (().300())
-2'9'10 -12"C
Above ...40"F Above5"C
190 178 168
'185 175 165 155

.'
"8 168 158
172 162 '55

$
AIL Mel.
(Ft)
9!XHBOO (300IHOOO)
1800-2700 (6000-9000) 2700-3700
(9OO()-l2000J
I ,~":",%t:...., I _ MOOt! use IN R1370J.3, 5.0 CA, 55 pllOI, and 1/2 tum air screw Above
r;----l
.. J50
145
~ - Lower Jet Needle 1 pOSition (raise E-<:IIPl end Il1stall RMK components
listed above - Productior'l SettIng
Indy 700 RMK SN70LCDCSP-02 Carburetor Type - Keihin PWK 39 Main Jet - 158 Long Hex Pilot Jet - 55 Cut Away - 5.0 Air Screw - 1/2 Turn Needle Jet -Fixed Jet Needle - R1370J-3
AMBIENT TEMPERATURE
BeloW -20' F
BeloW 29"C
"900
(c)'3000)
-20' to .. l0' F -29' \O - 12C
. 10"IO...40' F
Ab(we
.4 0 ~ F
-12' 10.S C
Above SoC
190
185 "5 165 155
"8 168
' 158
11'
)62
900-1800
1'J1. Mel. (AI
(3000.a000) 1600-2700 (6000-9000)
"8
,.8 158
2700-3700
(9CXX)--12000)
150
,...
155
c::J -Lower Jet Needle 1 posfllon (raIse E-ctlp) c::J .Below SOOOtt use IN Ri 370G3. 6.5 CA. 40 pilot. and , turn rur screw . Production Setting
Indy 700 XC SN70LCDCSP-01 Carburetor Type - Keihin PWK 39 Main Jet - 185 Long Hex Pilot Jet - 40 Cut Away - 6.5 Air Screw - 1 Turn Jet Needle - R1370G-4 Needle Jet -Fixed
AMBIENT TEMPERATURE
II Indicates E-(:lip Location from top of Jel Needle
BeloW '20' F Below 29' C
..900
(0-3000)
'90
"8 168 158
goo. 1800
All. Mel.
(3000-6000) 1800-2700
(ft)
(SOOo-9COO)
2700-3700
('9000-'2000)
.. .. .
'"
20' 10 ~IO' F 29' 10 12 'C
,IO \00-40' F 12' 10 .5 C
'185
17.
#4
"8 168 '58
,.5
-3
155
'"
'SO
.3
. .
Above ... 40~ F AboveS ' C
172
"" ,.2
'55 #3 145
'"
'"
Indy Storm EC80PL05 Carburetor Type - VM38SS Main Jet - 41 0-400-420 Pilot Jet - 50 Air Screw - 1.0 Turn Cut Away - 3.0 Needle Jet - Q-O (247) Jet Needle - 6CGY6-3
AMBIENT TEMPERATURE
# Indicates E-(:hp Loc:allon from lop of Jel Needle
BelOw -20' F Below -29 C '20' to .IO'F 29'10 ' 2' C
'41Q'4QO{420
"'0"0 .40' F '12' 10 .S' C 390/3801400 34013301350 300J290J3 10
Above +40' F AbOve 5' C
'"
All. Mel.
(Ft)
..900 (0-3000)
43014201440
37013601380 3201311)1330 112

290/28Of.l00
.3
9OCHBOO
(3000.6000)
1800-2700 (6000-9000) 27()()'3700 (9I>12OOO)
38013701390 #3 340/3301350
290128OJ3()()
.
'"
360050070 .3
32G'310030
""
'" .,
27C>26O'2al
Production Setting Mag blggesl. PTO-CentElf'-Mag Jell \0 righ t
.
'"
25012401260
'" .,
24012301250
lI2
'"
9/97
5.15i
Indy Storm SE ECBOPL05 Carburetor Type - VM3BSS Main Jet - 410-400-420 Pilot Jet - 50 Air Screw - 1.0 Turn Cut Away - 3.0 Jet Needle - 6CGY6-3 Needle Jet - 0-0 (247)
AMBIENT TEMPERATURE
Balow -20~ F Below-29' C
-20~
10 . ' O' F 29' lo-12' C
.\0 'o .40 F -12" to .S C
Above .40' F Abo ....e S"C 37013601380
'"
All.
Met. (Ft)
0-900
((}3000)
43014201440
'41G'4OQ{42Q 36005(Y370
390138Ot'400
3401330/350 300/2901 310 2
>3
380/310/390
90CHBOO
(3000-6000)
"
>3
34013301350 2901280f300
1800-2700 (6OOCJ.9000)
2700-3700 (9OO}t2000)
OJ 32OO10i330
27M6012BO
'" ..
>3
320/31 Of330
29012801300
240(2301250 '2
'" ..,
""
25012401260
.2
."
Indy Storm RMK EC80PL04 Carburetor Type - VM38SS Main Jet - 300-290-310 Pilot Jet - 55 Air Screw - 1.0 Turn Cut Away - 2.5 Needle Jet - P-6 (247) Jet Needle - 6CGY6-3
AMBIENT TEMPERATURE
Below 2Q' F
BalOw -29' C
'20' to .to F -29"10 j2' C
~10'tO
-lr 10 ..S C
"
All. Met. 1Ft)
0-900
((}3000)
43014201440
38013701390
34013301350
41014001420
360l350I370
39013801400
3#0030l35O
' 3001290131 0103
900-1800
(3QOO.6000)
"
"
180(}27oo
(6OIJG.9000)
.
#'
320131 01330
270/260/280
#'
.
" ..,
.40' F
AlXIYe .. 40' F AIlove5' C
37013601380
32013101330 '3 29CY.!80f300 24Q.'2J0I250
.'
.
#3
270(}37oo 1900(>-12000) - Product{Orl Setting
29012801300
" '"
25012401260
Mag btggest. PT().Centl3f-Mag lett to oght
'-'
Indy 440 XCR SN44LCOCSP-01 Carburetor Type - VM34SS Main Jet - 360 Pilot Jet - 40 Cut Away - 2.0 Air Screw - 1/2 Turn Needle Jet - P-4 (286 or 159) Jet Needle - 60H7-4
AMBIENT TEMPERATURE
if Indicates E<lip Location from lop of Jet Needle
Below -20"F Below -29"C -20" '0 .. 10- F -29lCl-t2"C .. 10"10 *40 F -12" 10 ..-S*C AboYe "40~ F AbOve S*C
0-900
(0-3000)
380
360
320
Alt.
901)-1eoo (3ooo-eooo) t800-27oo (6000-9000) 2700-3700 (9OCO-12000J
3#0
Mel.
(Ftl
300
.'
#3
"
.'
#3
3#0
#3 300
320 03 280 #3 250
#3
270 .3 2#0
290 103 260
F3
220 #3
270 i<3
.,
'"
5.15j
9197

Lite Lite Deluxe Lite Touring EC34-2PM02 VM30SS
()-3000)
#I Indicates E-clip location from top of Jet Needle

Alt.
Met{FtJ
AMBIENT TEMPERATURE
Below -20' F
~20
to
+10 ato
.j.40 ~ F
Above
+10 ~ F
-ZS"C 160
-29to -12-C 150
-12' lool-S oC
+.:IO" F Aoove S'C
Main Jet - 150 Pilot Jet - 35 Cut Away - 2.5 AL Air Screw - t .5 Turn Jet Needle - 50 P?-2 Needle Jet - 0 -6 (169)
900-1800
'"
145
#2
"0
iI2
135 125
(3QOG.5000)
#2
I"
112
130 112 120

#I
'"
(=~~)
2700-3700 (9IXX)-12000)
130 #2 115 #2
125 #2 115
#I
110 '1
" " 105 "

115
Sport Sport Touring TranSport XCF EC44-3PM024 VM34SS Main Jet - 185 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 6FJ6-3 Needle Jet - P-8 (166)
'*
Alt.
Met.(FtJ
AMBIENT TEMPERATURE Indicates E-dip Location from top 01 Jet Needle
Be'ow
B~ow
-20"f
-20 '0
.10F
.2910 -12'C
"185
+10 0 to
+40 F
Above
+40" F Above 5C
-29'C
0-900 (0-3000)
-12- 101"5C
"5
#3
.3 170
#3
175
9O(t.1800
(3000-6000) 1600-2700
(6000-9000)
'"
165 >2 ISO

#2
185
#3
160 #2
165
#3
155
#2
""
#2
135
125
2700-3700
19OO/}12000)
150
#2
I"
#2
135
#2
" ..,
Super ~ort EC50P 061 VM34SS Main Jet - 250 Pilot Jet - 45 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 60H?-3 Needle Jet - 0 -8 (480)
f: Indicates E-clip Loca1ion Irom lop Of Jet Neoole

AIL
Met.(Ft)
AMBIENT TEMPERATURE
Below
-20"F
Below
-29C
0-900 (0-3000)
-20 " to +10 " F -29(0 -12 C

250
+10"to ... 40" F -12" to+5 "C
Above ... 40" F Abo.... e5C
260
#3
.3 230
240 .3 220 .3 210

#2
230
#3
900-1800 {300o-6000} 180()'2700 (6000-9000) 2700-3700 (9().X)-12000J
250 '3 220

#3
'3
#3
210 200 200

#2
.,
210 200
#2
...,
210
#3
200
#2
Trail Trail Tou ring EC50PM043 VM34SS Main Jet - 230 Pilot Jet - 40 Cut Away - 3.0 Air Screw - 1.0 Turn Jet Needle - 60 H?-3 Needle Jet - P-8 (166)
Alt. Met.{Ft)
AMBIENT TEMPERATURE # Indicales E-ctlp location from lop of Jet Needle
Below -20F Below

-29~C
-20 ~
\0 +10"F
_29 "10 -12 ' C 230
+10'0 +40"F
-12- ,o ..S" C
Ab"". ... 40" F

Above S- C
0900 (NOOO)
2'0
#3
220
#3
900-1800 (3000-6000) 1800-2700 (6QOO.9000) 2100-3700 (9O12000)
'"
200
#3
210 .3 "0
220
#3
210 #3 195 160

#3
#2 #2
.00
#3
II.. '
180
1OO #3
#2
lao
'"
lao
9/97
5.15k

Trail RMK EC50PM051 VM34 (ACCS) Main Jet - 270 Pilot Jet - 45 Cut Away - 2_0 Air Screw - 1 Turn Jet Needle - 6EJ3-3 Needle Jet - 0-6 (480)
1/
AMBIENT TEMPERATURE Indicates E-cllp Location from top 01Jet Needle
All. Met.(FI)
Below 29' C
(().JOOOJ
B.1ow -20' F
310 310 03 310 .3 310 '3
20' to +10' F -29"'0 -12 ~ C

2SO
+,01 0 +40" F
.,.40"F
Above S C 250 250
Abo ... e
-12' to+S ' C

270 03 270 .3 '270 270
0-"'"
000-1800
(""""""")
1800-2700 (6000-9000)
2700-3700
"
" 2SO
03
" "
.3
,,OJ
" 250
250
(9OJO.12000)
200
"
20~
"
440 LC EC45PL091 VM34SS Main Jet - 270 Pilot Jet - 40 Cut Away - 2_ 0 Air Screw - .75 Turn Jet Needle - 6DH7-2 Needle Jet - P-2 (480)
AMBIENT TEMPERATURE
If Indicates E-Cllp Location from lop 01 Jet Needle
Alt. Met.(Ft)
Below -20' F
to
+10 ' \0
Below 29'C
0-900
(0.3000)
+10' F
29"\0
... 40 ' F
-12 " to+5 ' C
t2 C
' 270 250 240 220 200
+40' F AbOveS ' C 240 .2 230 .3 210 190
,.,.,,-
290 '2 260
900-1800
(3000-6000)
" 250
230
1800-2700
(6000-900))
2100-3700 f9;Xt2CXXJ)
" 240 " 220
"
" 210
" " "

'"
"
"
Below Below 29"C
"
20' 10 +10' F
29' \0 12" C
"
Above -T40' F Above SG C
1998440 XCR SN44-44LCDCSP-01 VM34SS

MainJet-360 Hex Pilot Jet - 45 Cut Away - 2.0 Air Screw - 1.5 Tums
AMBIENT TEMPERATURE II lnClicates E-clrp location trom top 01 Jet Needle

Alt. Mel.(FI)
20 ' F
380
1"1 0 \0 +40 " F ' 2- !o . S" C
(0-3000)
0900
OJ
340 300 270 03
360 03
320
340
OJ
300
270 .3 240
320 .3 ,"0 .3 250 220
Jet Needle - 6DH7-3 Needle Jet- P-4 (286)
900-1800
(3Q00.6000)
18(10.2700 (6000-9000) 2700.3700
" .,
03
290 250 03
"
"
"
.,
(901X> 12OC<l1
"
500 500 Classic EC50PL 171 VM3BSS Main Jet - 350 Pilot Jet - 45 Cut Away - 2.5 Air Screw - .75 Turn Jet Needle - 6F9-3 Needle Jet - P-6 (480)
AMBIENT TEMPERATURE Ii Indicates Echp Loca!I()(Ilrom top 01Jet Needle Alt. Met.(Ft)
Below
20"F Below
.20 t to
+10" F 29"'0 . 12"C
+'0"1 0 -T40 "F 12 " ,o+S"C
Abo..
+40"F Above 5 ~ C
29 C
0-900
CO-JOOOJ
370 330 '3 290 250

jJ
.,
.,
350
330
310
900-1aoo
(300(1.8000)
1800-2700 (6000-9000) 2700-3700 (9OC().12OCOJ
" 310 " 270

240
" 290
OJ
250 #2 220
" "
" " 230 " 210

270 .2
"
+10' 1 0 T40 " F 12 e 10 +S"C
500 RMK EC50PL 161 VM34SS (ACCS) Main Jet - 260 Pilot Jet - 55 Cut Away - 2.5 Air Screw - 1.25 Turn Jet Needle - 6FJ43-2 Needle Jet - P-O (480)
AMBIENT TEMPERATURE /I Indicates Ecllp Loeatlon from top 01 Jet Needle Al l. Met .(Ft) Below 20" F Belew ;?g C 20"- 10 +10uF 29'10 12 ' C Above AbcNe 5' C
+40"F
~900
(0-3000)
(3(lOO.6000)
290 '4 290 290 200 '3
270
900-1800
(6()o()'9000)
1800-2700
2700.3700 (9COO-12(X)O)
" "
" 270 " 270

270
260 .3 260 -260 260 1!2
210
"
" "
" " 240

240 240
"
"
"
9/97
5.151

Classic Touring EC50P1191 VM34SS Main Jet - 250 Pilot Jet - 40 Cut Away - 3.0 CH Air Screw - 3/4 Turn Jet Needle - 6EJ26-3 Needle Jet - P-2 (480)
AMBIENT TEMPERATURE
Ii IndICates E-elip
location from lOP of Jet Needle

20 ' to
+10F . 29\0 12 ' C
All . MeI.(FI)
Below -20 a F Below -29' C
+10" 0 .,..40"F 12 loTS - C
,"<we +40 "F
AboveS C
(Q.3000)
900-1800
(3000-6000)
0-900
260
>3
-250 230 210

H3
240 220 200 ,3
1800-2700 (6QOO.90001
2700-3700 (9(XX)- I?OCO)
"
" .,
"
'" "
220
>3
230 210 185

175
.,
"
"
' .5 180 '2
190
"
" "
WideTrak LX EC50PL20 1 VM34SS Main Jet - 195 Pilot Jet - 35 Cut Away - 3.0 Ai r Screw - 1/2 turn Jet Needle - 6EJ26-2 Needle Jet - P-6 (166)
AMBIENT TE1Io1PERATURE # Il1dlcates E-cUp Lacallen Irom top o! Jet Needle Alt.
Met.(FI)
Balow 20' F Below -29"C
20" \0 .,. IO' F

29~ to
+10' \0 +40 ' F - 12a ,o+5"C
Above
+40~ F
AbOve SoC
175
f2 C
0-900 (0-3000)
210 190 "5 155
900-1800
(3000-6000)
1800-2700 (60Cl0-9000)
2700-3700
(!JQ'12COO)
., " "
"
',95
.2 180 165
185 "0 155 " 0
"
" .,
" "
"0
"
" 150 "
" "5 " 135 "
XLT LTD XLT Touring EC58PL 130 VM34SS Main Jet - 240 Pilot Jet - 40 Cut Away - 2.5 Air Screw - 1.0 Turn Jet Needle - 60P17-3 Needle Jet - 0-4 (480)
AMBIENT TEMPERATURE 1/ Indicates Echp Loca ti on trom lOP 01Jet Needle

Al l. MeI.(FI)
Below
20~ F
-20" 1 0
Belo w
29~ C
+10' F 29' \0 12C
+10 G lo 't40"F 12 ' to +S C
Above
+<l O~ F
Above 5 ~ C
0,900
((}aooo)
250
13000-60001
1800-2700
900- 1800
(6000-9000) 2700-3700
(9CX12000)
" 230 " 210 " 190 "

Belo w 20"F Below
'240
220
220 21 0 190 175
210 195
200 160
" "
" "
"
"
"
" "
" " 165 "
180
XLT SP EC58PL 140 Type - VM38SS Main Jet - 330 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.5 Turn Jet Needle - 60H7-3 Needle Jet - 0-0 (247)
AMBIENT TEMPERATURE If Indicates Eclip locatIOn from lOp of Jet Needle Alt. Mel.(Ft)
20' 10
+10' F
29"1 0
+1 0' 10 +40' F
12- 10 +S' C
Above
+40~ F
Above S' C
29 C
12' C
10-30(0)
090<)
350
900- 1800
(3000-6000l
1800-2700 (6000-9000) 27QO-3700 llJ(:OO.l2OO))
" 320 " 290 " 270 "
' 330 300 270 250
310
300 270 240 220
" "
"
" 280 " 250

230
"
"
"
"
"
" "
XLT Classic EC58PL150 VM38SS Main Jet - 340 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.5 Turn Jet Needle - 60H7-3 Needle Jet - 0-0 (247)
AMBIENT TEMPERATURE 1/ Indicates Eclip localion trom top 01 Jet Needle

All .
Me1.(Fl)
Below 20 F Below -29 'C
20' to
+10' F 29' to 12 C
+1 0' 10 +40"F
12 \0
+5 ~C
Ab<We +4 0F Above S C
0-900 (0-3000)
360
330
900-1800
(3000-6000)
" " "
''''0 310 ,"0 260 '2
320 290 260 240
310 280
" "
1800-2700
(6000-0000)
2700-3700 {9OO<> 1200JJ
300 280
"
"
" " "
"
"
" " 230

250
"
9;97
5,15m

600 XCR EC59PLIJ20 VM38SS MainJet- pto/Cen/Mag
AMBIENT TEMPERATURE (PTO/CENTERIMAG) # Inc;licales E-chp location from lop of Jet Needle
All.
Met.(Ft)
BeIow-20"F
BelQw29"C
-20' [0
. ,O"F -291O-12"C
-350138CY380
33!Y3501350
-12",0.S< C
34 CV36G'360 31 013301330 25(V3OQ13OQ
.10"'0 .40"F
Above -.40 F
ADOve S"C
360/380/380
Pilot Jet - 40 Cut Away - 2.0 Air Screw - .5 Turn Jet Needle - 6CEY6-4 Needle Jet - P- (247)
0-900
(Q.3000)
313014001400
900-1800
(300().6000)
1800-2700
(6QOO.9(00)
" 34OJ36M60 " 31013301330

" 2601300'300
"
320/3401340 290131 013' 0
"
"
300'321>'320
27lV29<V290
2700.3700 i9OOG-120001
" .. "
"
B~ow
25M!701270
" .. "
26012801280
24012601260
"
" "
600 XC SN60-701 CDCSP-Ol Keihin - PWK 39 Main Jet-185 Long Hex Pil ot Jet - 45 Cut Away - 6.5 Air Screw - 1 Tu rn Jet Needle- R1368G-3 Needle Jet - 2.9mm Fixed
AMBIENT TEMPERATURE II In(!icales Eo(;llp Location from lop of Jet Needle
AIL
Met(Ft)
-20"F
-20" to
.. 10"F -29" '0
-12C
Below
29C
,.10' to +40'F -12 0 to +5"C 178 >3
Abov,
oF
Above 5C
0-900
(0-3000) 900-1800
'88
((.J
"85 #3
'72
#3
13000(6000)
1800-2700 (6000-9000)
178
,68
#3
158
'"
'75 '65
#3
#2
'"
'68 >3 '60 #2

150
'62
#3
2700-3700 (9IJOG.12000)
"
'56
#2
,"
'55
#2
600 RMK SN60-70LCDCSP-1J2 Type-Keihin PWK 39 Main Jet - 160 Pilot Jet - 45 Cut Away - 6.0 Air Screw - .5 Jet Needle R1368G-2 Needle Jet - 2.9mm
Fixed
AMBIENT TEMPERATURE Ii Indicales E-dip locallon from lop of Jel Needle
A'e MeL(Ft)
0900 (().3000)
9O().1800
13000-6000)
/;:,./.-I/;:;:z, ~V;; ~~,

178
#2
-20 & F Below 29"C
Below
-20" 10 +10& F _ 291 '12- C 0
+10 Q IO +40- F 12 IO ... soC
Abo><e +40'F Above sec
175
1800-2700 (81XJO.9000) 270(}'3700 (9C(lO-12000)
'68
#2
" '65
#2
'55 #2
'68
#2
',60
,62
#2
.,
'58
.,
'50
czz:a _
Shaded zone Tum Air Screw 10 1 1 um
.'
,,, " .,
'55
Ultra Ultra Touring EC68PL050 VM38 Main Jet - 340 Pilot Jet - 40 Cut Away - 2.0 Air Screw - 1.0 Turn Jet Needle - 6DH8-2 Needle Jet - P-4 (247)
# Indicates E-<:lip Locatron from lop of Jel Needle

AIL
Met(Ft)
AMBIENT TEMPERATURE
BelOW
-20F Below 29C
-20- '0 +10- F

-29~10
.1010 +40F 12- lo+5 C
-12"C ''''0 3'0 280
Abo><, .40"F Above5' C
(Q.3000)
0-900
350 #2 320
#2
,.,
#2
320
#2
300
#2
300 280 260 #2 240 #2
9(1).1800 (3000.6000)
1->
21(10.3700
(9(XX}12t'OO)
1800-2700
290
270
"
'" .,
270
#2
" "
260 #2
250
"
5.15n
9197

700 XC SN70-70LCDCSP-02 Kelhin PWK 39
MainJet-185 Long Hex Pilot Jet - 38 Cut Away - 6.0 Ar( Screw - 1 Turn Jet Needle - R1368G-3 Needle Jet- 2.9mm Fixed
it Indicates E-clip location from top 01 Jet Needle
Alt
AMBIENT TEMPERATURE
Below
MatIFt)
-20' F Below -29 C

Q
-20 0 to +lQ"F 29 IO -12C

Q
.10"to
+40F -12 0 to -+-S 'C
Above t40 F Above 5"C
~900
(D-3000)
90(}-\800
190 #3 178 170 158
1300D-60(0)
1800-2700 (6000-9OO0)
2700-3700 (9().12000)
., '" '"
' 185 #3 175 165

#3
#2
178 168 158

#2
'"
'" '"
172 162
#3
'"
#2
155 145
165
150
#2
"
Above
+40"F Above 5 ~ C
700 XCR EC68PL060 VM38 Main Jet - 380 Pilot Jet - 50 Cut Away - 3.0 Air Screw - 1 .0 Turn Jet Needle - 6CEY6-4 Needle Jet - 0-2 (247)
AMBIENT TEMPERATURE ;: Indicates E-cllp Location from lop 01 Jet Needle

Alt Mat.IF!)
Balow -20 F Below -29"C
-20" 10 tl 0F -29' \0 - 12' C
-12 ~
.10 4 \0 t 40"F to +S C
(o-SOOO) OOO-lana (3000-6000)
~"'o
400 370 340 310
1500-2700 (6000-9000)
{9(XX} t 2000)
.
'"
'"
#4
'3eo
#4 350
320
360 330 300 270 '12
.,
'" '"
340
#3
., .,
310
H2
280 250 #1
27(-3700
290 '12
""
700 RMK SN70-70LCDCSP-01 Keihin PWK 39

MainJet-1S8 Long Hex Pilot Jet - 42 Cut Away - 5.5 Air Screw - 1 Tum Jet Needle - R1371G-3 Needle Jet- 2.9mm Fixed
AMBIENT TEMPERATURE
" Indicates E-clip Locatkln trom lop Of Jet Needle Alt.

Met.{Ft)
Below -20"F Below
-20" 10
+10~F
-29"C
-29 "0 -12"C
+,0"10 +40F -12" to+S"C
Above
Above SoC
+4Q"F
0-900 (MODO)
00[).18OO
/,~;~ / /
i78
V'n;':I,1/; ,1j5/h I%2U ;% /."'"

175 #3 162 165
#3
(300D-SOOO)
tSOo.2700
(600G-9000)
168 158
#3
2700-3700 (9000-12000)
'" '"
185
ISS-
'"
148
#2
'" '"
162 #3 152 145 112
.,
f""77"Tl
~ Shaded zone should turn Air Screw 10 114 turn.
Storm
EC80PL052 VM38
PTO - CEN - MAG Alt.
Met.(Ft)
AMBIENT TEMPERATURE (PTO/CENTERIMAG) # Indicates E-clip Location from top 01 Jet Needle
Below _20F Below

-29~ C
_20 Gto +10 *F -29"10

-12~C
""0 ~ IO
Above
+40"F _12 0 to+S ' C
.40 F
Above SoC 37013601380
MainJet-41 0-400-420 Pilot Jet - 50 Cut Away - 3.0 CH Air Screw - 1.0 Turn Jet Needle - 6CGY6-3 Needle Jet - 0-0 (247)
~,oo
(~3000J
4301420/440
#3 38013701390
410/400'420
.'"
#3
39013801400
#3
34013301350 #3 30012901310 #2
#3
32013101330 #2
2901280/300
9OG-1900
(300o-6OQOl
1800-2700 (6000-9000)
#3
3GOI35Or'370
320010030
3401330/350
#3 #3
2700-3700 i9000-12lXXl)
2901280/300
270126CY280
"
#2
#2
25012401260
112
24012301250 #2
Main jels lislec1 leh 10 r19hl
PTOCenI8rMag
9/97
5.150
FUEL SYSTEM/CARBURETION Gasoline Volatility

Whenever servicing the carburetor or fuel system, it is important to heed the following warnings.
WARNING
Gasoline is extremely flammable and explosive under certain conditions.

Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored or used. Do not overfill the tank. Do not fill the tank neck. If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately. If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.
Explanation of Gasoline Volatility

In order for an engine to start easily and run properly, gasoline must be able to burn without causing detonation, vapor lock, flooding, or icing of fuel lines, fuel pumps, or carburetors. One of the sometimes misunderstood properties of gasoline is its volatility, or ability to vaporize at different ambient temperatures and altitudes during the year. When gasoline is blended, it is given a Reid Vapor Pressure (RVP) number which reflects its ability to vaporize or mix with air at a given temperature range. Gasoline vapor pressure is measured by putting a sample of fuel inside a closed container and applying a specified amount of heat to the container for a certain amount of time. This pressure will vary from about 7.0 PSI during the summer to approximately 13.5 PSI during the colder months. Service stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year. When the weather is very cold, gasoline must be able to atomize very quickly in order for an engine to start and warm up properly. If summer blend fuel , which has a low Reid Vapor number, is being used, little or no vaporization will occur. Droplets will form causing flooding and very hard starting. If winter blend fuel is being used during the summer months, it may cause vapor lock (boiling fuel) inside the fuel lines, fuel pump, or carburetor. This will cause warm engine driveability problems and hard starting when warm. Some states are limiting the Reid Vapor number to 9.0 PSI year around to help meet evaporative emissions standards. Warm Weather Low Vaporization Rate
Maximum Reid Vapor

Class A B C D E Cold Weather Pressure 7.0 PSI 9.0 PSI 10.5 PSI 12.0 PSI 13.5 PSI
Ambient Air Temp. Range

Low 60 F 50 F 40 F 3D F 20 F High 110 F + 11 D F 97" F 85 F 69 F High Vaporization Rate
Add 2.4 F for each 1000 feet above seal level.
11/95
5.16
Systems Float Chamber Venting
"-' Fuel flows through a carburetor by creating a pressure difference between the venturi and the float bowl. The greater the pressure difference, the greater the fuel flow. On some models the float bowl is vented to the handlebars. This provides consistent atmospheric pressure for a consistent fuel flow. If the vent lines become kinked, plugged, or exposed to fluctuating pressures (under hood) the pressure difference will change, causing erratic fuel flow. Polaris has introduced airbox venting on some models. The vent lines are connected to a baffle inside the airbox. This provides a more consistent pressure difference between the carburetor venturi and the float bowl as the vacuum inside the airbox changes. For example, if the airbox foam filter becomes plugged with snow when riding in powder, the airbox vacuum increases. Without airbox venting, the pressure difference would increase substantially, choking or flooding the engine. With airbox venting , the pressure difference remains the same, creating a leaner mixture to compensate for reduced air flow.
Vent Line Routing (Opposite Carb to Handlebar)
Tee Fitting --...::s:~r===>/r( One Way Check Valve
----A j
.;:l'lo&1~
Flow
~~$:i::~ Atmospheric Pressure
Drain Hose---tl
Direction Fuel Through Valve Some Models Have Interconnecting Lines Between each Carb
-V
_ I
Tee Fittings Are Orientated Vertically
1-[
Saffle Tube Air Box
-)1
Ie -
----- -
Some models have airbox venting
5.17
11 /95
FUEL SYSTEM/CARBURETION Fuel Delivery System - Typical

The fuel system contains many components which directly affect fuel mixture and driveability. When performing diagnosis or carburetor maintenance, the entire fuel delivery system should be inspected. The illustration below shows parts of the system requiring periodic maintenance to ensure there is no fuel or air leaks present. Fuel filters should be replaced at least once per season or more often If any contamination is suspected. Fuel lines should be replaced every other season or more often if they become brittle or swollen . Fittings should be inspected at that time for cracks or leaks. Test run and check the fuel system for leaks any time parts are replaced. Verify that all lines are routed correctl y away from any moving parts. Vent Lines
Carb Mounts
Cylinder Base Gasket
Weighted Pickup and Line
Impulse Line
Crank Seal
~
Check Valves
Crank / Seal Impulse Fitting at Crankcase
Fuel Hose - Indy StormlSKS/RMK

The Storm fuel system incorporates dual fuel pumps. It is important to pay particular attention to correct routing of the fuel lines in order to provide an adequate fuel supply to the engine. Fuel Shut Off Valve
FU~
vacuum / Impulse Line
To Carburetors
11/95
5.18
FUEL SYSTEM/CARBURETION Starter System - Closed Throttle

Mikuni carburetors use a starter system rather than a choke. In this type of carburetor, fuel and air for starting the eng;ne are metered with entirely independent jets. The fuel metered in the starter jet is mixed with air and is broken into tiny particles in the emulsion tube. The mixture then flows into the plunger area, mixes again with air coming from the air intake port for starting and is delivered to the engine through the fuel discharge nozzle in the optimum airlfuel ratio. The starter is opened and closed by means of the starter plunger. The starter type carburetor is constructed to utilize the negative pressure of the inlet pipe, so it is important that the throttle valve is closed when starting the engine.
II
I I I I
r::--=--=-_-_-__=___=__ :9L ---=--=--=--=--=--=--=--=--=--=-- --11 II

Cable Adjuster IS I I
[I
I I I I I I
I Cable Adjuster Lock Nut Plunger Spring Plunger Cap Starter Plunger ir
II
:I I I I
I II I
~I
1 11'ii"''=-'''9
Throttle Valve
i '~~~LJ~ .
9~~~~~_Emulsion Tub;
Inlet Bleed Air
Starter
I J=ie~:;:~
Starter Jet
5.19
111 95
FUEL SYSTEM/CARBURETION Pilot System (0-3/8 Throttle)

The pilot system's main function is to meter fuel at idle and low speed driving. Though its main function is to supply fuel at low speed , it does feed fuel continuously throughout the entire operating range . Fuel for the pilot jet is drawn from the float bowl, mixed with air regulated by the air screw, and delivered to the engine through the pilot outlet. The mixture is regulated to some degree by adjusting the air screw. When the air screw is closed, the fue l mixture is made richer as the amount of air is reduced . When the air screw is opened , the mixture is made more lean as the amount of air is increased.
Throttle Valve
Air Screw
iI
Ii
II
Ii
Pilot Jet
II II
i I ~~~~_:"- __ _ ~~_ :..::J!IE-~~:==:==== _I \
II
11/95
5.20
FUEL SYSTEM/CARBURETION Slide Cutaway (1/8-3/8 Throttle)

Throttle valve cutaway effect is most noticeable at 1/4 throttle opening. The amount of cutaway is pre-determined for a given engine to maintain a 14:1 air/fuel ratio at part throttle. A steep angle would indicate a fairly lean mixture because there is less resistance to air flow. A flat angle would provide a much richer mixture because there is more resistance to air flow. The venturi shape can be adjusted for each engine's breathing characteristics by using a different valve cutaway angle. A number will be stamped into the bottom of the valve (e.g. 2.5) indicating the size of the cutaway. The higher the number, the steeper the angle.
Cutaway Angle Throttle Valve Jet Needle Air Jet By-pass Pilot Outiet
.... .
Pilot Jet Needle Jet Main Jet
3.0
1.5
Leaner
Richer
5.21
11195
FUEL SYSTEM/CARBURETION Jet Needle/Needle Jet (3/8-3/4 Throttle)

The jet needle and needle jet have the most effect between 318 and 3/4 throttle opening. Some mixture adjustment can be accomplished by changing the location of the "En clip on the needle. Moving the clip down raises the needle in the jet passage and richens the mixture. Moving the clip up lowers the needle in the jet passage and leans the mixture . Letter and number codes are stamped into the needle and the jet indicating sizes and tapers of each.
Clip Position Throttle Valve Jet Needle Air Jet By-pass Pilot Outlet
...
')
...
Pilot Jet
~:t;:i,H--~-
Needle Jet
Main Jet
11/95
5.22
FUEL SYSTEM/CARBURETION Main System (3/4 to Full Throttle)

The main system is designed for delivering fuel between low speed and high speed operation. This system is made up of the jet needle, needle jet, and main jet. The main system begins to take effect as soon as there is enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly. This system works in conjunction with the needle jet system. During low speed driving, there is very little clearance between the jet needle and the needle jet; therefore, very little fuel from the main jet can pass between the jet needle and the needle jet. As the throttle valve opening is increased, the tapered jet needle is raised farther out of the needle jet, allowing greater fuel flow. Under full throttle opening, the cross sectioned area of clearance between the jet needle and the needle jet becomes greater than the cross sectioned area of the main jet. Thus the main jet is now controlling the amount of fuel flow.
Throttle Valve Jet Needle
Air Jet
Pilot Outiet
Pilot Jet Needle Jet Main Jet
5.23
11/95
FUEL SYSTEM/CARBURETION Function

The function of a carburetor is to produce a combustible air/fuel mixture by breaking fuel into tiny particles in the form of vapor, to mix the fuel with air in a proper ratio, and to deliver the mixture to the engine. A proper ratio means an ideal air/fuel mixture which can burn without leaving an excess of fuel or air. Whether the proper mixture ratio is maintained or not is the key to efficient engine operation. The engine of a vehicle is operated under a wide range of conditions, from idling with the throttle valve remaining almost closed, to full load or maximum output with the throttle valve fully opened. In orderto meet the requirements for the proper mixture ratio under these varying conditions, a low speed fuel system, or pilot system, and a main fuel system are provided in Mikuni VM type carburetors. The Mikuni carburetor has varying operations depending upon varying driving conditions. It is constructed of a float system , pilot system, main system, and starter system or initial starting device.
Float Guide Pin Needle Valve Float Arm Float
Float System
The float system is designed to maintain a constant height of gasoline during operation. When the fuel flowing from the fuel pump into the float chamber through the needle valve reaches the constant fuel level , the floats rise. When the buoyancy of the float and the fuel pressure of the fuel pump balance, the needle valve sticks fast to the needle seat, preventing further delivery of gasoline, thereby holding the standard level of gasoline. The fuel level in the bowl assists in controlling the amount offuel in the fuel mixture. Too high a level allows more fuel than necessary to leave the nozzle, enriching the mixture . Too Iowa level results In a leaner mixture, since not enough fuel leaves the nozzle. Therefore, the predetermined fuel level should not be changed arbitrarily.
11 /95
5.24
FUEL SYSTEM/CARBURETION Component Functions

Pilot Jet
From idling to low speeds, the fuel supply is metered by the pilot jet. There are several air bleed openings in the sides of the pilot jet which reduce the fuel to mist. The number stamped on the jet is an indication of the amount of fuel in cc's which passes through the jet during a one minute interval under a given set of conditions.
35
Indicator Number
Pilot Air Screw

The pilot air screw controls the fuel mixture from idle to low speeds. The tapered tip of the air screw projects into the air passage leading to the pilot jet air bleeds. By turning the screw in or out, the cross sectional area of the air passage is varied, in turn varying the pilot jet air supply and changing the mixture ratio.
Pilot Air Screw
Air/Fuel Mixture Ratio

A carburetor with a piston type throttle valve is also called a variable venturi type carburetor. In this type of carburetor, the needle jet and jet needle serve to control a proper air/ fuel mixture ratio at the medium throttle valve opening (between 1/4 and 3/4 opening). Having the proper needle jet and jet needle has a major impact on engine performance at partial load. The jet needle tapers off at one end and the clearance between the jet needle and the needle jet increases as the throttle valve opening gets wider. The air/fuel mixture ratio Is controlled by the height of the "E" ring inserted into one of the five slots provided in the head of the jet needle. The chart at right shows the variation of fuel flow based on the height of the "En ring.
..;- 2
-3 '"L- 4
4
15
50
75
100%
Throttle Valve Opening
5.25
11/95

Jet Needle
The jet needle has five adjustment grooves cut into the upper portion, and is tapered from approximately the middle of the needle to the lower end. The top is fixed to the center of the throttle valve by the needle clip, and the tapered end extends into the needle jet. Fuel flows through the space between the needle jet and jet needle. This space does not vary until the throttle reaches the 1/4 open point. At that time the tapered portion of the needle begins to move out of the jet, affecting fuel flow as the opening enlarges. If the needle clip is changed from the standard position to a lower groove, the needle taper starts coming out of the jet sooner, resulting in a richer mixture. Moving the clip higher produces a leaner mixture. If the taper is worn due to vibration, fuel flow may be significantly affected.
Leaner Groove
Richer
Needle Jet
The needle jet works in conjunction with the jet needle to regulate fuel flow rate. An air bleed opening in the side of the needle jet brings in air measured by the air jet. This air initiates the mixing and atomizing process inside the needle jet. Mixing is augmented by a projection at the needle jet outlet, called the primary choke. The letter number code stamped on the jet indicates jet inside diameter.
=I
Throttle Opening vs. Fuel Flow
In a full throttle condition the cross sectioned area between the jet needle and the needle jet is larger than the cross sectioned area of the main jet. The main jet therefore has greater control over fuel flow.
ft
Large
Clearance
Closed Throttle
One-half
Throttle
Full
Throttle
11 /95
5.26

Throttle Valve
The throttle valve controls the rate of engine air intake by moving up and down inside the main bore. At small throttle openings, air flow control is performed chiefly by the cutaway. By controll ing air flow the negative pressure over the needle valve is regulated, in turn varying the fuel flow. The throttle valves are numbered 1.0, 1.5, 2.0, etc., according to the size of the cu taway. The higher the number, the leaner the gasoline/air mixture.
I
~---*.
Cutaway
Mikuni Main Jet

When the throttle opening becomes greater and the area between the needle jet and jet needle increases , fuel flow is metered by the main jet. The number on the jet indicates the amount of fuel CCs which will pass through it in one minute under controlled conditions. Larger numbers give a greater flow, resulting in a ri cher mixture. Main jets are screwed directly into the needle jet base.
Round
Hex
Keihin Main Jet

The number on the Keihin (Round) main jet corresponds to the diameter of the metering orifice.
5.27
9/96
FUEL SYSTEM/CARBURETION Component Effect vs Throttle Opening

The throttle opening chart below demonstrates component relationship to fuel flow versus throttle valve opening. The pilot system's main function is that of a low speed jet. Its most effective range of fuel delivery is from idle to approximately 3/8 throttle valve opening. The throttle valve controls the rate of engine air by its movement up and down in the carburetor venturi. At small throttle openings the air flow is regulated chiefly by the valve cutaway, with greatest effectiveness at t /4 throttle opening. Throttle valves are numbered t .0, 1.5,2.0, etc., according to the size of the cutaway. Decreasing the cutaway number will increase the amount of fuel delivered in its effective range. The jet needle and needle jet have an effective operating range from approximately 1/8 to 7/8 throttle opening. The amount of fuel delivered during this range relies upon the jet needle clip position, as well as the needle jet size and other specifications. The main jet affects fuel delivery at 1/4 throttle and consistently increases to full throttle opening.
w
o
(jj
a;;
;!!;
EFFECT
Cl Z (jj
I
I I I I
o
C
w a;; w
1/8
1/4
3/8
1/2
5/8
3/4
7/8
FUll
THROTTLE OPENING
Throttle Valve Cut-Away Jet Needle/Needle Jet
11/95
5.28
FUEL SYSTEM/CARBURETION Jetting Guidelines

Changes in altitude and temperature affect air density, which is essentially the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. Carburetors on most Polaris models are calibrated for an altitude of 0-3000 It (0-900 meters) and ambient temperatures between -20 0 to + 10 0 F (-29 0to -120 C). All carburetors must be re-calibrated if operated outside the production temperature and/or altitude range. The main jet installed in production is not correct for all altitudes and/or temperatures.
A main jet that Is too small will cause a lean operating condition and may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts In this manual, the specification decal on the hood, or the jetting charts in the Owner's Safety and Maintenance Manual for each particular model. See additional Information regarding the use of oxygenated fuels on following page. NOTE: It is the dealer's responsibility to ensure that the correct jets are installed in the machine for a geographical area. Be very careful when jetting down in warm weather. As the weather turns colder it will be necessary to re-jet upward to prevent engine damage. When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encountered.
5.29
11/95
FUEL SYSTEM/CARBURETION Oxygenated Fuel Carbureted Models Oxygenated Fuel

Due to the increased emphasis on reducing auto emissions, some areas of the U.S. are required to use oxygenated fuels. Oxygenated fuels are those which include oxygen in the molecule due to the addition of an ether or alcohol. Oxygenated fuel containing a mixture of up to 10% ethanol can be used in all models of Polaris snowmobiles if these guidelines are followed: NOTE: The use of fuel containing methanol is not recommended.
On carbureted models
1. Use fuel with a minimum pump octane of 89 or higher (R+M)/2 method. NOTE: Some models are calibrated to use a minimum of 91 octane fuel. On these models, only 91 octane or higher should be used. Refer to the Specification Decal or Owner's Safety and Maintenance Manyal for octane recommendation. 2. When using 87 octane oxygenated fuel, install main jets that are one size larger than that listed on the jetting chart for a given altitude and temperature. For example, the minimum octane (non-oxygenated) fuel for the 1996 Indy Classic is 87. The main jet installed during production for use at altitudes of 0-3000 ft. and temperatures between -20 and +1 O F) is a 340. To use 87 octane oxygenated fuel, install 350 main jets. 3. Turn the pilot air screws in (clockwise) 3/8 turn from the standard setting. Example: ilthe production air screw setting is 1 turn out, the setting for 87 octane oxygenated fuel would be 5/8 turn out.
NOTE: The following Indy Classic charts are provided as an example only. Indy Classic
AMBIENT TEMPERATURE
Below -20"F 8e1ow-29"C
.20 10 +,O"F
-29' to -12"C +,0"'0 +40"F
'--"
-12 0 to .S C
Above +40 O F Above .soC
89 Octane Oxygenated
Attitude
\}900 (Q-.3000)
360
'340
320
300
900-1800
13~)
320
300
,eo
240 .}
260
MetE!l'S
(Feel)
(eoD0-9000)
2700-3700
1000-2700
,eo
240
,eo
}'
., 229
..
(9000-12000)
. 230 jt~
210 '"
ioo
c::J - Shaded zone should drop Jet Needle one position (raise E-Clip) Production Setting
Indy Classic
AMBIENT TEMPERATURE
Below lOF Below -29' C
-2Q"lo+l0F .2910 -12 C
+ 10"to .40"F
_12" 10 +soC
Above +40 O F
Above +soC
87 Octane Oxygenated
Altitude Meters
(Feet)
(0-3000)
""00
370
330
3BO
330
290
310
9Q().IBOO
(3()(]()-600())
1800-2700
310
270
290
(600009000)
27Q0.3700
,
0)
2,50
"'l~
..
250
(9000-12000)
2"
220 +
.10'"
c::J - Shaded zone should drop Jet Needle one position (raise E-Clip)
11/95
5.30
FUEL SYSTEMfCARBURETION Oxygenated Fuel EFI Models

Oxygenated Fuel
To use 87 octane oxygenated fuel on EFI models:
1. At altitudes below 5000 ft., the compression ratio must be reduced by installing .020" head gasket shims between the cylinder head gasket and cylinder head. The part numbers are shown below. No change is required if machine is operated at altitudes above 5000 feet (1500 meters).
EFI Cylinder Head Shims

Model
500 EFI/SKS/RMK RXL
Shim Part Number

(1) 5211416
(3) 5211414
Fuel System Deicers

If non-oxygenated fuel is being used, Polaris recommends the regular use of Isopropyl base fuel system deicer (Polaris PN 2870505). Add 1 to 2 ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean mixtures. Never use deicers or additives that contain methanol. Use only isopropyl fuel system deicers . If using oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives are not required and should not be used. Whenever servicing the carburetor or fuel system, it is important to heed the warnings found on page 5.1.
5.31
11/95
FUEL SYSTEM/CARBURETION ACCS System

1996 To Current Altitude Compensating Carburetor System (ACCS)
The Altitude Compensating Carburetor System (ACCS) is designed to automatically compensate for changes in altitude. This allows the snowmobile to operate in changing elevations without having to change jets, although extreme temperatures may require re-jetting for optimum performance. Refer to the jetting compensation chart on page S.ISf. The 1996 ACC System compensates for both high speed and low speed changes, eliminating the need to adjust air screws. On 1997 ACCS models, the air screw is adjustable. A vacu um line is connected to the float bowl. The ACCS valve is connected to this line via the 4-way manifold. At low altitude the ACCS valve supplies atmospheric pressure to the vacuum line and the float bowl (see III. 1). High Atmospheric Pressure Bellows compress Fuel fl ow increases Vacuum from Venturi To Float Bowls
This end fixed
Low Altitude I High Atmospheric Pressure
1996 to Current ACCS System
III. 1
At high altitudes the bellows expand, moving the plunger to the left and closing off some of the passageways through the ACCS valve (see III. 2). This prevents atmospheric pressure from reaching the float bowl , allowing the vacu um line to reduce the pressure in the float bowl. This reduces the amount of fuel supplied through the carburetor, preventing the mixture from becoming too rich .
Low Atmospheric Pressure Bellows expand Fuel flow decreases To Float Bowls
! \
High Altitude I Low Atmospheric Pressure
This end fixed
1996 to Current ACCS System
111.2
9196
5.32

Altitude Compensating Carburetor System (Cont.)
NOTE: The 1997 to current ACCS models are equipped with air screws to adjust the low speed (pilot) air/fuel mixture. Another feature of the 1996 ACC System automatically adjusts the slow (pilot) air system passageways. This feature serves the same function as an air screw on a standard carburetor system . '--' A spring loaded plunger is located inside the valve. At low altitude, the spring pushes the plunger into a closed position (see III. 3). Vacuum ACCS Valve Operation
Float Bowl
Low Altitude / Atmospheric Pressure

1996 ACCS Only
III. 3
In III. 4, the bellows has moved the primary plunger to the left, engaging the secondary plunger and removing it from its seat. Atmospheric pressure is now being supplied to the pilot air jet, supplementing the ai r flow in the secondary slow air system and making the fuel mixture leanerto compensate forthe thinner air at high altitudes.
ACCS Valve Operation
Vacu um
Float Bowl
Pilot air jet to 3 way manifold
~:
1 -----=====-----1
Ii I
1996 ACCS Only
High Altitude / Atmospheric Pressure III. 4
5.33
9196

ACCS System
Air Box
ACCS 4-way Manifold mounted to air box
4 Way Manifold I Float Bowl Vent Control
ACCS - yalve Vent line attachment to handlebars -
_ - - - ACCS 3-way Manifold - mounted 4 way manifold
,
3-way Manifold , , attachment (1996', ACCS Only) 4-way Manifold attachment A C""'S""""V -;-v-' l i cC"' c;a l - e
1"-1
PTO Carb Center Carb Mag Carb 3 Way Manifold I Pilot Air Control (1996 ACCS Only)
Vent line attachment to handlebars
1996 ACCS
Only
NOTE: There is only one ACCS valve. The illustration above has been divided to show the separation of system s. See page 5.7a for line connections.
9196
5.34
FUEL SYSTEM/CARBURETION Mikuni Carburetor Service

Carburetor Removal, Disassembly, and Inspection (Typical)
Typical VM 38 Shown . Refer to exploded views on pages 5.4 - 5.7a for other types. 1. Remove carburetor from engine. Before disassembling , clean outside of carburetor thoroughly with solvent.
Do not use compressed air to dry at this time. The float chamber could become pressurized resulting in damage to the floats or inlet needle and seat..
2. 3.
Remove slide valve . Inspect for nicks or burrs which may cause sticking. Remove jet needle by compressing return spring toward top cap and removing throttle plate which rests on top of needle "E" clip. Note the "E" clip position and inspect needle taper for wear. An indication of wear would be an hourglass shape or polished spots somewhere along the taper.
Gasket-----~
Spring
Cap ~
"E" Clip -----. Slide Valve
I --!/ V
------e
Retainer Plate Jet Needle
4. Remove choke plunger. Check condi tion of seal on tip of plunger. Any nicks or cuts will cause leakage and a rich fuel condition, usually most evident at idle and low speeds. Inspect the plunger seat for damage or foreign material. 5. Check choke cable movement. Plungers and springs should move back and forth freely.
SPring-. . . . .~
~---Plunger Seat
5.35
9/96
FUEL SYSTEM/CARBURETION Mi kuni Carburetor Service

Carburetor Disassembly and Inspection Cont.
6. Remove water trap assembly from float bowl and inspect O-ring, hose and clamp condition. Refer to exploded view corresponding with carburetor being serviced.
qjl____
H ose
Trap Nut
Clamp Drain Plug
j:/
7. Inspect choke fuel supply passage in bowl for obstruction.
8.
Use an automatic center punch to remove float arm Remove inlet needle and seat assembly.
pi~.
9.
Inspect needle for wear and replace sealing washers upon reassembly.
CAUTION: I
Do not bend float arm during disassembly. Do not use excessive force to remove float arm pin. The float pin tower castings are very easily damaged and are not repairable.
o
9196
5.36
FUEL SYSTEM/CARBURETION Mikuni Carburetor Service

Carburetor Disassembly and Inspection Cont.
10. Remove main jet and washer (or spacer ring) and push needle jet into the slide valve chamber to remove. Clean air bleed hole in needle jet.
11. Remove pilot jet.
CAUTION:
Wear eye protection when using compressed ai r or cleaning solvents. Review all fuel system warnings fo und on page 5.1 before proceeding. 12. Remove pilot air screw and clean all passages in the Dry all carburetor body wi th carburetor cleaner. passages and jets with compressed air. Replace gaskets and any parts which show wear or damage. 13. Reassemble carburetor, adjusting float level before installing float bowl. Refer to page 5.38 for float level adjustment and leak testing procedures.
5 .37
9/96
FUEL SYSTEM/CARBURETION Mikuni Carburetor Adjustments

Float Level Adjustment
1. 2. Remove float bowl. With carburetor in an inverted position, float arm (A) should be parallel with body (B). See illustration at right. Arms must be parallel to each other. To adjust float arm, bend tang contacting inlet needle.
3.
CAUTION{ I
Never bend the float arm itself.
Leak Testing Needle and Seat

1. After adjustment of float level, with carburetor still in an inverted position, install float chamber and connect pressure tester PN 2870975 to fuel inlet fitting.
Pressure Tester PN 2810975
2.
Apply approximately 5 PSI pressure and wait for one minute. The needle and seat should hold pressure indefinitely. If the pressure drops rapidly replace the needle and seat assembly and/or sealing washers.
9/96
5.38
Keihin Carburetor Service Carburetor Removal, Disassembly, and In spection
'-1. Remove carburetor from engi ne. Before disassembling, clean outside of carburetor thoroughly with solvent.
CAUTION:
Do not use compressed air to dry at this time. The float chamber could become pressurized resulting in damage to the floats or inlet needle and seat. Do not soak Keihin carburetors in carb cleaner. Clean only with aerosol cleaner.
2.
Remove slide valve . Inspect for nicks or burrs which may cause sticking.
3.
Remove jet needle by compressing return spring toward top cap and removing throttle cable . Disconnect cable holder and remove jet needle. Note "E" clip position and inspect needle taper for wea r. An indication of wear would be an hourglass shape or polished spots somewhere along the taper.
4.
Remove choke plunger. Check condi tion of seal on tip of plunger. Any nicks or cuts will cause leakage and a rich fuel condition, usually most evident at idle and low speeds. Inspect the plungerseat fordamage or foreign material. Check choke cable movement. Plungers and springs should move back and forth freely.
Sprin g"---..
5.
~----Plunger Seat
5 .38a
9/96
Keihin Carburetor Service Disassembly Cont.

6. Remove water trap assembly from float bowl and inspect O-ring, hose and clamp condition. Refer to exploded view corresponding with carburetor being serviced.
r'fn....__ Trap Nut

o I
Hose _
n ~ !/
Clamp Drain Plug
7.
Inspect choke fuel supply passage as shown for obstruction.
8.
Remove float arm pin. Remove inlet needle. NOTE: Seat assembly is not replaceable. DO NOT remove.
9.
Inspect needle for wear.
Do not bend float arm during disassembly. Do not use excessive force to remove float arm pin. The float pin tower castings are very easi ly damaged and are not repairable.
9/96
5.38b
FUEL SYSTEM/CARBURETION Keihin Carburetor Service

Carburetor Disassembly Cont.
10. Remove main jet.
11. Remove pilot jet.
Wear eye protection when using compressed air or cleaning solvents. Review all fuel system warnings found on page 5.1 before proceeding. 12. Remove pilot air screw and clean all passages in the carburetor body with carburetor cleaner. Dry all passages and jets with compressed air. Replace gaskets and any parts which show wear or damage.
5.38c
9/96

Carburetor Assembly
1. Install pilot jet and main jet.
2.
Install inlet needle and float assembly.
Adjust float with tange o!1ly
3.
Hold carburetor at angle shown so needle spring is not compressed. Measure from gasket surface of carb body to highest point on float. Measurement should be within specification.
H
.\ Float Heigtlt - Kelhln:

1$mm2mm
4.
To adjust float level, bend tang contacting inlet needle. See photo above.
Do not bend float arm. Adjustment shou ld be made with tang contacting inlet needle.
9(96
5.38d

5. After adjusting float level, place carburetor in an inverted position. 6. Connect pressure tester to fuel inlet fitting. Apply 5 psi pressure and observe for one minute. The needle and seat should hold pressure indefinitely. If the pressure drops, carefully inspect the needle and the needle seat. The needle can be replaced if necessary. The needle seat cannot be replaced. If the seat surface is damaged replace the carburetor.
Pressure Tester PN 2870975
'--
7.
Carefully inspect float bowl gasket and replace if necessary. Install float bowl on carburetor. Install idle screw and air adjusting screw. Install jet needle clip onto needle jet.
8. 9.
10. Install jet needle into th rottle valve. 11 . Screw cable holder into throttle valve to secure jet needle and throttle valve. 12. Inspect gasket under throttle cap. Install throttle cable, spring, and collar. Connect cable to slide valve. 13. Install carburetor top cap until seated on carburetor body.
5.38e
9/97
FUEL SYSTEM/CARBURETION Adjustments

1996 Throttle Gap Chart
Model
Engine Model
Throttle Gap Under
Air
Idle
Screw
CCW From Seat 1.5 1.25 1.25 1.5 1.0 1.0 1.0 1.5 1.0 1.0 1.5 1.5 1.0 1.0 1.0 1.0 ACCS 1.5 1.0 1.0 1.0 1.0
RPM
Cutaway
Lite , lite GT, Lite Deluxe

Sport. Transport, Sport Touring
Super Sport 440 440 XCR 440 XCR SP WideTrak GT
EC34-2PM02 EC44-3PMOI EC44-3PM02 EC4SPL02106 EC4SPL07 EC4SPLOB ECSOPM03 ECSOPM04/E04 ECSOPL11 ECSOPLE11 ECSOPL 12 ECSOPL14 ECSOPL15 EC5BPL02 EC5BPL03 EC5BPLEOS EC5BPL07 EC59PLOI EC6BPL01 EC6BPL04 ECBOPL04 ECBOPL05
.240"/6.1 mm .236"/6.0mm .201Y'/5.1mm .210"/S.3mm .210"/S.3mm .210"/S.3m m .240"/6.1 mm .240"/6.1mm .210"/S.3mm .210" /5.3mm .240"/6.1 mm .240"/6.1 mm .210"/5.3mm .221 "/5.5mm .193"/4.9mm .230"/5.Bmm . 193"/4.9mm .IB7"/4.Bmm
1600 1BOO 1600 1600 lBOO 2000 1600 1600 1600 1900 1600 1600 1600 2000 1700 1700 1700 2000 t500
Trail, Trail Touring

500, 500 SKS
Classic
WideTrak LX
Classic Touring
500 RMK XLT SP, 600 XCR XLT. XLT SKS
XLT Touring
XLT RMK 600 XCR SP Ultra SP. Ultra SKS Ultra RMK Storm RMK Storm, Storm SKS
.IB7"/4.Bmm
.250"/6.4mm
.21B"/5.Smm .218"/5.5mm
lBOO
1600 1600
91 97
5.381
FUEL SYSTEM/CARBURETION Throttle Gap Specifications

1997 Throttle Gap Chart
1997 Model Engi ne Model Th rottle Gap-U nder Cutaway (Under front of s lide on Kelh ln) Drill Si ze (Inchesl mm) .219"-7132(5.55mm) .180"-15(4.57mm) .172"-11 1 64(4.37mm) .190"-12(4.80mm) .172"-11164(4.37mm) .219"-71 32(5.55mm) .219"-7132(5.55mm) .219"-7132(5.55mm) .180"-15(4.57mm) .190"-12(4.80mm) .210--4(5.3mm) .219"-7132(5.55mm) .219"-71 32(5.55mm) .172"- 11164(4.37mm) .172"-11 1 64(4.37mm) 64(4.37mm) .172"-11 1 .210"-4(5.3mm) . 166' -19(4.22mm) .166"-19(4.22mm) . 166' -19(4.22mm) .228"-1 (5.79mm) .031 "-1132(0.79mm)" .078"-5164(1.98mm)" .228"- 1(5.79mm) .228"-1 (5.79 mm) Idl e Sync. Gap (U nder Cu1away) Air Screw (Turns) 1.5 1.0 .75 .75 1.0 1.0 1.5 1.0 1.0 1.0 .75 1.0 0.5 1.0 .75 .75 1.0 1.0 0.5 1.0 1.0 1.0 1.5 1.0 1.0 1600 1600 1600 1600 1800 1600 1600 1600 1600 1600 1600 1600 1600 1700 1700 1700 1600 1600 1600 1800 1800 1500 1500 1600 1600 PN2871810 PN2871811 Idle RPM Special Tool Required
Drill Size (InchesJmm)

.240"-8(6.10mm) .200"-8(5.10mm) . 190"-12(4 .80mm) .210"8(5.30mm) .190"-12(4.80mm) .240"-8 (6.10mm) .240"-8 (6.10mm) .240"-8 (6.10mm) .200"-8(5.10mm) .210' -4(5.30mm) .228"-1(5.80mm) .240"-8(6.10mm) .240"-8(6.10mm) .193" -11 (4.90mm) .193" -11(4.90mm) .190"-12(4.80mm) .228"-1 (5.80mm)
Lite, Lite GT. Lite Deluxe

Sport, Sport Trn9, Transport. XCF 440 XC 440 440 XCR WideTrak GT
EC34-2PM02 EC44-3PM02 EC45PL08 EC45PL09 SN44LCDCSP-Ol EC50PM03 EC50PM04 EC50PM05 EC50PM06 EC50PL17 EC50PL 16 EC50PL19 EC50PL20 EC58P L03 EC58PL07 EC58PL08 EC58PL09 EC58P112 EC59PL01 EC68PLOl EC68PL03 SN70LCDCSP-{)1 SN70LCDCSP-{)2 EC80PL04 EC80 PL04
Trail , Trail Touri ng

Trail RMK Super Sport 500. 500 Classic, 500 SKS 500 RMK
Classic Touri ng
WideTrak LX X LT. XLT SKS XLT RMK 600 XC XLT LTD. XLTTouring XLT SP. XLT LTD SP 600 XCR. 600 XCR SE Ultra, Ultra Touring, Ultra SP Ultra SPX. Ultra SPX SE 700 SKS. 700 XC 700 RMK Storm RMK
.187"-3/16(4.75mm)
.187"3116(4.75mm) .187"-3116(4.75mm)
.248"-1 /4(6.30mm)
.0469"-31 (1. 19mm)" 64 .0937'-31 (2.38mm)" 32 .248" -114(6.30mm) .248' -1 14(6.30mm)
Storm, Storm SE
Requires Special tool with two drill gauges spaced Smm apart. Measured on forward edge (engine Side) of slide.
5.39
9197
FUEL SYSTEM/CARBURETION Throttle Gap Specifications 1998 Models

1998 Model
Engine Model Throttle GapUnder Idle Sync. Gap Und er Cutaway (Front of slide on Keihin )
.240" -~73 (6.1mm) (15/64=.2344")
Air
Screw
Cutaway
(Front of slide on Keihin)
Idle RPM
(Turns oul)
1.5 1.0 1600 1600
Tool
Ute Deluxe Lite I Lite Touring

Sport / Sport Tour Transport XCF 440 XCR 440 Indy
EC34-2PM02A EC44-3PM024
.219" - 7/32 (5 .55mm) .180" - "'S (4.S7mm)
.200"(S. 1mm) (#7 or 13/64") .217"(S.5mm) (7/32") .208"-(S.3mm) (#7 or 13164") .240" - #73 (6.1mm) (IS/64) .240" - "73 (6.1 mm) (15/64 ) .200"(S.1 mm) (#7 or 13164") .240" - #73 (6 . 1mm) (lS/S4) .208"-(S.3mm) (#7 or 131S4") .187" - 311S" (4.8mm) .240" - #73 (S. 1mm) (lS/S4) .234" - A (S.94mm) (7/32") I .Smm (.059") Tool PN : 2872093 2.38mm (.094") Tool PN: 2871811
.18T' - 3/16" (4.8mm)
SN44-44LCDCSP-Ol EC4SPL091 ECSOPM043 EC50PMOSI ECSOPM061 ECSOPL171 (ECSOPL191 ) EC50PL lSI ECSOPL 140 (PL lS0) EC50PL201 ECS8PL130 SNS0-70LCDCSpO l
.200" - 13/64 (S.1 mm) .189" - #12 (4.80mm) .219" - 7/32 (S.SSmm) .2 19" - 7/32 (S .SSmm) .180" - #I S (4.S7mm) .219" - 7/32 (S.5Smm) .189" - #12 (4.80mm) .1SS" - #19 (4.22mm) .219" - 7/32 (5.SSmm) .2 13 / #3 S.5mm=0.21S5" .7mm (.028', Tool PN : 2872093 1.98mm (.078" ) Tool PN : 2871811 .16S" - #19 (4.22mm) .16S" - #19 (4.22mm) .228" - 1 lS.79mm) .70mm (.028") Tool PN: 2872093 1.3mm (.051") Tool PN: 2872092 .228" - 1 (S.79mm)
1.25 .75 1.0 1.0 1.0 .75 1.2S 1.S O.S 1.0 1.0
1600
1600 1600 1600 1600 I S00 lS00 1S00 1S00 1600 1S00
Trail
Trail Touring
Trail RMK Super Sport SOO; SOO Classic (Classic Touring) SOO RMK XLT SP (XLT Classic)
Widelrak LX
XLT LTD
XLTTour
SOO XC
O.S 1500
SOO RMK
SNS0-70LCDCSP-02
.5 1.0 1.0 1.0 1S00 1800 1800 IS00
SOO XCR
ECS9PL020 ECS8PLOSO ECS8PLOSO SN70-70LCDCSP-{) 1
Ultra Ultra Touring

700 XCR 700 RMK
.187" - 311S" (4.8mm) .248" - D (S.3mm) (114") 1.5mm (.OS9") Tool PN: 2872093 1.60mm (.063', Tool PN: 2872092 .248" - D (S.3mm) (114")
1.0 IS00
700 XC
SN70- 70LCDCSP-{)2
1.0 IS00
Storm
EC80PLOS2
Requires Special tool wi th two drill gauges spaced 8mm apart. Measured on forward edge (engine side) of slide.
9/97
5.39a
Adjustments Throttle Synchronization Procedure-1996 Mikuni Carburetors
'--' 1. Remove air box, noting position of throttle cable junction block. Reposition throttle cable and junction block in same position when air box is reinstal led. Rotate slide valve adjustment screws (idle screw) out (counterclockwise) approximately two turns. Loosen throttle cable adjuster sleeve jam nuts and turn adjuster down (clockwise) two turns. Referring to charts on pages 5.39-5.39a, select the correct diameter throttle gap drill gauge for the engine. Place drill gauge beneath slide valve cutaway as shown in illustration at right. Turn idle screw in until there is a slight drag on gauge. NOTE: Drill gauge must be in center of carb bore. This indicates proper throttle gap . Repeat procedure on all cylinders. Hold throttle cable junction block in same location as noted in step #1 . This is very important, since synchronization changes if throttle cable or junction block are improperly positioned. With drill gauge installed under throttle sl ide as shown , turn cable adjuster out (up) until the gauge starts to move. NOTE: The dri ll gauge must be centered in the carburetor bore. Turn cable adjuster clockwise (down) 113 turn. Repeat for all cylinders. The throttle slides must raise from the idle position in unison. Check by visually observing a drill gauge in all carburetors, noting and comparing while lightly depressing the throttle lever. Check throttle lever freeplay. If adjustment is required, the throttle cabl e adjusters must be turned equally to maintain synchronization . Tighten jam nut while holding cable adjusters. Check oil pump adj ustment. Reinstall air box and correctly position throttle cable and junction block. Start engine and adjust idle stop screws evenly until proper idle RPM is achieved. (See chart above.) Re-check throttle lever freeplay and reset by turning cable adjusters evenly. Tighten cable adjuster jam nuts.
2.
3.
4. '-' 5.
6.
See chart for size
o --==:::-J 1"-...1>u........., _'----"" f-
7.
a.
9.
10.
Throttle Free Play (Std.) 0.010 - 0.030" (.25-.76mm) EZ Throttle 0.050 - 0.060" (1.25-1 .50mm)
11 . 12.
5.39b
91 97
Adjustments Throttle Synchronization Procedure-1997 to Current Mikuni and Keihin (With Idle Gap Specified)
1. Remove air box, noting position of throttle cable junction block. Reposition throttle cable and junction block in same position when air box is reinstal led. Drill gauges with Bmm ap
Throttle Cable Synchronization (Throttle Gap)
2. Referring to chart on page S.39a-b, select correct

diameter Throttle Gap synchron ization drill gauge fo r your engine. NOTE: Keihin carburetors, require a special tool with two drill gauges separated by an Bm m gap. See chart on page S.39a and Illustrations at right. 3. Back out idle screws about three turns. Slightly lift throttle slides with throttle leve r and insert dri ll gauge under throttle slide . Allow throttle slides to return .
~=C~~~~~~= Bmm Tool Body
T ===r----~~~I
KEIHIN Carburetor Synchronization Tool KEIHIN Insert tool under slide; push in until tool body stops against carb body
4.
Loosen lock nut and turn throttle cable adjuste r (on top of carburetor) in (clockWise) or out (counterclockwise) as required until a slight drag can be fe lt on the gauge . 6 . Securely tighten throttle cable synch ronization lock nut. 7 . Repeat steps 3 through S on remaining carbureto r. Idle Gap Synchronization
S.
Forward
8.
9.
Referring to chart on page 5.39a, select correct diameter Id le Gap drill gauge fo r the engi ne. Slightly lift throttle slides with th rottle lever and inse rt idle gap drill gauge under throttle slide. Allow th rottle slides to return .
KEIHIN
~orward
10. Turn idle adjustment screw in as required until only a slight drag can be felt on the gauge. 11 . Repeat steps B through 10 for remai ni ng cylinders. 12. Verify prope r throttle lever free play and adjust if necessary, by loosening cable adjuster locknuts and turning adjusters out equally until throttle lever freeplay is correct.
Throttle Free Play (Std.) 0.010 - 0.030" (.25-.76mm) EZ Throttle 0.050 - 0.060" (1.25-1.50mm) MIKUNI See chart for size
Tool must extend to front edge of slide
~ t~( ~~ ~Ir l ' =~n

-1 ,=77 z zi
9/97
o
n
5.39c
FUEL SYSTEM/CARBURETION Adjustments Choke Choke Adjustments

With the dash mounted choke control toggle flipped to the full off position , the choke plunger must be seated on the fuel passage way in the carburetor. If the plunger is not seated on the passage way, the engine will flood or run too rich, causing plug fouling and very poor engine performance. If cable slack is too great there will be excessive toggle free play resulting in hard cold starting. Also, the half on position used for intermittent applications will not function.
Choke Toggle Position
If the choke lever assembly becomes damaged, a lever kit is available . This allows replacement of the lever assembly rather than the entire cable assembly. Installation instructions are included with the kit.
~ Half On
o
il
Full On
Choke Lever K1ts2! 2 Cylinder PH 2200188 3 Cylinder PH 2200189
Contents of Lever Kit
Adjustment Procedure
1. Flip choke toggle to full off position. 2. Loosen adjustment locknut (A) on carburetor(s). 3. Turn cable sleeve adjusting nut (8) clockwise on carburetor(s) until 1W (.6 cm) or more choke toggle free play is evident. 4. Turn cable sleeve adjusting nut counterclockwise on one carburetor until toggle has zero free play, then rotate it clockwise until1/B"-1 /4N(.3-.6 cm) toggle free play is evident. 5. Tighten adjustment locknut (A) . 6. Repeat steps 4 and 5 for remaining carburetor(s) .
1/8-1/4" (.3-.6 cm) Freeplay ----
I-
l/
11/95
5.40
FUEL SYSTEMICARBURETION Adjustments

The amount of air drawn into the cylinders is influenced by such factors as altitude, temperature, humidity, etc. Suppose the amount of air drawn into the cylinders at an elevation of zero is taken as 100 (the temperature and humidity in this case are considered constant). The amount of air in question decreases in proportion to a rise in elevation as shown in Chart A. Reduction in the amount of air drawn into the cylinders changes the air/fuel mixture ratio, resulting in a marked drop in power output. Chart A 100 r
90 I-
80 I-
500
1000 1500 Altitude (m)
2000
Chart B shows the relationship between a rise In temperature and the amount of air drawn Into the cylinders. In this case, the atmospheric pressure (elevation) and the humidity are considered unchanged and the amount of air going into the cylinders at 32 F (0 C) is taken as 100.
Chart B 100
r
90 I-
80
------------,
o
32 10 50 20 68
,
30 86
C) 40 (O
104
(O ~
Temperature
On Mikuni VM carburetors the pilot system and the main system are of independent construction. The fuel flow in these two systems is shown in Chart C.
Total amount of fuel
Main fuel system

Pilot fuet system
Throttle valve ooenlng (%)
-t
CHART C
5.41
11 /95
FUEL SYSTEM/CARBURETION Fuel Pump - Operation

The fuel pumps on all Polaris engines are basically the same. The differences are in the size and location of the pumps. Pumps may be mounted to the engine or to the chassis. In the two cycle engine, the pressure in the crankcase changes with the up and down stroke of the piston . The amplitudes of pressure vary according to the RPM and degree of throttle opening. Whether idling or at full throttle, the pressure built up in the crankcase has enough amplitude to operate the pump. When the piston is on the upstroke, crankcase pressure in that cylinder becomes less positive. The diaphragm in the fuel pump moves toward the engine, causing a negative pressure or suction in the pump chamber. This causes the inlet valve from the fuel supply to open and permits fuel to enter the chamber. This same suction causes the outlet valve (to the carburetor) to close so that fuel cannot return form the carburetor. When the piston begins its downward stroke, the pressure from the crankcase becomes positive, causing the fuel pump diaphragm to move in the opposite direction and reversing the pressure in the fuel pump chamber. This causes the inlet valve in the pump to close and the outlet valve to open, filling the float bowl in the carburetor. When the float level in the carburetor reaches its standard level, the needle valve will close, preventing more fuel from entering the carburetor, even though the fuel pump continues to try to provide the carburetor with fuel.
Maintenance
The impulse operated diaphragm fuel pump does not require any specific scheduled maintenance. However, the following procedures should be observed . Operation: The pump may be checked for operation by removing the fuel supply line from the carburetor and placing it into a container. With the engine idling at approximately 2000 RPM, a steady flow of fuel should be visible.
Cleaning: The pump and impulse line must be disassembled and cleaned of foreign material in the event of piston or other internal engine part failures which produce fragments.
Inspection:
Disconnect impulse line from pump. Connect Mity Vac' to impulse fitting (or line) and apply 4-6 PSI pressure. Diaphragm should hold pressure indefinitely. The diaphragms and check valves must be carefully examined for cracks, holes, or other damage. If in doubt as to the condition of any internal parts, replace all diaphragms, check valves, and gaskets.
11/95
5.42
FUEL SYSTEM/CARBURETION Exploded View Fuel Pump
Taic Giken Description of Parts 1. Vacuum (from crankcase) 2. Diaphragm 3. Gaskets 4. Check Valves 5. Fuel Outlets (to carbs) 6. Fuel Inlet (from tank)
~>----2
!P---2
5.43
11/95
FUEL SYSTEM/CARBURETION Exploded View - Twin Cylinder (Typical) Fuel Pump
3_-1
Parts Description 1. Pump Body Assembly 2. Lower Gasket 3. Diaphragm 4. Upper Gasket 5. Screw (6 used) 6. Check Valve
11/95
5.44
FUEL SYSTEM/CARBURETION Exploded View - 3 Cylinder Fuel Pump
Parts Description
1. Pump Valve Body 2. Diaphragms and Gaskets 3. Screw (6 used) 4. Check Valves NOTE: Be sure of proper order and position of gaskets and diaphragms upon reassembly. 5. Fuel Outlet (3 to carbs) 6. Fuel Inlet (from tank) 7. Vacuum/Pressure (from crankcase)
5.45
11/95
FUEL SYSTEM/CARBURETION Water Trap Service
WARNING '--"
Fuel spillage will occur during this installation. Gasoline is extremely flammable and explosive under certain conditions. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not weld or operate a torch near the fuel system. Remove fuel tank before any chassis welding is performed.
If you get gasoline in your eyes or if you swal low gasoline, see your doctor immediately.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. 1. 2. 3. 4. 5. 6. Turn fuel valve off. Remove air silencer. Position a shop cloth or container below drain plug and water trap plug. Remove drain plug and sealing a-Ring, or slide clamp upward and remove water trap plug. Drain waterlfuel. Clean trap with electrical contact cleaner and dry with compressed air. Lightly grease a-ring and install water trap assembly into bottom of float bowl, or reinstall trap plug in hose and position. Tighten securely. Float Bowl
DrainplUg~
--a-Ring
7. Turn fue l on , start engine and check for possible fuel leaks. 8. Reinstall air box. The water traps should be periodically inspected and drained. Draining frequency will depend upon fuel supply, riding conditions, and fuel handling precautions. Clamp t---Hose
~aterTrap
Plug
11/95
5.46
Troubleshooting
Fuel system diagnosis should follow a specific path, first examining the fuel tank, then the filters, fuel lines, vent lines , fuel pump, impulse hose, air box, exhaust system and finally the carburetors. The following troubleshooting information assumes that the general mechanical condition of the engine (pistons, rings , bearings, etc.) is good. When the fuel/air mixture is diagnosed as improper due to spark plug readings, clean the carburetor and blow its passages clear with compressed air. Use the spark plug firing end condition as a guide for further determination of whether the mixture is too rich or too lean. Use the throttle lever to determine at what degree of throttle valve opening the problem exists. CONDITION Mixture Too Rich SYMPTOMS -Slack spark plug tip; plug fouling -Heavy exhaust smoke -Engine runs worse after warm up -Engine "loads up" -Spark plug electrodes white -Fluctuation in engine speed -Power loss -Engine overheats -Cylinder scoring / Holing pistons -Sackfiring - detonation -Throttle diagnostic opening check points -Incorrect ignition timing -Improper track tension (too tight) -Incorrect carburetor jetting - Fuel leaks (lines, fittings, fuel pump) -Needle and seat leaks -Plugged exhaust -Carburetor vent line problems -Clutching incorrect for conditions / worn belt
Mixture Too Lean
Poor Fuel Mileage
Troubl<lshooting Tips, 0-1/4 Throttle: Pilot air screw misadjusted
Pilot jet of wrong size, loose, or obstructed Obstruction of pilot jet Incorrect throttle synchronization Choke plunger not seating (rich) Carburetor mounting air leak (lean) Crankshaft seal air leak (lean) Fuel pump diaphragm damaged (rich) Float level incorrect Air bleed obstructed
I ,
. , I
5.47
9/96
FUEL SYSTEM/CARBURET/ON
Troubleshooting Troub leshooting Tips, 1/4-3/8 Throttle:
Obstruction in main jet or needle jet Jet needle worn or out of adjustment Pilot system malfunction Incorrect throttle valve cutaway Incorrect throttle synchronization
Troubleshooting Tips, 3/8-3/4 Throttle:

Main jet incorrect size or clogged (lean) Needle jet damaged or loose Needle jet/jet needle worn (rich) Incorrect throttle synchronization
Troubleshooting Tips, Full Throttle:

Main jet size (rich or lean) Fuel filter blocked (lean) Fuel vent lines or check valves plugged Exhaust system plugged Air box restricted Fuel pump weak Exhaust leaking into engine compartment (rich) Water in float bowl (lean) Incorrect throttle synchronization
9/96
5.48
CHAPTER 6 CLUTCHES
Clutch Service Tools .. . . ... . .. . .... . . ....... 6.1 Torque Values . . . ....... . .. . .. . . ........ . .... 6.2 1996 Specifications ...... ..... .. .. . . .... 6.3 - 6.5 1997 Specifications ............ ...... . . . ..... 6.6 - 6.8 1998 Specifications .................. . . . .. . .. 6.8a - 6.8b Drive Clutch Weight Identification ... . . ... .. .. ... 6.9 - 6. 12 Drive Clutch Spring Rates . ............ ... .. 6.13 Drive Clutch Spring Data . . ... . ........ .. . .... . 6.14 Driven Clutch Spring Data / Rates ... . . . . . . . . ... 6.15 P-85 Drive Clutch, Exploded View .. . . . ......... 6.16 P-85 Driven Clutch, Exploded View ..... . ...... . 6.17 P-90 Drive Clutch , Exp loded View .... . . . . . . ... 6.18 P-90 Driven Clutch, Exploded View ... . .. . . ..... 6.19 Clutch Operation ........ . ........... . .. . . ... . 6.20 - 6.22 Drive Clutch Removal . .. . . .. . . .... ... .... .. ... 6.23 Drive Clutch Disassembly/Inspection ........... 6.24 - 6.25 Spider Roller Removal ... . ... . ........... ... .. 6.26 Spider Roller Installation. . . . . . . . . . . . . . 6.26 - 6.27 Spider Button Shimming ... . .. . . . .. . .. . . . .... .. 6.27 - 6.28 Drive Clutch Assembly . .. .. .. . . . ...... . . . .. ... 6.29 - 6.30 Drive Clutch Installation . . . ... . .. . . . . . . .. . ... . 6.30 - 6.3 1 Spider Indexing ............................. 6.32 Driven Clutch Removal ........ .... . ... . . . ... . 6.33 Driven Clutch Disassembly ... . .. . . . . . ....... 6.34 - 6.35 Driven Clutch Assembly ........ . . .. .. .. ..... .. 6.36 Driven Clutch Helix Ramps ... . . . . . .... .. .... .. 6.37 Driven Clutch Installation ... .. .. .. . . . . . . . .... 6.39 Drive Belt Data .......... .. . ... . . . . . . . . . .. ... 6.40 Drive Belt Inspection . . ..... .... ...... ....... .. 6.41 Drive Belt Deflection ...... . . . . .... . . ... .. . .... 6.42 - 6.43 Clutch Offset/Alignment . . . ... . .. .. . . . . . .. .... 6.44 - 6.45 Torque Stop Adjustment ...... . .. .. ....... . .... 6.45 Belt to Sheave Clearance ..... . .......... . .... 6.46 P-85 Clutch Bushing Service . ........ . . . ....... 6.47 - 6.52 P-90 Cl utch Bushing Service .. . .. .. . .. . . ... . ... 6.53 - 6.60 Troubleshooting ...... . ..... .. .. . . . ...... .. ... 6.61 - 6.63
CLUTCHES Service Tools
WARNING
All drive clutch maintenance, disassembly and assembly must be periormed only by an authorized Polaris dealer who has attended current model Dealer Service Seminars, has received a certificate of completion , and displays the Polaris Servicing Dealer decal.
Because of the cri tical nature and precision balance incorporated into the drive clutch, it is absolutely essential that no attempt at clutch disassembly and/or repair be made without factory authorized tools and service procedures,
Essential Drive Clutch Tools

Refer to the Service Tool Catalog (PN 9914681) for photos and descriptions of all tools, Description Offset Alignment Tool - 21 /32" (1.7 cm) P-90 Clutches ... , ... . Offset Alignment Tool - 5/8" (1 .6 cm) P-85 Clutches . . , .. . .... . T-Handle Drive Clutch Puller (Large Shaft 10) .. ......... ... . Drive Clutch Puller 14mm (Small Shaft 10). . ...... . . ,., .. . . Strap Wrench ..... , ... .. . .......... , ... . .. ........ . , . , Replacement Strap for 2870336 . . .. .. , .. .... .... , ..... ' .. Spider Spanner Nut Driver (Jam Nut) ...... . . .. .. . ... .... Spider Removal / Installation Tool ..... . . . . . . . . . . . . . .. Holding Fixture . .......... ... . ...... . ... .. .. . . .. ..... , Holding Fixture Tab ... , ..... ' . , . , . , ... , ... . . . ' , , ... , . Tapered Reamer ., . . . , . , ........ , .. , , , ..... .. . .... . ' Spider Button Tool ... , , . .... , ........ , .. .... , . . . . . . . . . .. Clutch Bushing Rebuild Tool Kit (P-85/P90) ......... _.... ,. P-85 Drive Clutch Compression Tool . . . . . . . . . . . . . . . . . . .. Driven Clutch Puller (P-90) .. , .......... .. . . . .. ... .. ..... , Torque Wrench, 250 ft. lb .. , ....... , .. . , Torque Wrench, 0-600 in. lb..... . ... , .. . Clutch Compression Tool . , ..... .... , , . , Part Number 2870914 2870426 2870506 287 1757 2870336 2870389 2870338 2870341 2871358 5130518 2870576 2870985 2871025 2870984 2871056 Commercially Available Commercially Available 8700220
\.......
6.1
9/97
CLUTCHES Clutch Torque Values

Bolt Size Area Where Used
7/16" ... . Drive Clutch Retaining Bolt
Torque Minimum-Maximum
40-45 It. Ibs. (5.52-6.21 kgm)
14mm . .. Drive Clutch Retaining Bolt . . ............. . . ... .. . 50 It. Ibs. (6.9 kgm) 1/4" .... . Drive Clutch Cover Bolts .... . ... . .. ... .... . ... 90 in. Ibs. (1.03 kgm) #10-24" . Drive Clutch Weight Pin .. ... . .. ..... . .... . .. . ... 30 in. Ibs. (.34 kgm) 1-1 /4" .. . Drive Clutch Spider .. . .... .. .. . .... .. ... . . ... . . 1-1 /4" . .. Drive Clutch Spider Jam Nut ....... ... ... . . ..... . 5/16" . . .. Driven Clutch Retaining Bolt ....... . ..... .. . . 200 It. Ibs. (29.60 kgm) 235 It. Ibs. (32.43 kgm) 15 It. Ibs. (2.07 kgm)
#8-32" . . Driven Button Screw. . . . . . . . . . . . . . . . . . . . . . . . . .. 20 in. Ibs. (.23 kgm) 1/4" . . . . . Driven Adjust Plate Screw . . . . . . . . . . . . . . . . . . . . .. 10 It. Ibs. (1.38 kgm) see decal
9/97
6.2
CLUTCHES Specifications 1996 Clutch Specifications 0-3000 Feet (0-900 Meters)

Machine Model
Engine Model
Operating RPM 200
Production Clutch Part No.
Spring Color. Wire

Dia.
Shift WI.
I. D.lGram
Bore Taper
Dia.
Clutch Center Distance +.100" -.000 11.030"
Driven Helix Angle & Location
Chaincase Gearing
Indy Lite!GT Indy Lite Deluxe Indy Sport Indy Sport Tou ring Indy TranSport
EC342PM02
7000
1321601 1321602 1321594
SilverI Gold .218
to
t . t60
36S B-2
36.5 B-2
16:39
EC443PMOI
6800
Brown
.200
10
1.160
12.00"
16:35 16:39 15:39 17:35
Indy Super Sport
EC50PM06
7000
1321619
Red! While .192 Red! Whrte . t92 Red! White .192 Brown .200 Brown
10Al Bushed 10Al Bushed 10AL Bushed 10 Bushed 10 Bushed 10 MB Bushed 10 MB Bushed 10M Bushed 10M Bushed 10M Bushed 10 M Bushed 10 MB Bushed 10 M Bushed 10 M Bushed 10 M Bushed 10 M Bushed 10M Bushed 10MB Bushed 10 AL Bushed 10 AL Bushed 10 Bushed 10 Bushed
1.160
12.00"
36S B-2
36 #2 36" #2 36 " #2 36 " #2 34" #2 34 " #2 R-8 iI2 36 #2 36" iI2 36" #2 34 " #2 36 " #2 36 " #2 34 " #2 34 " #2 34 " #2 34" #2 R-l #2 36 ' #2 36" #2 36' #2 R-3 #2 R-3 #2
Indy Trail
EC50PM04
7000
1321659
1.190
12.00"
21:39
Indy Trail Touring
EC50PME04
7000
1321660
1.190
12.00"
20:39
Indy WideTrak GT Indy WideTrak LX Indy 440 l C Indy 440 XCR Indy 440 XCR SP Indy 500 Indy 500 SKS Indy 500 RMK' Indy Classic Indy Classic Touring Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMKIndy XLTIXLT SKS Indy XLT RMK ' Indy XLT Touring Indy XLT SP! 600 XCR Indy 600 XCR SP Indy RXL Indy Ullra SP!SKS Indy Ultra RMKIndy Slorm! (I ndy Storm SKS) Indy Storm RMK
EC50PM03 EC50PLE12 EC45PL06 EC45Pl07 EC45Pl08 EC50PL11 EC50PL11 EC50PLEll EC50PL 14 EC50PL 13 EC50PL 13 EC58PL03 EC58Pl07 EC58PLE05 EC58Pl02 EC59PlOl EC65Pl05 EC68PLOI EC68PL04 EC80PL05 EC80PL04
6600 7000
1321661 1321644
1.190
12.00" 12.00" 12.00" t2 .00" 12.00" 12.00" 12.00" 12.00"
19:41 19:41 21:39 21:39 21:39 21:39
1.190
1.190 1.190 1.190 1.190 1.190
8000 8250 8250 7750 7750

7750 7750
1321580
1321648 1321643 1321663 1321655 1321666
1321606
1321663 1321655 1321665
1321656
8000
8000 8000 8000 8250
1321664 1321678
8500
8500
1321650 1321650
1321682 1321678 1321651 1321658
8000 8200 8200 8250 8250
.200 Gold .207 Blue .207 Blue .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Blue .207 Blue .207 Blue .207 SilverI Gold SilverI Gold Blue .207 Blue .207
20:39
20:39 21:39 20:39 21:39
1.190 1.190 1.190 1.190

1.177 1.177 1.174 1.177 1.177 1.177 1.177 1.177 1.177 1.177
12 .00"
12.00" 12.00" 12.00"
20:39
20:39 21:39 18:39 20:39 21:39 21:35 21:35 21:35 20:35 23:37 (20:35) 20:35
12.00" 12.00"
12.00"
12.00"
12.00"
12.00"
12.00" 12.50"
10-60
Bushed
10-60
Bushed
12.50"
'---"
NOTE: RMK production setup IS 6000-9000 feet. Refer to page 6.4 for 1996 RMK production setup.
6.3
9(97
CLUTCHES High Elevation Specifications
1996 HIGH ELEVATION RECOMMENDATIONS

3000 Ft. to 6000 Ft.
Machine Model
Indy lite! GTIDefuxe
6000 Ft. to 9000 Ft.

ChainChainShilt Weight 10M While 10 Bushed 10M Bushed 10 10AL Bushed 10 Bushed 10M Bushed 10MS Bushed 10MR Bushed 10MW Bushed 10MW Bushed tOMW Bushed 10MW Bushed 10MW Bushed 10MW Bushed 10MW bushed 10MW bushed 10MW bushed lQMW Bushed 10MW Bushed 10MW Bushed 10MR Bushed 10MW Bushed 10MW Bushed 10MR Bushed 10M Bushed 10MS Bushed Clutch Spring Gold Gold Gold
9000 Ft. to 12000 Ft.

case
Shift Weight
10M While or
Shift Weight 10MS 10 10 10 10 Bushed
Clutch Spring Gold RedfvVhite

RedlWhite Red!White
Driven Helix
3605" #S-2
Gearing
16:39
16:35
case
Driven Helix 36.50 OS-2

36.5" #S-2
36.5 OS-2
Gearing
16:39
16:35
Clutch Spring Blue Gold Blue Gold
Driven Helix
36.5
Chaincase Gearing
16:39
16:35 16:39 15:39 17:35 21:39 20:39 19:41 19:4 1 21 :39 21 :39 2 1:39 21:39 20:39 20:39 21:39 20:39 21:39 20:39 20:39 21:39 20:39 21:39 20:39 lB:39 21:39 21:35 20:35
10M Aed
10 or 10M Blue 10 or 10M Blue
100r 10M Blue
10MB Bushed
#8-2
36.5" #S-2 36.5 OS-2 36.5 O S-2 36.5 OS-2
36" #2 36" 02 36" 02 34" '2 34" #2 R-B 36#2 36" 02 34.2 36" 02 36#2 36" 02 3602 36" 02 34" #2
Indy Sport Indy Sport Touring

Indy TranSport
36.5 OS-2
36.5" OS-2 36.5" OS-2 36.5" OS-2 3602

36' 02 3602 34' 02 34' .2 R-B 36#2 36#2 34#2 36' #2 36" 02 36#2 3602 36#2
16:39 15:39 17:35

21:39
16:39 15:39 17:35 21:39 20:39 19:41 19:41 21:39 21:39 2':39 21:39 20:39 20:39 21:39 20:39 21:39 20:39 20:39 21:39 20:39 20:39 20:39 18:39 21:39 21 :35 20:35
Blue Gold
Blue Gold RedNJhite Gold Gold RedlWhite Reds'White RedIWhite Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Slue Blue Blue Slue Blue Blue Blue
Gold
Gold Gold RedlWhlte RedlWhile Red/White Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue
36.5" OS-2 36.5OS-2 36 0 #2 36#2 3602 34#2 34#2 R-B 36#2 36" .2 34#2 36" 02 3602 3602 36#2 36" .2 3402 34#2 34' 02 34" 02 34" 02 34" #2 A-l 02 34'" ft2 36 #3
Indy Super Sport Indy Traill Touring

Indy WideTrak GT Indy wideTrak LX Indy 440 LC Indy 440 XCA Indy 440 XCRSP Indy 500 Indy 500 SKS Indy Clas-
AedM'hite
Gold RedlWhite RedIWhite RedNIhile Blue Blue Blue Gold Gold Blue Gold Gold Gold Gold Gold Gold Gold Blue Gold Gold Blue Blue Blue
t OAl
Bushed
10 Bushed 10 Bushed 10MW Bushed 10MW Bushed 10MS Bushed 10MB Bushed 10MB bushed 10MS Bushed 10MS Bushed lOMS Bushed 10MB Bushed 10MS Bushed 10MB Bushed 10MS Bushed 10MB Bushed 10MW Bushed 10MS Bushed 10MS Bushed 10MW Bushed 10 Bushed 10 Bushed
20:39 19:4 1 19:41 21:39 21:39 21:39 21:39 20:39 20:39 21:39 20:39 21:39 20:39 20:39 2 1;39 20:39 21:39 20:39 lB:39 21:39 21:35 20:35
10 Bushed 10MS Bushed

10MS Bushed 10MW Bushed 10MA Bushed IOMA Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MA Bushed laMA Bushed laMA Bushed 10MA Bushed 10MA Bushed 10MA Bushed IOMR Bushed 10MA Bushed laMA Bushed 10MB or 10MW 10MW Bushed
sic Touring
Indy Classic Indy 500 RMK Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy XlT
Ind~XLT
34"
#2 34#2 34" #2 34" 02
34"
02
SK
Indy XLT SP Indy XLT Tounng Indy XLT RMK Indy 600 XCR XC
Ind~ 600
34#2 34" #2 3402
34"
#2 34" 02 A-l #2 36#2
3402 R-l 02 34 #2
SP
Indy AXL
36 113
9/97
6.4

1996 HIGH ELEVATION RECOMMENDATIONS (Cont.)
3000 Ft. to 6000 Ft.
Machine
Model
Chain~
6000 Ft. to 90ao FI. Chain-
9000 FI. to 12000 FI.
Chaln-
Shift
Weight
Clutch Spring
Driven Helix
case
Gearing
Shift
Weight
Clutch Spring
Blue Blue Slue
Blue
Driven Helix
case
Gearing
Shih
Weight
Clutch Spring Blue
Driven
Helix
case
Gearing
Indy Ultra
10M
Bushed
Blue Blue Blue

Blue
SP
Indy Ultra AMK
Ind~ Ultra
36" #2 36 #2 36 #2 R3 '2 A3 #2 R3 #2
21:35 20:35 20:35 23:37
10MB
Bushed
10M
Bushed
10MB
Bushed 10MB Bushed
36 #2 R9 #2 360 '2 A3 ,2 R3 #2 R3 ,2
21:35 20:39 20:35

21-37"
or
10MW Bushed 10MW Bushed

10MW Bushed
360 #2 A9 #2 3$0 #2 A3 #2 R3 #2 R3 #2
21:35 20:39 20:35

2137"
Blue
Blue Blue
10M
Bushed
SK
Indy Storm
1058
Bushed
la-56
Bushed
lOAl Bushed
Ind~ Storm
10-58
Bushed
Blue
Blue
20:35 20:35
1056
Bushed
Blue
20:35 20:35 20:39
10Al
B ushed
Blue
Blue
20:35 20:35 20:39
0'
SK
Indy Storm
10sa
Bushed
RMK
10-56 Bushed
81ue
10AL Bushed
Cannot be used with reverse kit
6.5
9/97
CLUTCHES Specifications 1997 Clutch Specifications 0-3000 Feet (0-900 Meters)

Machine Model
Engagement RPM 300
Operating RPM 200
Production Drive ClutchPart No.
Spring Color, Wire Oia.
Shift WI.
I.D.lGram
Driven Spring Color
Clutch Center Distance +. 100.... -.000
Driven Helix Angle & Location
Chaincase Gearing
Indy Ute/GT Indy Lite Deluxe Indy Sport
4100 4000 3500 4000 3600 3600 4000 3800 3800 3800 4900
7000 7000 7000 7000 7000 7000 7000 6500 7000 7750 8250
1321601 1321 602 1321687 1321594 1321659 1321659 1321660 1321683 1321698 1321661 1321692 1321662 1321686
Silver/Gold .218
RedIWhite .192 Brown .200
RedlWhite .192 Red/White .192
10 10AL Bushed 10 Bushed 10AL Bushed 10AL Bushed 10AL Bushed 10 Bushed 10 Bushed 10 Bushed 10 MB Bushed 10 Bushed S53R Bushed 10M Bushed 10M Bushed 10 M Bushed 10MB Bushed 10 M Bushed 10MB Bushed 10 M Bushed 10M Bushed 10 M Bushed 1054 10 AL Bushed 1054 Bushed 10-54 Bushed 1060 1060 Bushed 10-58 Bushed
Red Red Red Red Red Red Red Red Red Red
11.030" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00"
36.5 B2
36.5 " B2 36.5 4 B2 36 #2 36 #2 36 " #2
16:39 17:35 16:39 15:39 21:39 21:39 20:39 19:40 20:39 19:41 19:41 21:39 21:39 22:41 21:39 20:39 21:39 20:39 21:39 19:39 21:39 20:40 20:39 21:39 18:40 21 :39 21 :39 21 :35 20:35 21 :35 21:35 20:35 21 :35 20:35 21:39 23:37 (20:39)
Sport Touring Indy TranSport

Indy Super Sport
Indy Trail Indy Trail Touring Indy Trail RMK

Indy XCF Indy WideTrak GT
Indy WideTrak LX
Indy 440 LC Indy 440 XC Indy 440 XCR Indy 500 Indy 500 SKS Indy 500 EFI Indy 500 RMK-
RedlWhite .192 ReclNl/hite .192 Brown .200 Brown .200 Gold .207 Dark Blue .218
34"
#2 36 " #2 36 #2 34 #2 R8 #2 R8 #2 36 #2 36 " #2 36 #2 34 " #2 34" #2 34 " #2
Silver Silver
Red
4900
4000
8250
7800 7800 8000 7800 7800 7800 8000
1321704
1321663
Almondl
Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Blue .207 Gold .207 Dark Blue .218 Almond square
3800 4000 4000 4200
1321655 1321690 1321691 1321665 1321689 1321571 1321678 1321656 1321665 1321693 1321708 1321650 1321682 1321682 132 1688 1321708 1321695 1321696 1321651 (1321658)
Red Red Red Red
12.00" 12.00" 12.00" 12.00"
Indy Classic

Indy XLTIXLT LTD Indy XLT Touring Indy XLT SKS Indy XLTSP Indy XLT RMK' Indy XLT LTD SP Indy 600 XC Indy 600 XCR Indy 600 XCR SE Indy RXL
Indy Ultra Indy Ultra SP Indy Ultra Touring
4200 4000 4400 4200 4800 4000 4500
8300 8000 8300 8300 8500 8000 8200
Red Red Red Red Gold Red Red
12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00"
34 "
~2
34 0 #2 34 #2 R-1 #2 36
~2
Blue
.207 Dark Blue .218
36 #2 R-8 #2 36 #2 R-11 #2 R-4 #2
Indy Ultra SPX Indy Ultra SPX SE Indy 700 SKS Indy 700 RMK
4800 4200 4200 4800
8600 8000 8000 8400
Almond square
Gold
12.00" 12.50" 12.50" 12.50"
Dark Blue
.218
Dark Blue
Silver Silver
Gold
Indy Storm Storm SE (RMK)
.218 Almond square
NOTE: RMK production setup IS 6000-9000 fee t.
9/97
6.6
3000 Ft. to 6000 Ft .

Machine
ModeJ Shift
1997 HIGH ELEVATION RECOMMENDATIONS 6000 Ft. to 9000 Ft.

Chaincase Gearing
1S:39 17:35 1S:39 15:39 21:39 21:39 20:39 19:40 20:39 19:41 19;4 1 21:39 21:39 21:39 20:39 20:39 19:39 21:39 21:39 20:39 21 :39 20:40 18:40 2 1:39 21 :35 20:35 Chain-
9000 Ft. to 12000 Ft.

Chain-
Weight
10M
Clutch Spri ng Gold

RedM'hite
Driven
Helix
36.5"
#B-2
Shift Weight
10M White
Clutch
Spring
Gold Gold Gold Gold
Driven Helix 3S.5" #B-2
case
Gearing
Shift Weight
10M While or 10M Red 10M Blue or 10 Bushed 10M Blue
Clutch
Sp ring
Blue Gold
Driven Helix
3S.so #B-2
case Gearing
16:39 16:35 1S:39 15:39 20:39 21 :39 20:39 t9:40 16:35 19:41 19:41 2 1:39 20:39 21:39 20:39 20:39 19:39 21:39 21:39 20:39 20:39 2 1:39 19:39 18:40 21:39 20:39 20:35
lnd); Lite!
GT Deluxe
16:39
16:35
Blue
10
Indy Sport
36.5"
Bushed Indy Sport

Touring
Indy TranSport 10M Bushed 10M
#8-2
Brown
tOAL Bushed
10M
36.5
#B-2
RedI'vVhite
Gold Gold Gold
Red,while
36.5 118-2
36.5"
#B-2
Bushed
10M
36.50
#B-2
16;39
15:39 20:39 2 1:39 20:39 19:40 16:35 19:41 19:41 21:39 20:39 21:39 20:39 20:39 19:39 21:39 21:39 20:39 20:39 21:39 19:39 18:40 21:39 20:39 20:35
Bushed
10M Blue Bushed 10MB
36.5"
1f82
Brown
RedIWhite RediWhile RediWhite RedlWhile RedIWhite Red/While Blue Dark Blue Gold Gold Gold Blue Gold Gold Gold Gold Gold Gold Dark Blue Almond Blue
36.50
#B -2 3S0 #2 360 #2 360 #2 340 #2 3S o #2 3S o #2 34' .2 R-8 #2 3S' .2 3S O #2 3So #2 340 #2 3S' #2 340 #2 34 0 #2 340 #2 34 0 #2 340 .2 34 0 #2 R-1 .2 3So #2
Bushed
tOAl Bushed
lOAl Bushed 10 Bushed 10M Bushed 10 Bushed 10 Bushed 10MW Bushed 10M Bushed 10MB Bushed 10MB bushed 10MB Bushed 10MB Bushed 10MB Bushed
10MB Bushed
Bushed
10 Bushed 10 Bushed 10MB Bushed 10M Bushed 10M Bushed 10MB Bushed 10MR Bushed 10MB Bushed 10MW Bushed 10MW Bushed 10MW bushed 10MW Bushed lOMW bushed 10MW Bushed 10MW Bushed 10MR Bushed 10MW Bushed 10MW Bushed 10MW Bushed 10M Bushed 10MB Bushed
36.5" #8-2
36 0 #2 360 #2 3So #2 34 0 #2 36 0 #2 36 0 #2 34 0 #2 R-8 #2 3So #2 3So #2 360 '2 340 #2 360 '2 340 .2 340 .2 34' #2 34 0 #2 34 0 ,2 340 #2 R-1 .2 34 0 #2 36" #3
36.5
#B-2 3So #2 3So #2 3So #3 340 #2 3S' #2 3So #2 340 #2 R-8 #2 3S O #2 3S O #2 360 #2 340 #2 36" #2 34 0 #2 340 .2 340 .2 340 #2 340 #2 34 0 #2 A-1 .2 34 0 #2 36 0 #3
Indy Super
Sport
Indy Traill Touring
I n~Trai l
Red/VI/hite
RedlWhite RedlWhite Gold RedN.Jhile RedJWhile Blue Dark Blu e Blue Blue
Bushed
10MB Bushed 10MW Bushed 10MB Bushed 10MB Bushed lQMW Bushed 10MA Bushed 10MW Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10M R Bushed 10MR Bushed 10MR Bushed IOMR Bushed IOMA Bushed 10MA Bushed 10MA Bushed 10MB or 10MW 10MW Bushed RediWhite RedIWhite Gold Redl'Nhite AedlWhite Blue Dark Bl ue Blue Blue Dark Blue Blue Blue Blue Blue Blue Blue Dark Blue Dark Blue Almond Blue
R K XCF Indy WideTrak GT Ind'k wideTra LX Indy 440 LC Indy 440 XC Indy 500/ Classic Indy 500 SKS Indy 500 RMK
Ind~ Classic au ring
Dark Blue
Blue Blue Blue Blue Blue Blue Blue Dark Blue Almond Blue
Indy 500 EFI Indf' XLTI XL LTD Indy XlT SKS Indy XlT SP Indy XLT Touring Indy XLT RMK Indy SOO XC Indy 600 XCR Indy AXL
10MB Bushed 10MW Bushed 10MB Bushed 10MB Bushed 10MB Bushed 10 Bushed 10 Bushed
6.7
9/97

3000 FL to 6000 FI.
6000 Ft. 10 9000 Ft.

Chain-
9000 Ft. to 12000 FI.
Machine
Model Indy Ultra!
Ultra S P
Shift Weight
Clutch Spring
Dri ven
case
Gea ring
Shift
WElight
Helix
Clutch Spring
Driven
Helix
Chaincase Gearing
ChainShift Weight
Clutch Spring
Dark Blue Almond
Driven Helix
case
Gearing
10
Bushed
Dark Blue
Almond
Indy Ultra
10
Bushed
SPX Indy Ultra Touring 700 SKS Indy 700 RMK

Indy Storm
36' '2 R-8 .2 36' #2

R-ll
21035 21 :35 20:35 20:35

20:39
10M Bushed 10M Bushed 10M Bushed 10-58 Bushed 10-58 Bushed 10-56 Bushed 10-56 Bushed
Dark Blue Almond Dark Blue Dark Blue

Dark Blue
Almond
36' '3 R-8 .2 36' .3

R-ll
20:35 20:35 21:39 20:35 20:39

"21 :37
10MB
Bushed
10MB
Bushed
36' '3 R-8 .2 36' '3

R-ll
20:35 20:35
2 1:39
10
Bushed
Dark Blue
Dark Blue
Bushed
1056
10-56
10MB
Dark Blue
Dark Blue or Almond
10-58
10-58
20:35 20:39
21:37
#2
Dark Blue
Almond
R-ll
#2
R- 11
10-56 Bushed
.2 R-4 '2 R-36 .2
#2
R-4
Dark Blue or Almond Almond Almond
23:37 20:39
.2
Almond
Indy Storm RMK
10-58 Bushed
Almond
R-36 .2
or 20:35 20:39
10-54 Bushed
1054
#2 R- ll .2 R-4
'2
R-36 .2
or
20:35
20:39
Bushed
Cannot be used with reverse kit
9/97
6.8
Polaris Industries Inc_
CLUTCHES 1998 Clutch Specifications
1998/0-3000 Feet (0-900 Meters)

Machine Engagement Operating
Model
RPM 300
RPM 200
Service Drive
Cl utch
Part No.
Drive Clutch Sp ri ng Color, Wire Dia. Silve r/Gold
ShihWt.
t.D.lGram
Driven Spring Color
Clutch Center Distance +.100
Driven Helix
Angle & Location

36.5 G
Chaincase Gearing I Chain
Pitch 16:39 64P 17:35 62P 17:41/66 15:39 /64 22:41 68P 19:39 66P 22:41 70P 22:41 68P 20:40 66P 18:41 66P 22:41 68P 22:41 68P 17:41 66P 19:40 66P 19:41 66P 22:41 68P 22:41 68P 22:41 68P 20:40 66P 22:40 70P 23:40 68P 19:40 68P 23:40/68P 22:40/68P 24:40 70P 24:40 68 P 21 :41 70P 25:40 70P
Lite Lite OeluxefTrng Sport Sport Touring TranSport 440
4100 4000
7000 7000 7000 7750 7000 8250 7000 7000 7000 7000 7800 7800 7800 7000 8300 8000 8300 8000 8000 8500 8000 8200 8000 8600 8000 8400
1321596 1321596 1321596 1321739 132 1721 1321762 1321735 1321738 1321735 1321735 1321736 132 1737 1321736 1321737 1321738 1321733 1321733 1321734 1321734 132 1694 132 1732 1321713 1321733 1321734 1321694 1321732 1321713 1321740
10 10AL 10 10 MB Bushed 10 Bushed S-53R Bushed 10AL Bushed 10 Bushed 10AL

Bushed
Silve r
-.000 11.030" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00"
.218 RedlWhite .192 Brown .200 Gold .207

RedlWhite
A-1 Red Red Red

Silver
36.5 <>
B-2
36.5 <)
3500
3800 4000 5000 3600 3600 3600 3600 4000 3800 4000 3800 4200 4200 4200 3800 4200 4800 4200 4500 4200 4000 4200 4500
XCF
440 XCR
Trail
.192 Almond! Gold RedlWhite .192

RedlWhile
/Blue
Silver tBlue
Red
Silver
Trail Touring
Trail RMK~ See Note Below Super Sport
12.00"
12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00' 12.50" 12.00" 12.50" 12.00" 12.50' 12.00" 12.50' 12.50"
500
500 Classic
500 RMKSee Note Below
Classic Touring WideTrak LX
XLTSP XLT LTD

XLT Classic XLT Touring
600 XC 600 XCR 600 RMKSee Note Below Ultra Ultra Touring 700 XC 700 XCR 700 RMK' See Note Below Storm
.192 RedfWhite .192 Red/White .192 Gold .207 Gold .207 Gold .207 Brown .200 Dark Blue .218 SilverlGold .218 Dark Blue .218 SHve r/Gold .218 Dark Blue .2 18 Almond (square) Dark Blue .218 Dark Blue .218
Dark Blue
Red
Silver
10AL Bushed 10M Bushed 10M Bushed 10MB Bushed 10 Bushed 10 MB Bushed 10 M Bushed 10 M Bushed 10 MB Bushed 10-58 Bushed 10-54 Bushed 10-58 Bushed 10-54 Bushed 10-60
Bushed
Gold Red
Silver Silver Sliver
B-2 34 #3 34 '2 R8 #2 36 #2 36 #2 34 '2 36 #2 36/#2

34<>/#2
Red Red
SHver Sliver
Gold
SilverI Blue
Red
Silver
34 #2 34 #2 36 #2 R32 #2 34 #2 34 #2 34 #2 R32 #2 R-1 #2 R-8 #2 36 #2 36Mod #2 R-8 #2 R- 11 #2 R-4 #2
.218 Almond (square) Dark Blue .218 Almond (square)
10-54
Bushed
Gold
10-60
Bushed
Silver I
Blue
10-58
Bushed
Gold
* NOTE: RMK production setup is 6000-9000 ft. Refer to Page 6_8b for production RMK Specs
6.8a
9/97
CLUTCHES 1998 High Elevation Clutch Specifications
3000 Ft. to 6000 Ft.

Machine Model ChainShift Weight 10M Blue
10 Bushed 10M Bushed 10M Bushed 10M Bushed 10 Bushed 10M Bushed 10 Bushed 10M Bushed 10 Bushed
10MW Bushed Clutch
6000 Ft. to 9000 Ft.

Chain-
9000 Ft. to 12000 Ft.

Chain-
Spong
Gold
Ute! Deluxe {fouling

Sport Sport Tour
Driven Helix 36.51> #A-l
case
Gearing 16:39
17:35 16:39 15:39 22:41
Shift Weight
10M White 10AL Bushed 10M Bushed 10M Bushed 10MB Bushed 10MB Bushed
10MB Bushed
Clutch Spring
Gold
Driven Helix
case
Gearing 16:39
16:35
36.50
#A-l
36.5 #B-2
Shift Weight 10M While or 10M Red

10M Blue or 10 Bushed
Clutch Spring Blue Gold RedIWhite Gold

Gold
Driven Helix
case
Gearing
16:39 16:35
16:39
36.5'" #A-l
36.5 #B2 36.5 #B-2 36.5 #B2
AedNVhile
Brown
36.5"
#B-2
Gold Gold
lng TranSport
Super Sport
Trail
TraiiTouring Trail RMK
36.5 #B-2
36.5" #B-2 36 #2 36 #2 36 #2
36.5" #B2
36.5 #B-2
16:39 15:39
21 :41
10M Blue Bushed 10M Blue Bushed

10MB Bushed 10MW Bushed 10MB Bushed
1QMW Bushed
Brown
RedJ'vVhile
RedlVl/hite RedJ\IVhite Red,while RedlWhile RediWhile Gold Almond! Gold Gold Gold Gold Blue Dark Blue SilverGold Dark Blue SliverGold Almond! Gold Almond Dark Blue Dark Blue Dark Blue AlmondGold Almond Dark Blue Almond
Gold
Gold
RedJWhite
Red/white
15:39 21:41 22:41 20:40

18:41
RedJWhite
RedlYVhite RedflNhite RedJVVhite
3S #2 36 #2 36 #2 34 #2
3S #2 3S #2 36 #2 34 #3 34' #2 36 #2 34 #3 R-32 #2 3S #2
22 :41
20:40
18:41
22 :41
20:40
lB :41
RedJWhite Red/INhile Gold RedlWhite
34
#2 34 #2 36 #2 34 #3 AB #2 36 #2 34" #2 34 #2 34 #2 A-32 #2 34 ' #2 34 #2 34" #2 R3 #2 R- l #2 R-B 36 #2 36 #2 Rll #2 R-B #2 Rll A4 #2
10MB Bushed 10M Bushed 10MB Bushed

10MW Bushed
XCF
WideTrak LX
19:39
19:41
Gold
RedlVVhite Gold Almond! Gold Dark 81ue Dark Blue Dark Blue Blue Dark Blue Dark Blue Dark Blue Blue Almond! Gold Almond Dark BIlle Dark Blue Dark Blue AlmondGold Almond Dark Blue Almond
34
#2 36 #2
19:41 19:41 22:41 21:41 22:41
10MB Bushed
10MW Bushed 10MR Bushed
19:4 1 19:41
22:41 21 :41 22:41
440 LC 440 XCR

500
500 Classic
22:41
22:41 22:4 1 22;41 17:41
34
#3 RB #2 36" #2 34 #2 34
Gold
Almond! Gold Dark 81ue Dark Blue Dark Blue Blue Dark Blue Dark 81ue Dark Blue Blue Almond! Gold Almond Dark Blue Dark Blue Dark Blue Almond Gold Almond Dark Blue Almond
S 53 Blue
10MB Bushed
10M Bushed
10MW Bushed
10MB Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MR Bushed 10MA Bushed 10MR Bushed 10AL
10MB or lOMW 10 Bushed
10MB Bushed 10MB Bushed 10MB Bushed 10MB Bushed

10MB Bushed
10MW Bushed 10MW Bushed

10MW Bushed
22:41
17:41
34
#2
22:41
17:41
500 AMK
C~ssic
34
#2 34 #2 R-32 #2 34 #2 R32 #2 34 #2 R-3 #2 R-l #2 R-B 36' #3 36 #3
Rl l #2
'2
34 #2 R32 #2 19:40 21 :41
21;41 21:41
19:40
22:41 22:41 22:41
19:40
21:41 21:41 21 :41 19:40 21:41
Touring
XLT SP XLTLTD
XLT Classic XLT Touring
10MR Bushed
10MW Bushed
34
#2 R32 #2 34 #2 R-3 #2 R-l ,2 R-B 36< #3 3S #3
10MB Bushed
10MB Bushed
lOMR Bushed 10MW Bushed 1054 10M Bushed 1054 Bushed 10M Bushed 10M Bushed
20:40 22:40 23:40

19:40
19:40 21 :41
21 :41
600 XC 600 XCR SOO RMK

Ultra Ultra Touring
1056 10 Bushed 1056 Bushed 10 Bushed 10 Bushed 10-sB 10 Bushed

1058 Bushed
21:41
19:40 22:41 21:40
19:40 22:41 21:40 23:40 23:40 21 :41

21 :41
23:40 22:40 24:40 24:40

21 :41
10MB Bushed 10MB Bushed 1054

10MB Bushed 10-56 Bushed
700XC 700 XCR 700 AMK

Storm
1056
Bushed
R- Il
#2 R-B #2
R-'l
23:40 23:40
21 :41 21:4 1
10M Bushed 10-58 Bushed

10-56 Bushed
R-B #2
R l1
1056 Bushed
25:40
A4 #2
10-54 Bushed
R-4 #2
9/97
6.8b
CLUTCHES Drive Clutch Weight Identification - Actual Size
u
Gram Weight: 34 1 PN 5630 107
y
Gram Weight: 35 1 PN 5630 139
W Gram Weight: 37.5 1 PN 5630109
G - (8 Modified) Gram Weight: 41.5 1 PN 5630063
B
8
A
A
Alp
NP
Gram Weight: 47.5 1 PN 5630094
01
01 Gram Weight: 48.5 1 PN 5630224
Gram Weight: 43 1 Gram Weight: 47.5 1 PN 5630084 PN 5630080
02
02 Gram Weight: 49 1 PN 5630225 Polaris Industries Inc.
o
o
Gram Weight: 51 PN 5610088
03
o
Gram Weight: 53 1 PN 5630174 03 Gram Weight: 32 .5 1 PN 5630227
6.9
9/97
04
04 Gram Weight: 57.5 1 PN 5630229 M 1 (Modified) Gram Weight: 46.0 1 PN 5630301
N1 (Modified) Gram Weight: 51.5 1 PN 5630302
K1 Gram Weight: 39 1 PN 5630144
P1
J1
Gram Weight: 44 1 PN 5630065
Gram Weight: 42 1 PN 5630089
05 Gram Weight: 53.5 1 PN 5630234
06 Gram Weight: 50 1 PN 5630243
07
07 G ram Weight: 52 1 PN 5630244
08
09 08 Gram Weight: 47.5 1 Gram Weight: 51.5 1 PN 5630249 PN 5630245 10 Gram Weight: 51.5 1 PN 5630272 Polaris Industries Inc.
9/96
6.10
lOA 15 G ram Weight: 55.0 1 Gram Weight: 55.5 1 PN 5630286 PN 5630274
10M Gram Weight: 49.5 1 PN 5630273
10M Blue Gram Weight: 47.5 1 PN 5630324
10M Red Gram Weight: 44 1 PN 5630325
10MIW Gram Weight: 46 1 PN 5630369
10AlL Gram Weight: 53 1 PN 5630368
10 Bushed Gram Weight: 51 .5 1 PN 1321526
10M
10M B
10M-W Bushed Gram Weight: 46 1 PN 1321527

10M Bushed Gram Weight: 49.5 1 PN 1321528
10M Blue Bushed Gram Weight: 47.5 1 PN 1321529
10M Red Bushed Gram Weight: 44 1 PN 1321530
6.11
9/96
10 66
10-AL Bushed Gram Weight: 53 1 PN1321531
10-66 Bushed Gram Weight: 66 PN 132 1584
10-62 Bushed Gram Weight: 62 PN 1321586
10A Bushed Gram Weight: 55 PN 132 1589
s
53B
10-54 Bushed Gram Weight: 54 1 PN 1321685 9/97 853B Gram Weight:49 1 PN 132 1730
S
53R
S
55R
853R Gram Weight:51 1 PN 132 1731
855R Gram Weight:53 1 PN 1221759 Polaris Industries Inc.
6.12
CLUTCHES Drive Clutch Spring Rates

The fol lowing chart will aid in the setup and balance of engine RPM power curves for special converte r tuning requirements such as high operating altitude, heavy loads, mountainous terrain, etc.
Drive Clutch Spring Compression Rate Chart
Drive Clutch Spring Compression Rate Chart

340 320 300
Almond
- - - - 7041566
-'
I"
I..
1
P-90TRAVEL P-85 T1 RAVEL
280 260
.
/
I-.-.0/ /..ff1; ---+-/---:/,-L-J+- . ..::....7-~-I'l

,.
ftt 7 ..~
' 1- 1
Dark Blue
7041526 7041080
Silve r/Gold
_ _ _ _ _ _ Blue/Blue-Gold
V - - 7041286
~ -. -
. ~__ .?-:j{L / ~
I
_ _ _::1:
Red
Almond/Gold
645
220 200
- - + - - ----I//i1
-~7h;'
~~ 4
'"..y "/
/
/ -
~ 180
Z
-,.4-:
/
./.' I
....\
~
~
160 -'
140
},/ r,,1 ;;,'/.,/!-.-' 'I
/ ./' Y ~.Y .~.

"
./
.*'
' ~-;;j 7
... "
#' I//.
/.
I
'---
"'l/ /
I , ' _--- / ' ' , ' ----1//
..
, '_
y
,. .,. ~ - 7 ' ..-_..: ,/ I

.-i
, ' 11
L.j
,,;
,'~---- ~~::~50
7041061
Orange
Pink
-----~::8h~te ~
7041060 7041065
Yellow
:~:~:48
I' ___
~
/y
./
/'
/'
___
7041102
- - Green
u.. 120
100 Y
80 -
r. /-" ' ~] .:/.~ I / / - - -- -~ ' ?/ / .1. __ / ." v 1, / - __ '~ ~- I / till'" ~ , , ' /'- _-'~ / '
r _
----/d
, /
r, '-:--,/ I : --/,/f :P
.1 , /
~:;..
/
//
/';./
/'
7"
/' /' ,
-I-
//1/' __
'/ /'
/'
-.l ~ ""-::;; '-~

./
7"""""'K
" I1
1 '
~I
'
7041168
Purple
7041063
. _ Whlte
7041132
--- ib~~021
Black 704 1022
- - Blue/Green
'/ /
,
.-"
_J
,~/
/
60 - / / ' / ' /' , / . 40"':/ 20 - /
,,
J"
I
2.25
,-r-:- / " - '' ...........

I I
AI'
/. ' ' /
,/
7041157
ATVonly
2.00
175
-r
1.50
1.25 1.19
I I
COMPRESSED SPRING LENGTH (INCHES)

6 .1 3
9/97
CLUTCHES Drive Clutch Spring Data

PART NU MBER COLOR CODE WIRE DIAMETER FREE LENGTH +/- .125"
7041021 7041022 7041063 7041062 7041065 7041060 7041080 7041083 7041102 7041061 7041 132 7041 168 70411 48 7041150 7041286 7041080 7041526 7041566 7041645
CAUTION:
Clea r Black Purple Silver Pink Orange Blue/Gold Red Yellow Brown White Green Gold RedlWhite Silver/Gold Bl ue Dark Bl ue Almond Almond/Gold
.157" .140" .168" .208" .1 77" .196" .207" .192" .192" .200" .177" .177" .207" .192" .218"
.201"
4.38" 4.25" 4.37" 3.12" 4.69" 3.37" 3.50" 3.77" 2.92" 3.06" 2.92" 3.05" 3.25" 3.59" 3.05" 3.55" 3.52" 3.65" 4.0"
.218"
.201" (Square)
.207"
Never shim a drive clutch spring to increase its compression rate. T his may result in complete stacking of the coils and subsequent clutch cover fai lure. Maximum efficiency of the variable speed drive system is dependent upon many factors. Included In these are converter offset and alignment, belt tension, belt to sheave clearance. and internal condition of the drive and driven clutch components. One of the most critical and easily serviced parts is the drive clutch spring. Due to the severe stress the spring is subject to during operation, it should always be inspected and checked for tolerance limits during any clutch operation diagnosis or repair. With the spring resting on a flat surface, measure free length from outer coil surfaces as shown. Refer to the chart above for specific free length measurements and tolerances. In addition to proper free length, the spring coils should be parallel to one another when placed on a flat surface . Distortion 01 the spring indicates stress fatigue. Replacement is required.
9/97
6. 14
CLUTCHES Driven Clutch Spring Rates Driven Clutch Spring Data

Part Number Description
7041198 7041501 7041 499 7041296 7041646
Red Gold Silver Blue Silver / Blue
Refer to page 6.37 for driven clutch helix information
Driven Spring Charts

140
/
J-- - -
Blue Silver or Silver/Blue
120 100 80
,Q
/-----
Gold
Vi'
.c ()
60 40 20
.
Q)
!!
f0
::>
a ;-________________________,
Degree of Rotation
150
80 70
___ Silver/Blue -+-_ - - Blue
60 50
Silver Gold
i!l 40 c
..--..--
---
~_-
Red
::>
30 20 10
'" .3
"0
O+ ________________________--j
2.5"
Pola ris Industries Inc.
Compression Distance (in)
1.375"
6.15
9/97
CLUTCHES P-85 Drive Clutch Exploded View - Typical

2.
3.
Do not lubricate drive clutch components
Ref. Qty Description

1. 2. 3. 4. 5. 6. 7. 8. 1 Asm. , Drive Clutch Basic 62 (Less 6,14) 6 Bolt 6 Washer, Spring Lock 1 Cover, Bearing 1 Ring, Retaining, Cover 1 Spring, Clutch 3 Pin, Roller 1 Kit - Shim, Drive Clutch 6 BuMon, Guide 6 Washe r, Multilube Asm., Roller & Bushing Nut, Jam Spacer, .050mm Spacer, .032mm Spacer, .020mm Asm., WeighVBushing Pin, Weight, Hardened Nut, FLEXLOC Bearing, Sleeve Insert, Moveable Kit-cl utch rebuild, inc1.7-11 , 15
9.
10. 11. 12. 13.
3 1 AR AR AR 14. 3 15. 3 16. 3 17. 1 18. 1
9/96
6.16
CLUTCHES P-85 Driven Clutch Exploded View - Typical
Do not lubricate driven clutch components except inside of helix hub to reduce fretting and corrosion.
~--------------------
14.
y
15.
~----------------~
Ref. Qty Description

1. 2. 3. 4. 5. 6. 7. 8. '9. 10. 11. 12. 13. 14. 15. 16. 14 1 1 2 1 1 1 1 NR 3 1 3 1 3 1
Screw
Plate, Driven Ring, Retaining Washer Ramp. Dri ven Key, Square Spring, Driven Clutch Bushing, Driven Large DU Washer Pin, Adjustment, Driven Cam, Adjustment, Driven Screw Cap, Driven Button Asm., Driven Clutch - Adjustable (IncLl.-13.)
AR 7556804 Washer .030" AR 7555898 Washer .020"
6.17
9/96
CLUTCHES P-90 Drive Clutch Exploded View - Typical
Do nol lubricate drive clutch components
3. 6.
9j\} ~~
./
13. 11.
12 .
~
7.
14.
B.
1.
Ref. Qly Description

1.
2. 3. 4. 5. 1 Asm., Drive Clutch Basic 42 (I ncl. 2.4.,7.-12.,14.,15.) 6 Bolt 6 Washer, Spring Lock 1 Cover, Bearing 1 Ring, Retaining, Cover 1 Spring, Clutch 3 Pin, RoHe r 6 Button, Guide 6 Washe r, Multilube Asm., RoH and Bushing er Spacer, .050mm Spacer, .032mm Spacer, .020mm Bearing, Moveable 1/2" Weight, Shift Pin, Weight, Hardened Nut, FLEXLOC Gear, Ring Screw
6.
7.
8. 9.
10. 3 11. AR AR AR 12. 1 13. 3 14. 3 15. 3 16. 1 17. 6
9/96
6.18
CLUTCHES pogO Driven Clutch Exploded View - Typical
2.
4.
~"
6.
3.
Do not lubricate driven clutch components except inside of helix hub to reduce fretting and corrosion.
7.
A - Snap Ring Retainer (Used on some models) e.g. Lite GT, Sport Touring, TranSport. Can be retro-fit to all P-90 models used in heavy load conditions. Install Extreme Duty P-90 Mounting Kit PN 2200752.
1.
9. 10.
Ref. Qty. Description
1. 2. 3. 4.
5.
6. 7.
1 3 3 1 1
Asm . Driven Clutch Bolt, Tap Buon, Ramp Ring, Retaining, Extension Ramp, Stationary, Cast
B.
1 Spring, Clutch 1 Bearing, Moveable, 1" 1 Bearing, Moveable, 1/2"

Washer
9. AR Washer
10. AR
6.19
9/96
CLUTCHES
Operation
The Polaris drive system is a centrifugally actuated variable speed belt drive unit. The drive clutch, driven clutch, and belt make up the torque converter system. Each cl utch comes from the factory with the proper intemal components installed for its specific engine model. Therefore, modifications or variations of components at random are never recommended. Proper converter setup and adjustments of existing components must be the primary objective in converter operation diagnosis.
'-../
CAUTION:
All converter maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and unde rstands the proper procedures as outlined in this manual. Because of the critical nature and precision balance incorporated into the drive clutch, it is absolutely essential that no attempt at clutch disassembly and/or repair be made without factory authorized special tools and service procedu res. Any unauthorized modifications to clutches , such as adding or removing weights, will void the warranty.
Relationship Between Drive Clutch Weights And Spring In Maintaining Operati ng RPM
The drive clutch is an RPM and torque sensing unit designed to transfer the maximum amount of horsepowe r from the engine to the ground. This is accomplished by weights and a spring inside the unit which react to the centrifugal force from the engi ne RPM. The spring and weights work in combination. In a properl y set up clutch, the maximum desi red operating RPM will be reached immediately after clutch engagement, under ful l throttle conditions. To gain optimum power this RPM should be maintained. As centrifugal force pushes the weights against the rollers, the moveable sheave will force the belt to climb up the drive clu tch sheave and increase vehicle speed.
9000 ------:;:==-=_:-:_=-==
/ 8000------------~.~---------
__ _
ENGINlOPERATING RANGE 250 RPM __ _
7000
a:
~ 6000
5000---------;r~/-------------
ENGAGEMENT 4000~-~-~==~--------------
3000------------------------
If the weights are too light, or the spring rate too high, the maximum RPM will be too great and the drive belt wi ll not move into highest ratio at the top of the clutch. Engine damage may also occur if RPM is too high.
9/96
6 .20
CLUTCHES Operation
9000----------------------8000-----------------------______ ENGINE OPERATING RANGE 250 RPM
: ;:
7000------------------------
~ ::::
,.7
c-=------
ENGAGEMENT- - - - - - -
4000------------------------
3000------------------------
If the weights are too heavy, or spring rate too low, the engine RPM will be low and the drive clutch will upshift too quickly, keeping engine RPM below peak horsepowe r, possibly causing engine damage.
9000-----------------------8000----------------------7000------------------------
SoOo-/,
- - -
- - -
ENGINE OPERATING RANGE 250 RPM
5000~/~-----------------------
ENGAGEMENT~-----------------------3000------------------------
If the weights and sp ring are matched properly, the engine RPM w ill increase quickl y to the desired range and remain the re on both upshift and backshift.
6.21
9196
CLUTCHES Driven Clutch Operation

The driven clutch operates in conjunction with the drive clutch . Its function is to maintain drive belt tension preventing slippage, and sense variations in load requirements necessary to maintain optimum engine torque output and load requirements from the track. Output torque is transmitted through the chaincase jacks haft and chaincase to the front drive shaft and track. When the load on the driven clutch is increased and becomes greater than the torque delivered from the engine, the driven clutch becomes dominant and overrides the drive clutch . The driven clutch downshifts into a ratio which will match the increased load. Because the driven clutch can sense and shift into the proper ratio, engine RPM will remain within the specified range.
Driven Clutch Adjustments

The driven clutch has a provision for varying the torque requirement to change its ratio. It can be readjusted by rel ocating the spring in the helix which in turn increases or decreases the amount of load required to change the ratio.
'-'"'
Driven Clutch (Typical P-85)
9/96
6 .22
CLUTCHES Drive Clutch Removal

1. Hold clutch with strap wrench. Remove drive clutch retaining bolt, grease puller thread and tip lightly and install puller into clutch. Tighten puller with a wrench, or strike t-bar with a hammer until clutch is removed.
Strap Wrench PN 287033 Clutch Puller PN 2870506- 3/4-16 ID Clutch Ctutch Puller PN 2871757-14mm 10 Clutch
NOTE: Some 1997-Current P-85 domestic engine drive clutches have a 14mm inner diameter (10) on the shaft. These clutches require puller PN 2871757.
2.
Slight galling or scoring of bore taper can usually be corrected using a tapered reame r. Place reamer in a vise and lubricate with cuttin g oil. Clean clutch taper by manually rotating clutch clockwise. Do not ream taper more than required to remove galling or scoring.
Tapered Reamer PN 2870576
CAUTION:
Never use an air impact wrench for installing or removing a drive clutch. It will loosen the spider torque value and could cause engine crankshaft damage.
Date Code
Identification
This number indicates internal clutch component vari ation for individual engines. For easy identification, refer to the three numbers behind date code on cl utch cover plate. These numbers are the last three digits of the clutch part number.
Last 3 digits of part number
6.23
9/97
CLUTCHES Drive Clutch

Disassembly and Inspection
1. Install drive clutch in clutch compression tool (8700220). Mark both moveable and fixed sheave, cover, and spider with a permanent marker.
Sheaves must be marked to provide a reference point for clutch balance and spider indexing. If the sheaves are not marked, and spider shim washers are changed or misplaced, the will clutch will be out of balance and must be replaced. See page 6.32 for indexing procedure.
2 . Carefully and evenly remove cover attaching bolts.

Do not allow side loading or misalignment of cover or bushing may be damaged. Remember there is spring tension on the cover. Inspect cover bushing for wear. See page 6.47 for inspection and repair procedure.
Drive Clutch Compression Tool PN8700220 '

f'
Drive Clutc* HOlding Fildure

PN 2871~a "
3.
Mount drive clutch securely in the holding fixture. On models equipped with a spider jam nut (P-85 Clutches) , remove jam nut in a counterclockwise direction (standard thread) using the special tool.
Spider Spanner (Jam Nut) Toot

PN 2870338
4.
Install spider removal tool and remove spider in a counterclockwise direction (standard thread).
Spider Removal Tool

PN 2870341
9/97
6.24

Disassembly, Cont. 5. Measure the total thickness of the spacer washers installed beneath spider and mmN.
....CAUT,IQ.N{
NOTE: In order to maintain proper belt-to-sheave clearance and clutch balance, the same washers (or equivalent total thickness) must be reinstalled during assembly. If sheaves are not marked, or if total thickness of existing shim washers under spider is not recorded, clutch will be out of balance when reassembled and must be replaced. Be sure to follow indexing procedure on page 6.32 if beltto-sheave clearance is being adjusted. 6. Inspect both sheave surfaces for wear or damage. Inspect movable sheave bushing. See page 6.49 for inspection and repair procedure .
7.
Using an 1/8" Allen wrench with a 3/8" combination wrench, remove drive clutch fly weights. Note direction of weight pin with nut on trailing side. Inspect each weight. Surface should be smooth, with no waves or galling. Place bolt inside weight to check flyweight bushing and pin surface for wear.
NOTE: The weight bushing is not a service part and both weight and pin must be replaced if worn . Direction of rotation
8.
Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Roller can also be inspected by rolling with finger to feel for flat spots, roughness , or loose bushing . Also inspect to see if roller and bushing are separating. Bushing must fit tightly in roller. Replace roller and pin if roller fails to roll smoothly (flat spots) or if bushing is loose.
6.25
9/97
CLUTCHES Drive Clutch Spider Roller Removal

1. Remove spider buttons using button removal tool. Remove shims (if any are installed) and note location.
Spider Button Removal Tool PN 2870985
2.
Place spider on a vise or in an arbor press. Using a pin punch , drive out the roller pin.
Roller Installation
1. Start a replacement roller on each leg, driving a pin in .100"-.125" (.25-.32 cm) beyond the first land of the spider leg (A). Remove any aluminum burrs from pin protruding from spider.
2.
Install one washer onto pin.
9/96
6.26

Roller Installation, Cont.
3. 4. Place roller on pin as it protrudes from first land. Place a second washer on other side of roller.
5.
Install service tool as shown.
6.
Place spider on a vise anvil and drive roller pin through to second land of spider.
CAUTION:
Use care to start the pin straight. Aluminum burrs could pass through into the roller bushing causing it to bind and stick. Also use care to make sure the roller remains aligned when the pin is driven through. The roller bushing could be damaged causing premature wear and roller failure.
\......;
Spider Button Shimming

1. Determine how many shims are to be used.
NOTE: A shim kit is available which contains an assortment of shims, including .002", .005", and .010" .
Shim Kit PN 2200387
6.27
9/96
CLUTCHES Drive Clutch Spider Button Shimming, Cont.

9. Measure the dimension between towers at the lowe r half of the towers as shown.
10. Install spider buttons using a soft face hammer.
11. Record width of spider buttons on each leg.
12. Add shims beneath trailing side spide r button to obtain specified button-to-tower clearance when assembled.
Button to Tower Clearance-
P-85! P-90 = .002" (.05 mm)
9/97
6.28
CLUTCHES
Drive Clutch Drive Clutch Assembly 1. Place the correct number of spacer washers beneath the spide r.
2.
Assemble clutch making sure "X" marks on movable sheave and spider are aligned to achieve prope r balance.
NOTE: If belt to sheave clearance is being changed by adding or removing washers from under the spider, and the sheaves were marked before disassembly, follow indexing procedu re on page 6.32.
3.
Torque spider to specification . Spider Torque - P8S and P90 200 ft. Ibs. (27.6 kgm) Spider Removal Tool PN 2870341
\.........
4.
Torque jam nut to specification (P-85 Clutches). Install weights with weight pin nut on trailing side. Use new nuts to ensure proper retention. Torque nut to 30 in. Ibs. Jam Nut Torque - P8S models only 23S ft. Ibs. (32.43 kgm) Jam Nut Tool PN 2870338 Weight Pin Nut Torque 30 In. Lbs . (.34 kgm)
6.29
9/97

Assembly, Cont.
5.
Install spring and cover. Torque cover bolts evenly to specification . CAUTION: Carefully align bushing with shaft during installation of coverto prevent bushing damage. Maintain alignment by tightening cover bolts evenly and carefully.
Spider Cover Bolt Torque 90 in. Ibs. (1.03 kgm) Installation
1.
Slight galling or scoring of the bore taper can usually be corrected using a tapered reamer. Place reamer in a vise and lubricate with cutting oil. Clean taper by manually rotating clutch clockwise.
Tapered Reamer PN 2870576
2. Check crankshaft taper for galling or scoring. If necessary clean taper evenly with 200 grit emery cloth .
3.
Both clutch taper and crankshaft taper should be clean and dry.
NOTE: Do not use harsh cleaners which may cause clutch taper to corrode during use. This will cause difficulty when removing clutch in future. Clean clutch taper with lacquer thinner or isopropyl alcohol.
9/96
6.30

Installation, Cant. 4. Slide clutch fully onto crankshaft taper.
5.
Install retaining bolt with any spacers, washers or O-rings. See appropriate parts manual for type and placement of retaining bolt components.
6. Torque retaining bolt to specifications. Hold clutch with strap wrench. Drive Clutch Bolt Torque (Large 10 Shaft)40 - 45 ft. Ibs (5.52 - 6.21 kgm) Drive Clutch Bolt Torque (Small 10 Shaft)50 ft Ibs. (6.9 kgm)
NOTE: Re-torque clutch to specification after first period of operation (such as a test ride) .
6.31
91 96

Spider Indexing
NOTE: Spider indexing affects clutch balance and belt to sheave clearance. Read procedures carefully before proceeding. 1. Before disassembling drive clutch , mark spider, cover, moveable sheave, and stationary sheave in line with a permanent marker as shown .
2. Disassemble drive clutch as described on page 6.24. Take care to note the amount and thickness of the shim washers under the spider.
3.
Add or remove spider washers as required to ach ieve desired belt to sheave clearance. For example: If belt to sheave clearance is .020" too large, removing one .020" shim will position the movable sheave closer to the fixed sheave reducing belt to sheave clearance by .020" .
NOTE: The following washers are available for fine tuning:
Washers: PN 5210754 PN 5210753 PN 5210752
.050" .032" .020"
4.
Install spider washer(s) and spider aligning Xs. Notice as the spider seat location is changed, the sheave marks made before disassembly no longer align . There are two ways to bring the sheave marks into alignment. Vary the amount and thickness of spacer washers (Washer thickness may vary slightly) . Re-index marked spider leg to another tower. This can be done because spide r has little effect on overall clutch balance.
Re-indexing the spider 1/3 turn clockwise, or 1 leg, will allow the realignment of the moveable and stationary sheaves as previously marked. For example: .020" or .032" washer removed - re-index spider clockwise 1/3 turn .050" or .064" washer removed - re -index spider clockwise 1/3 turn Two .050" or .064" washers removed re-index clockwise 213 turn
NOTE: Alignment marks should be within 1" (25 mm) after final assembly and torquing.
9/96
6.32
CLUTCHES Driven Clutch Driven Clutch Removal

1. Remove driven clutch retaining bolt.
2. Slide driven clutch off jackshaft. It may be necessary to use a puller on some driven clutches. P-85 clutches (externally adjustable) can be removed using a 3-point flywheel or steering wheel puller and the 1/4-20 adjustment bolt holes. Use a suitable spacer on the end of the jackshaft.
pogO Driven Clutch Puller

PN 2871056
3. Inspect jacks haft keyway (splines I P-90s) for wear or damage.

NOTE: Notice the number and thickness of shim washers between driven clutch and jackshaft bearing. These must be replaced to maintain proper offseValignment.
6.33
9/96
CLUTCHES Driven Clutch

Disassembly
1. Place clutch on bench.
CAUTION: Wear eye protection during disassembly and assembly of driven clutch.
2.
Hold fixed sheave and tum movable sheave 1/4 tum. Hold movable in place tap helix down with a soft faced hammer. Remove snap ring and washer. NOTE: On models equipped with snap ring retainers as shown below, retainer may stay on back of snap ring when clutch is removed. Pry lightly to remove retainer and gain access to snap ring. (Refer to illustration below.)
If retainer stays with clutch, p evenly to remove (P-90)

Snap Ring
Retainer
3. Allow sheaves to return and force the helix out. Before removing helix, note driven clutch spring position. Remove helix.
4.
Inspect helix ramps and movable buttons and for wear or damage. P-90 driven clutch ramp buttons are secured by TorxT screws. P-S5 buttons can be M removed by applying heat to the button housing or drill button with an 1/S" drill bit. The ramp buttons should be replaced when worn . See Maintenance section for inspection intervals.
9/97
6.34

Disassembly, Cont.
2. Remove driven clutch spring. Both spring tabs should line up. If not spring is fatigued and should be replaced.
Tabs Aligned
3.
Slide moveable sheave off and inspect sheave surfaces for wear or grooving. Note size and number of shim washers between sheaves.
4.
Note condition of moveable sheave bushing. Install helix into bushing. It should slide freely without binding. See page 6.51 for bushing replacement.
5.
Polish helix with a fine emery cloth to remove any sharp edges or build up which may cause sticking.
6.35
9/97

Assembly
1. Install appropriate washer(s) on fixed shaft.
Optional Thin Adjustment Washer (P-85) .048" - PN 7555899
2.
Slide moveable sheave on fixed shaft.
3.
Install driven clutch spring . Be sure spring tab is seated in hole in moveable sheave. Refer to specifications in front of this section for driven spring setting. P-85 driven clutches have 1 spring locat ing hole in the movable sheave and 4 holes in the helix. P-90 driven clutches have 2 spring locat ing holes in the movable sheave, and 3 in the helix
NOTE: The driven clutch helix/moveable assembly has several different spring locations which affect clutch shift ing and RPMs. Tighter spring tension will raise engine RPMs during clutch upshift and allow quicker downshift when pulling or negotiating a hill. The lighter tension positions will tend to have a slower downshift and a harder upshift. pogO
Example: Spring! Position
Moveable Helix Sheave B-1 B 2 A-I B-3

A 2
Spring Tension
A - 3 Soft P-90 production settings are usually B2 PS5 production settings are usually #2 4.
T
6.36
Align inner keyway (PS5) or boss spline (P-90) between the helix and movable sheave. With the spring in place, slide helix onto shaft .5" (12mm).
9/96
CLUTCHES Driven Clutch Assembly, Cont. Helix An gles and Effects

The driven clutch helix was selected for overall performance in relation to the other driven system components. In fine tuning situations requiring a slight adjustment of engine operating RPM or improved backshift, we recommend trying a helix change before changing other components. Polaris has several helix angles available for the P-85 and P-90 driven clutch. Refer to the chart below for specific angle effects and identification.
Helix Ramps'
Description 34 34M' 36 36M' 38 40 42 44 40-36' R1' R2' R3' R4' R5' R6' R7' R8' R9' R10' R11' R32' R12' T-1' 36.5 40-38-36 38-36 38-36-34 34 PN 5130896 5130751 5130895 5130717 5130723 5130724 5130725 5130726 5130898 5131287 5131288 513 1289 5131290 5131291 5131292 5131293 5131294 5131295 5131296 5131297 5131623 5131298 5131013 5130383 5131161 5131162 5131163 5131164 Degrees 34 34 36 36 38 40 42 44 40-36 40-32 42-32 45-32 50-32 40-34 42-34 45-34 50-34 40-36 42-36 45-36 50-34 50-36 42-36-34 36.5 40-38-36 38-36 38-36-34 34 Type P85 P85 P85 P85 P85 P85 P85 P85 P85 P85 P85 P85 PB5 P85 P85 P85 P85 P85 P85 PB5 PB5 PB5 P-85 P90 P90 P90 P90 P90 The helix spring should always be adjusted within its limits before a helix change is performed. The normal rate of change between helix angle steps is 250 RPM under full throttle. This is approximately the same result as in going from the No. 1 to No.4 spring position (P-85). Increasing spring tension increases engine RPM. RPM changes may not be evident if other drive or driven clutch components are substandard.
NOTE:
' NOTE: All R-Series, Mod(M), T1 , and 40-36 helix

ramps are cut 0.060" deeper in the snap ring pocket. These are made so the driven clutch can open far enough for full shift out with wide 1 7/16" belts (standard on Storm and 6001700 twins).
If these helix ramps are used with narrow beits, 2 (two) additional (for a total of three) .030" 1.8 mm washers (PN 7556804) should be installed under the snap ring to prevent the belt from touching the inner hub at full shift which can cause belt failure.
Wide belt models (Storm and 600&700 twins) use only the existing washer under the snap ring .
5. Hold fixed sheave and turn movable sheave 1/4 turn counterclockwise.
5.
Force helix down into place , exposing snap ring groove.
6.37
9/97
CLUTCHES Driven Clutch Assembly, Cont.

6. Install retainer (where applicable on P-90) spacer washer(s), and snap ring. Snap ring should be installed with flat (machined) side up or toward jackshaft bearing. NOTE: On models equipped with snap ring retainers as shown below, retainer may stay on back of snap ring when clutch is removed. Pry lightly to remove retainer and gain access to snap ring. (Refer to illustration below.)
Preload 1/4 turn
Snap Ring
Retainer
NOTE: Always install snap ring with chamfer towards helix (sharp edge outward)
7.
Allow sheaves to close. Test clutch by pre-loading movable sheave 1/4 turn counterclockwise and releasing. Sheave should open and close smoothly with a positive stop. Some helix ramps have more than one washer beneath the snap ring. Refer to page 6.37 for more information.
9/97
6.38

Installation 1. Install proper number of spacer washers on jackshaft between clutch and jacks haft bearing. Inspect Jackshaft Bearing Excessive vibration or abnormal drive belt wear can be caused by a worn bearing or jackshaft on the driven clutch side. To inspect bearing fit, watch the bearing area closely as you try to force the jackshaft up and down. If movement is detected, disassemble to determine which parts are worn. Replace the jackshaft if the new bearing is loose on the shaft. The bearing should be greased at 1000 mile (1600 km) intervals and before storage.
NOTE: Spacer washers between driven clutch and jackshaft bearing set the oHset. Refer to adjustment procedure on page 6.44 to adjust oHset between the drive and driven clutch. 2. Lightly grease jackshaft keyway or spline . With square key in place (P-85s) slide clutch onto jackshaft.
'--
3.
Install spacer, bolt and washer to hold driven clutch in place.
Driven Clutch Retaining Bolt Torque15 ft. Ibs. (2.08 kg-m)
4.
P-85 and P-90 driven clutches should float from side to side (.040-.080" (1-2 mm. Without a slight free float , jackshaft bearings could be side loaded, causing premature bearing failure. NOTE: Some models with P-90 clutches use a snap ring retainer cup to captivate the snap ring. On these models end float should be adjusted between .000 and .010" (.000-.254 mm) Torque bolt to specification.
Driven Clutch Torque/Float P-85/ P-90 - .040-.080" (1-2 mm) P-90 with retainer .000-.010" (.000-.254 mm)
6.39
9/97
CLUTCHES
Drive Belt Drive Belt
Part No. Belt Width * (Projected) Side Angle Overall* Center Outer Notes to CircumCenter' terence * +.100"
-.000"
32 11042 321 1045 3211057 3211058 321 1059 321 1061 3211065 3211066 3211067 1.375" (34.93mm) 1.375" (34.93mm) 1.438" (36.53mm) 1.250" (31.75mm) 1.250" (31.75mm) 1.375" (34.93mm) 1.438" (36.53mm) 1.375" (34.93mm) 1.375" (34.93mm) 1.375" (34.93mm) 1.438" (36.52mm) 1.438" (36.52mm) 1.438" (36.52mm) 32 32 28 28 28 32 28 28 28 12.00" 12.00" 12.50" 11.00" 12.00" 12.00" 12.50" 12.00" 12.00" 47.250" 47. 125" 48.375" 43.3 13" 45. 125" 47. 188" 48.375" 47.250" 47.250" Common production belt for P-85 systems Close tolerance version of 3211042 Obsolete original Storm Belt
Indy Lite belt (P-90) Longer Indy Sport Belt (P-90) CVT version of 3211045 CVT Double Cog Storm belt Double cog - CVT - thicker than 32 11070. Production on higher horsepower snowmobiles. Double cog Good for short runs on higher horsepower engines (Drag Racers) - Good for lower horsepower trail riding Common production belt for late model P-85 systems Double cog Good for short runs on higher horsepower engines (Drag Racers) - Good for lower horsepower trail riding Double cog Good for short runs on higher horsepower engines (Drag Racers) - Good for lower horsepower trail riding Double cog - CVT
3211070 3211073
28 28
12.00" 12.50"
47.250" 48.375"
32 11 074
28
12.00"
47.625"
3211075
28
12.00"
47.625"
* Belt dimensions given are nominal dimensions. There is a variance for all critical dimensions. Clutch set-up must be inspected when a new belt is installed and, If necessary, clutch set-up must be adjusted.
The drive belt is an important component of the converter system. In order to achieve maximum eHiciency from the converter, drive belt tension (deflection), clutch offset, and alignment must be adjusted properly.
General Belt Selection Guidelines

NOTE: Refer to appropriate parts manual for proper bell. Production be lt is recommended unless tuning for a specific applicalion.
CVT Increased service life for high horsepower and extended high speed running Need 1-2 grams heavier drive clutch weight Good for prolonged high speed running. Good for aggressive riders Standard Compound 9/97 More aggressive at low speeds Reduced heat and drive clutch sheave wear Used for short, higher horsepower runs (Drag Racing) Good trail belt for lower horsepower engines.
6.40
CLUTCHES Drive Belt

Drive Belt Inspection
1. Measu re belt width and replace if worn severely. Generally, belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection.
o
The top edges have been trimmed on some drive belts. It will be necessary to project the side profiles and measure from corner to corner. Place a straight edge on each side of the drive belt. Place another straight edge on top of belt. Measure the distance where the side straight edges intersecl the top, as shown in the illustration at right.
I..---.!rojected B e l~ Width
o o
\
Solution
2.
Inspect belt for loose cords, miSSing cogs, cracks, abrasions, thin spots, or excessive wear. Replace if necessary. Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages the belt.
3.
Belt Wear I Burn Diagnosis
Belt Wear I Burn Diagnosis

Possible Cause Of Wear Or Burning
Driving at or about engagement RPM for extended periods in all types of conditions Cold weather startups Drive at higher RPM if possible. Gear the machine down. Make sure belt deflection is at 1.25" to achieve optimum starting ratio
Be palient Warm up engine at least 5 minutes or until it readily responds to throWe input. For the quickest most efficient driveaway In ext reme cold weather, take drive belt off machine and bring it in 10 a warm environment. Break skis and track loose from the snow. Engage throttle aggressively for short durations for initial cold driveaway
When possible, do not go in deep snow when towing another machine. Use fast. effective throttle to engage the clutch . Not all machmes are intended for pulling heavy loads or other machines. Lower the gear ratio . Remove windage plates from driven clutch . If possib le. move to better snow conditions and reduce RPM. Avoid riding in very high ambient temperatures. Break loose snow and ice under tunnel. Allow longer than normal warmup. Allow belt to warm sufficiently and increase grip ability on clutch sheaves. Use fast, effective throttle when engaging clutch . Maintain good state of tune including throttle and choke synchronizalion . Check lor fouled spark plug(s) . Check for foreign material in carbs Make sure no water or ice in luel tank, lines , or carburetors . Use caution when loading machine. Carbide skags may go uge rnto trailer and prevent drive train from spinning freely. Use enough speed to drive completely onto trailer. If machine cannot be driven complelely onto trailer, it may need to be pulled or pushed to avoid belt wear I burning Check for correct clutch components. Use fast. effective throttle to engage the clutch .
Towing another machine at or about engagement RPM
Spinning track while vehicle is stuck (high RPM , low vehicle speed, high ambient temp . Example : 8000 RPM, 1Om ph vehicle speed. 60 mph indicated on speedometer. Ice and snow piled up between track and tunnel overnight or after stopping for a long period of time (enough to fe-freeze the snow). Poor running engine (Bog , Miss, Backfire . etc .)
Loading machine on trailer
Clutch malfunction Slow. easy beH engagement - easing on the throttle
6.41
9/97
CLUTCHES Drive Belt

Belt Deflection Too much belt deflection - If the belt is too long or the center distance too short. the initial starting ratio will be too high. resulting in performance loss. This is due to the belt rising too high in the drive clutch sheaves upon engagement.
Belt too high on initial engagement
Not enough bell deflection (belt too tight) - If the drive belt is too short or the center distance too long. the ratio will again be incorrect. In addition. the machine may creep when the engine idles. causing damage to the internal face of the drive belt.
91 96
6.42
CLUTCHES Drive Belt

Measuring Belt Deflection
"--' IMPORTANT NOTE: Do not apply excessive pressure to force belt into driven sheaves . This will result in an improper measurement. If belt deflection cannot be adjusted within specification using methods below, inspect center distance and compare to specifications beginning on page 6.3. 1. Measure belt deflection with both clutches at rest and in their full neutral position. 2. Place a straight edge on the belt and apply downward pressure while measuring at the point shown. Straight Edge
1 1/4" (3.2 cm)
Belt Deflection 1 1/4" (3.2 cm)
Adjusting Belt Deflection (P-90)

1.
Belt deflection on P-90 clutches is controlled by adding or removing shim washers from between the driven To change belt deflection, clutch sheaves. disassemble clutch as outlined on page 6.34. Adjust shim stack between clutches to achieve desired belt deflection. At least 1 washer must remain between clutch sheave. Remove washers to decrease belt deflection Add washers to Increase belt deflection Reassemble clutch as outlined on page 6.36.
2.
3.
Adjusting Belt Deflection (P-85)

Belt deflection can be adjusted without removing the clutch from the jacks haft.
1.
Pull belt into driven clutch to slightly open sheaves. Loosen three bolts on adjustment cam. Turn cam counterclockwise to reduce distance between sheaves. Do not rotate past #1 position. Torque bolts to specification.
Used to adjust belt tension. One must always be installed.
2. 3. \...., 4.
Optional Thin Adjustment Washer (P-85) .048" - PN 7555899
Production washer is usually .075" with other .020 or .030 washers as required. May use optional, thinner (.048") washer PN 7555899 if required to obtain proper sheave width. Either the .075" or .048" washer must be installed in this location to provide support the adjustment pins.
6.43
9/96
CLUTCHES Drive Belt

Clutch Offset Inspection
NOTE: Proper offset aligns the fixed sheaves of both clutch assemblies. This allows the clutches to be aligned throughout the shift range. 1. 2. 3. Remove drive belt. Belt deflection adjustments affect offset. Set belt deflection first. Install proper alignment tool, depending on type of clutch, as shown in III. 1. Rear of driven clutch moveable sheave should just contact tool when clutch is pushed inward on jackshaft. Clutch Alignment (Tools) P90 - 21/32" Offset (PN 2870914) P85 - 5/8"Offset (PN 2870426) P90 Electric Start 1.28" Offset (straight edge) P85 Electric Start 1" Offset (straight edge)
"
Offset - Non-Electric Start Models
.:; _ _ A
'."
.-'-: .
'" :, -..;;
No gap at point "Au
21/32" Offset All models with P90 driven clutch 5/8" Offset All models with P85 driven clutch
NOTE: Up to .060" (1.5mm) air gap allowed at point "B", 8 Up to .125" is acceptable on new machines.
'"
Clutch Offset Adjustment

Determine direction driven clutch needs to be adjusted. (Refer to Clutch Offset Inspection procedu re above). 2. Remove driven clutch retaining bolt, and remove driven clutch. 3. Add or take out washers on jackshaft between the driven clutch and jackshaft bearing to achieve proper offset. 4. Most models require the driven clutch to float on the jackshaft. After adjusting offset, add or remove shim washers from the retaining bolt to provide a .030"-,060" (.75-1 .5mm) of float on jackshaft, This will prevent side loads on the jackshaft bearing. NOTE: On models with driven clutch snap ring retain er (Transport , Lite Touring, Sport Touring, etc.) the clutch is mounted firmly on the shaft without float. NOTE: When checking electric start models , use a straight edge as shown in III. 2. If alignment is off, loosen the engine mounts and shift engine as required to obtain the proper off set and alignment. Driven Clutch 80lt Torque 12 ft. Ibs. (1.66 kgm) 1.
III. 1
Offset Alignment Tool
Offset -Electric Start Models NOTE: Up to .060" (1.5mm) air gap allowed at point "B". (. 125" on new machines)
Straight Edge
8
P90 Electric Start - 1.28" P85 Electric Start - 1.00"
III. 2
9/97
6.44
CLUTCHES Drive Belt

Clutch Alignment Inspection
NOTE: Drive clutches are purposely misaligned slightly forward to compensate for the engine shifting on it's mounts. Under load , the engine will pull back slightly so both clutches are in alignment.
After clutch offset has been verified , inspect alignment. 2. Install proper alignment tool, depending on type of clutch, as shown in III. 1 page 6.44. 3. The re should be a .060" - .090" (1.5 - 2.25 mm) gap between fro nt of driven cl utch and tool, with the tool just touching at the rear. Up to .125" (3. 1 mm) gap is acceptable in the front on new machi nes .
1.
Clutch Al ignment Adjustment

1. Loosen all 4 engine mounting bolts. 2. Adjust engine torque stop until clutches are in proper alignment. 3. Tighten engine mounts securely. 4. Recheck both clutch offset and alignment. 5. Verify proper to rque stop adjustment.
Torque Stop Adjustment

NOTE: There are two types of torque stops cu rrently used . Refer to the illustrations below for adjustment of each type.
1. After aligning clutches, adjust torque stop by loosening lock nut and rotating stop to proper clearance as shown. Hold torque stop and tighten jam nut to 15-17 It. Ibs. (2.07-2.35 kg-m) .
ENGINE MOUNT TORQUE STOP
CRANKCASE TORQUE STOP
Adjust gap between stop and engi ne mount to .010" - .030" (.25 - .75 mm) .005" (. 13 mm)
(('~~ . . -'i!~" ~ :1 -:- ... /~< .
'"
~'.
"\ 1
I~
Il}.."
\ ~~~~" ~'--Y.,e! 8/~ \\ ~~

/' Adjust gap between stop and engine crankcase to .100" (2.5"mm) .010" (.25 mm)
Lock Nut
6.45
9/97
CLUTCHES Drive Belt

Belt to Sheave Clearance Inspection
NOTE: The distance between the belt and the moveable sheave on the drive clutch is very important. This distance controls the starting ratio (lowest starting ratio is most preferable) and the position of the clutch weight to engine RPM . The distance between the belt and moveable sheave should be as close to .020" (.5 mm) as possible without creating a drag on the belt, when positioned around the hub at the bottom of the sheaves.
1.
Force belt to one side of drive clutch . NOTE: Measure total belt to sheave clearance with a new belt. Install feeler gage between other sheave and belt.
Belt to Sheave Clearance -
2.
.020".015"(5 mm.4mm)
Belt to Sheave Clearance Adjustment

Belt to sheave clearance can be adjusted in two ways. 1. 2. Try several new belts to achieve proper clearance . Can add or remove shims from under the spider to increase or decrease belt to sheave clearance. See Spider indexing on page 6.32.
NOTE: Spider indexing affects clutch balance and belt to sheave clearance. Read procedures carefully before proceeding. NOTE: Belts with various widths will also affect belt deflection since they will fit differently in the driven clutch . Deflection should be checked per procedure on page 6.43.
9/96
6.46
CLUTCHES Clutch Bushings P-85 Kit PN 2871025
'---'
Item
Oty.
1
2 3 4 5 6 7 8
Part Description P-85 Drive Clutch Moveable Bushing Removal and Installation Tool P-90 Drive Clutch and Driven Clutch
Part No. 5020627 5020628 5020629 5020630 5020631 5130862 5222768 5020632 5010279 5020633 9912260
1 1 1
1 1 1
Bushing Installation Tool Drive Clutch Cover Bushing Removal and Installation Tool (for all drive clutches) P-85 Driven Clutch DU Split Bushing Installation Tool P-90 Driven Clutch Bushing Removal Tool P-85 Driven Moveable Sheave Removal Tool P-85 Driven Moveable Sheave Removal Bridge Main Puller Adapter
Adapter Reducer 9 Number Two Puller Adapter 10 Instruction 11 You will need to supply: Piston pin puller (PN 2870386) Bench vise Soft face hammer (for P-85 Driven Moveable) Small scribe or pick (for Cover Bushing Removal) Hand held propane torch (for P-90 Driven) Loctite RC 860 Retaining Compound (2870584)
'--"
P-85 Drive Clutch Cover Bushing Removal

1. Disassemble clutch as outlined in this section. 2. Inspect or measure bushing and replace if worn beyond service limit. Note: Bushing must be installed in cover. There are two types of bushings used. Refer to the following specifications .
Cover Bushing Inspection: Garmax Style. (Installed Dimension ) Nominal Bearing Bore: 1.125" ,(28.57mm) Service Limit: 1.140" (28.95mm) Cover Bushing Inspection: TeflonlBro[!ZIl Style Service Limit: Replace cover bushing if more bronze than Teflon T" is visible. Nomin;3.1 Bearing Bore: 1.125" (28.57mm) 1.132" (28.75mm) Service Limit: (Measure When Bushing is Installed)
6.47
9/97
CLUTCHES Clutch Bushings P-85 P-85 Drive Clutch Cover Bushing Removal Cont.
3. On models equipped with snap ring, rem ove round wire snap ring from inside of clutch cover using a small scribe or pick and set aside. Install main adapter (Item 8) on puller. From outside of clutch cover, insert removal tool (Item 3) into cover bushing. With inside of cover toward vise, slide cover onto puller. Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed.
4. 5. 6. 7.
8. 9.
Turn clutch cover counterclockwise on puller rod until bushing is removed. Remove nut from puller rod and set aside.
10. Remove bushing and bushing removal tool from puller. Discard bushing.
P-85 Drive Clutch Cover Bushing Installation

1. On Garmax style bushings (PN 3576516) apply Loctite 680 retaining compound (PN 2870584) to the outer surface of the bushing. Retaining compound is not required on bronze I Teflon type bushings (PN 3576510). Do not lubricate bushings, or premature wear will result. 2. Working from inside of cover, insert bushing and bushing installation tool into center of clutch cover.
3. With main adapter on pul ler, insert cover onto puller rod , placing outside of cover toward vise. 4. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. Turn clutch cover counterclockwise on puller rod until bushing is seated. Remove nut from puller rod and take installation tool and clutch cover off rod . Squeezing ends of snap ring, gently fit ring into clutch cove r.
5. 6. 7.
9/97
6.48
CLUTCHES Clutch Bushings P-85

P-85 Drive Clutch Movable Sheave Bushing Removal
1. Inspect bushing and replace if excessively worn. Install handle end of piston pin puller (PN 2870386) securely into bench vise and lightly grease puller threads. Remove nut from puller rod and set aside. Install main adapter (Item 8) onto puller. See III. 1.
2.
3.
4.
5. Working from inside of moveable sheave, insert removal tool (Item 1) into center of sheave. Wilh towers pointing away from vise , slide sheave onlo puller rod. 6.
Install nut removed in step 2 onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Turn sheave counterclockwise on puller rod until it comes free. III. 1 Main Adaptor
7.
8. Remove nut from puller rod and set aside.

9. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. 10. Remove retaining ring from inside adapter and set aside.
6.49
9/96
CLUTCHES Clutch Bushings P-85 P-85 Drive Clutch Movable Sheave Bushing Installation
1. 2. 3. Place main adapter (Item 8) on puller. Push new bushing into center of sheave by hand. Insert installation tool (Item 1) into center of sheave and with towers pointing toward vise, slide sheave onto puller rod. Install nut on puller rod and hand tighten. Turn barrel to apply additional tension if needed. Turn sheave counterclockwise until bushing is seated. Remove nut from puller rod and set aside. Remove sheave from puller. Remove installation tool. Insert retaining ring removed in step 9 and installation tool into center of sheave.
4. 5. 6. 7. 8. 9.
10. With towers pOinting toward vise, install sheave onto puller rod. 11. Install nut on puller rod and hand tighten . Turn barrel to apply additional tension if needed. 12. Turn sheave counterclockwise until ring is seated. 13. Remove nut from puller rod and set aside. 14. Remove sheave from puller. 15. Remove installation tool. Do not lubricate bushings, or premature wear will result.
9/96
6 .50
CLUTCHES Clutch Bu shings P-85 P-85 Driven Clutch Movable Sheave Large Bushing Removal
NOTE: The P-85 driven moveable has a split bushing. Note the position of this split during bushing removal. See III. 2.
Note position of split
Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon'" is visible on the bushing.
1.
Inspect bushing and replace if excessively worn. Insert bushing removal tool (Item 6) into sheave, centering split on tool. NOTE: The split must be touching the tool. See III. 2. Bushing removal tool
2.
III. 2 3. Install main adapter as illustrated. Install bridge (Item 7) onto puller with legs pointing toward clutch. See III. 3. From the outside, insert thumb through center of sheave. Using downward pressure, hold bushing removal tool tightly in place.
4.
Main Adaptor
5. With back side toward vise, slide sheave onto puller. 6. Install nut onto puller rod and hand tighten. Slowly align clutch with bridge and turn puller barrel to increase tension if needed. Turn sheave counterclockwise until bushing is removed and sheave comes free.
Remove nut from puller and set aside. Remove tool and bushing from puller. bushing.
7.
8. 9.
Bridge
Discard
III. 3 L -_ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
10. Remove bridge and adapter from puller.
6.51
9/96
CLUTCHES Clutch Bushings P-85 P-85 Driven Clutch Movable Sheave Large Bushing Installation
NOTE: The P-85 driven moveable has a split bushing. The bushing is held in place after installation by screws.
11 . Insert bushing (PN 3569803) into clutch and tap lightly with a soft face hammer.
III. 4
12. Install adapter number two (Item 10) onto puller. See
III. 5.
13. Slide clutch sheave onto puller with back side away from vise. 14. Tum puller barrel until rod extends past back side of sheave. 15. Insert large installation tool for DU bushing (Item 4) onto rod. 16. Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed. 17. Turn clutch sheave counterclockwise until bushing is seated. 18. Remove nut lrom puller rod and set aside. 19. Remove installation tool and slide clutch sheave from puller.
NOTE: The screws hold the bushing in place.
III. 5 ~--------------------------~
Adapter Number Two
91 96
6.52
CLUTCHES Clutch Bushing P-90 Polaris Kit PN 2871226
\.......-
Item 2 3 5 8 9 10
Qlli. 1
1 1 1
Part Description P-90 Drive Clutch and Driven Clutch Bushing Installation Tool Drive Clutch Cover Bushing Removal and Installation Tool (for all drive clutches) P-90 Driven Clutch Bushing Removal Tool Main Puller Adapte r Adapte r Reducer Number Two Puller Adapter
Pad NQ. 5020628 5020629 502063 1 5020632 501 0279 5020633
P-90 Drive Clutch Moveable Sheave - Bushing Removal
Moveable Sheave Bushing Inspection: Replace t he cover bushing if more brass than Teflon"" is visible on the bushing.
1.
Install handle end of piston pin puller securely into bench vise and lightly grease pu ller th reads . Remove nut from puller rod and set aside.
2.
3.
Install main adapte r (Item 8) onto puller. Piston Pin Puller PN 2870386
Main Adaptor
4.
Insert adaptor #2 into bushing from belt side as shown. With towers pOinting toward vise, slide sheave and bushing onto puller rod. Install nut removed in step 2 onto end of puller rod and hand tighten. Turn puller barrel to increase te nsion on sheave if needed. Nut is left hand thread.
5.
6.53
9/96
CLUTCHES Clutch Bushing pogO

6. Turn sheave and puller barrel together counterclockwise on puller rod until bushing is removed. Remove nut from puller rod and set aside. Pull bushing removal tool and adapter from puller rod . Remove bushing from tool and discard.
7. 8.
Drive Clutch Moveable Sheave - Bushing Installation

9. Place main adapter (Item 8) on puller.
10. Push bushing into center of sheave on tower side by hand.
Bushing PN 3576504
11 . Insert installation tool (Item 2) into center of sheave and with towers pointing away from vise, slide sheave onto puller rod. 12. Install nut on puller rod and hand tighten. Turn barrel to apply additional tension if needed. 13. Turn sheave and barrel together counterclockwise until bushing is seated. 14. Remove nut from puller rod and set aside. 15. Remove sheave from puller. 16. Remove installation tool.
.- . /
9/96
6.54
CLUTCHES Clutch Bushing P90

P90 Drive Clutch Cover Bushing Removal
1. Install main adapter (Item 8) on puller.
Main Adaptor
2.
From outside of clutch cover, insert removal tool (Item 3) into cover bushing. With inside of cover toward vise , slide cover onto puller. Install nut onto puller rod and hand tighten . Turn puller barrel to increase tension as needed.
3. 4.
5. 6. 7.
Turn clutch cover counterclockwise on puller rod until bushing is removed. Rernove nut from puller rod and set aside. Remove bushing and bushing removal tool from puller. Discard bushing.
6.55
9/96
CLUTCHES Clutch Bushing P-90 P-90 Drive Clutch Cover - Bushing Installation
8. On Garmax style bushings (PN 3576516) apply Loctite 680 retaining compound (PN 2870584) to the outer surface of the bushing. Retaining compound is not required on bronze I Tefion type Do not lubricate bushings (PN 3576510). bushings, or premature wear will result. Working from inside of cover, insert bushing and bushing installation tool into center of clutch cover.
9.
With main adapter on puller, insert cover onto puller rod, placing outside of cover toward vise.
10. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 11. Turn clutch cover and barrel together counte rclockwise on puller rod until bushing is seated. 12. Remove nut from puller rod and take installation tool and clutch cove r off rod.
9/97
6.56
CLUTCHES Clutch Bushing P-90

P-90 Driven Clutch Moveable Sheave Bushing Removal NOTE: Bushings are installed at the factory using Loctite'" 680. In order to remove the bushing it will be necessary to apply heat.
13. Install main adapter (Item 8) onto puller. 14. Insert adapter reducer (Item 9) onto puller, sliding it inside the main adapter.. 15. Remove ramp buttons from moveable sheave. Main Adapter
Adapter Reducer
16. Using a hand held propane torch, apply heat directly on bushing until tiny smoke tailings appear.
CAUTION: I
Clutch components will be hot! In order to avoid serious burns, wear some type of insulated gloves for the rest of the removal process.
6.57
9/96
CLUTCHES Clutch Bushing P-90

17. Working from the top, install bushing removal tool (Item 5) into center of clutch sheave with smaller diameter toward bushing to be removed . See illustration at right.
"
Bushing Removal Tool (#5)
18. Install sheave onto puller. 19. Install nut onto puller rod and tighten by hand. Turn puller barrel for further tension if needed.
20. Turn clutch sheave counterclockwise until bushing is removed. Repeat steps 17. - 20. for other bushing. 21. Remove nut from puller rod and set aside. 22. Remove adapters from puller. 23. Remove bushing and removal tool from adapters. Discard bushing .
9/96
6.58
CLUTCHES Clutch Bush ing pogO pogO Driven Clutch Moveable Sheave - Bushing Installation
'--24. Working from the top, insert adapter numbe r ten onto puller. See illustration at right.
Adapter Number Ten
25. Start new bushing evenly in moveable sheave.
26. Install sheave onto puller with new bushing upward as shown. Install adaptor number two.
6 .59
9/96
CLUTCHES Clutch Bushing pogO

27. Install nut onto puller rod and hand tighten against installation tool.
28 . Turn clutch sheave counterclockwise until bushing is seated. 29. Remove nut from puller rod and set aside. 30. Remove installation tool and clutch sheave from puller. 31. Repeat installation procedure for other moveable bushing .
9196
6.60
CLUTCHES Troubleshooting
SYMPTOMS PROBABLE CAUSE REMEDY
Harsh drive clutch engagement
-Drive belt worn too narrow -Excessive belt to sheave clearance with new belt (high periormance version without detent shift weight)
-Replace -Periorm belt to sheave clearance adjustment with shim washers beneath spider -Replace -Adjust alignment offset -Inspect, adjust or replace -Measurement should be taken .25" in from outer circumference on sheave face. Maximum allowable tolerance is .015" (.6 mm). -Inspect/replace -Install new buttons or shim out existing buttons -Inspect/replace
Drive belt turn over
-Wrong belt for application -Clutch alignment out of spec -Engine mount broken or loose -Driven clutch sheaves have excessive runout, are bent or damaged
Noise in drive system
-Broken drive clutch components -Excessive drive clutch button - tower clearance -Bearing failure! chaincase, jacks haft or front drive shaft
-Inspect/adjust or replace -Drive chain loose or worn, sprocket teeth broken -Driven clutch bushing worn excessively or spring broken -Drive chain adjustment too tight/too loose -Drive belt suriace flat spots Over rev during initial acceleration or during heavy pulling at low ground speeds. Engine bogs after engagemen!. -Spider roller position remaining in detent -Inspect/replace -Inspect/replace Inspect/adjust Inspect/replace -Add spider shim washers -Add driven washers -Improper driven clutch setup -Worn belt -Excessive belt deflection -Improper offset/alignment -Inspect/adjust -Broken or misadjusted torque stop -Inspect/adjust/replace -Broken motor mount -Inspect/replace -Jacks haft bearing seizure -Replace -Reduce gear ratio (chaincase models) -Replace -Subtract driven clutch washers
6.61
9196
CLUTCHES Clutch System Troubleshooting

SYMPTOMS PROBABLE CAUSE REMEDY
a) Replace with recommended spring b) Install correct shift weight kit to match engine application c) Replace spring; refer to proper installation location d) Install new belt and/or adjust bell tension e) Install correct parts and/or adjust to match engine application and ma chine use
Engine RPM below specified operating range, although engine is properly tuned
a) Wrong or broken drive clutch spring b) Drive clutch shift weight too heavy c) Driven clutch spring broken or installed in wrong helix location d) Drive belt too long e) Improper driven clutch setup
Erratic engine operating RPM during acceleration or load variations
Drive clutch binding or driven clutch malfunction Converter sheaves greasy; belt slippage
-Disassemble drive clutch; inspect shift weights for wear and free operation Clean clutches; install new belt
-Clean and polish stationary shaft hub; reassemble clutch without spring to determine problem area
-Replace ramp buttons -Inspect moveable sheave for excessive bushing clearance/replace
Engine RPM above specified operating range
a) Incorrect drive clutch spring (too high spring rate) b) Drive clutch shift weights incorrect for application (too light) c) Drive clutch binding d) Driven clutch binding e)Converter sheaves greasy; belt slippage f) Improper driven clutch setup
a) Install proper spring
b) Install proper shift weights c) Disassemble and clean clutch; inspecting shift weights and buttons. Reassemble without the spring 10 detennine probable cause. d)-Disassemble, clean and inspect driven clutch , noting worn sheave bushing and ramp buttons and helix spring location e) Clean clutches; install new belt f) Install correct parts and/or adjust I 0 match engine applica~on and rna chine use a) Replace with recommended spring b) Install correct shift weight kit to match engine application c) Replace spring; refer to proper installation location d) Install new belt aneVor adjust belt tension e) Clean clutches; install new belt f) Install correct parts and/or adjust to match engine application and rna chine use
Burnt Belts / Premature Wear Also see Belt Wear / Burning Diagnosis Chart on page 6.63
a) Wrong or broken drive clutch spring b) Drive clutch shift weight too heavy c) Driven clutch spring broken or installed in wrong helix location d) Drive belt too long e) Converter sheaves greasy; belt slippage. f) Improper driven clutch setup
9/97
6.62
CLUTCHES Belt Wear I Burn Diagnosis

Belt Wear I Burn Diagnosis Possible Cause Of Wear Or Burning Driving at or about engagement RPM for extended periods in all types of conditions Cold weather startups Solution Drive at higher RPM if possible. Gear the machine down. Make sure belt deflection is at 1.25" to achieve optimum starting ratio Be patient. Warm up engine at least 5 minutes or until it readily responds to throttle input. For the quickest most efficient driveaway in extreme cold weather, take drive belt off machine and bring it in to a warm environment. Break skis and track loose from the snow. Engage throttle aggressively for short durations for initial cold driveaway When possible, do not go in deep snow when towing another machine. Use fast, effective throttle to engage the clutch. Not all machines are intended for pulling heavy loads or other machines. Lower the gear ratio. Remove windage plates from driven clutch . If possible, move to better snow conditions and reduce RPM. Avoid riding in very high ambient temperatures. Break loose snow and ice under tunnel. Allow longer than normal warmup. Allow belt to warm sufficiently and increase grip ability on clutch sheaves. Use fast, effective throttle when engaging clutch. Maintain good state of tune including throttle and choke synchronization. Check for fouled spark plug(s). Check for foreign material in carbs. Make sure no water or ice in fuel tank, lines, or carburetors. Use caution when loading machine. Carbide skags may gouge into trailer and prevent drive train from spinn ing freely. Use enough speed to drive completely onto trailer. If machine cannot be driven completely onto trailer, it may need to be pulled or pushed to avoid belt wear / burning. Check for correct clutch components . Use fast, effective throttle to engage the clutch.
Towing another machine at or about engagement RPM
Spinning track while vehicle is stuck (high RPM, low vehicle speed, high ambient temp. Example: 8000 RPM , 10mph vehicle speed, 60 mph indicated on speedometer. Ice and snow piled up between track and tunnel overnight or after stopping lor a long period of time (enough to re-freeze the snow). Poor running engine (Bog, Miss, Backfire, etc.)
Loading machine on trailer
Clutch malfunction Slow, easy belt engagement - easing on the throttle
6.63
9/97
CHAPTER 7 BODY AND STEERING

Torque Specifications .... . . . .. .. .. ...... .... . 7.1 Steering Specifications ... .. ....... . . .. .. ... . .. 7.2 - 7.2b Steering Assembly, Exploded View ...... ...... 7.3 - 7.9c Steering Inspection ...... .. .. ...... . . . . . . . . . . . 7.10 Camber Definiti on . .. ................... . ... .. 7.11 Rod End Torque Procedure ... ............ . . . .. 7.11 Rod End Engagement Guidelines . ... .... . . .. ... 7.11 Camberrroe Quick Reference By Front End Type . 7.12 Steering Adjustment - All Models . .. . ..... ...... 7.13 - 7.18 Steering Stop Adjustment (1996) . .. .. ...... .... 7.18 XTRA-10 CRG / XC-10 CRC Adjustment (Using Travel Bars) .. . . . . . . ......... .. . .. . . .. 7.18a -7.18e Ski Spindle Bushing Removal / Replacement .. ... 7 .181 - 7.18g Steering Arm Orientation .... . .... ............. 7.18h Ski Skag Removal / Installation ...... . ..... ..... 7.19 Ski Skin Installati on . .. .. . . . . ... . ...... .. .. ... . 7.19a Ski Installation ... ... .... .... . . . ............. 7.19b Handlebar Torque . .. . ........ . . .... . . . . . .... . 7.20 Fuel Tank and Seat Removal ............ .. . ... . 7.21-7.22 Seat Cover Replacement ................... . .. 7.23-7.25 Taillight Assembly Replacement - Standard Indy .. 7.26 Seat Interchangeability Chart ............... . ... 7.27 - 7.27a Nosepan Replacement Procedure - Standard . . . 7.28 Nosepan Replacement Procedure - Evolved ..... 7.29 Nosecone Alignment - Standard .... . . .... . ..... 7.30 Hood Adjustment - Evolved .................... 7.31-7.32 Decal Removal and Installation. . . . . . . . . . . . . .. 7.33 Troubl eshooting ..... ... ... . .... . ..... . .. .... 7.34
BODY AND STEERING Torque Specifications

Torque Application List
Due to the special grade bolts and nuts required for specific applications, observe the following torque values in the areas specified or refer to steeri ng rod end orientation pages in this chapter for diagrams depicting location, orientation, and torque values of fasteners. Al ways use gen uine Polaris parts a nd fasteners. Boll Size Area Where Used Torque Minimum-Maximum Outer Radius Rod End to Trailing Arm (Top & Bottom) ... 28-30 ft. Ibs. (3.86-4.14 kg-m) Inner Radius Rod End To Bulkhead (Top) . . ...... . ..... 35-40 ft. Ibs. (4.83-5.52 kg-m) Inner Radius Rod End To Bulkhead (Bottom) .. . .. . ..... 40-50 ft. Ibs. (5.52-6 .9 kg-m) Radius Rod , Drag Link, or Ti e Rod End Jam Nuts ....... 24-25 ft. Ibs. (3.31 -3.45 kg-m) Bellcrank (Center Steering Arm) (Non-CRC) . . . . . . . .. 55-60 ft. Ibs. (7 .59-8.28 kg-m) Pitman Arm Pivot Idler Arm Pivot Drag Link to Steering Post Arm . . . . . . . .. .... ... 28-30 ft. Ibs. (3 .86-4.14 kg-m) Drag Link to Bellcrank or Pitman Arm . .. . 28-30 ft. Ibs. (3.86-4.14 kg-m) Steering Arm Pinch Bolt .......... . . . .. .. ... . . . ...... 28-30 ft. Ibs. (3.86-4.14 kg-m) Tie Rod to Steering Arm ......... . ... . . . .... . .. 28-30 ft. Ibs. (3.86-4.14 kg -m) Tie Rod to Bellcrank ........ . ..... . . _. . ... . ... 28-30 ft. Ibs. (3.86-4 .14 kg -m) Trailing Arm Rear Support . .. . ....... . ...... 40-45 ft. Ibs. (5 .52-6.21 kg-m) IFS Shock (Top & Bottom) .................. . .. . .. 28-30 ft.lbs. (3.86-4.14 kg-m) Steering Post to Bulkhead ....... . .. . .. 15-17 ft. Ibs. (2 .07-2.35 kg-m) Upper Steering Bracket to Hoop ..................... 8-10 ft. Ibs. (1.10-1.38 kg-m) Handlebar Block ................. . .. . ... . ... . ....... 8-10 ft. Ibs. (1 .10-1 .38 kg -m) Side Panel to Nosepan Brace , Rubber Washer ....... . . 4-6 in . Ibs. (.05-.07 kg-m) Side Panel to Nosepan. Well Nut .................... . 4-6 in. Ibs. (.05-.07 kgm) Throttle Block Set Screw ... ..... . .......... . .. 30-35 in. Ibs (.35-.40 kg-m) Ski Pi vot Bushing Bolt .... .. ... . . ........ 25-28 ft. Ibs. (3.45-3.86 kg-m) Choke to Plastic Console . . . . . . . ...... 20-25 in . Ibs. (.23-.29 kg-m)
3/8 . .
7/ 16 .. ... 1/2 1/2 ......
3/8 3/8 . . 3/8 3/8 .. .... 3/8 ......

7/16 .....
3/8 . .....
5/16 .. . .. 1/4
1/4 . ..... 1/4 1/4
3/8 . . .. . . 3/8
7.1
9197
BODY AND STEERING 1996 Steering Specifications

Model Suspension Type Reference Width 37" Front Vertical Travel
Indy Lite/GT/Deluxe Indy Sport Indy TranSport Indy Sport Touring Indy Super Sport Indy 440 XCR Indy 440 XCR SP Indy WideTrak GT I LX Indy Trail Indy 440 LC Indy Trail Touring Indy 500 Indy 500 SKS Indy 500 RMK Indy 500 EFI Indy 500 EFI SKSlRMK Indy Classic Indy Classic Touring Indy XLT Indy XLT SP Indy XLT LTD/LTD SP Indy XLT SKS Indy XLT RMK Indy XLT Touring Indy RXL Indy 600 XCR I XCR SP Indy Ultra SP Indy Ultra SKS Indy Ultra RMK Indy Storm Indy Storm SKS Indy Storm RMK
Lite IFS-38x7
7"
7.25"
38"
Std. IFS XTRA- l 0 CRC XTR A-l 0 CRC IFS-38 Std. IFS XTRA-10 Std.IFS XTRA-l 0 XTRA-12 XTRA-10 XTRA-12 XTRA-12
41 "
7.25"
8.4'"
Use Max Set Up Width See 1997 XTRA-l0 CRC Use Max Set Up Width See 1997 XTRA-l 0 CRC
38"
9.15" 7.25" 7.25" 8.4" 7.25" 8.4"

9.8"
41 "
4 1"
41"
41"
42.5" 41 " 42.5" 42 .5"
8.4"
9.8"
9.S'"
XTRA- l 0 XTRA-l 0 XTRA-12 XTRA-12 Std.IFS XTRA-l0 XTRA-l0 Std.I FS Std.IFS
41 "
38"
8.4"
7.0 9.8" 9.8" 7.25" 7.25"

8.4"
42.5" 42.5" 41" 41" 38" 41 "

38"
7.0"
7.25" 7.0"
CAUTION: I
1996 Models: Reference width is measured from center of spindles near grease fitting on bottom of spindle, with the front suspension compressed to the point of maximum width. On Std. IFS (non XTRA models) the point of maximum width is when radius rods are parallel to the ground. On XTRA models, radius rods are non-parallel , and widest point is when lower radius rod is parallel to the ground . Always verify adequate tie rod and radius rod end thread engagement after installing or adjusting front suspension or steering componen ts. Refer to page 7. 11 . Caster: Camber: Toe-infToe-out: Fixed Adjusted with suspension fully extended - front end elevated. Adjusted at Normal Ride Height
NOTE: Precision camber and toe setup can be performed on Xtra- l 0 CRG and XC-l0 models. Refer to page 7.18a.
9197
7 .2
BODY AND STEERING 1997 Steering Specifications

Model Indy Lite/GT/Deluxe Indy Sport I Touring Indy TranSport Indy Super Sport Indy 440 XC Indy 440 XCR Indy XC F Indy WideTrak GT/LX Indy 440 UC Indy Trail 1 Trail Touring Indy Trail RMK Indy 500 I 500 SKS Indy 500 RMK Indy 500 EFI Indy Classic I Touring Indy XLT 1 XLT SKS Indy XLT RMK Indy XLT Touring Indy XLT SP Indy XLT LTD I LTD SP Indy RXL Indy 600 XCR Indy 600 XCR SE Indy 600 XC Indy 700 XC Indy 700 SKS Indy 700 RMK Indy Ultra SP Indy Ultra SPx/SPX SE Indy Ultra/UltraTouring Indy Storm I Storm SE Indy Storm RMK CAUTION: Suspension Type Lite 38x7 XTRA-10 XTRA-10 CRC XC- 10 CRC XTRA-10 CRC 38x7 XTR A-10 38-RMK XTRA- 10 38- RMK XTRA-1 2 XTRA-1 2 XTRA-1 0 38-RMK XTRA- 12 Reference Width Maximum Set Up Width*( 1/4") Camber 5/16"(8mm) 0 Vertical Travel
37" 38"
41 " 41 "
36 112 (92.70 em) 37 3/8" (94.90 em) 39 1/8" (99.40 em) 391/4" (99.70 em)
39" (99.00 em)
1" 7 1/4" 9 1/2" 9 1/2" 9 1/2" 7 1/4" 9 1/2" 81/4" 9 1/2" 81/4"
10"
1/2" (13 mm)

0
0 0 0
3/4" (19 mm)

1" (25.5 mm)
41"
4 1"
39 1/4" (99.70 em) 37 3/8" (94.90 em) 39 1/8" (99.40 em)

36 3/4" (93.35 em) 39 1/8" (99.40 em) 36 3/4" (93.35 em)
3/4" (19 mm) 1/2" (13 mm)

0 0 0 0 0 0 0 0 0
38"
41"
38"
4 1"
0 0
38"
42 .5" 42.5"
40 1/2" (102.90 em) 40 1/2" (102.90 em)

39 1/8" (99 .40 em) 36 3/4" (93.35 em)
10"
41"
38"
42.5"
9 1/2" 81 /4"
10"
401/2" (102.90 em)
XTRA- 12 XTRA-10 CRC
42.5" 41"
40 1/2" (102.90 em) 391/4" (99 .70 em)
10"
3/4" (19 mm)
91/2"
XC- 10 CRC XTRA- 10 CRC 38-RMKCRC XT RA-10 CRC XTRA-12 XTRA-10 38-RMK
4 1/1
41 "
39" (99.00 em)
1" (25.5 mm)
39 1/4" (99.70 em) 31" (94.00 em) 39 114" (99.70 em) 40 1/2" (102.90 em) 39 1/8" (99.40 em)
36 3/4" (93.35 em)
3/4" (19 mm) 3/8" (9.5mm) 3/4" (19 mm)

0 0 0
9 1/2"
8 1/4"
38"
41 /1
9 1/2"
10"
42.5"
41 "
9 1/2"
8 1/4"
38"
1997 - Current models have torsion bar attached to inside of trailing arm - Maximum set up width is listed for these models to prevent possible disengagement of the torsion bar from the trailing anm, which could interfere with steering. This measurement must be taken from center of spindles near grease fitting on bottom of spindle wrth front of machine elevated and suspension fully extended. See pages 7.13 for measurement method and adjustment procedure.
Indicates upper rad iu s rod non-adjustable.
Caster: Fixed Camber: Adjusted with suspension fully extended - front end elevated . Toe-inlToe-out: Adjusted at Normal Ride Height NOTE: Precision camber and toe setup can be performed on models equipped with Xtra- 10 CRC or XC-10 front suspension. Refer to page 7. 18a. Polaris Industries Inc.
7.2a
9/97
SUSPENSION 1998 Steering Specifications

Model Indy Lite/Deluxerrou ring Indy Sport / Touring Indy TranSport Indy Super Sport Indy XCF / Indy 500 Indy 440 XCR Indy WideTrak LX Indy 440 UC Indy Trail Indy Trail Touring Indy Trail RMKl500 RMK Indy Classic 1 Touring Indy XLT Classic Indy XLT Touring Indy XLT LTD Indy 600 XC Indy 700 XC Indy 600 XCR Indy 700 XC R Indy XLT SP Indy 600 RMK Indy 700 RMK Indy Ultra Indy Ultra Touring Indy Storm CAUTION: Suspensian Type Lite 38x7 XTRA-10 XTRA-10 CRC XC-10 CRC 38x7 XTRA-10 Reference Width Maximum Set Up Width*( 114") 361/2" (92 .70 cm) 37 3/8" (94.93 cm) 39 1/8" (99.40 cm) 39 1/4" (99.70 cm) 39" (99. 00 cm) 37 3/8" (94.93 cm) 391 /8" (99.40 cm) Camber 5116"(8mm) 0 1/2" (13 mm) 0 3/4" (19 mm) 1" (25.5 mm) 1/2" (1 3 mm) 0 7.25" 9.5" Vertical Travel 7" 7.25"
37"
38"
41" 4 1"
0 0 0
9.5
9.5"
41" 38" 41 "
0 0 0 0 0 0 0 0
38- RMK XTRA-12 XTRA-12
38" 42.5" 42.5"
36 3/4" (93.35 cm) 401 /2" (102.90 cm) 401 /2" (102 .90 cm)
0 0 0
8.25"
10" 10"
XC-10 CRC XTRA-10 CRC 38-RMK CRC XTRA-12 XTRA-1 2 XTRA-1 0
41 /1
4 1"
39" (99.00 cm)
1" (25.5 mm) 3/4" (19mm)
9,5" 9 .5"
391 /4" (99.70 cm)
38" 42.5" 42 .5" 41"
37" (94.00 cm)
3/8" (9.5mm) 0
8.25" 10" 10" 9.5"
40 1/2" (102.90 cm) 401 /2" (102.90 cm) 39 1/8" (99.40 cm)
0 0 0
0
0
*1 997 - Current models have torsion bar attached to inside of trailing arm - Maximum set up width is listed for these models to prevent possible disengagement of the torsion bar from the trailing arm, which could inteliere with steering. This measurement must be taken from center of spindles near grease fitting on bottom of spindle with front of machine elevated and suspension fully extended. See pages 7. 13 for measurement method and adjustment procedure.
Indicates uppe r radius rod non-adjustable. ----"'
Caster: Fixed Camber: Adjusted with suspension fully extended - front end elevated . Toe-inrroe-out: Adjusted at Normal Ride Height NOTE: Precision camber and toe setup can be peliormed on models equipped with Xtra- 10 CRC or XC-10 front suspension. Refer to page 7. 18a.
9/97
7 .2b
BODY AND STEERING Steering Rod End Orientation

1996 to Current Indy Lite/GT/Deluxe
Illustration depicts proper orientation of rod ends and bolts on steering components.
Steering Post 15- 17ft.lbs. 2.07-3.35
~.
28-30 ft. Ibs (3.86-4. 14 kg-m)
28-30 ft. Ibs (3.86-4.14 kg-m) Drag Link Bell Crank
/
Steering '--Post Arm .--"\\'\lii~ (Steeri ng Frog) 24-25 ft. Ibs. 3.32-3.46 kg-m Rod End
Steering Tie Rod
28-30 ft. Ibs (3.86-4.14 kg-m)
Steering Arm Replace locking fasteners if removed. See torque chart on page 7. 1 for to rque specs.
7 .3
9/97
BODY AND STEERING 1996 CRC Steering Assembly Exploded View

1996 440 XCRl440 XCR SP
Illustration depicts proper orientation 01 rod ends and bolts on steering components.
Steering Post Arm (steeri ng lrog)
Steering Post
28-30 It. Ibs. (3.9-4. 1 kg-m)
D -Ring
Pitman Arm
Drag Link
. 0 ./
'~., /
1 J)
1
End
___.lb~~---- Rod
".,"-...
Idler A rm
35-40 It. Ibs. (4.8-5.5 kg-m)
)\)~~:---_ _ Rod End

28-30 It. Ibs. (3.9-4. 1 kg-m)
Steering Tie Rod Rod End Steerin Arm Replace locking lasteners il removed. See torque chart on page 7.1 lor torque specs.
'-"
~~ V
28-30 It. Ibs. (3.9-4. 1 kgm)
9/97
7.4
BODY AND STEERING Steering Assembly Exploded View

1996 WideTrak GT/LX
Ill ustration depicts proper orientation of rod ends and bolts on steering components .
Steering Post
Drag Li nk Rod End Bell Crank Rod End
Steering Post Arm (steering frog)
Steering Tie Rod
Steeri ng Arm Replace locking fasteners if removed. See torque chart on page 7.1 for torque specs .
7 .5
9/97
BODY AND STEERING Steering Assembly Exploded View 1996 Indy 440 LC/Super Sportl500fTraii
Steering Post
Drag Link
Rod End
Rod End
Bell Crank
Steering Tie Rod
Replace locking fasteners if removed . See torque chart on page 7.1 for torque specs.
Steering Arm
9/97
7 .6
BODY AND STEERING Steering Assembly Exploded View 1996 Indy 600XCRl600 XCR SP/Ultra SP/Storm/Storm SKS
Ill ustration depicts proper orientation of rod ends and bolts on steeri ng components on models listed above.
Steeri ng Post
Drag Link Or Tie Rod End Jam Nuts 24-25 ft. Ibs. 3.32-3.46 kg-m
Drag Link
Bell Crank
Rod End 28-30 ft. Ibs (3.86-4.14 kg-m) Steering Tie Rod
28-30 ft. Ibs (3.86-4. 14 kg-m)
Steering Ann
Replace locking fasteners if removed. See torque chart on page 7.1 fo r torque specs.
7.7
9197
BODY AND STEERING Steering Assemb ly Exploded View

1996 XTRA-10 1996 - Current XTRA-12 Models
Illustration depicts proper orientation of rod ends and bolts on steering components on models listed above. Refer to chart on page 8.1 for suspension type.
NOTE: On Xtra 10 and Xtra 12 three cylinder models the drag link is on the left side. On twin cylinder models the drag link is on the right side with the same rod end configuration. Three cylinder configuration shown.
Steering
post ~
Drag Link Or Tie Rod End Jam Nuts 24-25 ft. Ibs. 3.32-3.46 kg-m 28-30 ft. Ibs (3.86-4.14 kg-m) Rod End Bell Crank Rod End Steering ne Rod Steering Post Arm (steering frog)
Drag Link
28-30 ft. Ibs (3.86-4. 14 kg-m)
Steeri ng Arm
28-30 ft. Ibs (3.86-4.14 kg -m)
Replace locking fasteners if removed. See torque chart on page 7. 1 for torque specs .
9/97
7.8

All 1997 to Current Models Except XTRA-12 Front Suspension or CRC
Steering Post
Drag Link Or Tie Rod End Jam Nuts 24-25 ft. Ibs. 3.32-3.46 kg-m
Drag Link Bell Crank Rod End
Steering Tie Rod
28-30 ft. Ibs. (3.86-4.14 kg-m)
28-30 ft. Ibs (3.86-4. 14 kg-m)
Steering Arm
Replace locking fastene rs if removed. See torque chart on page 7.1 for torque specs.
7 .9
9/97
Models: 1997 XCF, 440 XC, 600 XC, 600 XCR, 700 SKS, 700 RMK, Ultra SPX, Ultra SP 1998 XCF, 500, XLT SP, 600 XCR, 600 RMK, 700 XCR, 700 RMK
Illustration depicts proper orientation 01 rod ends and bolts on steering components.
Idler Arm and Pitman Arm Pivot
35-40 ft. Ibs. (4.8-5.5 kg-m)

Idler Arm-tO-RaCk\ 28-30 It. Ibs. (3.9-4. 1 kg-m)
Nut On Top 28-30 ft. Ibs. (3.9-4. 1 kg-m)
Steering Post
Drag Link
Steering Rack
Rod End W/Stud
Torsion Bar
Upper Radius Rod Trailing Arm
28-30 ft. Ibs. (3.9-4. 1 kg-m)

Steering Arm Weld Positioned Up
Indicates direction of bolt
Spindle
91 97
7.9a
Polaris In dustries Inc.
All 1997 to Current XTRA-10 and 38 Wide (Non-CRC) Models

Illustration depicts prope r orientation 01 rod ends and bolts on steering components .
Steering Post
Drag Link Or Tie Rod End Jam Nuts 24-25 It. Ibs. 3.32-3.46 kg-m
Drag Link Bell Crank
Steering Tie Rod
28-30 It. Ibs (3.86-4. 14 kg-m)
Replace locking fasteners il removed. See torque chart on page 7. 1 for torque specs.
Steering Arm 28-30 It. Ibs. (3.86-4.14 kg-m)
7 .9 b
9197
BODY AND STEERING XC-10 CRC Steering Assembly Exploded View

1997440 XCR, 700 XC; 1998 440 XCR, 600 XC, 700 XC
Illustration depicts proper orientation of rod ends and bolts on steering components for most models.
35-40 ft. Ibs. (4.8-5.5 kg-m)
NOTE: Typical XC-10 shown. Orientation of drag link and placement of pitman and idler arms reversed on some models
Trailing Arm
~ Steering Arm
28-30 ft. Ibs. (3.9-4.1 kg-m)
~--
-~~~
____- - / 7
Drag Link
Jam Nuts 28-30 ft. Ibs. (3.9-4. 1 kg-m)
Idler Tie Rod Ends 28-30 ft. Ibs (3.9-4.1 kg-m)
Pitman Arm Steering Rack Tie Rod
Jam Nuts 28-30 ft. Ibs. (3.9-4.1 kg-m)
9/97
7.gc
BODY AND STEERING Steering Inspection

Inspection
Prior to perform ing steering alignment, inspect all steering and suspension co mponents for wear or damage and replace parts as necessary. Refer to steering assembly exploded views in this chapter for identifi cation of components and torque values of fasteners. While disassembling , make notes of what direction a bolt goes through a part, what type of nut is used in an application, in which direction do the steering arms go on - weld up or weld down, etc. Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store. Always use genuine Polaris parts and hardware when repl acing front end components. The following components must be inspected at this time: NOTE: Always follow rod end engagement guidelines found on page 7. 11 . Maximum setup width must be checked on 1997 to Current models whenever front suspension components are adjusted or replaced. ---./ ---./
o o o o o o o o o
o o
Tie rods and tie rod ends Radius rods and radius rod ends Torsion bar and bushings I linkage (where applicable) Handlebars and steering post assembly Spindles and bushings Trailing arms and bushings Skis and skags Bell crank I Pitman Arm I Idler Arm Steering arms Shock absorbers, shock mounts, sprin gs All related fasteners - check torque. Refer to steering exploded views at the end of this section.
Alignment Bar Specifications Material: Diameter: . ...... . .. .... Length: C-l018 .623" - .625" (5/8") (15.82 - 15.87 mm) 48" (122 em)
PN 8700231 See General Information Chapter or Service Tool Catalog for ordering information.
48" (122 cm)
T
Alignment Bar PN 8700231
0 =.623-.625" (5/8) (15.83-15.88 mm)
9/97
7 .10
BODY AND STEERING Steering Adjustment Guidelines - All IFS Camber Definition - All IFS
The following definitions of camber use automotive terminology to describe positive and negative positions. Refer to the illustration at right.
a (Neutral) Camber - Spindle is 90' (perpendicular) to ground
Positive, Negative, and Neutral (DC Camber )
o
o
+ (Positive) Camber - Spindle bottom is canted inward toward chassis - (Negative) Camber - Spindle bottom is canted outward from chassis
Front View
Radius Rod and Tie Rod End Torque Procedure

Radius rod and tie rod ends must be parallel to their respective mounting surface after tightening jam nut as shown at right. Hold tie rod or radius rod and tighten jam nut. If possible, support the edge of the rod end as shown to keep it from rotating out of position until jam nut is tight. When tie rod ends are properly tightened, the tie rod should rotate freely approximately 1/8 turn. Tie End
ng Surface Incorrect Correct
Rod End Engagement Guidelines - All IFS
Tie Rod Or Radius Rod End Tie Rod Or Radius Rod End Must Engage Rod A Minimum Of 2x Thread Diameter When Adjustment Is Complete EXAMPLE 7/16" Rod End x 2 = 7/8" Minimum Thread Engagement =7/8" 11mm x 2 = 22mm Minimum Thread Engagement =22mm
JamNut
/
WII
1'1 .r I If I _1" .1' 0.
Tie Rod Or Radius Rod Diameter Of Rod IEnd x 2 = Minimum Thread Engagement Thread Engagement
~
"- ,
7.11
9/97
BODY AND STEERING

Steering Adjustment - All IFS Quick Reference Camber I Toe Chart - All IFS
Use the General Instructions and illustrations on following pages to adjust camber and toe. Refer to tables below for specifications. Suspension Type Lite Standard IFS Adjustment Toe Camber Toe Camber XTRA-10 XTRA-12 IFS-38x7 38-RMK Toe Camber Toe Camber Toe Camber Toe Camber Specification' 1/8 - 1/4" Toe Out 0 1/8 - 1/4" Toe Out 0 1/8 - 1/4" Toe Out 0
1/8 - 1/4" Toe Out
Method Ride Height Front Elevated Ride Height Front Elevated Ride Height Front Elevated Ride Height Front Elevated Ride Height Front Elevated Ride Height Front Elevated
Maximum Setup Width 1/4" (6mm) 361/2" (92.70 cm) Refer to rod end engagement guidelines Page 7.11 40 1/2" (102.90 cm) 40 1/2" (102.90 cm) 37 3/8" (94 .90 cm) 36 3/4" (93.35 cm)
Z
~
0 :D 0
0 1/8 - 1/4" Toe Out 1/2" (12.7 mm) 1/8 - 1/4" Toe Out 0
s:
0)
~ ,~
Ii'1IL
'NOTE : All camber specifications are 5/16" ( 8mm)
Use the General Instructions and illustrations on following pages to adjust camber and toe. Refer to tables below for specifications. Suspension Type 38-RMK CRC XTRA-l0 CRC (. ) XC-10 CRC (. ) Adjustment Toe Camber Toe Camber Toe Camber Specification' 1/8 - 1/4" Toe Out 3/8" (9.5 mm) 1/8 - 1/4" Toe Out 3/4" (19 mm) 1/8 - 1/4" Toe Out 1" (25.4 mm) Method Ride Height Front Elevated Ride Height Front Elevated Ride Height Front Elevated 39" (99.00 cm) 39 1/4" (99.70 cm) 37" (94.00 cm) Maximum Setup Width 1/4" (6mm)
C(
j
'NOTE: All camber specifications are 5/16" ( 8mm) An alternate method of alignment using the Camber and Toe Alignment Travel Ba rs (Kit PN 287 1537) can be performed on snowmobiles equipped with XTRA-l 0 CRC or XC- l 0 CRC front suspension. The travel bars are not intended for use on 38 RMK CRC or non-CRC models. Refer to page 7.18a.
9/97
7.12
BODY AND STEERING Steering Adjustment - All IFS

Prior to performing steering alignment, the suspension should be inspected for damage or wear and replacement parts installed as required. See inspection on page 7. 10.
WARNING
A maximum set up width is listed for 1997 to Current models. Maximum set up width is the maximum allowable distance between ski spindle centers with front end of vehicle off the ground and suspension fu lly extended. The Maximum Set Up Width specifications listed on page 7.2a and 7.2b are maximum width measurements, and are critical to ensure adequate torsion bar engagement with the trailing arm. If the suspension is set too wide on 1997-current models, t he torsion bar can come loose and interfere with steering . Do not attempt to set the suspension wider than the specified Maximum Set Up Wid th. On 1996 and earli er models, be sure to follow thread engagement guidelines for steering tie rod and radi us rod ends as shown on page 7.11. Spindle Centering I Set Up Widt h 1. 2. 3. 4. 5. Make sure the track is properly aligned. Refer to Maintenance Chapter for procedure. This will be used as a reference point for final toe out measurement. Support the front of the machine 1-2" (2.5-5.1 cm) off the floor. Remove skis and ski pivot bushings. Disconnect adjustable torsion bar linkage where applicable. Measure spindle to chassis centering as shown . - - - - -- - -- - - - - - - - - - - - , and record measurement. Both spindles should be an equal distance +1- 1/8" (3 mm) from the center of the chassis after adjusting camber, width, and toe alignment. This measurement is controlled by adjusting radius rod length. On 1996 models - adjust camber first and then verify adequate thread engagement of rod ends as shown on page 7.11 . On 1997 to current models, measure set up width and record. This measurement is controlled by adjusting radius rod length , and must not exceed the Maximum Setup Width listed in the appropriate table (at the front of this section) after all steering adjustments are complete. See illustration below for procedure.
6.
Spindle To Chassis Centering Left = Right 1/8".
Set Up Width' Measu re from center of one spindle to center of the other spindle with front end elevated and suspension fully extended to determ ine set up width.
' Do not exceed maximum
7.13
9;97
BODY AND STEERING Steering Inspection - AIIIFS
CAMBER INSPECTION
All Models - Elevate Front End - Shocks Installed Typical CRC Shown - Style varies by model Suspension Free Hanging With IFS Shocks Installed
Upper radius rod
Lower radius rod
Radius Rod End Jam Nuts
~~t---_______ Attaching Bolts _---------'~~

Measure Here Refer to specifications for: -IFS type -Specified amount of camber See page 7.2 - 7.2b or page 7.12
o To adjust, lengthen or shorten appropriate lower radius rod until top of bar is within specified camber
distance. Measurement should be taken from top of alignment bar to top of ski pivot bushing hole in spindle (bushing removed). Radius rod must be re-attached to trailing arm before measu ring .
CAMBER - ACCEPTABLE RANGE
EXAMPLE: Specified Camber = 314" (19mm) Specified Tolerance 5116" (8mm) Acceptable Range = 7116 - 1 1116" (11-27mm)
Refer to specifications on page 7.2 - 7.2b or page 7. 12 _ _ ___ Range,
9/97
7.14
BODY A ND STEERING Steering Ad just ment - All IFS

Camber Adjustment
1. Determine which spindle requires the greatest amount of correction by installing the alignment bar through one side to the opposite spindle. Remove the bar and instal l it through the other side to the opposite spindle.
2.
Using a 3/8" (1 cm) drive 11 /16" (1.7 cm) crow foot wrench and 20" (51 cm) long 3/8" (1 cm) drive extension, loosen the radius rod end jam nut and remove the lower radius rod bolt from the spindle requi ring the most camber correction . Adjust the opposite side next. To adjust camber, change lower radius rod length until alignment bar measurement is within specified range for each spindle. Refer to charts on page 7.12 for cambe r specifications. On models with neutral camber (0) the bar should slide freely through both spindles ( 5/16"). CAUTION:
3.
I
Bulkhead
Radius rod ends must remain parallel to the bulkhead after rod end jam nuts are tightened to specified torque. See il lustration at right. 4. TIghten all jam nuts. Torque radius rod attaching bolts to specification. Reinstall adjustable torsion bar linkage (where applicable). On 1996 mode ls verify adequate thread engagement of rod ends as shown on page 7.11. WARNING
\
Rod end parallel to mounting surface when jam nut is tight.
Jam Nut
Rod End
After camber adjustment is complete, be sure to measure set up width on 1997 models as outlined on page 7.13 and compare to specifications listed on page 7.2a . 7.2b. Do not attempt to set suspension wider than the specified maximum set up width. II set up width exceeds maximum, adjust upper and lower radius rods equally to maintain camber adjustment.
Radius Rod End Jam Nut Torque 25 ft. Ibs . (3.45 kgm)
Radius Rod Attaching Bolt Torque 3/8" (o uter) 28-30 ft. Ibs. (3.86-4. 14 kg-m) 7/16" (inner top) 35-40 ft. Ibs. (4.83-5 .52 kg-m) 1/2:' (inner bottom) 40-50 ft. Ibs. (5.52-6.9 kg-m)
Adjustable Torsion Bar Attaching Bolt Torque 15 ft. Ibs. 2.07 kgm) Polaris Industries Inc.
7.15
9/97

Handlebar Centering
5. With alignment bar installed through spindles (on 0 camber models). center handlebars by adjusting drag link length (A). On models with negative camber, the alignment bar cannot be installed through spindles. On these models, the pitman and idler arm (9) (or bellcrank on non-CRC models) should be pointed straight forward. Lubricate ski pivot bushings with Polaris Premium All Season Grease and install in spindle. Follow procedure in Illustration A for steel or 9 for composite skis. Torque ski bolts to specification . Install new cotter pin in castle nut. Perform Toe Adjustment on page 7.17.
6.
7.
9/97
7.16

Toe Adjustment, All Models
",-----. Toe adjustment on all models must be performed with the vehicle weight on the suspension (no rider), at Normal Ride Height. An alternate method of toe alignment (using the travel bars) can be used set toe on models equipped with XTRA-10 CRC and XC- t 0 CRC fron t suspension . Refer to page 7.18d . 1. Make sure the track is properly aligned. This will be used as a reference point for toe out measurement.
Lift 3-5" (7.6-12.7 em) and work suspension to find average
2.
To obtain normal ri de height of the front suspension, lift the front end 3-5" (7 .6-12.7 cm) with the front bumper. Lift the machine several times, working the suspension and front skis until an average is obtained.
NOTE: To prevent carbide skags from grabbing, make sure the surface under the skis will allow full side-to-side movement. Avoid rough concrete, asphalt, or carpet which may cause carbide skags to grab or catch and restrict movement. Toe Adjustment Normal Ride Height NOTE: Measurements A&B shou ld be taken 10" (254 mm) from center of ski spindle. SERVICE HINT: Before final measurement is taken, skis should be pushed together lightly at the tips to remove play in the steering components. This will help achieve accurate measurement. If a strap is used be sure it is not too tight or it will alter measurement (this is most important on models with composite skis). " A" 1/8-1/4" greater than "8" at normal ride height
(\
Toe A lignment: All Models Measurement " A" should be 1/8" -1/4" (3.17 - 6.35 mm) greater than measurement " 8 " at normal ride height.
~~, ~ Tr .8~F==i==='J=~ !=i! ) ~

B
10"
tJ---++-_----''---_ _ I
10"
:1...
t
Straight / Edge
~ _
-+-I
~:--- Track
7.17
9/97
BODY AND STEERING

Steering Stop Adjustment Steering Stop Adjustment
1996 Models 1. Remove alignment bar and turn handlebars fully to the right. Loosen upper radius rod bolt (A) and adjust steering stop (8) so it contacts steering arm squarely at (C). Torque bolt (A) to specification. Verify stop is correctly adjusted after bolt is tight. Repeat procedure for left side, turning bars fu lly left.
c
A
Upper Radius Rod Bolt to Spindle Torque

28 ft. Ibs. (3.66 kgm)
Adjust Both Steering Stops
1997 Models Steering stops are not adjustable on 1997-current models .
9/97
7.18
BODY AND STEERING Controlled Roll Center (CRC) Steering Alignment

XTRA-10 CRC and XC-10 CRC Steering Alignment
The following steering alignment procedure can be perform ed on XTRA-l0 CRC or XC-l0 CRC front suspensions only, and should not be used for 38-RMK CRC or non-CRC front suspensions. Note: Use 1996 adjustment procedure for 1995 XCR 440 SP.
General Set Up Tips

Before adjustments are performed on CRC steering, inspect all front suspension and steering components. See page 7.10. While disassembling, make notes of what direction a bolt goes through a part, what type of nut is used in an application, in which direction do the steering arms go on - weld up or weld down, etc. Some of the bolts used in the IFS are special, and cannot be purchased at a hardware store. Always use genuin e Polaris parts and hard ware when replacing front end components.
Tools
Tools required: 5/8" alignment bar - PN 5333508 6' tape measure Travel location bars -13.70" long (PN 521 1714) Travel location bars -15.20" long (PN 521 1713) Travel location bars -11 .65" long (PN 5211822) Chassis stand or blocking
(t
(<g
Camber - All Years 13.70"
J)
Toe Alignment - 1995/ 1996 Only ~) 15.20"
(t
Toe Ali gnment-1997:T ) 11 .65"
NOTE: The CRC Travel Location Bars are incl uded in kit PN 2871537, along with a 46' alignment bar, and assorted hardware. Kit components are also available separately. See Chapter 1 for tool ordering information. Refer to the chart below for travel bar application for width, camber, and toe adjustments on XTRA-l 0 CRC and XC-l 0 CRC models. See text on fo llowing pages for specific procedures. 1995 -1996 CRC Models When Measuring Set Up Width' Travel Location Bar Length Suspension Fully Extended - Shocks Installed To Inspect / Adjust Camber Install 13.70 Bars To Inspect / Adjust Toe Install 15.20 Bars
1997 - Current XTRA-l0 CRC and XC-10 CRC Models When Measuring Set Up Width' Travel Location Bar Length Suspension Fully Extended - Shocks Installed To Inspect / Adjust Camber Install 13.70 Bars To Inspect / Adjust Toe Install 11 .65 Bars
WARNING
A maximum set up width is listed fo r 1997 to Cu rrent models. Maximum set up width is the maximum allowable distance between ski spindle centers with front end of vehicle off the ground and suspension fully extended. The Maximum Set Up Width specifications listed on page 7.2a and 7.2b are maximum width measurements, and are critical to ensure adequate torsion bar engagement with the trailing arm. If the suspens ion is set too wide on 1997-current models, the torsion bar can come loose and interfere with steering . Do not attempt to set the suspension wider than the specified Maximum Set Up Width . On 1996 and earlier models, be sure to follow thread engagement guidelines fo r steering tie rod and radius rod ends as shown on page 7.11.
7.18a
9/97
BODY AND STEERING CRe Steering Adjustment

CRC Steering Adjustment
To ensure accurate adjustment of the CRC steering mechanism, all steps listed below must be performed in sequential order. Spindle to Chassis Centering (must also be checked after adjustment) Set-Up Width adjustment(must also be checked after adjustment) Camber Adjustment Handlebar Centering Toe Adjustment Verify Spindle to Chassis Centering and Set-up width are within limits Securely support the front of the machine high enough to remove the skis. Make sure machine is level. Remove skis. Follow procedure on page 7.13. '-...-/
1. 2. 3.
Spindle to Chassis Centering Set Up Width Measurement

4. Follow procedure on page 7.13.
A WARNING
'A maximum set up width is listed for 1997 - Current models. This is the maximum allowable distance between ski spindle centers with front end of vehicle off the ground and suspension fully extended. The maximum set up width specifications listed on page 7.2a-7.2b are maximum width measurements, and are critical to ensure adequate thread engagement of steering tie rod and radius rod ends. If the suspension is set too wide on 1997-current models, the torsion bar can come loose and interfere with steering. Do not attempt to set the suspension wider than the specified Maximum Set Up Width. For t 995-1996 models , use rod end thread engagement guidelines as shown on page 7.11 .
Camber Adjustment - XTRA-10 CRC and XC-10 CRC

5. 6. Remove IFS shocks and install 13.70" travel location bars. The travel location bars will locate the IFS at a given point of travel where the camber should be neutral (0 0 ). Disconnect tie rods from steering arms. NOTE : If toe adjustment is correct, the spindles will not be horizontally aligned with the 13.70" travel location bars installed. Disconnecting the tie rods will eliminate bind on the alignment bar and allow for more precise camber adjustment. It may also be helpful to secure the tie rods so they don't interfere with inspection or adjustment. Determine which spindle requires the greatest amount of correction by installing the alignment bar through one side to the opposite spindle, then remove the bar and install it through the other side to the opposite spindle. Camber Adiustment Install 13.70" Travel Location Bars
7.
'"
"",
,
,,0 '
'
Loose:n~____-------------=~~~
Remove Alignment Bar
9/97
7.18b
BODY AND STEERING CRC Steering Adjustment

Camber Adjustment - XTRA-10 CRC and XC-10 CRC, (Cont.)
'-8. Using a 3/8" drive 11 /16" (1.7 cm) crow foot wrench and 20" (5 1 cm) long 3/8" (1 cm) drive extension , loosen the radius rod end jam nut and remove the lower radius rod bolt from the spindle requiring the most camber correction. Adjust the opposite side next. Change radius rod length until alignment bar slides freely through both spindles. When adjustment is correct, tighten jam nuts to 24-25 ft. Ibs. (3.3 1-3.45 kg-m). Torque radius rod attaching bolts to 28-30 ft. Ibs. (3.86-4.14 kg-m).
9.
CAUTION: I
Radius rod ends must remain parallel to the mounting brackets after the rod end jam nuts are tightened to the specified torque. See illustration at right. 10. Tighten all jam nuts. Torque radius rod attaching bolts to specification. 11. Re-check set specifications. up width and compare to Rod end parallel to mounting surface when jam nut is tight. Rod End Bulkhead
Jam Nut
Handlebar Centering-CRC
12. With alignment bar in spindles and tie rod ends disconnected, center the steering rack by pointing the pitman arm and idler arm straight forward. 13. Center the handlebars by adjusting drag link length. Tighten jam nuts to 24-25 ft. Ibs. (3.31-3.45 kg-m). 14. The steering arms should be parallel to the ski centerline or slightly inward. Refer to steering arm orientation on page 7.18g. Handlebar Centering - CRC
Adjust Drag Link To Center Bars
Pitman Arm and Idler Arm Point Straight Forward
15. Re-attach steering tie rod ends (C) to steering arms. It may be necessary to loosen the tie rod adjustment jam nuts (B) and adjust tie rod length (A) as required until rod end studs can be installed in steering arm. Torque tie rod end attaching nuts to 28-30 ft. Ibs. (3.86-4.14 kg-m). If tie rod adjustment was necessary, do not tighten them until toe adjustment is complete. 16. Perform toe adjustment on following page.
7.18c
9/97

Toe Adjustment- XTRA-l0 CRC I XC-l0 CRC
17. Remove alignment bar from spindles. 18. Remove 13.70" travel location bars and install correct toe alignment bar. 1996 Models - Install 15.20" Toe Alignment travel bars. 1997 to Current Models - Install 11.65" Toe alignment travel bars.
19. Install skis.
20. With the front of the machine still securely supported off the ground, install a block or space r between the rear of the ski frame and the bottom of the trailing arm. The block should be 3.75" - 4.0" long. The blocks will keep ski-to-ground surface orientation correct for more accurate toe adjustment.
Toe Alignment Bar Installed
III. 1
21. Adjust toe so skis I carbides are parallel - zero toe out or toe in with toe alignment travel bar installed. Measure from equal point on ski to straightedge to determine the amount of adjustment required per ski.
NOTE: Measurements A&B should be equal and taken 10" (254 mm) fore and aft of spindle center as shown with toe alignment travel bars installed.
I
A
I I
(II
r-
I-
10"
.,
I ..
~
l~
1 -;
L:J~;
I I
'1'1
~.}0~
'"
'"
el l
I I
fJ;
,6
Straightedge Against Trac~
I'-
9/97
7.18d

Toe Adjustment - XTRA-10 CRC and XC-10 CRC, cont.
22. To adjust toe, hold tie rod flats or support edge of tie rod end wi th a wrench or flat stock to keep it from rotating. Loosen jam nuts on each end of both tie rods. Turn tie rod as required to adjust toe.
-11 _---
Toe Measurement - CRC
23. Hold tie rod and tighten jam nuts. Be sure to position inner and oute r tie rod ends parallel to their respective mounting surface as shown. When tie rod ends are properly tightened, the tie rod should rotate freely approximately 1/8 turn.
Surface
Tie Rod Jam Nut Torque 28-30 ft. Jbs. (3.86 - 4.14 kg-m) Incorrect Correct
7.18e
9/97
BODY AND STEERING Ski Spindle Bushing Replacement

Ski Spindle Bushing Removal
1. Using a a scribe, center punch, or paint, mark the spindle and steering arm for reference during reassembly. Note direction of steering arm bolt and remove. Also note orientation of grease fitting for ski pivot bushing. The fitting faces forward on models with leading spindle, and rearward on trailing spindles.
2.
Remove steering arm.
3. Slide spindle and ski assembly out bottom of trailing arm. Inspect spindle for wear or damage.
4.
Remove old bushings and washer from bottom of spindle tube with a drift punch . Inspect condition of washer and replace if worn. Install new bushings, tapered end first.
Bushing
~~
O J
VVasher
~)f:
9/97
Il
7.181
BODY AND STEERING Ski Spindle Bushing Replacement

Ski Spindle Bushing Installation
5. Grease spindle shaft and new bushings with Polaris All Season Grease.
All Season Grease

PN 2871322 (3 oz.) PN 2871423 (14 oz.)
6.
Install spindle into trailing arm with grease fitting facing forward (standard and leading spindles) or rearward (trailing spindles).
Standard
Leading Type
Trailing '97+
7.
With ski facing straight forward, attach steering arm. Align with marks made in step 1, or refer to page 7.18h.
8.
Install steering arm bolt and torque to specification.
Spindle Bolt Torque

28-30 ft. Ibs. (3.86-4.14 kg-m)
7. 18 9
9(97
BODY AND STEERING Steering Arm Installation Steering Arm Orientation
WARNING
Steering arm orientation is important to ensure proper steering tie rod end thread engagement and steering performance. Always mark steering arms and spindles before removal for reference upon reassembly. When installing new parts or after steering arm installation, refer to the illustrations and text below. Always verify proper steering operation after completi ng adjustments or repairs. t. The steering arms on each spindle should be parallel to slightly inward in relation to each ski. When correctly installed (III. 1) the centerline of the ski and centerline of the ski bolt hole in the spindle will form (approximately) a 90 angle or slightly greater.
r Forward
Correct
As Close To 900 As Possible
Threads engage \---s.!-.I""I tie rod at least 3/4" (19mm). Steering Arm Bolt Torque 30 It. Ibs. (4.15 kg-m) III. 1
2.
If the steering arm is installed incorrectly the threads of the steerin g tie rod end will not engage the tie rod sufficiently, and the angle formed between ski and ski bolt centerlines is considerably less than 90 as shown at right.
r Forwa rd
\
I
!
[i
,
\
Incorrect
Threads do not \ " engage tie rod at ~ least 3/4" 19mm) ~.
!t )
I
< 90
~ ~I
3. Reinstall torsion bar linkage (where applicable). Torque attaching botts to specification.
III. 2
~I
--'
9/97
7.18h
Polaris industries inc.
BODY AND STEERING Ski Skag Removal - IFS

When performing normal maintenance or tune-up, check the ski skags for wear. To prevent damage to the skis, and for greater steering control, replace all skags which are half worn or greater.
'--'
Ski Skag Removal

1. 2. 3. Remove retaining nuts as shown. Push bolt down through ski. Pull rear of skag from ski as shown. This frees the skag for removal from the ski.
Ski Skag Installation

1. Push skag forward, then up into position.
2. Reinstall nuts and torque to specification.
Ski Skag Retaining Nut Torque Steel Ski, Steel w/skins, Aluminum - 15 ft. Ibs. (2.1 kg-m) Plastic Ski - 20-25 ft, "bs. (2.763.45 kg-m)
Ski Skag Removal - EZ Steer

1. 2. Remove the three nuts from the skag. Pull down and rearward to remove the skag.
Ski Skag Installation - EZ Steer

1. 2. 3. Install flat bar as shown. Install IFS carbide skag. Reinstall nuts and torque to specification.
Ski Skag Retaining .Nut Torque 15 ft. Ibs. (2.1 kgm)
7.19
9/96
BODY AND STEERING Ski Skin Installation

Ski Skin Installation
1. Lift and support front end of machine for easier access to skis. Ski Toe
WARNING
Be sure the machine is stable and solidly supported before proceeding. Serious injury may result if machine tips or falls. 2. Remove cotter pin from ski boll. Remove ski bolt and take off ski. Note direction of rubber ski stop. Remove the bolts from the skag. Pry the back of the skag downward from the ski and remove from the front slot.
,--.,
3. 4.
5. Place heel of ski on a solid surface and slide plastic ski skin onto toe of ski as shown. 6.
Tap ski skin toe with plastic mallet to be sure it has snapped completely onto the toe. Check to see that the skag holes line up . Working from the toe of the ski, continue snapping ski skin onto ski. NOTE: Clamps may be used if the skin is difficult to install. Replace skag removed in step 4. Replace ski removed in steps 2 and 3. Refer to Page 7.19b.
7.
8.
9.
10. Repeat procedure for second ski.
9/97
7.19a
BODY AND STEERING Ski Skag Removal

Ski Installation
SKI INSTALLATION - STEEL SKIS
o
o
Install ski over spindle, slightly in front 01 ski saddle with ski pointing outside. Slide ski forward until spindle is just behind ski saddle and turn to the lorward position. Slide ski forward so spindle is behind ski saddle. Apply soapy water solution to the rear portion of the rubber ski stop. Install ski stop on top of ski saddle with large portion forward.
o o
Push ski back to slide spindle into place. From outside of ski, install bolt and castle nut. Torque to 36 It. Ibs. Install cotter pin and bend both legs
SKI INSTALLATION - COMPOSITE
with large portion toward front of ski.
o Install ski stop
Install cotter pin and bend both legs.
From outside of ski, install bolt . washers and castle nut. Torque to 36 ft. Ibs. (4.97 kg-m).
o Install ski to spindle.
0 Carefully lower machine
7.19b
91 97
BODY AND STEERING

Handlebar Torque Handlebar Torq ue and Sequence - Indy Style
1. 2. Remove handlebar cover and foam . Using a 7/16" (11 mm) wrench , loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or right for access to back nuts.
3. Adjust handlebar to the desired height. Be sure that handlebars, brake lever and throttle lever operate smoothly and do not hit the fuel tank, windshield or any other part of the machine when turned fully to the left or right. IMPORTANT: When adjusting the handlebar, be sure the serrations in handlebar and adjuster block match be fore torquing. 4. Torque the handlebar adjuster block bolts to specification following sequence shown . The gap should be equal at front and rear. 5. Replace handlebar cover and foam.
Handlebar Adjuster Block Bolt Torque 11-13 ft.lbs. (1.5 -1 .8 kgm)
Socket Screws
Handlebar Torque and Sequence Evolved and Aggressive Style

1. Remove two plastic fasteners holding console cover located below handlebar cover on hood side of steering post. Using a 7/16" (11 mm) wrench, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or right for access to rear nuts. Adjust handlebar to the desired height. Be sure thai handlebars, brake lever and throttle lever operate smoothly and do not hit the gas tank , windshield or any other part of the machine when turned fully to the left or right. Torque the handlebar adjuster block bolts evenly to specification. The gap should be equal at the front and rear.
2.
3.
4.
Bottom of Adjuster Block
..,. ,
5. Replace console cover.
Handlebar Adjuster Block Bolt Torque -
WARNING
11-13 ft.lbs. (1.5 - 1.8 kgm)
Improper adjustment of the handlebars, or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars which could result in loss of control.
9(97
7.20
BODY AND STEERING Fuel Tank and Seat Removal
A WARNING
Gasoline Is extremely flammable and explosive under certain conditions. Do not smoke or allow open flames or sparks in or near the area where work Is being performed. If you should get gasoline in your eyes or If you should swallow gasoline, see your doctor immediately. If you should spill gasoline on your skin or clothing, Immediately wash If off with soap and water and change clothing. Prolonged exposure to petroleum based products may cause paint failures. Always protect finished surfaces and wipe up any spills Immediately.
Two Piece Fuel Tank/Seat Removal

1. 2. 3. 4. 5. Remove tank cover by disconnecting snaps. Remove vent line at front LH side of tank. Remove gas cap and rubber grommet. Remove air silencer box. Disconnect fuel line from fuel pump and plug line to prevent fuel spillage from tank. See photo one at right. Roll front tank hold-down spring forward off tank saddle. If machine is equipped with a fuel gauge connector, this should be unplugged. Remove two bolts holding rear of seat to tunnel.
6. 7. 8.
9.
Slide seat rearward enough to gain access to taillight connector at RH side of fuel tank. Unplug connector. Slide seat off machine and set aside.
10. Fuel tank can now be removed from chassis by disconnecting two springs at center of fuel tank.
7.21
11/95
BODY AND STEERING Fuel Tank and Seat Removal

One Piece Fuel Tank/Seat Removal
1. Remove front tank retaining spring located behind driven clutch area. 2. Remove fuel cap and grommet. 3. Remove fuel lines. 4. If machine is equipped with gauges, unplug gauge wires. 5. Remove two bolts in tool box. 6. Disconnect taillight wiring. 7. Remove two console bolts attaching console to tunnel. 8. Remove two console bolts located under hood. 9. Remove fuel cap and lift console up. Replace fuel cap. 10. Lift up at rear of seat and slide out.
11 /95
7.22
BODY AND STEERING Seat Cover Replacement (Plastic Base)
Seat Cover Replacement

1. '---' Remove seat cushion assembly as outlined on page 7.22.
2. Remove seat and seat covering to be replaced. Carefully remove staples by loosening with a small flat blade screwdriver. Pull each staple straight out with a pliers.
'---
3.
On some models , it will be necessary to drill out the rivets holding the strap buckles. Reach inside the tool box and rotate the "0" ring buckle which secures the cerrter hold down strap. Push the "0" ring through the slot in the tool box and carefully pull it through the foam cushion .
Reassembly Note: For ease of assembly, hook a wire to the center strap. This will allow you to pull the center strap back through the foam and into the storage box.
4.
Place the seat foam on the seat base assembly as shown in III. 1. Drape the seat cover over the seat foam. Insert and pull the two seat bucket hold down straps, attached to the seat cover, through the two holes in the seat foam and the routed-out holes located in the storage box area on the plastic seat base. HINT: A stiff wire attached to the 3 bar slide on the hold down strap will aid in this process. Seat Foam
5. 6.
NOTE:Use the rear two holes for a longer length seat

and the forward two holes for the standard length seat.
For Use With Long Seat
~~~~~
Storage Box Area Plastic Seat Base
III. 1
7.23
11 /95
BODY AND STEERING Seat Cover Replacement

4. Turn the assembly over and begin upholstering by lining up the seat cover vinyl side flaps with the indented square location indicators located on the pl?stic seat base as shown in III. 1A.
CAUTION: I
Apply staples in the stapling channel only. See III 1. If you apply staples outside the channel , you will damage the fuel tank reservoir in the seat base. If this happens you must replace the entire seat base assembly. 5. 6. Using a staple gun, tack each side of the vinyl cover in place using two staples. If cover has a Polaris emblem carefully align emblem with bottom edge of seat. This will help ensure that the cover is positioned properly. Align the two sewn seams located at the rear of the seat cover with the two back corners of the seat base. See III. 1. Pull the vinyl tight and tack the seat cover to the plastic seat base in each corner. Use two or three staples per corner.
7. Now that the seat cover is correctly positioned, and tacked to the plastic seat base in four places, turn the assembly over and inspect it. If the seat cover seems to fit correctly and everything looks straight, including the tool compartment flap, continue with step 11. Bottom View Of Seat Assembly Stapling Channel Tack Cover Here First Location Indicators Staples Sewn Seams Tack Cover Here Second
Vinyl Seat Flaps Stapling Channel
III. 1 8. Staple the remainder.of the unattached seat cover to the plastiC seat base as shown in III. 1. HINT; Always staple between two existing staples and follow this procedure until the seat cover is completely stapled to the seat base . See III. 2. Tum the seat cushion assembly over and inspect for wrinkles or imperiections. If imperiections are visible, remove the staples in the affected area and staple correctly.
Staple Here First
9.
Staple PN 9810341 Stainless Steel
Staple Here Third Staple Sequence
111.2
9/97
7.24
BODY AND STEERING Seat Cover Replacement

Models With Twist-Lock Fasteners In Tool Flap
10. Close tool flap cover, making sure it is aligned properly, and mark grommet holes. 11 . Align twist lock with mark from step 10. alignment with grommet in tool flap. Verify Tool Flap Cover
12. Using twist lock as a template, drill two .160" to .164" holes through vinyl and seat base. 13. Rivet twist lock to seat base using rivets provided.
~~?'" Grommets
All Models
"---14. Trim excess vinyl from the bottom around the back of the seat area only after a satisfactory fit is obtained. See III. 1, page 7.24. 15. Reinstall seat by reversing disassembly steps as they apply to your particular model.
Seat Cover Installation Instructions
OnefTwo Piece Seat and Tank Covering Instructions PN 9912521 440 & 600 XCR Seat Covering Instructions PN 9912842
.'-...
7.25
9/97
BODY AND STEERING
Taillight Assembly Replacement

Taillight Assembly Replacement - Standard Indy
1. After removal of seat cover, drill out three rivets from top of taillight. 2. 3. 4. Remove taillight assembly and wire harness. Install new taillight assembly and rivet into place. Connect taillight wire harness. NOTE: Taillight harness wires must be routed away from any possible contact with seat cover staples to prevent electrical shorts.
5. 6.
Pull seat cover tightly and evenly into position and re-staple to seat pan. Inspect cover for a wrinkle-free finish before reinstalling on the snowmobile.
11/95
7.26
BODY AND STEERING Seat Interchangeability

Seat Length Matrix, 1996
The following chart lists seat interchangeability for 1996 models. Arrows indicate interchangeability. For production seats only.
1 Up
Lite
Standard Length
Mid
Length
Long
Length
2Up Lite
XCR
Performance
Deluxe 2 Up Touring
Standard 2 Up Touring
2Up
WideTrak
Ute
ule Deluxe
Sport
Super Sport
Storm
Storm SKSI RMK 600 XCR SP
Trail Lite GT
440XCR 600XCR
Classic Trg .
XLT Trg .
Sport Trg. TranSport
WldeTrak GT
WideTrak LX.
Indy 440 Indy 500 500 EFI SKSI RMK
500 SKS/RMK 500 EFI

Classic
XLT SP XLT
-c:::::::......
I-----
~ XLT SKS/RMK
RXL
Ultra SP
~ U l tra
Ultra SKS RM K

The following chart lists seat interchangeability for 1997 models. Arrows indicate interchangeability. For production seats only.
1 Up Lite
Standard Length
Mid Length
Long Length
2 Up
lite
XC Performance
Deluxe 2 Up Touring
2 Up
WideTrak
Ule
Lite Deluxe
Sport
StormiSE Storm RMK 600 XCRISE Ultra SP)(fSE
500 EFt 700 SKS/RMK XLTLTD

Ultra
Lite GT
440 XC 600 XC XCF (no side pads l
Classic Trg. XLT Trg. Ultra Trg.
Sport Trg. TranSport Trail Trg.
WideTrakGT WideTrak LX
Super Sport
Ultra SP
RXL Trail RMK 440 500 XLT Trail Classic 500

SKS/RM~
XLT SpecIal
XLT SKSiRMK
7.27
9/97
BODY AND STEERING Seat Interchangeability

The following chart lists seat interchangeab ility for 1998 models. Arrows indicate interchangeability. For production seats only.
1 Up Lite
Standard Length
Mid Length
Long Length
2 Up Lite
XC
Performance
Deluxe 2 Up Touring
2 Up
WideTrak
Lite
Sport Super Sport XLT LTD
XLT Special 600 XC 700 XC

6001700 XCR
500 (Option 2) Classic XLT Classic
Lite Tr9
XCF (w/o pads) 440 XCR
Trail Tr9. Classic Tr9.

XLTTrg.
Sport Trg. TranSport
WideTrak LX
lite Deluxe
Ultra Trg.
Storm
Trail 440 500 (Option 3 UUra Trail RMK 500 (Option 3) 500 RMK
6001700 RMK
9197
7.27a
BODY AND STEERING Nosepan Replacement Procedure

Nosepan Replacement Procedure - Standard Indy/Aggressive Body Styles
When installing a replacement ABS nosepan , the following procedures must be closely observed to ensure correct fit to the frame and maximum strength. ABS material is not rigid. Consequently, it must be installed in such a manner that it can expand or contract with temperature changes. 1. Remove damaged nose pan by drilling out rivet heads. Engine mountings and other mountings attached to the forward part of the machine should be removed for ease of installation. The following aluminum rivets must be used to attach nosepan: PN 7621448, 3/16 x .652, Quantity required - 7 PN 7621403, 3/16 x .527, Quantity required - 39
2.
All holes are to be drilled into the nose pan using a 7/32" drill bit (.218"). NOTE: This will be larger than the diameter of the 3/16" rivet. 3. Position new nosepan in place and attach to bulkhead at the top using (7) 3/16 x .652" rivets (PN 7621448). See illustration below. All remaining holes require 3/16 x .527" rivets (PN 7621403). Make sure there is 1/4" (.6 cm) clearance around the exhaust outlet. Install foil (PN 5810108) in the same location as the original part.
4. 5.
Rivet PN 7621448
@
8
Rivet PN 7621403
11
9/96
7.28
BODY AND STEERING Nosepan Replacement Procedure

Nosepan Replacement Procedure - Evolved Style
"IMPORTANT: When installing a replacement nosepan, this rivet sequence must be followed correctly in order to ensure proper nosepan and body panel fit. NOTE: The rivet for polyethylene nosepans is PN 7621467. NOTE: Rivet holes 14 through 19 may require drilling into the bulkhead. Circled rivet numbers 1,2,5 and 6 are locating holes used for proper alignment.
10
Front of Nosepan
. .
15
17
19 29 21 23
,,
22 '24
+
.,
30
26
31
33
32
NOTE: 1. When transfer drilling holes do not force pan into a position which is not uniform with the other side. (Use the same method to drill both sides)
2.
Rivet holes across from one another in unison.
7.29
9/97
BODY AND STEERING Nosecone Alignment

Nosecone Alignment Indy Style
To check nosecone alignment, place the nosecone in its mounting position. Look at the center extruded portion of the hood and nosecone to see if they are parallel. If adjustment is necessary, use the following procedure. 1. Remove nosecone and close hood. 2. Loosen six hood mounting bracket nuts located on bulkhead. 3. Slide hood to right or left depending on centering of nosecone. 4. Position nosecone on front of machine.
Hood and nosecone must be parallel at this point
5. If proper alignment has been achieved, remove nosecone, tighten nuts loosened in step 2. 6. Install nosecone and secure with five mounting bolts and locknuts. 7. If proper alignment was not achieved, repeat step 3.
11/95
7.30
BODY AND STEERING

Hood Adjustment Hood to Belly Pan Alignment - Evolved Style
'The gap between the hood and belly pan should always be 3/16" 1/8"(4.8 mm 3 mm). Refer to II I. 2 for adjustment procedures. NOTE:Hood may have to be removed to make this adjustment. The gap between the hood and the belly pan should be 3/16" 1/8".
If gap is too large at this pOint, move hole in hi nge brace toward bottom of slot in hood brace.
If gap is too little at this pOint, move hole in hinge brace toward top of slot in hood brace.
o
III. 2
Hood Adjustment - Evolved Style

1.
Check to see that hood and upper hood hinge are properly alig ned. To adj ust, loosen nuts (A) and align properly. Tighten nuts. See II I. 1.
f----------.,
/
I I I I I I I I
2. With hood open, loosen nut (8 ). See III. 1. 3. Close hood and remove both rubbe r plugs. Then, using a 7/16" (.4 cm) socket with an 8" (20 cm) extension , loosen nut (C). Adjust hood to pan gap. Tighten nuts. 4. Check outer perimeter alignment and fro nt and rear alignment of hood, side bumpers and side panels. There should be 3/16"(.5cm) + 1/8"(.3cm) -0 clearance between hood to side panels and side bumpers. If adjustment is required, open hood and loosen nuts (D). Adjust and re -tighten one nut per hinge. Close hood and recheck alignment. After correct alignment is achieved, tighten all nuts.
/II HOOd ~1I

Upper 0 ': I _ _ _ _ _ _ _ _ _ JI Hinge L Hood and Hinge need not be flush
/ I
r-------/ :
~
I I --- I I
1
$
, ./ D
I I I
L--- P)~:J
I tK I I
5.
III. 1
7.31
9196
BODY AND STEERING

Hood Adjustment Nosepan, Front Bumper and Side Bumper Adjustment - Evolved Style
1 . Open hood remove panels. 2. and side
t
Fill Hole wi Rivet & Washer
FORWARD
Remove foil tape covering right side nose pan bracket.
3. Drill out rivets (3) and slide bracket Lh Side Panel Bracket RH Side Panel Bracket outward 1/4" (6.35 Move Oul 1/2" Move Out 1/4" mm) as shown in the illustration below. Be sure to mount the bracket at the same angle as before, so the side panel fits squarely against the mounting bracket. 4. Transfer drill holes in bracket to 3.16" (.1875" or 4.75 mm) and rivet in new location using rivet PN 7621485.
5. Apply a new section of foil tape (PN 58 10908) over the bracket. 6. Repeat this procedure for the left side with the following exceptions: move the bracket outward 1/2" (12 .7 mm). Fill the open hole at the tip of the bracket with a rivet and washer.
9/96
7.32
BODY AND STEERING Decal Removal and Installation

Decal Removal
1. 2. 3. Before removi ng old decal, it is important to note its position by marking it in several locations. Remove old decal completely. NOTE: A small amount of solvent will aid in removing the old decal. The decals are UV based . If heat will not remove decal, gently buff area with a mild abrasive. Use 3M Scotch Brite' Graphics Removal Discs with a No. 1 Roloc and holder, or an equivalent low RPM buffing disc.
I;,Ef~tJfION:1
Maintain 2500-3500 RPM to prevent damage to hood caused by excessive heat. 4. Remove any remaining decal adhesive with acitrus based cleaner or equivalent non-solvent based cleaner. Thoroughly clean area where the new decal will be installed using a solution of mild soap (such as dishwashing liquid) and clean water. NOTE: Use approximately four ounces soap to one gallon water.
'!!j'SM S~otohbrltElTM'G:~;illc$'~erti6vaI61~c
3M PH 048011-16855
No.1 Roloc and
5.
3M PH 048011-15408
holder
Decal Installation
1. Apply a solution of mild soap mixed with clean water to the area where the new decal is to be applied. Do not wipe off. 2. Carefully remove decal backing and apply new decal. 3. If decal does not have a pre-mask, apply additional soapy water solution to top of decal after it is in position. 4. Holding decal in pcsition, remove all trapped air and soapy water solution from under decal using a clean, soft rubber squeegee to prevent scratching of decal surface. 5. If decal has a pre-mask, carefully remove.
NOTE: If the decal being applied needs to be stretched around a radius, follow these recommendations:
Fasten a straight edge to tail end of decal. 7. Pull or stretch remaining portion of decal around radius and into position. NOTE: A small amount of heat applied to the decal will aid in forming it to the radius. The mass of the decal which was secured in previous steps will hold it in position while pulling. B. Again, apply soapy water solution to top of decal and remove trapped air using a clean, soft rubber squeegee. Use care to prevent scratching the decal surface. 9. Apply a small amount of heat to the decal to fasten it securely. 10. Carefully remove excess decal material.
6.
7.33
11/95
BODY AND STEERING Troubleshooting

Problem
'Machine darts from side to side
Possible Cause
-Incorrect ski toe alignment
Solution
-Adjust to correct toe alignment
-Incorrect camber -Loose or worn steering components or fasteners -Cracked or broken skis, skags, or carbides Tie rod hits trailing arm -Steering arm installed incorrectly -Tie rod ends worn Steering has excessive freeplay -Steering bellcrank bushing worn or loose -Drag link worn or loose -Steering post loose -Steering post bushings worn -Tie rod ends worn -Spindle bushings worn Front end bounces or sags -IFS shock spring preload too soft -Improper shock charge or valving (if so equipped) Nosecone is not centered -Hood misaligned
-Adjust to correct camber -Tighten or replace
-Replace if necessary -Index correctly in relation to -spindle -Replace if necessary -Tighten or replace if necessary
-Tighten or replace if necessary -Tighten as needed -Replace if necessary -Tighten as needed -Replace if necessary -Adjust spring tension on shocks -Recharge, service, or replace -shocks -Remove nosecone and center -hood
'Some machines with a wide front end may experience darting while following narrower machines on a trail. This is caused by the skis moving in and out of the narrower track left by the previous machine.
9(96
7 .34
CHAPTER 8 SUSPENSION
IFS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8.1 - 8.2 Rear Suspension Specifications .. . .. . ............. 8.3 - 8.5 IFS - Torsion Bar Service .............. . .... ..... 8.6 - 8.7 Rear Suspension Operation ...... . ...... ......... 8.8 - 8.9 Rear Suspension Tuning ..... ... . ..... ... . ... . ... 8.10 IFS Shock Adjustment ... . ... . . . ....... _......... 8.11 Indy Select Shock Adjustment ................... .. 8.12 Rear Suspension Adjustment . ... _. . . . . . . . . . . . . .. 8.13 Tunnel Mounting Positions . . ........... . ... ... _... 8.14 - 8.15 Hi-Fax Replacement ... ............ . .. .. ........ . 8.16 - 8.17 1996 Sport Style Suspension Service . .. . . ......... 8.18 - 8.21 1997 XTRA Lite Style Suspension Service ..... . _. .. 8.22 - 8.27 1996 WideTrak Style Suspension Service.. ... . .. . 8.28 - 8.32 1997 Standard Indy 133.5/141" Service ... . ...... . 8.33 - 8.37 XTRA 10 Suspension Service .... . ......... ....... 8.38 - 8.48 XTRA 12 Suspension Service ...... ... ............ 8.49 - 8.60 Rear Suspension Set Up .......... . ... . . .. .. ... .. 8.61 Compression Adjustable Shocks .... . .... . . ........ 8.62 XTRA 12 Shock Removal ..... . ...... . . . .......... 8.63 XTRA 12 Shock Installation ......... ..... ..... . . .. 8.64 Wheel Kits ... . ............... .. .. _. . . . . . . . . . . . .. 8.65 - 8.67 FOX Shock Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8.68 FOX Shock Maintenance ...... . .. ... . . .... . .... 8.69 8.78 FOX Remote Shock Maintenance ... . ........... . . 8.79 - 8.82 Shock Valving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.83 - 8.87 Additional FoxT" Shock Hardware . . . . . . . . . . . . . . . . . . 8.88 - 8.89 8.90 - 8.94 Troubleshooting
SUSPENSION IFS Specifications
1996 Independent Front Suspension (IFS)

Model Front Suspension IFS 37 IFS38 IFS 38 IFS 38 IFS 41 IFS Xl ra 10 CRC IFS Xl ra 10 CRC IFS 41 IFS 4 1 IFS 38.5 IFS 41 IFS41 Xlra 10 IFS 41 IFS 41 IFS 41 Xlra 10 IFS 41 Xlra 10 IFS 42.5 Xlra 12 IFS 41 Xl ra 10 IFS 38 I FS 42.5 Xtra 12 IFS 42.5 Xlra 12 IFS 42.5 Xtra 12 IFS 42.5 Xlra 12 IFS 41 Xlra 10 IFS 38 IFS 42.5 Xlra 12 IFS 42.5 Xtra 12 IFS 41 IFS 38 IFS 4 1 Xtra 10 IFS 41 IFS 38 Shock PN Shock Description Hyd Hyd Hyd Hyd AirlHydlCam IFPIThread Adj. IFPIThread Adj . IFPICam IFPfCam Hyd Air/ HydiCam Air/HydiCa m AirlHydiCam AirlHydiCam Air/HydiCam Airl HydiCam Airl HydiCam AirlHydiCam AirlHydiCam Ai rl HydiCam Air/HydiCam Air/HydiCam IFP Airl HydlThread Preload Adj Air/HydlThread Preload Adj Ai rlHydiCam AirlHydlThread Preload Adj IFP AirlHydlThread Preload Adj Airl HydlThread Preload Adj IFP IFP IFS Spring PN" 7041261 7041261 704126 1 704126 1 7041261 7041396 7041 489 704 1252 7041358 7041261 7041261 7041405 704126 1 7041261 704 1405 7041405 704 1396 7041405 7041405 704 1396 704 1396 7041396 704 1396 704 1405 7041396 704 1396 7041398 7041 405 704 1396 704 1405 7041358 7041358 Spring Rate 105#/in 105#/in 105#/in 105#/in 105#/in 50#lin 741125 IIlin. 120#l in 16011 105#l in 105#lin 65#lin 105#/in 105#lin 65#lin 65#/in 50#lin 65#/in 65#/in 50#(,n 50#/in 50#/in 50#lin 65#l in 50#lin 50#/in 75#/in 65#l in 50#lin 65#/in 1601l/in 160#/in
Indy Lil elGTIDeluxe Indy Sport Indy Sport Touring Indy TranSport Indy Super Sport Indy 440 XCR Indy 440 XCR SP Indy 600 XCR Indy 600 XCR SP Indy WideTrak GTILX Indy Trail Indy Trail Touri ng Indy 440 LC Indy 500 Indy 500 SKS Indy 500 RMK Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy Classic Indy Classic Touring Indy XLT Indy XLT SP Indy XLT SKS Indy XLT RMK Indy XLT Touring Indy RXL Indy Ultra SP Indy Ultra RMK Indy Ultra SKS Indy Storml SKS Indy Sionm RMK KEY:
~,
7041284 7041284 704 1285 7041284 7041473 7041401 7041494 7041474 7041474 7041284 7041 388 7041423 7041388 7041 388 7041 423 7041423 7041 424 7041423 7041423 704 1424 704 1427 7041424 704 1385 704 1423 704 1427 7041 427 704 1385 7041474 7041 427 7041423 7041474 7041494
Hyd . Hydraulic Siandard Shock Gas IFP . Gas Charged Internal Floating Piston, Fox Shock Gabriel Select Adjusl able Shock NOTE: All pounds referred to in the spring rate co lumn are 10%
Add a suffix of ",067" to sp ring part numbe r when orde ri ng

8.1
9197
SUSPENSION Rear Suspension Specifications
1996 Rear Suspension

Model Rear Suspensian Front Track Shock Front Track Shock Spring
PW
Spring Rate
Oese.
Hyd Hyd Hyd Hyd Hyd IFP Gas
FoxY'" Re-
Rear Track Shock
Rear Track Shock Oese.
Spring
PW
Spring Rate
Torsion Spring Dia .
PN Indy Lite/GT/Dlx Indy Sport Indy Sport Trg. Indy TranSport Indy Super Sport Indy 440 XC R Indy 440 XCR SP Indy 600 XCR Indy 600 XCR SP Sport Style Sport Style
Xtra 10
PN 704 1127 7041127 704 1253 7041 127 7041253 7041253 7041508 7041253 7041253 7041140 7041140 7041253 7041253 7041 253 7041253 7041253 7041351 7041253 7041351 7041404 704135 1 704135 1 704 1253 7041404 704 1351 704 1253 7041253 7041253
181#/in
7041142 7041142 7041430 7041 142 7041430 704 1402 7041507 7041402 7041402 7041281 7041281 7041430 7041430 7041430 7041430 7041430 7041433 7041430 7041433 7041485 7041433 7041386 7041430 7041486 7041386 7041402 7041430 7041402
7041154 7041154 7041438 7041154
Hyd Hyd
Indy Select
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 704 1261 N/A N/A N/A N/A N/A 704 1253 NlA 7041253 7041482 7041253 7041253 N/A 7041482 7041253 N/A NlA N/A
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
105#/i n
.393 .393 .421 N/A .406 .406 .421 .406 .406 .468 .468 .406 .421 .406 .406 .406 .406 .406 .406 .437 .406 .406 .406 .437 .406 .406 406 .406
181#lin
200/var
181#lin
Sport Style Xtra 10

Xlra 10
Hyd Indy Select

Fox IFP Gas Fox lFP Gas Fox IF P Gas Fox IFP Gas
200{var 7041441
200Nar
190#lin
7041444 7041492 7041444 704t444 7041290 7041280 704144 1 7041438 7041441 7041441 7041438 7041440 7041438 7041440 704 1481 7041440 7041480 7041438 7041481 7041480 7041444 7041438 7041444
Xtra 10
Xlra 10
mote
IFP Gas IFP Gas Hyd Hyd Hyd Hyd Hyd Hyd Hyd
Indy Select Thread Adj
200/var
Xtra 10
WideTrak
200/var
181#lin
181 #lin
Indy WideTrak GT
Indy WideTrak
Hyd (2) Hyd (2) Cam Adi

Indy Select
Style
WideTrak
LX Indy Trail Indy Trail Trg . Indy 440 LC Indy 500 Indy 500 SKSI RMK Indy 500 EFI Indy 500 EFI SKS/RMK
Indy Classic Indy Classic
Style
Xlra 10
Xtra 10
200/va r 200/va r 200/var 200/var

200/va r
N/A N/A N/A N/A N/A

200/var
Indy Select
Indy Setect Indy Select Indy Select
Xlra 10 Xlra 10 Xlra 10
Xtra 12
75125 Itlin
200/var
Nitrogen Cell
Indy Select Nitrogen Cell Nitrogen Cell Nitrogen Cell Fox IFP Gas
/I!in
N/A
Xtra 10
Xtra 12 Xlra 12 Xtra 12
Hyd Indy Select

Thread Adj Indy Select
75125
#frn
200/var
/llin 2501t!in 200/var
90150
/I/in
Trg . Indy XLT Indy XLT SP Indy XLT SKSI RMK Indy XLTTrg.
Thread Adl
Indy Selec t Thread Adj
75125
/llin
"!in
200/Var /I!i n N/A
250#/in
Xtra 12
Fox IFP Gas Thread Adi Hyd Ryde AFX

Thread Adj
75 125
#lin 200lvar
Xtra 10
Xtra 12 Xlra 12 Xtra 10 Xtra 10
Indy Select
90 150
Nitrogen Cell Fox IFP Gas Fox IFP Gas Indy Select
#llin
75t25 :lli n 200/Var #lin N/A N/A N/A
Indy RXL
Indy Ultra SP Indy Ultra SKSI RMK
Indy Storml
Fox IFP Thread Adi

Fox IFP Gas
200lvar
200/var
200/var
Hyd
Fox IFP Gas
Xlra 10
Fox IFP Gas
SKS/RMK
Add a suHix of "-067" to spring part number when orde ring
9/97
8.2
SUSPENSION IFS Specifications
1997 Independent Front Suspension (IFS)

Model Front Suspension Lite IFS 38x7 IFS 38x7 IFS 38x7 IFS Xtra-l 0 IFS Xtra-l0 CRC IFS Xtra- l 0 IFS 38 RMK IFS 38x7 IFS Xtra-l 0 IFS Xtra-l 0 CRC IFS XC-l0 CRC IFS Xtra-l 0 IFS 38 RMK IFS Xtra-12 IFS Xtra-1 2 IFS Xtra-12 IFS Xtra-l 0 IFS Xtra-12 IFS Xtra-12 IFS 38 RMK IFS Xtra- t 2 IFS Xtra- l 0 CRC IFS Xlra-l 0 CRC IFS Xtra-12 IFS Xtra-12 IFS Xtra-12 IFS Xtra-l0 CRC IFS Xtra-l0 CRC IFS XC-l 0 CRC IFS Xtra-l 0 CRC IFS 38 RMK IFS Xtra l0 IFS 38 RMK Shock PN Shock Description Hyd Hyd Hyd Hyd Nitrogen Cell Thread Adj. Indy Select Thread Adj. Nitrogen Cell Thread Adj. Nitrogen Cell Thread Adj. Hyd Nitrogen Cell Thread Adj. Gas IFP Thread Adj. Gas IFP Thread Adj. Nitrogen Cell Thread Adj. Nitrogen Cell Thread Adj. Nitrogen Cell Thread Adj. Indy Select Thread Adj. Nitrogen Cell Thread Adj. Nitrogen Cell Thread Adj. Indy Select Thread Adj. Indy Select Thread Adj. Nilrogen Cell Thread Adj. Gas IFP Thread Adj. Gas IFP Thread Adj. Gas IFP Thread Adj . Ryde AFX Thread Adj. Indy Select Thread Adj. Ryde AFX Thread Adj. Indy Select Thread Adj . Gas IFP Thread Adj. Gas IFP Thread Adj. Nitrogen Cell Thread Adj. Nitrogen Cell Thread Adj. Gas IFP Thread Adj. Gas IFP Thread Adj . IFS Spring Spring Rate 10511lin 10511/in 105111in 10511/in 50#fin 80#lin 80#/in 80llfin 105#/in 80#/in 120#lin 120#/in 80lllin 80#/in 75#/in 100#/in 7511/in 80#/in 80lllin 100#/in 80#/in 80#/in 120#/in 120#/in 120#/in 120#/in 140#/in 120#/in 120#/in 120#/in 80#/i n 80#/in 120#fin 1401//in Select
PW
Indy Lite/GT/ Deluxe Indy Sport Indy Sport Touring Indy TranSport Indy Super Sport Indy XCF Indy TraillTrail Touring Indy Trail RMK Indy WideTrak GT/LX Indy 440 LC Indy 440 XC Indy 440 XCR Indy 500/SKS Indy 500 RMK Indy Classic Indy Classic Touring Indy 500 EFI Indy XLT/ SKS Indy XLT LTD/LTD SP Indy XLT Touring Indy XLT RMK Indy XLT SP Indy 600 XC Indy 600 XCR/SE Indy RXL Indy Ultra Indy Ultra Touring Indy Ultra SP Indy Ultra SPXlSE Indy 700 XC Indy 700 SKS Indy 700 RMK Indy Storm/SE Indy Storm RMK 704 1284 704 1535 704 1562 7041535 704 1496 7041 523 704 1496 7041 544 7041535 704 1496 7041 593 7041494 7041496 7041544 7041539 7041503 704 1539 7041538 7041503 7041503 7041543 7041 537 7041536 7041540 7041524 7041503 7041524 7041523 7041540 704 1494 7041538 7041543 704 1540 704 1545 704126 1 7041261 7041261 7041261 7041396 7041552 7041552 704 1552 7041261 7041552 7041489 7041489 7041552 7041552 7041398 704155 1 7041398 7041552 7041552 704 1551 7041552 7041552 7041550 7041575 7041550 704 1550 704 1549 7041550 7041575 70411489 7041552 7041552 7041575 7041574
KEY: Hyd - Hydraulic Standard Shock Gas IFP - Gas Charged Internal Floating Piston, Fox Shock Gabriel Select Adjustable Shock NOTE: All pounds referred to in the spring rate co lumn are 10% Add a suffix of "-067" to spring part number when ordering
8.3
9/97
SUSPENSION Rear Suspension Specifications 1997 Rear Suspension

Model
Rear Suspension
Front Track
Front Track
Spring
Shoc k
Oese.
PW
Spring Rate
Shock
Rear Track Shock
Rear Track
Shock
Spring PW
Spring Rate
Oesc.
Hyd Hyd Hyd Indy Select Hyd Indy Select Ryde AFX
Indy Select
Torsion Spring Oia.
PN
Indy Ute/Dlx Indy Lite GT Indy Sport Indy Sport Trg. Indy TranSport Indy Supe r Sport Indy XCF Indy Trail Xtra Lite Xlra Lite
PN
Hyd Hyd Hyd Hyd Hyd Hyd Ryde AFX Hyd Hyd Hyd Hyd Hyd Hyd IFP Gas RA
7041516 7041516 70415 16 7041430 704 1142 7041430 7041 596 7041 430
7041430
704 1570 7041127 704 1569 704 1253 7041 127 704 1253 704 1253 7041253 7041253 7041253 704 1140 704 1140 7041253
7041508
80#An
181#lin 60#fl n 20D/var 181 #fin
7041515
N/A
N/A N/A NI A NIA NIA
NlA NlA N/A NIA NIA NIA N/A N/A N/A NlA
.393 .393 .393 .42 1
704 1154 70415 15 7041438 70411 54

704 1441
Xtra lite
Xtra 10 133.5 Sport Style Xtra 10 121 Xtra 10 121 Xtra 10 121 Xtra 10 133.5 Xtra 10 133.5 WideTrak Style
.406 .406 .406 .406

.421
.42 1
200/var
200/var 200/var
7041597 7041441 7041438 7041577 7041290

7041280 7041441 7041492
N/A
N/A NlA NlA N/A 7041261 N/A NIA
Indy Trail Trg.

Indy Trail RMK
200/var
200lvar 181#"n
181.#!in
200/var 190nli"
Indy Select Indy Select Hyd (2) Hyd (2) Cam AdJ
Indy Select tFP Gas
7041430 7041281 7041281 7041430

7041507 or
Indy WideTrak GT
Indy WideTrak LX Indy 440 LC Indy 440 XC
N/A
105#/in
.468 .468 .406 .421
WideTrak Style
Xlra 10 121
NI A NIA
Xtra 10 Fox'tl.t
704164 1
Indy 440 XC R Indy 500 Indy 500 SKS Indy 500 RMK
Xtra 10 Foxtl,O
7041641 7041430
7041430 7041430 7041586 7041485 7041586 704 159 0 7041 586 7041486 704 1430 7041430
IFP Gas RA Hyd Hyd Hyd Hyd Indy Select

Indy Select
7041508 7041253 7041253

7041253 704 1351 7041404 7041351 7041253 7041351 7041404 7041253 7041253 7041351
, 90#/in
7041599 7041441 7041567 704 1577 704 1587 7041481 704 1587 7041567 7041587
IFP Gas
Indy Select Indy Select Indy Select Gas Bag
NIA NlA NIA NlA 7041561 704 1484 7041561
N/A N/A N/A N/A 85#fln 275#fln

65#/in
.421 .406 .406 .421 .406 .437 .406 .421 .406 .437 .406 421 .406
Xtra 10121
Xtra 10 133.5
200/var
200/var 200/var
Xtra 10 133.5 Xtra 12 121 Xtra 12 133.5

Xtra 12 121 Xira 10 121 Xtra 12 121
Indy Classic
Indy Classic Trg.
75/ 125 lilin 901150

#lin
Indy Select Gas Bag

Indy Select Gas Bag
Indy 500 EFI Indy XLT Indy XLT LTDI LTD SP Indy XLTTrg . Indy XLT SKS Indy XLT RMK Indy XLT SP
7511 25 #/in
Hyd
Indy Select Indy Se lect
200/var
751125
#/in
N/A
7041561 7041484 NIA NIA 7041561
N/A 85#fl n
275#/in
Xlra 12 133.5 Xtra 10133.5 Xtra 10 133.5

Xlra 12 121
90/150
If/in 200/var
704 1481
7041567 7041577 7041480
Indy Select
Indy Select Indy Select
Hyd Hyd IFPGas
N/A NIA 85#fln
200/var
75/125
7041386
IFP Gas
Fox il
#lin
Add a suffix of "-067"' to spring part number when ord ering
9/97
8.4
Pola ris Industries In c.
SUSPENSION Rear Suspension Specifications 1997 Rear Suspension Cont.

Model Rear Suspension Front
Track Shock
Front Track Shock Oese.
Spring
PN '
Spr ing Rate
Rear Track Shock
Rear Track Shock Oesc .
Spr ing
Spring
PW
Rate
Torsion Spring Dia.
PN
Indy 600
PN
IFPGas IFP Gas AFX
xc
Xlra 10 121 Fox a , Xlra 10 121 FoxTl.' Xtra 12 121 Xlra 12 121 Xlra 10 121 Xlra 12 133.5
Xlra 10 12 1
7041 584
704 1253
7041253
200/var
7041585
IFP Gas IFP Gas Ryde AFX Gas Bag Indy Select Ryde AFX IFP Gas Indy Select IFP Gas IFP Gas
N/A N/A
N/A N/A
.421 .421 .406
Indy 600 XCRI SE
7041 589
7041559
200lvar
704 1595 704 1560

7041440 7041567
Indy RXL
Indy Utlra
Indy Ultra SP Indy Ullra Trg, Indy Ullra SPXI SE Indy 700 SKSI RMK Indy Slorm/SE
Indy Storm RMK
7041 35 1 704135 1
7041253 7041404 7041253
75/125
#/in
7041561 7041364
N/A
85 #/in
126#lin
704 1433 704 1590 7041594

7041 589 704 1606
Indy Select
Hyd AFX
IFP Gas
75/125
#=/in 200/var
.406
.421 ,437 .421 .421 .421 .42 1
NlA
275#lin
90/150
#fin
7041548 7041595
7041438
7041484
N/A N/A N/A N/A
200/var 200/var
200lvar 200lvar
N/A N/A N/A N/A
FoxTI.I
Xlra 10 133.5 Xl ra 10 121
FOXTM
Hyd IFP Gas

IFP Gas
7041 253
7041253
704 1589 7041 589
704 1595 704 1588
Xl ra 10 133.5
704 1253
, Add a suffix of "067" to spring part number when orderin g
8.5
9; 97
SUSPENSION 1998 IFS Data - Set-Up & Adjustment 1998 Model

Lite/Lite DlxlLite Trg Sport TranSport Sport Touring XCF Super Sport Trail Trail Touring Trail RMK WideTrak LX 440 LC 440 XCR 500 500 RMK Classic Classic Touring XLT LTD XLT Touring XLT SP XLT Classic 600 XC 600 XCR 600 RMK Ultra Ultra Touring 700 XC 700 XCR 700 RMK Storm
Front Suspension Type

Lite IFS 38x7 IFS 38x7 IFS 38x7 IFS Xtra-1 0 CRC IFS Xtra-10 IFS Xtra- 10 IFS Xtra-10 IFS 38 RMK IFS 38x7 IFS Xtra-1 0 IFS XC-10 CRC IFS Xtra-1 0 CRC IFS 38 RMK IFS Xtra-12 IFS Xtra-12 IFS Xtra-12 IFS Xtra-12 IFS Xtra-10 CRC IFS XTRA-12 IFS XC-10 CRC IFS Xtra-10 CRC IFS 38 RMK CRC IFS Xtra-12 IFS Xtra-12 IFS XC-10 CRC IFS Xtra-1 0 CRC IFS 38 RMK CRC IFS Xtra-1O
Shock Description
Hyd Hyd Hyd N Cell Thr Adj. Select Thr Adj. N Cell Thr Adj. N Cell Thr Adj. N Cell Thr Adj. N Cell Thr Adj. Hyd N Cell Thr Adj. Gas IFP Thr Adj. N Cell Thr Adj. N Cell Thr Adj . N Cell Thr Adj . Select Thr Adj. Select Thr Adj. Select Thr Adj. Select Thr Adj. Select Thr Adj. Gas IFP Thr Adj . Gas IFP Thr Adj. N Cell Thr Adj . Select Thr Adj. Ryde AFX Thr Adj. Gas IFP Thr Adj. Gas IFP Thr Adj . N Cell Thr Adj. Gas IFP Thr Adj.
IFS Shock PN
7041284 7041535 7041535 7041562 7041523 7041496 7041496 7041496 7041544 7041535 7041496 7041692 7041496 7041544 7041539 7041503 7041503 7041503 7041523 7041503 7041697 7041540 7041543 7041503 7041524 7041697 7041540 7041543 7041540
Spring IFS Spring Rate PN*

7041261 7041261 7041261 7041598 704 1552 7041552 704 1552 704 1683 7041552 7041261 7041552 7041489 7041552 7041552 7041405 7041551 7041398 7041550 7041405 7041398 7041613 7041575 7041551 7041550 7041549 7041613 7041575 7041551 7041575 105#/in 105#/in 105#/in 105#/in 80#/in 80#/in 80#/in 80#lin 80#/in 105#/in 80#/in 74/120# 80#/in 80#/in 65#/in 100#/in 75#/in 120#/in 65#/in 75#/in 75#/in 120#/in 100#/in 120#/in 140#/in 75#/in 120#lin 100#/in 120#/i n
Spring PreLoad
3 Shims 1 Shim 3 Shims
.13"
1.0"
1.0" .75"
.13" .3"
3 Shims
.8"
.625
.8"
.6"
.75"
.4"
.25"
.13#
.75"
.75
.75
11
1.5"
.13"
.13/1
.63"
.75"
1.5/1
.13"
1.55"
KEY: Hyd - Hydraulic Standard Shock; Gas IFP - Gas Charged Internal Floating Piston, Fox Rebuildable Shock; Select - Gabriel Select Adjustable Shock. non-rebuildable; Ryde AFX; Ryde AFX Adjustable Shock, non-rebuildable; N Cell - Nitrogen Cell: Thr Adj. - Threaded Adjuster: NOTE: All pounds referred to in the spring rate column are 10%
All springs shipped as service parts are black. You must add a suffix of "-067" to spring part number when orderin g
PRELOAD (Threaded Adjusters)

J
.J
9/97
8.5a
SUSPENSION 1998 Rear Suspension Data
Model
Rear
Suspension
Front Track Shock
PN
Front Track Shock (Type)
Front
Front
Track
Rear
Track
Track Shock
Spring
Rear Track
Torsi on Spring Part Number
Tors ion Spring Diameter I Angle
Shock
Spring
Shock PN
Shock Oese.
Left / Right
(Rear Track
(Rear Shock
Spring Rate)
PN' Ule/Dlx Xtra

L~e
Rate (Ib.nn.)
BO#/i n 80#"n 60#/;n BO#frn 181#lin
200Jvar
Shock Spring) 7041665 7041666 704 1665 7041666 7041154 7041667 7041441 7041 707 704144 1 7041438 7041 577 7041 441 7041280 704 1441 7041577 7041 587 7041 481 7041694 7041587 7041481 7041560 7041640 7041438 7041695 7041440 7041548 7041640 7041695 7041438 7041695 Hyd Hyd Hyd Hyd Hyd Ryde AFX
70415571704 1558 7041 46117041462 704152 117041522 704 146117041462 704132017041321
7041516 7041516 7041516 7041516 7041719 7041596 7041430 7041706 7041 430 7041430 7041430 7041430 704 171 1 7041430 7041430 704 1586 7041485 7041639 7041586 7041486 7041559 7041639 7041606 7041642 7041433 7041594 7041639 7041642 7041606 7041642
Hyd Hyd Hyd Hyd Hyd Ryda AFX Hyd FOX IFP Hyd Hyd Hyd Hyd Hyd Hyd Hyd Selecl Select Ryde FX Select Select AFXlElecl Ryde FX Hyd FOX IFP Select
Select
7041570 7041570 7041569 704 1570 7041710 7041253 704 1253 704 1508 7041253 7041253 7041253 7041253 7041712 7041253 7041253 7041351 7041404 704 1253 7041351 7041404 7041351 7041253 7041253 7041253 7041351 7041404 7041253 704 1253 7041253 704 1253
.393 .421 .406 .421 .406 .406 .406 .421 .406 .437 .421 .406 .468 .406 .421 .406
(85#An)
80' 77' 82' 77' 75' 77' 77' 77' 77' 77' 77' 77' 74'
Lite Trng
Sport Sport Tmg
Xl ra Ulel33
Xtra Ute
Xu. Ule 133 141 GT Xua l 0 Xtral0

Xlra 10
TranSport
XCF 440 LC 440 XC R
70414631704 1464 704146317041464

704 146117041462 704146317041464 704146517041466 704 146117041462
200/var
1901tlin
Select
FOX IFP
Trai l
Trail Trng
Trail RMK
Xua 10 Xua 10 133.5 Xua 10 133.5 Xua 10 WideTrak 156 Xlra 10 Xua 10133.5 Xtra 12 Xtra 12 133.5
Xtra-10
200/var
200/var
Select
Select
Select
Select
200/var
Super Sport
WideTrak LX
200/var
181 It/in 200/var 200/var
704146317041464
704123917041240
Hyd
Se lect Select Gas Bag Select
500 500 RMK

Classic
Classic Trg
704146317041464
704146117041462 704139417041395
77'
n'
55'
75/125 90/150
(7041561)
704148717041488
#/in
20D/var
(7041 484) Ryde AFX Gas Bag Se lect Ryde AFX RydeA FX
Select
.437 (275#"n) .421 .406

(85#nn)
77' 77' 55' 77' 55' 77' 77'
XLTSP XLT LTD XLT Trng XLT Classic 600 XC 600 RMK 600 XC R
Ultra
7041461 /7041462
704139417041395
Xl ra 12 Xua 12 133.5 Xtra 12

Xtra 10
75/125 90/150 75/125 200/var

20Q/var 200/var
(7041561)
704148717041488
(7041484) 7041394/7041395 (7041561 )

704146117041462 704 146117041462 704146117041462
.437 (275#/ln) .406 (85#/in) .421 .421 .421 .406 (126#"n) .437 (275#"n) .421 .421 .421
.421
Xual0 136 Xlra 10 Xtra 12 Xtra 12 133.5 Xtra-l0 Xlra 10 Xlra 10 136 Xtra 10
FOX IFP
Gas Bag
77'
55' -
75/125 90/150
200/var 200/var
7041394/7041395 (7041364) 7041487/7041488 (7041484)

7041461 17041462
Ultra Trng 700 XC 700 XCR 700 RMK

Storm
Ryde AFX Ryde AFX FOX IFP
77'
77' 77'
Ryde FX FOX IFP Hyd FOX IFP
7041461/704 I 462 7041461/7041462

704146117041462
200/var
Select
FOX IFP
77'
77'
200/var
' All springs shipped as selVice parts are black. You must add a suffix of "-067" to spring part number when ordering.
Polaris Indus tries Inc.
B. 5b
9/97
SUSPENSION IFS - Torsion Bar Adjustable Torsion Bar

Operation: For high performance applications the torsion bar can be adjusted for any number of varying conditions. Adjustment: Each side is individually adjustable. 1. Rider must be in position on the machine. 2. Loosen rod end jam nuts on both left and right sides. 3. Adjust rod until there is a small amount of free play detectable on all rod ends. 4. Tighten jam nuts securely. Maintenance: Periodic inspection of the support area, set screw and bar arm bolts is recommended to prevent arm to spline loosening. Period ic lubrication of the bushings is required using Polaris Low Temp or Premium All Season grease. NOTE: Refer to kit instructions for proper assembly.
Torsion Bar Support
4lb/ /;="~'-"'
(
Torsion Bar Housing
let
~~
~
Torsion Bar
,.--~
SetScrew
N u t - - .......
JamNut~
~A Rod Ends
Bar Arm Bolt
'Nut ............... Torsion Bar Bracket
--:Q ~~
.
serew _
~<
'Washer Bolt
Polaris Low Temp Grease PN 2870577 Polaris Premium All Season Grease PN 2871423
Parts for new style liquid tWin models.
Adjustable Torsion Bar Kit

PN 2871035
9/97
8.6
SUSPENSION IFS - Torsion Bar Torsion Bar Removal

1. 2. Remove trailing arm assembly. Using a small pin punch. tap out the rivet mandrels in the center of the torsion bar support rivets.
3. Using a 1/4" bit. drill out the center portion of the rivets. 4. Punch out the rivet body. 5. Remove support and torsion bar. 6. Repeat procedure for second torsion bar.
Torsion Bar Installation

1. Rivet support in place using Polaris PN 7621449 rivets. NOTE: These high strength "a" rivets are the only replacement rivets recommended for this applica tion.
Torsion Bar Support Rivets PN 7621449
2. 3. 4.
Reinstall torsion bar. Reinstall trailing arm assembly. Check camber and toe adjustments. Chapter 2. Refer to
NOTE: Accurate set up is critical for proper function of front suspension. Refer to Body and Steering . Chapter 7. for set up dimensions.
8.7
9/96
SUSPENSION Rear Suspension Operation Rear Suspension Operation

The primary function of the rear suspension is to provide a comfortable ride in all types of riding conditions. It separates the rider from the ground, whi le allowing for complete vehicle control. The rear suspension also must provide weight transfer and maintain track tension. The rear suspension has many adjustable features for fine tuning to achieve optimum comfort. The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider.
Weight Transfer
The shifting of weight from the skis to the track is called weight transfer. As engine torque is applied to the drive axle the torque is transferred to the track, pulling it forward. This energy also tries to pull the suspension forward . The front torque arm reacts to this force by pushing down on the front of the track, in effect applying more weight to the track and reducing the weight on the skis. It is important to note that energy used to lift the front of the machine is not available to push the vehicle forward .
Changing the angle of the front torque arm changes the suspension's reaction to the force. Adjusting the length of the limiter strap will change the front torque arm angle. Shortening the strap limits the extension of the front of the suspension; reducing the angle of the torque arm and increasing ski pressure . Lengthening the strap al lows the front of the suspension to extend further; increasing the angle of the torque arm and decreasing ski pressure. limiter strap adjustment has a great affect on weight transfer. It is important to check track tension whenever limiter strap length is changed . Front track shock spring preload also affects weight transfer. A stiffer spring and/or more preload on the spring transfers more weight to the track. A softer spring and/or less preload keeps more weight on the skis. Keep your riding application in mind when choosing springs and setting spring preload . Soft springs/preload will increase ski pressure, but may bottom out. Stiff sp rings/preload will provide more track pressure (reduced ski pressure), but may resu lt in a less comfortable ride. During acceleration, the rear of the suspension will compress and the IFS will extend, pivoting the machine . Because of this pivoting effect, rear spring and spring preload also have some effect on weight transfer. Softer rear springs, or less preload, allow more weight transfer to the track and redu ce ski pressu re. Stiffer re ar springs, or increased preload , allow less weight transfer to the track and increase ski pressure. The main function of the rear torque arm is to support the weight of the vehicle and rider, as well as to provide enough travel to absorb bumps and jumps. Shock valving also has an effect on weight transfer. Refer to shock tuning information beginning on page 8.83.
9/96
8.8
SUSPENSION Rear Suspension Operation

Springs
Two types of springs are employed in Polaris suspensions, coil springs and torsion springs. Following is some of the terminology used when referring to coil springs.
Free length- the length of a coil spring with no load applied to the spring Installed length - the length of the shock absorber between the spring retainers. If the installed length of the spring is less than the free length, it will be pre-loaded. Spring rate- the amount of force required to compres s a coil spring one inch. For example , if 150 pounds of force are required to compress a spring 1 inch, the spring rate would be 150 it/in. Straight rate spring - the spring requires the same amount of force to compress the last one inch of travel as the first one inch of travel. For example, if a 150 it/in. spring requires 150 pounds of force to compress it one inch, 300 pounds of fo rce would compress it two inches, 450 pounds of force would compress it three inches, etc. Progressively wound spring - the rate of the spring increases as it is compressed. For example, a 100/200 it/in . rate spring requires 100 pounds of force to compress the first one inch, but requires 200 additional pounds to compress the last one inch.
Coil Spring
When a bump is encou ntered by the suspension, the force of the bump compresses the spring. If the force were 450 pounds, a 100 it/in. sp ring would compress 4.5 inches. A 150 it/in. spring wou ld only compress 3 inches. If the suspension had 4 inches of spring travel the 100 #/in. spring would bottom out, while the 150 #/in. sp ring would have one inch of travel remaining. Torsion springs are much like coil springs, although shaped differently. The rate of the torsion spring is controlled by the free opening angle, the installed opening angle, and the wire diameter of the spring. Torsion Spring
Load reduces opening angle
r:o~~ ---...-~
--
8.9
9/96
SUSPENSION Rear Suspension Tuning

Many factors influence the overall handl ing characteristics of snowmobile suspensions. Riderweight, riding style, course conditions, and the condition of suspension components are some of the things that you have to consider when tuning a suspension. On new machines, or whenever new suspension parts are installed, the sled should be ridden for at least one tank of fuel to allow moving parts in the shocks and suspension to wear in . The shock springs will also take their initial set and the setup will be more accurate.
'--'
Suspension Tuning
To begin suspension tuning, check the condition of shocks and other suspension parts. Begin by taking the shocks apart, inspecting all parts for damage , and changing the oil. Even new shocks should get an oil change after break in to clean break-in material from the shocks and valve body. If oil is low, inspect seal cap O-Ring and seals for damage. If air or foam is evident in the oil , the O-Ring in the floating piston must be replaced. Afterchanging the oil reassemble shocks, making sure oil level , floating piston depth (IF P), and nitrogen pressure are correct. The use of nitrogen in Fox shocks provides consistent damping at extreme temperatures. Don't overcharge the shocks. Excess nitrogen pressure may cause sea l Ustiction" and prevent proper shock action. If too much oil is added, or if the IFP depth is set incorrectly (too low) shock travel will be limited. Inspect and grease all suspension parts, making sure they pivot freely. All suspension components should be greased when disassembled. Regular maintenance greasing should be done with no weight on the component to allow grease to reach important contact areas . When everything is working correctly, set the preload on the springs for the correct sag. There should be 1 1/2" of sag on the rear suspension when you sit on the snowmobile, measured at the rear bumper. Bounce on the suspension a couple of times to overcome any "stiction" and settle the sled to an accurate reference point. The rider should have their weight placed correctly on the machine. Adjust spring preload to achieve the 1 1/2" sag dimension. When they get off the machine it should return to 1/2" of sag. If the sag is less than 1/2" stiffer springs may be needed. If it is greater than 1/2" softer springs may be needed. This may seem backwards at first, but if the spring is too soft, the preload must be greatly increased to prevent excess sag. This shows up in the form of less unloaded sag. Therefore, a stiffer spring is required. If the spring is too stiff, the preload will have to be backed off, and unloaded sag will be excessive. This is a very important step because the proper spring will also help ensure proper weight transfer. The front suspension should sag about 1" (measured at the front bumper) with the weight of the sled on it. Use stiffer or softe r springs as needed to keep from bottoming too hard, to ensure using all the travel.
Shock Tuning
The shocks work in two directions. Compression damping prevents the shock from bottoming hard while rebound damping keeps the shock from springing back too fast. Both compression and rebound damping can be adjusted for high and low speed damping characteristics. NOTE: When we refer to high and low speed, we are referring to the speed of the shock shaft or valve, not vehicle speed. To check low speed shock valving, drive the machine through rounded, soft bumps . Feel what each area of the snowmobile is doing so you can tell which shocks need to be adjusted. Low speed valving may also be checked on small chatter bumps, but the machine's reactions will be more difficult to feel. The ideal low speed rebound valving allows the machine to return to full up position quickly, but not so fast that it pushes you off the seat or bounces the skis up. The ideal low speed compression valving uses most or all of the travel , without bottoming out. The idea is to keep the skis and the track on the ice or snow without bouncing or a harsh ride.
...../
9/96
8.10
Polaris Indusuies Inc.
SUSPENSION IFS Shock Adjustment Front Shock Spring Preload Adjustment

The XTRA 10 and XTRA 12 suspension systems on Polaris snowmobiles have been designed to provide the rid er with a wide range of adjustment. Generally, the softest sp ring and spring preload adjustment give the best ride and also the best traction. Front shock spring preload will affect the ride height of the machine , the amount of rear suspension sag, and ski pressure or steering effort. Spring preload should be adjusted equally on both sides of the machine. Ski pressure must be equal to prevent undesirable handling characteristics. The front shock spring preload can be adjusted by grasping the spring and turning in a clockwise direction, (as viewed from the bottom), to increase preload.
NOTE: Access to the cam with the spanner wrench IS easiest from the inside of the ski.
High
preload Low --"""=",, preload
:g:
Turn ing clockwise increases preload
Spanner Wrench
(included with some models)
Cam Highest Preload
Softest Preload
9/96
SUSPENSION Indy Select I Ryde AFX Shock Adjustment Indy Select I Ryde AFX IFS Shock
Snowmobiles equipped with adjustable compression damping IFS shocks, will allow the driver to make adjustments to the compression valving of the front shocks by turning the screws located near the base of the shocks. By turning the screw clockwise, the compression of the shock is increased, stiffening the ride. By turn ing counter clockwise, the compression is decreased, softening the ride. The factory setting is in the softest position. (Screw all the way out - counterclockwise). If bottoming occurs, the compression damping should be used in conjunction with the spring preload to achieve the desired ride affect. 112 of a turn will affect the ride considerably. There are approximately 3 turns of adjustment available.
o
)
Adj ustmen Screw
I;
Indy Select I Ryde AFX Rea r Track Shock

Snowmobiles equipped with rear adjustable compression damping rea r track shocks will allow the driver to make adjustments to the compression valving of the rear shock by turning the screw located near the base of the shock. Turn spring clockwise to tig hte n preload Turn screw clockwise to tighten compression (stiffen)
Adjustment
Locate the adjustment screw near the base of the shock. NOTE: This adjustment is easiest to make with the machi ne tipped on its side.
WARNING
Be sure to shut off the fuel supply before tipping the machine to prevent fuel spillage and flooding of the carburetors. By turning the screw clockwise (a small screwdriver or dime work well), the compression valving is increased, stiffening the ride. To soften the ride, reduce the compression by turning the screw counter-clockwise. A great deal of ride performance is accomplished with a mere 112 to 1 turns. There are approximalely 3 full turns of adjustment available. 9196
8. 12
SUSPENSION Rear Suspension Adjustment

The primary function of the rea r suspension is to provide a comfortable ride in all types of riding conditions. The rear suspension has many adjustable features for fine tuning to achieve optimum comfort. The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider. The secondary function is to provide superb handling and stability, such as adjustments to vary ski pressure for steering and controlling the snowmobile's center of gravity. Refer to the suspension identification chart on page 8.3 to identify suspension type (e.g. 1996 Indy Classic - Xtra 12) . Adjustment procedures for each type are explained late r in this section.
Adjustable Features and Adjustment Options

Following is a list of possible adjustment features and options. Not all features apply to all suspension types. Independent Front Suspension (IFS) Front shock spring preload Optional springs Optional shock valving Indy Select / Ryde AFX adjustable compression rate Rear Suspension Spring preload - front track shock Spring preload - rear track shock Rear torsion spring Front rear scissor stop (FRSS) Rear rear scissor stop (RRSS) Optional coil springs Optional torsion springs Optional shock valving Limiter strap - front Limiter strap - rear Indy Select / Ryde AFX adjustable compression rate
8.13
9/96
SUSPENSION 1996 Tunnel Mountin g Positions Tunnel Mounting Positions for Deep Snow Operation
Suspension Mounting Bolt Torque: 7/16" 60 ft.lbs. (8.28 Kg-m) 3/8" 40 ft.lbs. (5.52 Kg-m)
121 " Standard Length Tunnel All Models
Rear
Front I ,l
I '.'
. I
I~
I
Factory Setting: A-A Any Other Combination will Result in Tunnel Damage
133" SKS Length Tunnel All Models
Rear
! :. :, I 0
Front
l'
A
Factory Setting: A-B or BB
,.-L- B
I
o I
Tunnel Mounting Positions - XTRA 10 133"

133" SKS stock mounting position. Optional position - lower hole.
Rear
Front
I
I
- 1
133" RMK stock mounting position. No optional positions for maximum deep snow performance.
Front torque arm stock mounting position. No optional positions.
For improved deep snow performance, tighten the front limiter strap 5/B - 3/4" (1.59 - 1.91 cm).
NOTE : XTR A 10 121", XTRA 12 121", and XTRA 12 133" have no optional tunnel mounting positions. XTRA 12 front limiter st rap may be shortened for more ski pressure and lower track approach angle.
9{97
8.14
SUSPENSION
1997 Tunnel Mounting Positions

1997 Model Tunnel Mounting Positions
(Upper) 1 Rear
1- - -
(Mid) 2
(Lowe r) 3
---tt~~~1~1========;~~t::~~
Suspension Mounting Bolt Torque:
(Upper) 1 (Lower) 2
7/16" 60 tUbs. (8.28 Kg-m) 3/8" 40 tU bs. (5.52 Kg-m)

Model Indy lite/Deluxe/GT Indy Sport/TranSport Indy Sport Touring Indy Super Sport 1 XCF Indy Trail Indy Trail Touring Indy Trail RMK WideTrak GT/LX Indy 440 1 440 XC Indy 500 Indy 500 SKS Indy 500 RMK Indy 500 Classic'Touring/EFI Indy XLT Indy XLT LTDiTouringiSPI LTDSP Indy XLT SKS Indy XLT RMK Indy 600 XC Indy 600 XCRISE Indy RXL Indy Ultra/Touring Indy Ultra SP Indy Ultra SPXlSE Indy 700 SKS Indy 700 RMK Indy Storml SE Indy Storm RMK
Front Torque Arm Tunnel Position Rear Mount Location Optional Positions (FronURear)
Fixed Fixed Mid Upper Upper Mid Mid Fixed Upper Upper Upper Mid Fixed Upper Fixed Upper Mid Upper Mid Fixed Fixed Upper Mid Mid Mid Mid Mid
Fixed Fixed Upper Fixed

Fixed
None
None
1/2 2/ 1 2/1 1/2 1/ 1, 2/1,3/2

None
Upper Lower Fixed Fixed Fixed Upper

Lower
2/ 1 2/1 211 , 212, 3/2 1/1, 211 , 3/2
Rxed Fixed Rxed Upper

Lower
None
211
None
211 , 212, 3/2 1/ 1, 211, 3/2
Fixed Fixed Fixed Fixed Fixed Fixed Upper

Lower
211
1/1
None None
211
111 1/ 1, 212 , 3/2 1/1, 211,3/2 1/1 1/ 1, 211, 3/2
Fixed
Lower
CAUTION : Use only combinations specified to preven t track and drive train damage. Always install bolts (PN 7517289) and nuts (PN 7542453) in open mount ing holes to prevent tunnel damage.
8.15
9/97
SUSPENSION Tunnel Mounting 1998 Rear Suspension Set Up I Tunnel Mounting Positions
Model Front Track Shock Mount Front Torque Ann Tunnel Position Rear Torque Ann Tunnel Mount Fixed Fixed (Below) Fixed Fixed (Below) Fixed Fixed Fixed Fixed Fixed Fixed (Below) Fixed (Below) Fixed Fixed Fixed Fixed (Below) Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed (Below) Fixed Fixed Fixed Fixed Fixed Fixed (Below) Fixed Options
Lile/Dlx Lile Trng Sport Sport Tmg TranSport XC F 440 LC 440 XCR Trail Trail Trng Trail RMK Super Sport WideTrak LX 500 500 RMK Classic Classic Trg XLTSP XLT LTD XLT Trng XLT Classic 600 XC 600 RMK 600XCR Ultra Ultra Trng 700 XC 700 XCR 700 RMK Storrn
NlA NlA NlA N /A N/A

Lower Lower Lower Lower Lower Upper Lower
N/A
Lower Upper
#3 #2 #3 #1 #2 #1 #1 #1 #1 #1 #2 #1 #3 #1 #2
Fixed Fixed
Z
0
"C
....
::::I
Q)
s:
0
::::I
(0
N/A N /A
Lower
s:::
~.
::::I
#2
Fixed Fixed Fixed
N /A N /A N /A
Lower Upper Lower
"tI 0
;:;:
::::I
(fJ
(fJ
#2 #2 #2
Fixed Fixed
NlA NlA
Lower Lower Upper Lower
#2 #2
Fixed
#2
NOTE: There are no optional front torque arm mounting positions. Do not re-Iocate the front torque arm.
9197
8.15a
SUSPENSION Hi-Fax Inspection I Replacement

Hi-Fax Replacement - All Models
Hi-Fax replacement on al l Polaris models is similar. When any area of the Hi-Fax is worn to 1/8" (.3 cm), it should be replaced. This will save wear on other vital components. The slide rail is designed to operate in conditions with adequate snow cover to provide sufficient lubrication . Excessive wear may be due to improper alignment, improper track adjustment or machine ope rati on on surfaces without snow. Replace Hi-Fax when worn to 5/16" (.79 cm) on XTRA 12 suspensions; 3/8" (.95 cm) on XTRA 10 and Sport style suspensions; 7/16" (1.1 cm) on XTRA Lite style suspensions.
Hi Fax Wear Limit
-------+---,
XTRA 10 & Sport SI Ie
3/8"
!XTRAi2=-l-t--'j
XTRA Lile
5 ~
5/16"
Suggested Hi Fax Wear Limit: XTRA 12 - 5/16" (_79 em) XTRA 10 & Sport Style - 3/8" (_95 em) XTRA Lite-7/16" {1_1 em)
Hi-Fax wear patterns are somewhat different on machines equipped with the XTRA 12 suspension than on conventional models. (The rear of the rail will wear rapidly at first.) After reaching a certain point, this rapid wear will cease. This area should be checked frequently, however, replacement is not necessary until a thickness of 5/16" (.79 cm) is reached. New Hi-Fax are best used in deep snow conditions. Marginal snow or hard-pack conditions are better suited to worn Hi -Fax, or Hi-Fax which have been cured or broken in .
Hi-Fax Removal
1. Remove suspension from machine.
NOTE: Some models may allow HI Fax to be removed by sliding it through track windows with the suspe nsion mounted in the machine. 2. Remove front Hi-Fax retaining bolt as shown.
9/97
8 .16
SUSPENSION
Hi-Fax Replacement
3. Use a block of wood or a drift punch and hammer to drive Hi-Fax rearward off the sl ide rail. With Hi-Fax material at room temperature. install new Hi-Fax by reversing steps 1 - 3.
4.
NOTE: Lightly coat Hi-Fax track clip area with a lubricant such as LPS2 or WD-40 to ease installation. NOTE: Wide Hi-Fax should be narrowed on the leading sides to allow it to fit through narrow windows.
Track Clip Removal - All Types

1. 2. 3. Position removal tool jaws on edge of clip. Squeeze handles together to spread clip. Remove clip.
Track Clip Replacement - Yokohama

'--...1. Install replacement clip and clipping tool as shown.
NOTE: For ease of operation. the tool may be placed in

a vise .
2.
Tighten drive bolt against forming die until clip is formed.
Track Clip Replacement - Camoplast

1. 2. 3. Place new clip in position on track. Connect clip installation tool on top of clip. Squeeze handles together to crimp new clip.
Track Clip Installation Tool (Camoplast) PN 2871041 Track Clip Installation Tool (Yokohama) PN 2870380
8.17
9/97
SUSPENSION. Rear SuspensIon Exp loded View -1996 Sport Style
Front Torque Arm Assembly
9/96
8.18
SUSPENSION Rear Suspension Components - 1996 Sport Style
Torsion Springs
Adjuster Eyebolt Front Track Shock Rail Bumper
Carrier Wheel
Front Track Shock
Front Torque Arm
Carrier Wheel Rear Torsion Spring
Pivot Arm Shaft Forward
Bogie Wheel
Slide Rail Pivot Rail Bumper Arm Shaft
--
Idler Wheel
8.19
9(96
SUSPENSION Suspension Adjustment - 1996 Sport Style

The Polaris Sport Style suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action. The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. It should be noted , however, that suspension adjustments involve a compromise or trade off. A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider.
~

IFS compression spring preload Rear torsion spring preload Rear shock compression (if equipped with Indy Select I Ryde AFX shock) Optional coil sp ring s for front track shock Optional torsion springs
Adjustment Procedures
It is a good idea to have cus tomers break the suspension in for approximately 150 miles (240 km) before fine tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style , and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The machine should be methodical ly tested under the same conditions after each adjustment (trail and snow conditions, vehicle speed,riding position, etc.) until a satisfactory ride is achieved. Adjustments should be made to one are a at a time, in order to properly evaluate the change. The purpose of the fron t track shock coil spring is to control ride height. If you find that in order to obtain the desired ride effect the spring preload is at its maximum, consider removing the existing spring and installing the next highest rate spring . See the chart on page 8.2 1.
--./
IFS Adjustments
IFS spring preload is one of the adjustment options which affects ride. Preload is the initial compression placed on the spring. The longer the installed length of the spring, the less the amount of preload; the shorter the installed length of the spring, the more the amount of preload. Increasing preload on the IFS spring will result in more bite on the skis, but will require more effort to turn . The IFS compression spring preload can be increased by adding shims (PN 5210953) under the spring. Always ve rify ski alignment before making adjustme nts to the IFS. See Body and Steering, Chapter 7 to check alignment. If the skis are misaligned, we recommend the camber adjustment be checked as this may also be affected.
9/96
8.20
SUSPENSION Rea r Suspension Adjustments - 1996 Sport Style

The Indy Lite Deluxe model comes from the factory with the rear suspension pivot mounted in the forwardmost hole in the rail. Do not change this mounting position . The other holes in the rail are for use on different machines utilizing the same rail. Rail Rear Suspension Pivot
Optional Suspension Adjustment Springs Torsion Springs

'-
#1 - Stock Position
Although your snowmobile suspension has the capability of providing you with the best ride possible, the following accessory rear springs are available to better suit individual riding preference . Soft Part No. LH Part No. RH Wire Size Sport TranSport Indy Lite Indy Lite Deluxe Indy Lite GT 7041318 7041319 .375 Option Option Option Option Option
.. ..... ................... .. ..... . ....

7041119 7041120 .393 Standard Standard Standard Standard Standard
Firm 7041320 7041321 .406 Option Option Option Option Option
Shock Coil Springs

Changing the rate of the front track shock coil spring can affect handling. Heavier springs will reduce darting and require less effort to steer. However. they will stiffen the ride and give the machine a tendency to push through corners. Lighter springs will increase ski pressure fo r positive pressure through curves. PN 7041127 PN 704 1140 PN 7041289 Standard Option Option Light Medium Heavy
181 #/in 181 #/in (longer free length than above)

200#Nariable
8.21
91 96
SUSPENSION 1997 XTRA Lite Style Exploded View
Rear Torque Arm Assembly
~-@
'-;~0
9/96
8 .22
SUSPENSION Rear Suspension Components -1997 XTRA Lite Style
Torsion Springs
Carrier Wheel Rear Track Shock
Front Track
Front Torque Arm Bogie Wheel Rear Torsion Spring
Rear Torque Arm Rear Pivot Arm
Hi-fax
Bog ie Whee I Forward
Slide Rai l Rail Bumper Wheel
--
8.23
9/96
SUSPENSION Suspension Adjustment - 1997 XTRA lite Suspension Adjustment

The Polaris suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action. The suspension can be adjusted to suit rider preference and deliver excellent performance fora given set of conditions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider. Adjustable Feat ures and Adjustment Options IFS compression spring pre load Rear torsion spring preload Optional coil springs for front track shock Optional torsion springs Adjustment Procedures
It is a good idea to break the suspension in for approximately 150 miles (240 km) before fine tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style , and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The machine should be methodically tested under the same conditions after each adjustment (trail and snow conditions, vehicle speed,riding position, etc.) until a satisfactory ride is achieved. Adjustments should be made to one area at a time, in order to properly evaluate the change. The purpose of the front track shock coil spring is to control ride height and front IFS preload . If you find that in order to obtain the desired ride effect the sp ring preload is at its maximum , consider removing the existing spring and installing the next highest rate spring. See the chart on page 8.26. IFS Adjust ments IFS spring preload is one of the adjustment options which affects ride. Preload is the initial compression placed on the spring. The longer the installed length of the spring, the less the amount of preload; the shorter the installed length of the spring, the more the amount of preload. Increasing preload on the IFS spring will result in more bite on the skis, but will require more effort to turn. The IFS compression spri ng preload can be increased by adding shims (PN 52 10953) under the spring. Always verify ski alignment before making adjustments to the IFS. If the skis are misaligned , correct the camber adjustment first.
9/96
8.24
SUSPENSION Suspension Adjustment 1997 XTRA Lite

Rear Suspension Adjustments
The primary adjustment for riding comfort is rear torsion spring preload adjustment. To check for the recommended settings: 1. 2. Lift the rear of the machine to relieve the rear springs. Slowly lower the machine and measure the distance between the ground and the running board at the rear of the tunnel. Without letting the suspension settle, the rider should carefully mount the snowmobile. Measure the distance between the ground and the same spot on the running board.
Torsion Springs
3.
'-----
4.
Torsion Spring Preload Adjuster Forward
If the difference is greater than 1 1/2", the rear spring should be adjusted equally on both sides until the desired 1 1/2" dror is obtained. See adjustment information below. Compensating adjustments for heavy or light drivers or cargo loads can be made by adjusting the preload adjuster.
--
NOTE: Rear torsion spring settings will affect ski-to-ground pressure. It may be desirable to tighten rear torsion springs for an increase in ski-to-ground pressure. If ski pressure is too light, the machine will be hard to steer around curves and will tend to push, or drive straight through curves. The XTRA Lite suspension comes from the factory with the rear suspension pivot mounted in the second hole from the front of the rail. Do not change this mounting position. The other holes in the rail are for use on different machines utilizing the same rail. These holes used for extra bogie wheel placement only
Rear Suspension Pivot
#2 - use to stiffen rear suspension
8.25
9/96
SUSPENSION Suspension Adjustment - 1997 XTRA Lite

Accessory Springs
Although this snowmobile suspension has the capability of providing the best ride possible, the following accessory rear springs are available to better suit individual riding preferences. Soft ...................................... , Part No. LH Part No. RH Wire Size Indy Lite Indy Lite Deluxe Indy Sport 7041555 7041556 .393/77' Option Option Standard 7041557 7041558 .393/80' Standard Standard Option ------
..
Firm
7041521 7041522 .406/82' Option Option Option
Shock Coil Springs

Changing the rate of the front track shock coil spring can affect handling. Heavier springs will reduce darting and require less effort to steer. However, they will stiffen the ride and give the machine a tendency to push through corners. Lighter springs will increase ski pressure for positive pressure through curves. PN 7041569 PN 7041570 PN 7041520 PN 7041571 Standard Standard Option Option Light Medium Heavy Light 60 #/in 80 #/in 90 #/in. 70 #/in. Sport Lite/Lite Deluxe All All
Maintenance
A visual inspection of the following items should be done on a weekly basis or before any long distance trip: Suspension pivot arm bolts for tightness Rear idler wheel bolts for tightness Rear idler adjusting bolt locknuts for tightness Bogle wheels and attaching boits for tightness Front torque arm limiter strap condition Slide rail hi-fax thickness - replace when worn to 7/ 16" (1.1 cm).
1,"'CAUTlON:>
If suspension bolts are removed, the threaded shaft must be cleaned thoroughly with a brake parts type cleaner. A new bolt, which must have a locking patch on the threads, must be installed.
if rear idler wheel assembly washers are removed , be sure they are reinstalled with the domed side of the washer facing out as shown.
Wheel
Rear Idler
.Co/~
Domed
Side of _________ Washer
-u::=:--=lI
Out
9/96
8.26
SUSPENSION Suspension Adjustment - 1997 XTRA Lite Suspension Lubri cation

To maintain rider comfort and to retard wear of the pivot shafts , the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease, PN 2871066, at 500 miles (800 km) initially; 1000 miles (1600 km) and before summer storage each year. The riding characte ristics of the snowmobile will be affected by lack of lubrication of these shafts . NOTE: A grease gu n kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles. Order PN 287 1312. Refer to the diagram below for suspension lubrication points.
* LUBRICATION PO INTS
Grease at fittings
Forward
8.27
9/96
SUSPENSION 1996 WideTrak Style Exploded View
9/96
8.28
SUSPENSION 1996 WideTrak Style Exploded View
Torsion Springs
Carrier Wheel
Front Track Shock
Front Torque Arm
Hi-fax
/ Bogie Wheel Rail Bumper Pivot Arm Shaft
Pivot Arm Shaft
Forward
Idler Wheel
NOTE: General representation only. Models may differ.
8.29
9196
SUSPENSION Suspension Adjustment -1996 WideTrak Style Models

The Polaris WideTrak style suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action. The suspension can be adjusted to suit rider preference and deliver excellent peliormance for a given set of conditions. It should be noted, however, that suspension adjustments involve a compromise or trade oH. A machine set up to peliorm well in the moguls would not suit the preference of a groomed trail rider. '---'

IFS compression spring preload Rear torsion spring preload Optional coil sprin gs for front track shock
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) before fine tuning adjustments are made. All settings will vary from rider to rider, depending on rider weight, vehicle speed , riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The machine should be methodically tested under the same conditions after each adjustment (trail and snow conditions, vehicle speed,riding position , etc.) until a satisfactory ride is achieved. Adjustments should be made to one area at a time, in order to properly evaluate the change. The purpose of the fronttrack shock coil spring is to control ride height. If you find that in orderto obtain the desired ride eHect the spring preload is at its maximum, consider removing the existing spring and installing the next highest rate spring. See the chart on page B.37.
IFS Adjustments
IFS spring preload is one of the adjustment options which affects ride. Preload is the initial compression placed on the sp ring. The longer the installed length of the spring, the less the amount of preload ; the shorter the installed length of the spring, the more the amount of preload . Increasing preload on the IFS spring will result in more bite on the skis, but wi ll require more effort to turn . The IFS compression spring preload can be increased by adding shims (PN 52 10953) under the spring . Always verify ski alignment before making adjustments to the IFS. See Body and Steering , Chapter 7 to check alignment. If the skis are misaligned , we recommend the camber adjustment be checked as this may also be affected.
9/96
8.30
SUSPENSION Rear Suspension Adjustments -1996 WideTrak Style

The primary adjustment for riding comfort is rear torsion spring preload adjustment. To check for the recommended settings: 1. Lift the rear of the machine to relieve the rear springs. 2. 3. 4. Slowly lower the machine and measure the distance between the ground and the running board at the rear of the tunnel. Without letting the suspension settle, the rider should carefully mount the snowmobile. Measure the distance between the ground and the same spot on the running board.
If the difference is greater than 1 1/2", the rear spring should be adjusted equally on both sides until the desired 1 1/2" drop is obtained. Compensating adjustments for heavy or light drivers or cargo loads can be made by adjusting the rear torsion spring eye bolt (A) length. Adjust spring tension so there is equal tension on the long leg of each spring.
NOTE: Rear torsion spring settings will affect ski-to-ground pressure. It may be desirable to tighten rear torsion springs for an increase in ski-to-ground pressure. If ski pressure is too light, the machine will be hard to steer around curves and will tend to push, or drive straight through curves.
Torsion Springs
Forward
8.31
9196
SUSPENSION Optional Suspension Adjustment Springs -1996 - Current WideTrak Style Front Track Shock Coil Springs
Changing the rate of the front track shock coi l spring can affect handling. Heavier springs will reduce darting and require less effort to steer. However, they will stiffen the ride and give the machine a tendency to push through corners. Lighter springs will increase ski pressure for positive pressure through curves. PN 7041127 PN 7041140 PN 7041289 Option Standard Option Light Medium Heavy 181 #/in (6.88" free length) 181 #/in (7 .50" free length) 200#Nariable
WideTrak GT
Rear Torque Arm
""'@~ ~~
"~
~,
9/97
8.32
SUSPENSION 1997 Standard Indy 133.5" /141 " Exploded View
\'- (l)
\
-~~
~
@
~,
c>
r? .
8.33
9/96
SUSPENSION 1997 Standard Indy 133.5" 1141" Exploded View
Torsion Springs
Carrier Wheel
Front Track Shock
Front Torque Arm
Hi-fax / Pivot Arm Shaft Slide Rail Rail Bumper Pivot Arm Shaft Idler Wheel
9/96
8.34
SUSPENSION Suspension Adjustment -1997 Standard Indy 133.5" 1141 "

The Polaris suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action. '-The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider.

IFS compression spring preload Rear torsion spring preload Optional coil springs for front track shock
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) before fine tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The machine should be methodically tested under the same conditions after each adjustment (trai l and snow conditions, vehicle speed,riding position , etc .) until a satisfactory ride is achieved. Adjustments should be made to one area at a time, in order to properly evaluate the change. The purpose of the fronttrack shock coil spring is to control ride height. If you find that in orderto obtain the desired ride effect the spring preload is at its maximum, consider removing the existing spring and installing the next highest rate spring. See the chart on page 8.37.
IFS Adjustments
IFS spring preload is one of the adjustment options which affects ride. Preload is the initial compression placed on the spring. The longer the installed length of the spring, the less the amount of preload ; the shorter the installed length of the spring, the more the amount of preload. Increasing preload on the IFS spring will result in more bite on the skis, but will require more effort to turn. The IFS compression spring preload can be increased by adding shims (PN 5210953) under the spring. Always verify ski alignment before making adjustments to the IFS. See Body and Steering, Chapter 7 to check alignment. If the skis are misaligned, we recommend the camber adjustment be checked as this may also be affected.
8.35
9/96
SUSPENSION Rear Suspension Adjustments - 1997 Standard Indy 133.5" 1141 "
The primary adjustment for riding comfort is rear torsion spring preload adjustment. To check for the recommended settings: 1. 2. 3. 4. Lift the rear of the machine to relieve the rear springs. Slowly lower the machine and measure the distance between the ground and the running board at the rear of the tunnel. Without letting the suspension settle, the rider shou ld carefully mount the snowmobile . Measure the distance between the grou nd and the same spot on the running board .
If the difference is greater than 1 1/2", the rear spring should be adjusted equally on both sides until the desired 1 1/2" drop is obtained.
Compensating adjustments for heavy or light drivers or cargo loads can be made by adjusting the rear torsion spring eye bolt (A) length. Adjust spri ng tension so there is equal tens ion on the long leg of each spring.
NOTE: Rear torsion spring settings will affect ski -to-ground pressure. It may be desirable to tighten rear torsion springs for an increase in ski-to-ground pre ssure. If ski pressure is too li ght, the machine will be hard to steer around curves and will tend to push, or drive straight through curves.
Torsi on Springs
Forward
9/96
8.36
SUSPENSION Optional Suspension Adjustment Springs 1997 Standard Indy 133.5" 1141 "
Shock Coil Springs
Changing the rate of the front track shock coil spring can affect handling . Heavier springs will reduce darting and require less effort to steer. However, they will stiffen the ride and give the machine a tendency to push through corners. Lighter springs will increase ski pressure for positive pressure through curves.
1997 Models
PN 7041127 PN 7041140 PN 7041289 Option Standard Option Light Medium Heavy 181 #/in 181 #/in (longer free length than above) 200#iVariable
An optional shock/spring assembly is available for the rear track shock. Order PN 2871042.
8.37
9196
SUSPENSION Rear Suspension Exploded View - XTRA 10 Style
'(l, ~s:::;;~i===O~\=:=~j'./~'d-~ '~,

'
,:'
-~
9/96
8.38
SUSPENSION Rear Suspension Components - XTRA 10 Style
Limiter Strap
Forward
Rear Torsion Spring Adjuster Cam low position shown CAUTION : Never allow long side of block to point toward rear as breakage will occur. FRSS low position shown
RRSSlow position shown NOTE: 1997 models have optional lower RRSS hole
FRSS - "Front Rear Scissor Stop" RRSS - "Rear Rear Scissor Stop"
The rear shock rod has two positions. The hole closer to the tube is less progressive than the lower one. This effectively changes the damping effect of the rear shock absorber in relation to vertical displacement of suspension. CAUTION: The rear torsion spring block should never have the long side pointing toward the rear or block breakage will occu r.
Front Limiter
The front limiter strap controls the amount of weight transfer, ski pressure, and to some degree the ride height. The rear limiter controls ride height and increases preload on the rear springs when tightened, which also decreases transfer (i.e. the lighter the torsion spring preload, the more weig ht transfer). Setting Longer Shorter Ski Pressure Decreased Increased Weight Transfer Increased Decreased
NOTE: RRSS has greatest affect on weight transfer on XTRA 10 suspensions.

8.39
9(96
SUSPENSION Rear Suspension Components - XTRA 10 121 " Style
Front Track Shock Limiter Strap Rear Track Shock
Rear Limiter Strap
Pivot Arm Shaft
Rear Torsion Spring
Pivot Arm Shaft Rear Torque Arm
Forward Carrier Wheel Rear Track Shock Rear Torsion Spring Front Torque Arm
Limiter Strap Idler Wheel
Slide Rail Front Track Shock Hi-fax
1997 Models have additional hole for movementol RRSS
9/96
8.40
SUSPENSION Rear Suspension Components - XTRA 10 133.5" 1136" Style
Rear Limiter Front Track Shock Rear Track Shock
Pivot Arm Shaft Forward
Rear Torsion Spring
Pivot Arm Shaft
Carrier Wheel Rear Track Shock Rear Torsion Spring
Front Torque
Limiter Strap Rail Bumper
Idler Wheel
Bogie Wheel
Slide Rail Front Track Shock Hi-fax
8.41
9/96
SUSPENSION Suspension Adjustment - XTRA 10 Style

The XTRN" 10 suspension has been designed and set up to deliver a soft rid e under average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action. The suspension can be adj usted to suit rider preference and deliver excellent performance for a given set of conditions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine set up to perform well in the moguls wou ld not suit the preference of a groomed trail rider.

Independent Front Suspension (I FS) Front shock spring preload Optional springs Adjustable compression valving via Ryde AFX / Indy Select shock Rear Suspension Rear torsion springs Front rear scissor stop (FRSS) Rear rear scissor stop (RR SS) Optional coil springs for front track shock Optional torsion springs Adjustable compression via Ryde AFX / Indy Select shock rear track shock Limite r straps - front and rear
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) and grease all suspension pivots before fine tuning adjustments are made. Use Polaris Premium All Season Grease. All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail condi tion s. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. Th e machine should be methodically tested under the same conditions after each adjustment (trail and snow conditions, vehicle speed,riding position , etc.) until a satisfactory ride is ach ieved. Adjustments should be made to one area at a time, in order to properly evaluate the change.
9/97
8.42

Compression Damping Adjustable Shock
Snowmobiles equipped with compressinon damping adjustable rear shocks allow the driver to make adjustments to the compression valving of the rear shock by turning the screw located near the base of the shock.
Adjustment
Locate the adjustment screw near the base of the shock. NOTE : This adjustment is easiest to make with the machine tipped on its side .
WARNING
Be sure to shut off the fuel supply before tipping the machine to prevent fuel spillage and flood ing of the carburetors. By tuming the screw clockwise (a small screwdriver or dime work well), the compression valving is increased, stiffening the ride. To soften the ride, reduce the compression by turning the screw counter-clockwise. An adjustment of 1/2 to 1 turn usually makes a noticeable difference in ride. There are approximately 3 full turns of adjustment available.
How to Adjust
If the suspension is "bottoming, " tighten the compression sc rew clockwise in 112 turn increments until the bottoming stops. Backing off 114 turn counter-clockwise at this point should give you the best possible ride ensuring use of the full travel of the suspension. The opposite procedure should be used if the suspension is too stiff upon initial set-up. If bottoming continues after the screw is bottomed out, the torsion spring should be adjusted using the adjustment block. Back the screw out to the original starting position after torsion spring preload has been increased. Riding conditions are ever changing. Keep in mind the Indy Select 1 Ryde AFX shocks can be adjusted at any time to achieve the best possible ride in any condition.
NOTE: Whenever shocks are replaced or reinstalled fo r any reason, the adjustment screw should be located toward the forward right side of the suspension. Access to the adjuster is not possible if reversed. Fox'" Shocks should be installed with the charge fitting up.
8 .43
9/97
SUSPENSION IFS Adjustments - XTRA 10 Style Front Suspension Setup and Adjustments
Spring preload is one of the adjustment options which affects ride. Preload is the amount of load the spring provides in the installed position. The longer the installed length of the sp rin g, the less the amount of pre-load; the shorter the installed length of the spring, the more the amount of pre-load. An increase in IFS shock spring pre-load will result in an increase in ski pressure. Th e front sp ring preload can be adjusted by using the spanner wrench (PN 2871095) provided in the tool kit. As the cam is rotated, spring length will be either increased or decreased. NOTE: The Sport Touring front spring is not adjustable, except by adding shims. To adjust front spring preload on th readed adjust models, grasp the spring and turn in a clockwise direction (as viewed from the bottom of the shock) to increase the preload. Turn in a counterclockwise direction to decrease preload. NOTE: Access to the cam with the spanne r wrench is easiest from the inside of the ski. When adjusting, be su re springs on both the left and right sides of the machine are at the same adjustment. For the best ride the spring preload should be as low as possible. Set the preload to use the full travel of the ski shock with occasionallight bottoming. The purpose of the shock coil spring is to control ride height. The purpose of shock valving is to control damping. If you find that in order to obtain the desired ride effect the spring preload is at its maximum, consider removing the existing spring and install the next highest rate spring. Hi gh preload ---"r~ Turning clockwise increases preload Cam
Spanner Wrench
~~;o~
u
Front Torque Arm Limiter Strap Adjustment

One method of changing ski-to-snow pressure is to change the length of the front torque arm limiter straps. The limiter strap is normally mounted in the fully extended position. Lengthening the straps decreases ski pressure under acceleration. Shortening the straps increases ski pressure under accele ration . To adjust models with quick adjust front limiter straps,turn the eyebolt nut to lengthen or shorten the strap s. To shorten the strap, tum the nut clockwise. To lengthen the strap, turn the nut counterclockwise. NOTE : Both limiter straps must be adjusted evenly and remain equal in length to avoid improper Hi-Fax and track wear. Turn nut to adjust
Turn ing clockwi se sho rten s strap. Turning counte rcl ockwise lengthens strap.
9/97
8.44
SUSPENSION Front Rear Scissor Stop (FRSS) - XTRA 10 Style

The purpose of the front rear scissor stop (FRSS) is to control the bump attitude of the rear suspension. As the front torque arm (FTA) hits the bump, it forces the rear scissor to collapse a predetermined amount, depending on the FRSS block position. This accomplishes two important things, it allows a lighter spring rate on the FTA because it can borrow spring rate from the rear torsion springs; and it prepares the rear portion of the suspension for the bump. The FRSS is made of a resilient material allowing smooth action and preventing any suspension component damage. This unique featu re is applied to the XTRA'" 10 rear suspension. Patents are pending.
Front Torque Arm (FTA)
.. -1 :;.... ...
~
Rear Scissor
... ...... ....., ,,, , , ,
'
FRSS with short (low) leg to rear. Note the FTA comes up higher before rear scissor begins to collapse.
Front Torque Arm (FTA)
Rear Scissor
-- - FRSS with long (high) leg to rear. Note this forces rear scissor to collapse with less FTA movement than when in short position.
8.45
9/96
SUSPENSION Rear Rear Scissor Stop (RRSS) - XTRA 10 Style

The RRSS controls weight transfer from the rear suspension to the skis. It also influences the stiffness of the ride by controlli ng the amount of coupling action between the front and rear torque arms. To increase the stiffness of the suspension, the RRSS should be set in the high position . NOTE: The RRSS can be totally removed fo r maximum weight transfer. However, unless the torsion springs and rear shock valving are changed, the ride will be compromised. Always maintain equal adjustment on both sides. FRSS - low position shown Scissor Stop Block Position Medium Be sure rear scissor stop face is square with the face of the scissor arm to ensure complete contact. Low .-------------------, RRSS -low position shown
"
o
0
High
A
'I
Low
./
Rear Spring Tension

Rear spring tension adjustments are made by rotating the eccentric spring block (A) as shown with the engine spark plug tool. The block provides three spring tension positions. This adjustment is easier if the long spring leg is lifted over the roller and replaced after the block is properly positioned. Always maintain equal adjustment on both sides. Soft Tension Long End to Front
A
. 0
Medium Tension (Short End Up)
Firm Tension (Long End Up)
9/97
8.46
SUSPENSION Optional Springs - 1996 - Current XTRA 10 Style

The following optional springs are available to bette r su it individual ridi ng preference. NOTE: There are no options for the front ski springs. "-The following optional spri ngs are available to better suit individual riding preference.
Front Track Spring Part No. 704 1361 -067 7041253-067 7041 362-067 7041364-067 Torsion Spring Part No. 7041463-067 Left 7041464-067 Right 7041461-067 Left 7041462-067 Right 7041465-067 Left 7041466-067 Right
0406/77 0406/77 0421 /77 A21n7 A37n7 .437n7
Spri ng Wire Dia. x Free Lengt h - Rate .343 x 7.0 - 243 #/in. .312 x 7.5 - 200Nar. .26 1 x 7.0 - 85 #/in. .283 x 7.5 - 126 #/in. Wire DiaJDeg ree s
The following optional front ski springs are available fo r the 440 XCR.
Front Ski Spring Part No. 7041396-067 7041398-067 7041351-067 7041405-067 Sp ring Wire Dia. x Free Length - Rate .283 x 11.88 - 50#/i n. .3 12 x 11 .88 - 75#/in. .331
x 11.88 -75- 125#/i n.
.283 x 11.88 - 65#/in.
NOTE: Springs on the front ski shocks and front (center) track shock are interchangeable. The fo llowing optional front ski springs are available for the 600 XCR .
Front Ski Sprin g Part No. 7041358-067 7041359-067 7041360-067 7041366-067 Spring Wi re Dia. x Free Length - Rat e .331 x 9.5 - 160#/in .
.3 12x9-146#~n .
.33 1 x 9 - 120/170#/in. .33 1 x 9 - 110/140#/in.
The following optional front track springs are available for the 440 XCR SP.
Front Track Spring Part No. 7041509-067 7041510-067 7041511-067 7041512-067 7041 513-067 704 1514-067 Spring Wi re Dia. x Free Length - Rate .343 x 6.18 -140/2 40#/i n .362 x 6.25 - 165/245#/in. .225 x 5.25 - 50#/in . .263 x 5.25 - 85#lin. .295 x 5.25 - 135#/in. .297 x 5.25 - 1001180#/in.
CAUTION: Springs on front skis must be the same rate. Valving in shocks may have to be changed in some cases or loss of control could result. Ryde AFX shocks also available as an accessory for the IFS or rear track. These shocks offer more luning ability. See the accessory section at the back of this manual.
8.47
9/97
SUSPENSION Optional Springs -1997 XTRA 10 Style

Following is a list of all available springs for the XTRA 10 front and rear suspension. These springs can be used to better suit individual riding preference. Torsion Spring Part No. 7041463-067 LH 7041464-067 RH 7041461 -067 LH 7041462-067 RH 7041465-067 LH 7041466-067 RH Front Ski Spri ng Part No. 7041554-067 7041576-067 7041575-067 7041574-067 7041573-067 7041553-067 7041552-067 7041551-067 704 1550-067 7041549-067 Front Track Spring Part No. 7041361 -067 7041253-067 7041362-067 7041364-067 80# Fox 100# Fox 120# Fox 140# Fox 160# Fox 60# GabrieVArvin 80# GabrieVArvin 100# GabrieVArvin 120# GabrieVArvin 140# GabrieVArvin Spring Wire Dia. x Free Length - Rate .343 x 7.0 - 243 linn .312 x7.5 - 200IVar .26 1 x 7.0 - 85 #/in .283 x 7.5 - 126 #/in
A06f77" .406f77" .421f77" .421f77" A37f77" .437f77"
Wire Dia.lDegrees
Length/Rate - Application
9/96
8.48
SUSPENSION Rear Suspension Exploded View - XTRA 12 121 " Style
8.49
9/96
SUSPENSION Rear Suspension Exploded View - XTRA 12 133.5" Style
9/96
8.50
Limiter Strap
Rear Torsion Spring Adjuster Cam low position shown
Front Track Shock
RRSS FRSS factory setup shown, high position - with dot to rear
Front Track Spring FRSS - "Front Rear Scissor Stop" R RSS - "Rear Rear Scissor Stop"
8.51
9/96
Front Track Shock
Rear Track Shock
Limiter Strap
Coil Spring Rear Torsion Spring Forward
Coil Spring FRSS RRSS
Rear Torsion Spring Limiter Strap Front Track Shock Carrier Wheel Rear Track Shock
Front Torque Arm
Rear Torque Arm
Slide Rail Pivot Arm Shaft Rail Bumper Bogie Wheel Idler Wheel
Rear Scissor Pivot Arm Shaft
9/96
8.52
SUSPENSION IFS Adjustments - XTRA 12 Style

Spring preload is one of the adjustment options which affects ride. Preload is the amount of pressure at which the spring is held. The longer the installed length of the spring , the less the amount of preload ; the shorter the installed length of the spring, the more the amount of preload. To adjust spring preload on the ski , grasp the spring and turn in a clockwise direction (as viewed from the bottom of the shock) to increase the preload. Tum in a counterclockwise direction to decrease preload.
High preload -----
~
--t.:r
LOW ~
preload
Turning clockwise increases preload
CAUTION:
If the plastic nut is unscrewed from the threaded body the nut will break. Always leave one thread showing above the plastic nut or the spring coils will stack, resulting in damage. For the best ride the spring preload should be as low as possible. Set the preload to use the full travel of the ski shock with occasional light bottoming. To determine if your machine is using full travel, push the shock jounce bumper down as far as it will go on the shock rod and test ride the machine. The bumper will move up on the rod in direct relation to the amount of travel. For example, if the shock travel is full, the bumper will be seated at the top of the shock. The purpose of the shock coil spring is to control ride height. The purpose of shock valving is to control damping. If you find that in order to obtain the desired ride effect the spring preload is at its maximum, consider one of these options : Remove the existing spring and install the next highest rate spring , or Reduce the preload on the existing spring and change the shock valving to obtain the desired effect. NOTE: Shock valving can only be adjusted or changed on models equipped with Indy Select or Fox shocks.
Always leave at least one thread showing above nut
PUsh jounce bumper down as far as it will go on shock rod
Shock rod
'-
WARNING
Changing shock valving requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Shocks contain high pressure nitrogen gas. Extreme caution should be observed when handling and working with high pressure service equipment. See Fox'" Shock rebuilding information later in this chapter. Always verify ski alignment before making adjustments to the IFS. See page 7.17 to check alignment. If the skis are misaligned , we recommend the camber adjustment be checked as this may also be affected.
8.53
9/96
SUSPENSION IFS Front Torque Arm Limiter Strap Adjustment - XTRA 12 Style
One method of changing ski-to-snow pressure is to change the length of the front torque arm limiter straps using the holes provided . The limiter strap is normally mounted in the fully extended position. It is important to note that decreasing limiter strap length will stiffen the whole suspension . Lengthening the straps decreases ski pressure. Shortening the straps increases ski pressure. The preferred method fo r changing ski pressu re is to move the FRSS to the forward most hole. See page 8.56.
9/96
8.54

The XTRA'M12 suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action. The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. It should be noted, however, that suspension adjustments involve a comprom ise or trade off. A machine set up to perform well in 1he moguls would not su it the preference of a groomed trail rider.

Independent Front Suspension (I FS) Front shock spri ng preload Optional springs Optional shock valving Compression adjust Indy Select / Ryde AFX shock (see page 8.62) Rear Suspension Spring preload - front track shock Spring preload - rear track shock Rear torsion spring pre-load Front rear scissor stop (FRSS) Optional coil springs Optional torsion springs Optional shock valving Limiter strap - front Compression adjust Indy Select Ryde AFX shock (see page 8.62)
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) and grease all suspension pivots before fine tuning adjustments are made. Use Polaris Premium All Season Grease.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The machine should be methodically tested under the same conditions after each adjustment (trail and snow conditions, vehicle speed ,riding position, etc.) until a satisfactory ride is achieved. Adjustments shou ld be made to one area at a time , in order to properly evaluate the change.
8.55
9/97
SUSPENSION Rear Suspension Adjustments - XTRA 12 Style

The primary rear suspension adjustments are the front track spring preload and the rear torsion spring preload. It is important to note that adjusting the limiter strap does not change weight transfer from the rear suspension to the skis as in a conventional suspension. Instead it will increase the entire rear suspension preload and decrease travel. To increase ski pressure the front rear scissor stop (FRSS) should be set to low. To decrease ski pressure the FRSS should be set to high. To properly adjust the rear suspension , start with the lightest preload setting that will prevent heavy bottoming. Adj ustments should be made to one area at a time, in order to properly evaluate the change.
,---, I
NOTE : Rear spring settings wi ll affect ski-to-ground pressure. If ski pressure is too light it may be desirable to tighten rear springs for an increase in ski-to-grou nd pressure. It is also possible to reposition the FRSS for increased ski pressure.
Front Track Shock Spring
Front track shock spring preload is adjusted by grasping the spring and turning in a clockwise direction to increase the preload. Turn in a counterclockwise direction to decrease preload.
Forward
....---
Note direction of bolts
Rear Track Shock Spring

The rear track shock coil spring does not have a threaded adjuster. One option to decrease preload for less aggressive riders is removal of the rear track shock spring.
Mount limiter strap on front of bracket as shown
Front Rear Scissor Stop (FRSS)

To adjust the FRSS compress the rear suspension until the rear scissor pivots away from the FRSS. Tu rn adjuster to desired position. The dot on the stop indicates the high position. High position is with the dot located toward the rear of the machine . (See illustration) Medium position is with the dot toward the front of the machine.
FRSS shown in high position , as indicated by dot on Rear stop scissor
CAUTION:
@ low @J medium
@
high Forward RRSS
Be sure both blocks are in the same position or suspension damage may occur.
NOTE : It may be necessary to loosen the FRSS mounting bolts to adjust the position. Tighten after adjustment. If the FRSS is in the low position but additional ski pressure is desired , move the FRSS to the optional front hole. Remove the attaching bolts and relocate the FRSS blocks in the forwardmost hole. Reinstall bolts and tighten.
Relocate FRSS to forward most hole in rail for additional ski pressure
Rear Rear Scissor Stop (RRSS)

The RRSS is not adjustable but can be changed to provide less weight transfer on 121" models. See chart below.
XTRA 12 RRSS Production Settings

Suspensi on 121" 133"
Length
Forward
Color Black Gray
Par! Number
Short Long
5410937 5411 041
NOTE: For less weight transfe r on XTRA 12 121" use long (gray) RRSS block.
91 97
8.56
SUSPENSION Rear Suspension Adjustments - XTRA 12 Style Rear Torsion Spring

Rear torsion spring preload is adjusted by turning the two position cam (A) on the short leg of the spring as shown with the engine spark plug tool. This adjustment is easier if the long spring leg is lifted over the roiler and replaced after the cam is properly positioned.
NOTE: See charts on page 8.60 for suggested set up for rider's weight and/or carrying capacity.
A
Soft Tension Long End to Front
~ A
Firm Tension (Long End Up)
8.57
9/97
SUSPENSION Optional Springs - 1996 XTRA 12 Style

The following optional springs are available to better suit individual riding preference .
Coil Spring Part No. For Use on Ski or Front Track Shocks 7041405-067 704 1398-067 7041404-067 Rear Track Spring Part No. 7041362-067 7041364-067 7041361-067 Torsion Spring Part No. 7041406-067 Left 7041407-067 Right 7041467-067 Left 7041468-067 Right Coil Spring Part No. For Use on Ski (or Classic Front Track) 7041405-067 704 1398-067 7041404-067 Rear Track Spring Part No_ Classic Only 7041362-067 7041364-067 7041361-067 .261 .306 .26 1 x 7.0 - 85#~n . .283 Spring Wire Oia. x Free Length - Rate .306 x 11 .88 - 65 #/in.
x 11 .88 - 75 #/in . .343 (or .362) x 11 .88 - 90/150 Mn.

.312 Spring Wi re Oia. x Free Length - Rate
x 7.5 - 126#/in. .343 x 7.0 - 243 #/in.

Wire DiaJOegrees
.421 /55" .421 /55" .437/55" .437/55"

Spring Wire Oia. x Free Length - Rate
x 11.88 - 65 #/i n. .3 12 x 11.88 -75 #/in . .343 x 11 _88 - 90/ 150 #/in.
Spring Wire Oia. x Free Length - Rate
x 7.0 - 85#/in . .283 x 7.5 - 126#/in. .343 x 7.0 - 243 #/in .
NOTE: A front track spring option kit is available for Classic Touring and XLT Touring Models. Order part number 2871349. This kit is included in the optional rear rack kit. See your dealer for more information.
Torsion Spring Part No _ Classic, Classic Trg. & XLT Trg. 7041406-067 Left 7041407-067 Right 7041467-067 Left 7041 468-067 Right .421 /55" Wire OiaJOegrees
.421 /55" .437/55" .437/55"
NOTE: Springs on the front ski shocks and front (center) track shock are interchangeable. CAUTION: Springs on front skis must be the same rate. Valving in shocks may have to be changed in some cases or loss of control could result.
9/96
8.58
SUSPENSION Optional Springs - 1997 XTRA 12 Style

Following is a list of all available springs for the XTRA 12 front and rear s uspension. These springs can be used to better s uit individual rid ing preference. Torsion Spring Part No_ 7041394-067 LH 7041395-067 RH 7041487-067 LH 7041488-067 RH 7041406-067 LH 7041407-067 RH 7041487-067 LH 7041 488-067 RH IFS Spring Part No _ 7041554-067 7041576-067 704 1575-067 7041574-067 7041573-067 7041553-067 7041552-067 7041551 -067 7041550-067 7041549-067 Front Track Shock Spring Part No_ 7041404-067 704 1396-067 704 1484-067 7041405-067 7041398-067 Rear Track Shock Spring Part No_ 7041362-067 7041364-067 7041361-067 7041561 -067 .26 1 x 7.0 - 85 #/In .283 x 7.5 - 126 #/In .343 x 7.0 - 243 #/in .261 x 7.5 - 85 #fln 80# Fox 100# Fox 120# Fox 140# Fox 160# Fox 60# Gabriel/Arvin 80# Gabriel/Arvin 100# Gabriel/Arvin 120# Gabriel/Arvin 140# Gabriel/Arvin Spring Wire Dia. x Free Length - Rate .343 x 11 .88 - 90/ 150 #fln .283 x 11 .88 - 50 #/in .406 x 9.0 - 275 #/in .306 x 11.88 - 65 #/In _ 312 x 11 _ - 75 #fln 88 Spring Wire Dia . x Free Length - Rate More Pre-load More Pre-load More Pre-load More Pre-load .406/65 .406/65 Wire DiaJDegrees
.406n7 .406n7
.42 1/55 .42 1/55
.437n7 .437nr
Length/Rate - Application
8_ 59
9/97
SUSPENSION XTRA 12 Rear Suspension Set Up

Rear Suspension Suspension Set Up
The following charts are only guidelines to be used for initial suspension set up. Set up may vary based on your desired riding style.
XTRA 12 121 "

Rider Weight 110-160Ibs. (50-73 kg) 1 60-210 Ibs. (73-95 kg) 210-260 Ibs. (95-118 kg) 260+ Ibs. (118+ kg) Front Track Shock Spring
75 #/in. 75/125 #fln Low-Medium Preload 75/125 #/in High Preload 90/150 #fln Low Preload Torsion Spring
Rear Track Shock Spring" 85 #/i n.

85 #/in.
.406 Low Setting .406 Low Setting .421 Low Selling .421 High Selling
Ultra 126 #/in . Ultra 126 #fln. Ultra 126 #/in. Ultra 200 #fln. Variable
85 #/in. 126 #fln.
'Indicates production set up for ave rage rider/ average conditions . , May be removed if ride is too stiff after other adjustments or changed to a lighter rate spring. See Rear Track Spring Options, page 8.58.
XTRA 12 133"
Rider Weight Front Track Spring (1)
Torsion Spring
Rear Track Spring (2) 275 #/in. 275 #lin . 275 #/in. 275 #/in.
275 #/in .
Front Track Shock (3)
Rear Track Shock (3)
110160 With rack plus 30 Ibs.
Soft
75-125 #/in. 90/150 #fln. 190 #fin.
.421 x 55 low .437 x 77 low .437 x 77 low .437 x 77 low .437 x 55 high .437 x 77 low .437 x 77 high .437 x 77 high .437 x 77 high
3/4
1.75 1 2 1.5 2.5 2.5 3
3/4
1.75 1 2 1.5 2.5 2.5 3
160200 with rack plus 30 Ibs. 200-260 with rack plus 30 Ibs. 260+ with rack plus 30 Ibs.
90-150 #fln. 190 #fln. 90- 150 #/in. 190 #/in. w/ 1.0 " pre-load 90- 150 #/in. 190 #lin. w/l .0 "pi
275 #/in . 275 #/in.

275 #/in . 275 #/in .
(1) Note: The front track spring preload may be adjusted using the threaded adjuster to the desired setting in combination with the listed configurations. (2) Note: For extreme conditions up to one inch of preload can be added to the rear track shock sprin g using spacers (PN 5210953) . (3) Note: This setting refers to the compression adjust screw in Indy Select shocks. Setting indicates number of turns in clockwise direction.
9/97
8.60
SUSPENSION Compression Adjustable Shocks Compression Damping Adjustable Shocks

Snowmobiles equipped with the Indy Select / Ryde AFX rear shocks allow the driver to make adjustments to the compression valving of the rear shock by turning the screw located near the base of the shock.
Adjustment
Locate the adjustment screw near the base of the shock. NOTE: This adjustrnent is easiest to make with the machine tipped on its side.
WARNING
Be sure to shut off the fuel supply before tipping the machine to prevent fuel spillage and flooding of the carburetors. By turning the screw clockwise (a small screwdriver or dime work well) , the compression valving is increased , stiffening the ride. To soften the ride, reduce the compression by turning the screw counter-clockwise. A great deal of ride performance is accomplished with a mere 1/2 to 1 turns. There are approximately 3 full turns of adjustment available.
How to Adjust
If the suspension is "bottoming ," tighten the compression screw clockwise in 1/2 turn increments until the bottoming stops. Backing off 1/4 turn counter-clockwise at this pOint shou ld give you the best possible ride ensuring use of the full travel of the suspension. The opposite procedure should be used if the suspension is too stiff upon initial set-up. The adjustment of the front track shock should be used in conjunction with the shock spri ng preload. To adjust spring, see page 8.60. If bottoming continues after the screw is bottomed out, the torsion spring should be adjusted per the adjustment block. See page 8.60. Back the screw out to the original starting position after the torsion spring has been tightened. Riding conditions are ever changing. Keep in mind the compression damping adjustable can be adjusted at any time to achieve the best possible ride in any condition.
NOTE: Whenever shocks are replaced or reinstalled for any reason, the adjustment screw should be located toward the forward right side of the suspension . Access to the adjuster is not possible if reversed. Fox'" Shocks should be installed with the charge fitting up.
9/96
8.62
SUSPENSION XTRA 12 Suspension - Shock Removal

XTRA 12 Suspension Shock Removal
'--Steps 1-4 (immediate ly below) may be used for either fron t or rear track shock removal. 1. Turn fuel valve to off position . 2. Loosen rear idler bolts (A), lock nuts (C) , and track adjuster bolts (B). Remove (4) suspension mounting
bo~s.
Front Track Shock Installation Fox Shocks - Gas fitting positioned downward (toward track) Indy Select Shocks - Adjuster screw positioned upward
3. 4. "---5.
Place a protective mat along side of machine. Tip the machine on its side onto protective mat. Note orientation of shocks before removal - gas valve (Fox) or adjuster screw (Select) up or down. Remove suspension. Lift rear torsion springs (0 ) from their lower mounts. Remove top bolt from front track shock. Remove lower front track shock bolt (lift torque arm to gain access). Rear Track Shock Installation Fox Shocks - Gas fitting positioned upward (toward rear) Indy Select Shocks - Adjuster screw positioned upward (toward rear)
6. 7. 8. 9.
10. With front track shock removed , loosen and remove top and bottom bolts from re ar track shock.
XTRA 12 Suspension Shock Installation

1. Reverse assembly, notes: above for steps with the following
Use new Flex-LacT " nuts for installation . Tighten shock bolts to 15-18 ft. Ibs. (2.07-2.48 kg/m) . Be su re the shock still pivots freely. Position torsion springs on top eccentric and lower mount.
Readjust and align track. See pages 2.12-2.16. Torque suspension mounting bolts to 60 ft. Ibs. (8.28 kg-m) . Secure jam nuts and tighten rear idler bolts.
8.63
9197
SUSPENSION
Wheel Kits Wheel Kit Mounting Recommendations
The following illustrations indicate proper installation of optional wheel kits.
XTHA lite
Use kit PN 2871651
Inside
XTRA 10 121 "
Inside Kit PN 2870602
Outside Kit PN 2871582
8.65
9196
SUSPENSION Wheel Kits

Wheel Kit Mounting Recommendations
XTRA 10 133.5"
Outer Kit PN 2870602
Inner Kit PN 2871582
XTRA 10 136"
Inne r Kit PN 2871582 Outer Kit PN 2870602
9/96
8 .66
SUSPENSION
Wheel Kits . Whee I K it Mountmg Recom mendations
XTRA 12 121 "
Outer 2 Kit PN 287060 Outer Kit PN 287 1582
XTRA 12 133.5"
No Wheel Kits re.comm ended for this suspension
8.67
9/96
SUSPENSION Fox Shock Data

FOXT" Shock Specifications
Shock PN Extended Length (in.) Compression (in) Stroke (in) IFP Depth (in) .025 (See NOTE:) 1.142
7041385 7041386 7041387 7041401 7041402 7041403 7041444 7041474 7041480 7041490 7041492 7041494 7041507 7041536 7041537 7041540 7041545 7041584 7041585 7041588 7041589 7041593 7041595 7041599 7041612 7041641 7041642 7041692 7041695 7041697 7041706 7041707
18.15 18.15 12.32 16.56 11.07 13.56 14.52 13.25 12:32 12.71 14.52 15.70 11.06 15.70 16.14 15.70 13.64 11.07 14.52 14.52 11.07 15.70 14.52 14.52 10.97 10.97 15.70 14.52 15.70 10.85 14.52
11.78 11.78 8.67 10.75 8.00 9.21 9.82 9.21 8.67 8.86 9.82 10.47 7.9 10.47 11.29 10.47 9.29 8.00 9.82 9.82 8.00 10.47 9.82 9.82 7.90 7.90 10.47 9.82 10.47 7.78 9.82
6.37 6.37 3.65 5.81 3.07 4.35 4.70 4.04 3.65 3.85 4.7 5.23 3.15 5.23 4.85 5.23 4.35 3.07 4.70 4.70 3.07 5.23 4.70 4.70 3.07 3.07 5.23 4.70 5.23 3.07 4.70
1.142 .633 1.139 .586 .795 .835 .728 .633 .700 .835 1.00 .25 (Reservoir) 1.00 2.00 1.00 .675 .586 .835 .835 .586 1.00 .835 1.50 (Reservoir) 1.00 .600 .600 1.00 .835 1.00 .600 1.50 (Reservoir)
Measure IFP depth from flat of piston as shown using IFP depth tool or dial caliper. IFP depths for non-current Fox shocks and kits are listed on page 8.89 .
NOTE: IFP depth listed applies to full travel set-up only (production shock travel). Refer to page 8.83 for IFP adjustment for limited travel. Bearing Cap IFP Depth --
..-
IFP Depth Tool PN 2871351
~ &'
8.68
,e
Part number stamped on body cap on some shocks .
Body Cap
9/97
SUSPENSION FOX Shock Maintenance

Changing oil on Fox' " Shocks is recommended annually and should be included when performing end of season storage preparation. This oif change is necessary to avoid any chance of corrosion which could be caused by moisture contamination. For competition use, shocks should be disassembled, inspected and serviced more frequently. When pe rforming maintenance on Fox' " Shocks , use Gas Shock Recharging Kit PN 2200421 . It consists of the necessary valves, pressure gauge, and fittings to deflate and pressurize the shocks . The Body Holder Tool, Internal Floati ng Piston (IFP), and Shock Rod Holding Tool are not incl uded in the Recharging Kit and must be ordered sepa rately. Refer to General Tools, Chapter 1 for part nu mbe rs.
Gas Shock Recharging Kit
PN 2200421
WARNING
Extreme caution should be observed while handling and working wi th high pressure service equipment. Wear a face shield, safety glasses, and ear protection during service of these shocks. Care should be observed while handling the Inflater needle and pressu re gauges. Mai ntain your equipment and keep it in good condition. If injury should occur, consult a physician immediately. Extreme cleanliness is of utmost importance du ring all disassembly and reassembly ope rations to prevent any di rt or foreign particles from getting into the shocks. Keep the parts in order as they are disassembled. Note the direclion and position of all internal parts for reassembly. 1 Bleed Screw Body Cap
2
Ref. # 1 2 3 4 5 6 7 8 Part No. 1500005 1500004 77 10424 5020617 1500003 1500006 1500002 5020618 Qly. 1 2 1 1 2 1 1 1 Description Pressure Valve O-Ring Retaining Ring Spring Retainer Body O- Ring Piston Ring (Floating) Piston Ring (Damping) Spring Retainer, Slotted
5
Internal Floating Piston (I FP) Shock Body

6
~4
5
Damper Rod
8
Jounce Bumper
8 .69
9/96
SUSPENSION FOX Shock Maintenance Disassembly

1. Remove spring and bushings from shock eyes. Thoroughly wash shocks in a parts washer or with soap and water to remove dirt and other debris. Dry thoroughly with compressed air. Position and clamp body cap of shock in soft jaws (aluminum or brass) of vise. Remove Allen screw from pressure valve.
2.
With valve outlet pointed in a safe direction, insert red tip of safety needle assembly into recess in shock pressure valve. Depress safety pin on safety needle and push gauge and needle assembly slowly toward shock, inserting needle. Be sure to push needle completely into shock valve. Release nitrogen in a safe direction away from everyone by turning T-handle clockwise (if equipped) or by depressing Schrader valve pin.
CAUTION:
It is possible for some residual pressure to remain in the shock regardless of the gauge reading. Always completely remove valve from body cap before further disassembly of shock. 3. 4. Remove valve and sealing a-ring from body cap. Extend shock shaft by pulling up on shock eyelet. Using a 1" (25 mm) wrench , loosen shaft bearing cap.
9/96
8.70

Disassembly, Cont .
~
5. If body of shock starts to unscrew from body, tighten and try again. To keep body from turning, it may be necessary to use Body Clamp Tool clamped lightly around body in soft jaws of vise as shown. NOTE: Position body clamp at least 1 1/2" below bearing cap.
Shock Body Clamp Tool PN 2871071
6.
Pull shock rod and piston straight out to avoid seal or valve damage. Be prepared to catch piston ring when removing the dampe r rod/valve piston.
7.
Remove shock from vise and dispose of used oil properly in suitable container. Set shock body aside.
8.
Mount damper rod in soft-jawed vise as shown. Loosen valve nut and clean the valve piston and valving washers with electrical contact cleaner. Dry thoroughly with compressed air. Tighten nut and torque to 12 ft. Ibs. (1.66 kg-m) .
Valve Nut Torque 12 fI. lbs. (1.66 kg-m)
8 .71
9/96

9.
If bearing cap and/or seals are to be replaced, remove nut, washer, and valve piston with valving washers and set aside. Keep washers in order and note orientation of slots in piston for proper re-installation. The side with the greater number of slots must face the damper rod nut (toward IFP).
Seal Replacement
1. Remove bearing cap from damper rod. Inspect seals, a-ring, and bushing inside cap. Inspect cap O-ring and replace if torn or damaged. Using a small screwdriver or scribe pry upper seal, main seal, and O-ring out of bearing cap. Use care to avoid scratching the seal cavity.
2.
3.
Clean seal cavity and inspect bushing for wear or damage and replace bearing cap if necessary. Lubricate new seals and O-ring with Polaris shock oil and install. Be sure the seals are seated completely in the seal cavity. Inspect jounce bumper (where applicable) and replace if damaged.
4.
5.
6. Inspect damper rod for nicks, scratches or abrasion. Install bearing cap and thick backing washer on damper rod. Install compression valve washer stack in same order as disassembly. Install valve piston with greater number of slots facing damper rod nut (toward IFP). Install rebound stack, washer, and a new nut. Torque nut to 12 ft. Ibs.
Valve Nut Torque 12 ft, Ibs. (1 .66 kg-m)
9/96
8 .72

Seal Replacement, Cont.
7. Inspect valve piston ring for wear. The outer surface of the ring should be even in color. Set aside damper rod assembly for reinstallation . Position shock in vise with Body Clamp Tool positioned as shown . Clean body clamp tool before installing. Lightly heat threaded area of body cap with a butane or propane torch to loosen Loctite,M sealant.
CAUTION:
8.
Never apply heat to shock body without first depressuriz ing shock and removing bearing cap and oil. Do not over heat. Damage to internal seals or personal injury could result.
Shock Body Clamp Tool PN 287107 1
9.
Using an open end or large adjustable wrench, unscrew the body cap from the body.
CAUTION:
If parts are hot, wear leather gloves to avoid burns.
10. Inspect Oring in body cap for damage. 11. Note location of Allen screw in internal floati ng piston (IFP) for reassembly in body tube. Remove IFP by pushing with handle of hammer against piston toward body cap end (external threaded end). Be prepared to catch piston ring and piston as it comes out. Remove Allen screw from center of piston. Inspect bleede r screw O-ring and IFP sealing O- ring for wear or damage. Replace O rings upon reassembly. 12. Carefully clean all parts thoroughly with electrical contact cleaner or solvent and dry with compressed air. Inspect shock body for scratches or wear.
8 .73
9/96

Reassembly
1. Install bleeder screw in IFP until O-ring is lightly seated. Lubricate IFP O-ring and piston ring with shock oil. Wrap piston ring around IFP and install into shock body to a depth of approximately 1/4" (.6 cm). Do not install the IFP to a depth greater than 114" (.6 cm) at this time.
2.
NOTE : Bleeder screw must be positioned toward body cap (externally threaded) end of shock body.
3.
Mount shock in soft jaws of vise using body clamp as shown. Slowly pour suspension fluid into the body of the shock until it comes within 114" (6 mm) from the top of the body. Allow time for air bubbles to ri se to the surface.
Suspension Fluid PN 2870995
4.
Position bearing cap on damper rod against valve piston. Submerge valve piston in a clean containerof suspension fluid and rotate to remove as much air as possible. Compress flexible piston ring around valve piston and install piston into shock body with th ree closely spaced slots (on nut side) at the highest point. Rock the damper rod lightly back and forth while installing to allow air to escape through the low speed orifice in the piston.
5.
9/96
8.74
SUSPENSION FOX Shock Maintenance Reassembly, Cont.

'--5. Wrap a shop towel around shock body and screw bearing cap in until hand tight enough to seat Oring . Invert shock and mount bearing cap flats lightly in vise. Caution: Be su re damper rod is fully extended. Pour shock fluid on top of IFP until covered to a depth of about 1/4" (5mm) . Do not remove bleeder screw at this time. Install body cap until O'ring is lightly seated .
7.
CAUTION:
Do not over-tighten vise or bearing cap may be damaged. 8. Mount shock in vise by top eyelet as shown . Support shock and strike body cap end 23 times with a soft faced hammer to remove all air trapped inside the valve piston. Allow shock to stand for 3-5 minutes.
9. Unscrew body cap and remove bleeder screw from the IFP. Slowly stroke shock to force air through piston orifice. Move the shock body slowly to prevent aeration of the oil. Allow all ai r to purge through the bleeder screw hole.
B.75
9/96

Reassemb ly, Cont. 10. Mount shock in vise by bearing cap flats. IMPORTANT: Fully extend damper rod. Set IFP tool to specified depth with a dial calipe r as shown.
IFP Tool PN 2871351
11. Place ashoptowel overthe end ollFP tool and slowly push IFP to specified depth.
12. Install the bleeder screw with a new O-ring and tighten securely using the flats on the tool to prevent the IFP from turning. Pou r out excess oil. It is not necessary to completely clean all oil from the nitrogen chamber, a small amount of oi l will lubricate the IFP. Verily the proper IFP depth 10 within .025" (.63mm) with a dial caliper. Be sure to measure to the flat portion of the IFP, not to the tape red outer edge. 13. Reinstall body cap with a new O-ring and tighten by hand. Mou nt shock with body cap end down in the soft jaws of a vise. To rque bearing cap to 8-10 ft. Ibs. (1 .10-1.38 kg/m) . This will also tighten the body into the body cap.
,~
-1
.!I:
,
I ,
CAUTtON:
Do not over tighten or damage to the bearing may result.
Bearing Cap Torque 8-10 ft. Ibs. (1 .10-1.38 kg-m)
9/96
8.76

Reassembly, Cont.
14. Install pressurizing valve with new aring and tighten secu rely.
15. Set the nitrogen tank pressure regulator to 200 205 PSI.
16. Insert the Fox'M Safety Needle and charge with nitrogen to 200 PSI. Pull the needle straight outward and remove from the pressurizing valve while holding the pressure hose on the fitting. Do not insert the needle again to check pressure as the volume inside the gauge will reduce pressure in the shock.
17. As a final check, push the damper rod through a full stroke. The damper rod must bottom out at full travel, and then slowly rise to fu ll extension. Shaft movement must be smooth and consistent throughout the entire compression and rebound stroke, without binding or loss of damping.
8.77
91 97

Reassembly, Cant.
18. To check for leaks , submerge the shock in water and look for bubbles or oil seepage around the bearing and body caps. 1 9. When reinstalling shocks on the machine, torque only to required specifications. If the shock is over tightened it will not pivot, possibly resulting in damage to shaft and seals. 20. When installing IFS shocks, tighten top mount fi rst. Pivot shock body into lower mount and determine if spacer washers are necessary to prevent twist or side loading of shock. Suspension assemblies should always be moved through entire travel without springs to verify free movement and proper alignment of all components.
Shock Eyelet Replacement
Top Shock Eyelet
D~~' PN 2871,3,:. ""~ _

i
I
I
Damper Rod Holdi ng
"" d.,.,.,
rod _ _ _ , do," """,,"

N
of eyelet and damper rod thoroughly with Loctite Primer N. Apply Loctite W 262 to threads before assembly.
ot ,
i
9/97
&~I
Q
8 .78
SUSPENSION FOX Remote Shock Maintenance

1996 FoxT " Remote Shock
The 1996 Indy 440 XCR SP features a remote shock limiter assembly. The shock length is adjusted by a variable volume of oil between the damping piston and the shock bearing end cap. The assembly has two separate and isolated oil reservoirs. One reservoir system provides damping , while the other system limits the extended shock length. The systems are kept independent of one another by means of the separator piston. Both systems use the same type of oil.
'NOTE: When servicing the remote shock limiter assembly, cleanliness is of utmost importance. Be prepared to set disassembled items on a clean suriace. Clean cloth or paper towels are recommended.
Disassembly
1. Clean the self-sealing quick-disconnect coupler near the remote limiter knob assembly to avoid contamination. Uncouple the connector. Remove the remote limiter knob assembly and shock from the snowmobile.
CAUTION:
2.
The hoses bend freely. Be careful not to twist, crush, cr kink the hose. 3. Thoroughly wash shocks in a clean parts washer or with soap and water. Dry with compressed air to remove sand, dirt, and other debris. Inspect hoses for damage. Replace if necessary. Position the main shock reservoir in a vise with the air valve facing up. Using the body cap tool clamp lightly near the hose end, taking care not to crush the reservoir.
4. 5.
Body Cap Tool PN 21171071
6. 7.
Remove the Allen screw from the air valve. With valve outlet pointed in a safe direction, insert red tip of safety needle assembly into recess in shock pressure valve. Depress safety pin on safety needle and push gauge and needle assembly slowly toward shock, inserting needle. Be sure to push needle completely into shock valve. Release nitrogen in a safe direction away from everyone by turning T-handle clockwise (if equipped) or by depressing Schrader valve pin.
8.79
9/96
SUSPENSION Fox T'" Remote Shock Maintenance

CAUTION: I
It is possible for some residual pressure to remain in the shock regardless of the gauge reading. AlwayscompleteIy remove valve from body cap before further disassembly of shock. 8. Push the reservoir cap into the reservoir until the wire retaining ring is exposed. Lightly tap the cap inward to break it loose if necessary. Using a scribe, remove the wire ring. Be careful not to scratch the bore of the reservoir since the reservoir cap O-ring must seal on this surface. Lightly lubricate the reservoir bore to ease removal of the reservoir cap and O-ring. Remove the reservoir cap by grabbing the air valve and gently working the cap out of the reservoir. Try to keep the cap straight with the reservoir, being especially ca reful when passing over the groove . Do not remove the air valve . Insure that the reservoir is secure in the vise. Remove the bleed screw from the internal floating piston (IFP) located inside the reservoir. Lightly lubricate the reservoir bore to ease removal of the IFP. Gently work the IFP out of the reservoir, catching the piston ring just after the O-ring is clear. Be especially careful when passing over the groove. Drain the oil out of the reservoir into a suitable co ntainer. Suspend the reservoir over a container. With the main shock positioned shaft up above the re servoir, stroke the shaft to force most of the damping oil out of the shock body and hose. Do not disconnect the hoses. The remote limiter knob assembly does not need to be connected at this time. Push a clean cloth or paper towel into the reservoir. Secure the aluminum body cap in a vise with the shaft pointing up. Position the remote limiter knob assembly below the level of the body cap. Using a 1" wrench, unscrew the shaft bearing cap. The bearing must loosen before the body cap. If the body cap loosens first, tighten and try again. Disassembly via the body cap is not recommended. Gently pull the shock rod and piston straight out to avoid seal or valving damage. Be prepared to catch the piston ring and some oil, using a clean cloth or paper towel held around the body at the bearing cap. Set the shaft assembly on a clean towel.
9.
10.
-../
11.
12. 13.
14.
NOTE: The alu minum body cap and external threaded by-pass sleeve do not need to be removed for general shock service or revalving. If they are being removed for replacement, do so now. NOTE: Do not attempt to drain the oi l out of the remote li miter knob assembly. This oil does not need to be replaced. 15. Clean the shock and reservoir internal surfaces by wiping with clean towels and flushing the surfaces with clean shock oil. Put 1" to 2" of shock oil in the reservoir and flush all surfaces. Pour into the shock body and flush all surfaces. Repeat. Discard oi l into a suitable container.
CAUTION: I
Do not clean the internal portions of the shock body, reservoir, hoses, or adjuster assembly with solvents . It is difficult to ensure that residual solvent is flu shed from the hoses without complete disassembly. 16. Clean the shaft assembly (bearing cap, separator piston, and valving) in a suitable solvent. Dry thoroughly. Inspect the damping piston and valving for damage and contamination. Inspect the shaft seals and shaft bearing (sleeve) for damage or wear. If condition is in doubt, replace O-ring seals on bearing cap and separator piston. Revalve at th is time if applicable. 17. Reassemble shaft assembly with valving. Do not over torque the damping piston nut.
Damping Piston Nut Torque 15 ft. Ibs. (2.07 kg-m)
9/96
8.80

Assembly 1. Position the shock with the aluminum body cap in a vice with the bearing cap end facing up. Put the Allen screw and O-ring seal into the IFP. Insure that the main IFP O-ring is in place and in good condition. Have a new IFP piston ring ready. While holding the reservoir below the level of the aluminum body cap, insure that the reservoir cap at the hose end is in position against the wire retaining ring. After removing the towel from the reservoir, fill the reservoir to the groove with new shock oil. Insert the IFP (with piston ring) into the reservoir. Slowly push the IFP into the reservoir until it bottoms out. This will purge the air from the reservoir and hose . Make sure the shock does not overfill with oil. Letting the reservoir hang freely, fill the shock body to about 1.5" from the end. Prepare the fully assembled shaft bearing cap assembly by sliding the bearing cap and separator piston against the eyelet. Using a new piston ring on the damping piston, slowly and carefully slip the damping piston into the shock. Be careful not to drag the piston ring over the threads and contaminate the oil. Slowly push the damping piston into the oil. Excessive speed will displace the IFP in the reservoir. Lightly tap the end of the shaft so the valves open enough to fill the piston cavities with oil. Stroke the shaft slowly to force air trapped below the piston through the piston orifice. Do not let the piston come out of the oil. Add enough oil to keep the piston submerged when the top out plate is even with the internal threads on the body. Slide the bearing and separator piston down to the top out plate. Wrap a towel around the shock body at the bearing. While pushing down on the bearing cap , gently work the separator piston into the shock past the threads, being careful not to damage the O-ring seal on the separator piston. Use a towel to catch overflowing oil. Continue to push down on the bearing cap and tighten the bearing cap into place. Torque to specification. Do not push the shaft in until the shock is pressurized. To fully extend the shaft, push in on the IFP.
2.
3.
"-4.
5.
6. 7.
Bearing Cap Torque -
8 - 10 ft. Ibs. (1.10 -1.38 kg-m)
B. Check the IFP depth. IFP depth can be changed by removing the bleed screw and adding oil through the reservoir. However, it is difficult to keep the IFP from rotating while tightening the sealing Allen screw.
Shock IFP Depth
4.57" (11.6 em) from end of reservoir

3':% /
: :l.;4-J'~
9.
Using a clean reservoir cap with a good O-ring , carefully insert the reservoir cap into the reservoir past the groove. Install the wire ring into the groove. Using the Fox safety needle pressurize the shock to 200 PSI.
10. Test the shock for smooth and consistent damping. Inspect for leaks.
8.81
9/96

Recharging the Remote Limiter Knob Assembly
1. Hold the remote limiter knob assembly in a vise using the body cap tool. Clamp lightly near the hose end. Remove the knob assembly using a 1 1/4" wrench. If necessary. apply heat lightly to soften the Loctite.
CAUTION:
Do not overheat. The knob or seals may melt.
Loctite
Body Cap Tool PN 2871071
IFP
""
2. Holding the remote limiter knob assembly below the shock bearing end cap. remove the bleed screw and steel ball from the bearing end cap. The separator piston will keep the pressurized damping oil from leaking out of the bearing end cap. Any pressurized leakage at this time indicates a damaged or missing seal on the separator piston. 3. Position the shock. shaft end uP. over a container suitable to catch oil. Holding the remote limiter knob assembly below the bearing end cap. push the IFP inside the remote limiter knob assembly in until the oil bleeding out of the bearing end cap appears free of air bubbles. or until the IFP bottoms out. Use a wooden dowel or hammer handle to avoid damage to the internal bore. Be prepared to collect the oil purged out of the shock. Install the ball and set screw into the bearing end cap and seal so that no air gets back into the hole. Secure the remote limiter knob assembly in a vice using the body cap tool. Clamp lightly. Position the shock below the level of the remove limiter knob assembly. NOTE: It may hang freely. Remove the Allen screw and O-ring seal from the IFP in the remote limiter knob assembly. Remove the IFP. being careful not to damage to O-ring and piston rings as they pass over the threads. Fill the remote limiter knob assembly with shock oil to about 1/2" from the reservoir end. Insert the IFP to a depth of .625" from the end of the reservoir to the main flat part of the IFP. The IFP should be completely submerged in oil. The oil under the IFP should be free of air bubbles.
4. 5.
6.
Remove Limiter Knob As.sembly IFP Depth .625" from end of reservoir
7. 8.
Install the Allen screw and O-ring into the IFP. Check the IFP depth. Back the knob all the way out of the knob assembly. Install the knob assembly into the remote limiter knob assembly reservoir. Apply blue Loctite T to the threads prior to assembly. Test the adjuster system by tightening the knob and reducing the extended length of the shock.
9.
10. Inspect for leaks.
9/96
8.82
SUSPENSION Typical Shock Valving Arrangement

Shown below is an example of how valving stacks are arranged. The tables on page 8.84 contain producti on valving specifications and piston orifice sizes fo r 1996-current FOX '" shocks. Optional valving (by shock part number) is listed in the tables on following pages. Refer to
Parts in box are an example of standard valving . Note direction of valve piston before disassembly. The side w ith the greater number of s lots should face the IFP (nut end of th e shaft).
Standard Valving
Compression Stack
I I I
I
~
-~-
Typical Valve Stack

Shaft End
-I
~ \.SJ
.800 x .0 10 .900x .010 1.00x .010
I
:
@
~
I I
Towa rd Shaft (Fewer slots)
I I
I I
I I
I
1.100X.010 !
Piston" Orifice
1.300 X.0 10!
I I I I I I I
Rebound Stack
~ 1.300 x .0 12
II
Orifice must be drilled to required size on replacement valve pistons.
@
0 1 . 2 5 0 X .0 10
IFP Depth Adiu stment For Limited Travel Setup Spacer Thickness IFP Depth Modifier
.25 .50 .75 1.0 1.25 1.50 1.75 2.00 2.25 2.50 2 .75 3.00 3.25 3.50 3.75 4.00 4 .25 4.50 4.75 5.00 .029 (Subtract) .058 .088 .117 .146 .175 Spacer .204 PN .234 5431355 .263 .292 .321 .350 .380 .409 .438 .467 .496 .526 .555 .584
I
I
I
I
I I
I
@)
1.100x .0 10
ll~ ~
1.000x.Q10
: @
I @
I
I
.900x.010 .800x.010 .700 x .010
L _________
\S2)
I
I J
I
Nut End
Changing oil on Fox'" Shocks is recommended annually and should be included when performin g end of season storage preparation . For competition use, shocks shou ld be disassembled, inspected and serviced more frequently.
8.83
9/97
SUSPENSION Shock Valving 1996 Production Valving Specifications

Shock PN
70413B5 IFS
70413B6 Front Track X 12
7041401 IFS
7041402 Front Track Xl0
704 1403 Rear Track X 10 1.250X.012
7041444 IFP. Rear

Track X 10
7041474 IFS , IFP. Cam
704 14BO IFP, Rear Track X 12
7041490 IFP
N/A
Compression Stack
6C 5C 4C 3C 2C lC
0.700X.00B 0.700X.006 1.250X.Ol 0 1.250X.Ol 0

O.BOOX.OOB 0.900X .00B 1.000X.00B 1.100X.00B 1.300X.00B
NlA
0.700X.006
0.BOOX.006 O.BOOX.OOB O.BOOX.OOB 0.BOOX.012 O.BOOX.OOB O.BOOX.OOB 0.BOOX .006 O.BOOX.OOB 0.900X.006 0.900X.010 0.900X.O l 0 0.900X.015 0.900X.00B 0.900X.00B 0.900X.006 0.900X.00B 1.000X.006 1.000X.Ol0 1.000X.Ol 0 1.000X.012 1.000X.00B 1.000X.00B 1.000X.006 1.000X.00B 1.100X.006 1.100X.00B 1. 100X.Ol0 1. tOOX.012 1.300X.006 1.300X.00B
0.07B 0.OB9
1.100X.006 1.100X.00B
1.100X.006 1. 100X.00B
1.300X.Ot2 1.300X.012 1.300X.00B 1.300X.O l 0 1.300X.006 1.300X.Ol0 0.075 0.072 0.067

0.07B
Orifice
Rebound Stack
0.07B
1.250X.00B 1.100X.00B 1.000X.00B 0.900X.00B O.BOOX.OOB 0.700X .00B
0.067
N/A
lR 2R 3R 4R 5R 6R
1.250X.012 1.250X.00B
1.250X.Ol0 1.250X.012 1.250X.00B 1.100X.012 1.100X.00B
1.250X.Ol0 1.250X.Ol 0 1.250X.Ol0 1.100X.Ol0 1.100X.Ol 0 1.100X.Ol0
1.250X.012 1.300X.012 1.100X.Ol0
1.100X.Ol0 1.300X.012 1.000X.Ol 0 1.000X.012
1.000X.00B 1.000X.O l 0 1.000X.Ol 0 1.000X.Ol0
1.000X.Ol0 1.300X.012 0.900X.Ol0 0.900X.012 0.900X.00B 0.900X.O l 0 0.900X.Ol0 0.900X.Ol0 0.900X.Ol0 1.300X.012 0.BOOX.Ol0 0.BOOX.012 O.BOOX.OOB O.BOOX.OOB 0.BOOX.Ol0 O.BOOX.OOB
0.BOOX.Ol0 0.700X.00B
0.700X.Ol0 0.700X.012
N/A
0.700X.00B
0.700X.Ol0 0.700X.00B
9/96
8.84
SUSPENSION 1997/1998 Production Valving Listed By Shock Part Number

Shock PN
Compress.
7041 385 IFS SC 7C 6C 5C 4C 3C 2C lC

N/A N/A
7041494 IFS
N/A
7041536 IFS
7041537 IFS
N/A
704 1540 IFS
7041545 IFS
7041593 IFS
N/A N/A
7041692 IFS 1.250x.Ol 0 .SOOx.OOS .900x.Ol0 1.000x.O l0 1.100x.008 1.300x.Ol0 1.000x.006 1.300x.008 0.081 1.250x.Ol0 1.100x.O l0 1.000x.008 .900x.008 .SOOx.008 .700x.008
Slack
N/A
1.250x.O l 0 .SOOx.O l 0 .900x.O l 0 1.000x.O l 0 1.00x.Ol0 1.300x.Ol0 0.081 1.250x.Ol0 1.100x.00S 1.000x.008 .900x.008 .SOOx.008 .700x.008
704 1507 Front Track
0.700X.00S O.SOOX.OOS 0.900X.00S 1.000X.008 1.100X.008 1.300X.008

0.078
N/A N/A N/A

.SOOx.OOS .900x.00S 1.00x.008 1.100x.008 1.300x.Ol 0
0.078
N/A
.700x.00S .800x.00S .900x.00S 1.000x.008 1.100x.008 1.300x.008
0.D78
N/A N/A N/A

.SOOx.OOS .900x.008 1.000x.Ol0 1.100x.008 1.300x.010 0.07S 1.250x.015 1.100x.012 1.000x.Ol0 .900x.008 .800x.008 N/A
N/A N /A
N/A
.800x.00S .900x.008 1.000x.008 1.100x.008 1.300x.Ol0

0.078
1.250x.Ol0 .SOOx.Ol0 .900x.Ol0 1.000x.01O 1.100x.Ol0 1.300x.Ol0 0.081 1.250)(.0 10 1.100x.008 1.000x.008 .900x.00S .800x.00S .700x.00S 7041706
Front Track
Orifice Rebound Stack
lR 2R 3R 4R 5R 6R
1.250X.008 1. 100X.008 1.000X.00S 0.900X.008 0.800X.008 0.700X.008

7041697 IFS
1.250)(.010 1. 100x.Ol0 1.000x.Ol0 .900x.Ol0 .800x.008 .700x.008 7041584 Front Track
1.250x.008 1.100x.008 1.000x.008 .900x.008 .800x.008 .700x.008 7041589 Front Track
1.250x.Ol0 1.100x.Ol0 1.000x.Ol0 .900x.O l0 .800x.008 .700x.008 7041642

Front Track
Shock PN
Compress. Stack
SC 7C 6C 5C 4C 3C 2C lC
1.250)(.010 .800x.008 .900x.Ol0 1.000x.008 1.100x.008 1.300x.008 1.000x.006 1.300x.008 0.086 1.250x.Ol0 1.100x.008 1.000x.008 .900x.00S .800x.008 .700x.008
NIA NIA
1.250x.Ol0 .800x.008 .900x.012 1.000x.012 1.100x.012 1.300x.012 0.075 1.250x.Ol0 1.100x.Ol0 1.000x.O l 0 .900x.O l0 .800x.Ol0 .700x.O l 0
NIA
1.250x.O l 0 .900x.O l0 1.000x.012 1.100x.012 1.300x.012 .900x.006 1.300x.008 0.075 1.250x.Ol0 1.100x.Ol0
1.DOOx.01D
NIA
.700x.Ol 0 .800x.Ol0 .900x.Ol 0 1.000x.01O 1.1 OOx.O l 0 1.250x.012 1.300x.012 0.D75 1.250x.Ol0 1.100x.Ol0 1.000x.012 .900x.O l 0 .SOOx.O l0 .700x.Ol0
NIA NIA
1.250x.Ol0 .SOOx.008 .900x.0 12 1.000x.012
1.100x.0 12
N/A
.700x .Ol0 .800x.Ol0 .900x.Ol0 1.000x.O l 0 1.100x.Ol0 1.250x.012
1.300x .012
1.250x.Ol0 .SOOx.O l 0 .900x.012 1.000x.012

1.1 OOx.0 10
1.300x.012 1.000x.006 1.300x.Ol0 0.075 1.250)(.010 1.1 00x.Ol0 1.000x.O l 0 .900x.O l 0 .SOOx.Ol0 .700x.Ol0 7041707
Rear Track
1.300x.012
0.D75
Orifice Rebound
0.D75
Stack
1R 2R 3R 4R 5R 6R
1.250x.Ol0 1.100x.0 10 1.000x.O l 0 .900x.Ol0 .800x.Ol0

.700x.Ol0
1.250x.Ol0 1.100x.01O 1.000x.012 .900x.Ol0 .800x.Ol0 .700x.Ol0
.900x.O l 0 .SOOx.Ol0 .700x.Ol 0 7041585
Shock PN
Compress. Stack
7041480
Rear Track
7041492
Rear Track
Rear Track
7041588 Rear Track
7041595
Rear Track
7041599
Rear Track
7041695 Rear Track 1.250x.Ol0 .900x.012 1.000x.008 1.000x.012 1.100x.015 1.300x.015 .900x.012 1.300x.012 .OS6
1.250x.012
NIA NIA
0.700X.006 0.800X.006 0.900X.006 1.000X.006 1.100X.006 1.300X.006
0.067
1.250x.O l 0 .900x.Ol0 1.000x.0 12 1. 100x.0 15 1.250x.Ol0 1.300x.015 1.000x.006 1.300x.0 12 0.072 1.250x .O l0 1.100x.0 12 1.000x.012 .900x.012 .800x.012 .700x.01 2
N/A
1.250x.Ol0 .900x.Ol 0 1.000x.Ol0 1.100x.015 1.300x.015 1.000x.006 1.300x.O l 0 0 .086 1.250x.012 1.100x.01 2 1.000x.012 .900x.012 .800x.012 .700)(.012
N /A
.700x.008 .800x.008 .900x.O l 0 1.000x.008 1.100x.008 1.250x.008 1.300x.008 0.078
1.2S0x.012
N /A
1.250x.O l 0 .900x.O l 0 1.000x.012 1.100x.015 1.300x.015 .900x.012 1.300x.012 0.086 1.250x.012 1.100x.0 12 1.100x.012 1.000x.012
.900x.012
1.250x.Ol0 .900x.Ol0 1.000x.012 1.100x.015 1.250x.Ol0 1.300x.0 15 1.000x.006 1.300x.012

0.072
1.250x.Ol0 .900x.Ol0 1.000x.012 1.100x.015 1.250x.Ol0 1.300)(.012 1.000x.006 1.300x.012 .072 1.250x.Ol0 1.250x.Ol0 1.100x.012 1.000x.012 .900x.012 .800x.012 .700x.012
lR 2R 3R 4R 5R 6R 7R
1.250X.O l0 1.100X.Ol0 1.000X.O l0 0.900X.O l0 0.800X.Ol0 0.700X.O l 0
1.250x.Ol0 1.100x.012 1.000x.0 12 .900x.012 .800X.012 .700x.0 12
1.100x.012 1.000x.012 .900x.0 12 .800x.012 .700x.012
1.100x.012
1. t O .012 Ox
1.000X.0 12 .900x.012 .SOOx.012 .700x.012
.800)(.012 .700x.012
N IA
NIA
N /A
N/A
N /A
8.85
9/97
SUSPENSION Optional Shock Valving (By Shock Part Number)
1996/1997 Optional Valving Specifications - Light

ShoCk PN 70413S5 IFS N/A N/A N/A 0.SOOX.006 0.900X.006 1.000X.006 70413S6 Front Track X 12 N/A N/A N/A 7041401 IFS N/A N/A 1.250x.00S .SOOx.OOS .900x.00S 1.000x.00S 1.100x.00S 1.300x.00S 0.07S 1.250X.006 1.100X.OO8 0.OS1 1.250X.Ol0 1.100X.Ol0 .OS9 1.250x.00S 1. 1OOx.OOS 1.000x.00S .900x.00S .SOOx.OOS .700x.00S .075 7041402 Front Track X 10 OJ N/A N/A N/A 7041403 Rear Track Xl0 N/A N/A 1.250x.Ol0 .SOOX.012 .900x.015 1.000x.012 1.100x.Ol0 1.300x.01O .072 1.250x.012 1.100x.012 1.000x.012 .900x.012 .SOOX.012 .700x.012 N/A 1.300X.006 0.067 1.300X.00S 0.07S .OS1 1.250X.OO8 1.100X.OOO N/A N/A 7041444 IFP, Rear Track X 10 7041474 IFS, IFP, CamG] 70414S0 IFP, Rear Track X 12 7041490 IFP N/A N/A N/A .SOOx.OOS .900x.00S 1.000x.00S 1.100x.00S 1.300x.00S .OS1 1.250x.Ol0 1.100X.Ol0 1.000x.Ol0 .900x.Ol0 .SOOx.OlO .700x.Ol0
Com
pressian
Stack
Orifice Robound
lR 2R 3R 4R 5R 6R
Stack
* Use existing washer here (no change)
NtA
Not Applicable
IJJ Spring In Third Groove

@]
Install Springs PN 704 t 252 - 8.5" Installed Length
1996/1997 Optional Valving Specifications - Extra Light

Shock PN 70413S5 IFS N/A N/A N/A 0.SOOX.006 0.900X.OO8 1.000X.006 1.100X.006 1.300X.OO6 0.07S 1.250X.006 1. 100X.006 1.000X.006 0.900X.OO6 0.SOOX.006 0.700X.006 70413S6 Front Track X 12 N/A N/A N/A 7041401 IFS N/A N/A 1.250x.00S .SOOx.OOS .900x.00S 1.000x.00S 704 1402 Front Track X 10 N/A N/A 1.250X.Ol0 O.SOOX.OOS O.SOOX.OOS 1.000X.00S 1.100X.00S 1.250X.00S 0.Q75 7041403 Rear Track X 10 N/A N/A 1.250x.Ol0 .SOOx.Ol0 .900x.012 1.000x.Ol0 1. 100x.008 1.300x.00S .OS1 1.250x.Ol0 1.000X.006 1.100X.006 1.300X.006 0.067 7041444 IFP, Rear Track X 10 N/A N/A N/A 7041474 IFS,IFP, Cam N/A NfA 70414S0 IFP, Rear Track X 12 N/A NfA N/A 7041490 IFP N/A N/A N/A .SOOx.OOS .900x.OOS 1.000x.008 1.100x.008 1.300x.00S .OS9 1.250X.006 .OS6 1.250x.Ol0 1.100x.Ol0 1.000x.00S .900x.00S .SOOx.OOS NfA .700x.00S
Compres-
slon Stack
.
1.000X.00B 1.100X.006 1.300X.006 0.07S
.
0.OS9 1.250X.00S 1.100X.00S 1.000X.OOS 0.900x.00S O.SOOx.OOS
1.100x.006 1.300x.00S .093 1.250x.00S 1.100x.00S 1.000x.00S .900x.00S .SOOx.OOS .700x.00S
Orifice Rebound Stack lR 2R 3R 4R 5R 6R
. .
1.100x.Ol0 1.000x.012 .900x.012 .SOOx.012 .700x.012
1.100X.006 1.000X.OO8
* Use existing washer here (no change)
N/A = Not Applicable
9/97
8.86
SUSPENSION Optional Shock Valving (By Shock Part Number)
1996/1997 Optional Valving Specifications - Heavy

Shock PN 7041385 IFS 704 1386 Front Track X 12 704 1401 IFS 7041402 Front Track X 10 1.250x.Ol0 .900x.OIO 1.000x.012 1.100x.012 1.300x.012 .900x.006 1.300x.008 .075 No change No change No change No change No change
No change
7041403 Rear Track X 10
7041444 IFP Rear Track X 10 1.250x.Ol0 .900x.010 1.000x.OIO 1.100X.015 1.300x.01 5 1.000x.006 1.300x.OIO .072 1.250x.Ol0 1.100x012 1.000x.012 .900x.012 .800x.012 .700x.012
7041474 IFS . IFP. Cam
7041480 IFP. Rear Track X 12
7041490 IFPIZl
Compressi on Stack
7C 6C 5C 4C 3C 2C IC
N/A N/A
N /A N /A N /A
1.000X.008
N/A
1.250x.Ol0 .800x.Ol0 .900x.012 1.00x.010 1.100x.008 1.300x.008 .081 1.250x.008 1.100x.008
N /A
1.250x.012 .800x.012 .900x.015 1.000x.015 1.1 00x.012 1.300x.012 .072 1.250x.012 1.100x.012 1.000x.012 .900x.012 .800x.012 .700x.012
N/A
1.25x.Ol0 .800x.D10 .900x.Ol0 1.000x.OIO 1.100x.008 1.300x.008 .078 1.250x.OIO 1.100x.008 1.000x.008 .900x.008 .800x.008 .700x.008
NlA NlA
.800X.008 .900X.008 1.000X.008 1. 100X.012 1.300X.012 .067
N/A N /A
.800x.008 .900x.Ol0 1.00x.OIO 1.100x.008 1.300x.OIO .078 1.250x.01O 1.1 00x.01O
l. l 00X.010 1.300X.OIO 0.078
1.100X.008 1.300X.008 0.078
Orifice Rebound
lR 2R 3R 4R 5R 6R
1.100X.Ol0
1.100X.012 1.000X.012 0.900X.012 0.800X.012
S tack
1.000x.008 .900x.008 .800x.008 .700x.008
1.000X.01 2 .900X.012 .800X.012
1.000x.01O .900x.Ol0 .800x.008 .700x.008
Use existing washer here (no change)
NIA = Not Applicable
1996/1997 Optional Valving Specifications - Extra Heavy

Shock PN 7041385 IFS
N/A
7041386 Front Track X 12
7041401 IFS
N/A
7041402 Front Track Xl0
7041403 Rear Track X 10

N/A
7041444 IFP. Rear Track X 10 1.250x.OIO .900x.OIO 1.000X.012 1.100X.015 1.250X.010 1.300X.015 I.OOOX.006 1.300X.012 0.067 1.250X.OIO 1.100X.012 1.000X.012 0.900X.012 0.800X.012 0.700X.012
7041474 IFS,IFP. Cam
7041480 IFP. Rear Track X 12

N/A N/A N/A
7041490 IFP
N/A N/A
Com-
8C 7C 6C 5C 4C 3C 2C lC
pressi an
Stack
N /A N /A
0.800X.Ol0 0.900X.01O 1.000X.01O 1.100X.OIO 1.300X.OIO 0.078 1.250X.01O 1.100X.OIO
NlA N /A N /A
0.800X.01O 0.900X.Ol0 1.000X.Ol0 1.1 OOX.OI 0 1.300X.OIO 0.067 1.250X.015 1.250X.015 1.100X.012 1.000X.012 0.900X.012 0.800X.Ol0
N /A
1.250x.Ol0 .800x.OIO .900x.012 1.000x.012 1.100x.OIO 1.300x.OIO .081 1.250x.010 1.100x.008 1.000x.008 .900x.008 .800x.008 .700x.008
N/A NlA
1.250X.Ol0 0.800X.008 0.900X.012 1.000X.012 l.l00X.012 1.300X.012 0.075 1.250X.Ol0 1.100X.01O 1.000X.Ol0 0.900X.OIO 0.800X.OIO 0.700X.01O
N /A
1.250x.012 .800x.012 .900x.015 1.000x.015 1.100x.012 1.300x.012 .067 1.250x.012 1.1 00x.012 1.000x.015 .900x.012 .800x.012 .700x.012
N /A N /A
1.250X.OIO 0.800X.01O 0.900X.OIO 1.000X.01O 1.1 OOX.OI 0 1.300X.OIO 0.078 1.250X.01O 1.100X.OO8 1.000X.008 0.900X.008 0.800X.008 0.700X.008
1.250x.OIO .800x.01O .900x.OIO 1.000x.Ol0 1.100x.OIO 1.300x.01O .072 1.250x.012 1.100x.012 1.000x.Ol0 .900x.OIO .800x.OIO .700x.OIO
.800X.008 .900X.008 I.OOOX.OO8 l.l00X.012 1.300X.012 .067 1.250X.012 1.250X.012 l.l00X.012
Orifice
Rebound
IR 2R 3R 4R 5R 6R
Sta ck
Use existing washer here (no change)
NIA = Not Applicable
8.87
9/97
SUSPENSION 1997/1998 Optional Valving Listed By Shock Part Number

LIGHT
Shoc k PN
Compression
HEAVY
7041707 Rear Track 1.25X.Ol0' 0.9x.008 1.0X.Ol0 1.1X.Ol0 1.2SX.00S 1.3X.Ol0 1.0X.006' 1.3X.00S 0.075 1.25X.Ol0' 1.IX.Ol0 1.0X.012' 0.9X.012' 0.SX.012' 0.7X.012 ' 70415931FS X-1O CRC 7041706
Front Track
70415931FS X-l0 CRC BC 7C 6C SC 4C 3C 2C lC
7041706 Front Track 1.25X.Ol0' 0.8x.Ol0 0.9X.Ol0 1.0X.Ol0 1.1X.00B 1.3X.Ol0 1.0X.006 1.3X.00S O.OSI 1.25X.Ol0' 1.1 X.Ol 0' 1.0X.Ol0' 0.9X.Ol0' O.SX.OW 0.7X.Ol0'
7041707 Rear Track
N IA N/A N IA
0.8X.00B 0.9X.008 1.0X.006 1.1X.00S 1.3X.006 0.07S
NA
0.8X.Ol0 0.9X.Ol0 1.0X.Ol0 1.1X.012 1.3X.012 1.0X.006 1.3X.Ol0' 0.07S 1.25X.Ol0' 1.1X.012 1.0X.012 0.9X.Ol0 0.SX.Q10 0.7X.Ol0
1.25x.Ol0' 0.8X.012 0.9X.012' 1.0X.01S 1.1X.01S 1.3X.012' 1.0X.006 1.3X.Ol0 0.075 1.25X.012 1.1X.012 1.0X.012 0.9X.Ol0' 0.SX.01O' 0.7X.Ol0'
N/A
1.25X.Ol0' 0.9X.012 1.0X.012' 1.1X.01S' 1.3X.01S' 1.0X.006' 1.3X.012' 0.075 1.25X.Ol0 1.25X.012 1.IX.012' 1.0X.012' 0.9X.012' 0.SX.012'
0.7X.012'
Stack
Orifice
Rebound Stack
lR 2R 3R 4R 5R 6R 7R
1.25X.Ol0' 1.1X.Ol0 1.0X.00S' 0.9X.00S' O.SX.OOS' 0.7X.00S'
NIA
N/A
N /A
N/A
N/A
" Use production washer here (no change)

LIGHT
Shock PN
Compression
HEAVY
7041599
Rear Track
7041692 IFS SC 7C 6C 5C 4C 3C 2C lC 1.25X.00S .SX.OOS' .9X.00S 1.0X.00S 1.1X.00S' 1.3X.Ol0' 1.0X,00S 1.3X.00S' O .OSI lR 2R 3R 4R 5R 6R 7R 1.25X.Ol0' 1.IX.OOS' 1.0X.00S' 0.9X.00S' O.SX.OOS' 0.7X.00S'
7041641 Front Track 1.25X.Ol0' 0.SX.Ol0' 0.9X.Ol0 1.0X.Ol0 1.IX.OOS 1.3X.Ol0 1.0X.006' 1.3X.00S O.OSI 1.25X.Ol0' 1.IX.Ol0' 1.0X.Ol0' 0.9X.Ol0' 0.SX.Ol0' 0.7X.Ol0'
7041692 IFS
7041641 Front Track 1.25X.Ol0' 0.SX.012 0.9X.012' 1.0X.015 1.1X.015 1.3X.012' I,OX.006' 1,3X,010' 0.075 1.25X.012 1.1X.012 1.0X.012 0.9X.Ol0' 0.8X.Ol0' 0.7X.Ol0"
7041599 Rear Track 1,25X.01O' 0.9X.012 1.0X.012' 1.1X.015' 1.25X,012 1.3X.015 1.0X.00S' 1.3X.012' 0.075 1.25X.Ol0' 1.25X.012 1.1X.012' 1.0X.012' 0.9X.012' 0.8X.012' 0.7X.012 '
1.25X.Ol0' .9X.00S 1.0X,010 1.IX.Ol0 1.25X.00S 1.3X.Ol0 I ,OX.006" 1.3X.00S 0.075 1.25X.Ol0' 1.1X.Ol0 1.0X.012' 0.9X.012' 0.SX.012' 0.7X.012"
1.25X,OW
O.SX.OW 0.9X.012 1.0X.Ol0' 1.IX.Ol0' 1.3X.012 1.0X.006' 1.3X.Ol0' O.OSI 1.25X.Ol0' 1.1X.Ol0' 1.0X.00S' 0.9X.00S' O.SX.OOS' 0.7X.008'
N/A
Stack
N /A
N/A
N /A
N /A
Use production washer here (no change)
9/97
8.87a
SUSPENSION 1997/1998 Optional Valving Listed By Shock Part Number
LIGHT
Shock PN Compo Stack 8C 7C 6C 5C 4C 3C 2C 1C
Orifice Reb .
HEAVY
7041695 Rear Track
N/A
7041540
IFS
7041595 Rear Track

N/A

N/A
7041540
IFS
7041595 Rear Track

N/A
7041642 Front Track

N/A 0.7X.OW'
704 1695 Rear Track

N/A 1.25X.OW
N/A N/A N/A
N/A N/A N/A
1.25X.01O' 0.9X ,OOa 1.0X.008 1.1X.01O 1,3X.012 O.9X.012' 1.3X.010 0.Oa6 1.25X.01 2' 1.1X.010 1.0X.010 0. 9X.Ol0 0.8X.01O 0.7X.010
N/A
O.7x.ooa o.ax.ooa 0.9X.00a 1.0x.ooa 1.1X.OW' 1,25X.01O 1.3X.008 0.Q75 1.25X.01 0' 1.1X.010' 1.0X.012' 0.9X.Ol0' 0.ax.010" 0.7X.010'
1,25X.010 0.9X.00a 1.0X.00a 1.1 X.OW 1.3X.012 0.9X.012 1.3X.010 0.086 1,25X.012 1.1X.010 1.0X.Ol 0 0.9X. Ol0 0.aX .010 a. 7X.01O
N/A
1.25X.010' 0.9X.012 1.0X.Ol0 1.1 OX.015' 1,3X.015' 0.9X.00a 1.3X.012' 0.Oa6 1,25X.012' 1.10X.012' 1.0X.012 ' 0.9X.012' 0.8X.012' 0.7X.012'
0.8X.012 0.9X.012 1,OX.012 1.1X.015 1.25X.012" 1,3X,012 ' 0.075 1.25X.01O' 1.1 X.Ol0' 1.0X.012' 0.9X.010'
0.9X.012 1.0X.010 1.10X.015' 1.3X.015' 0.9X.00a 1.3X.012" 0.oa6 1.25X.012' 1.10X.012' 1.0X.012'
a.9X .012'
0.aX.008 0.9X.OOa 1.0X.OOa' 1.1X.006' 1,3X.00a' O.Q7a
0.ax.01O' O.9X.010' 1.0X.012' 1.1 X.012" 1.3X.012" 0.07a 1,25X.015 1.1X.012 1,OX.012 0.9X.010 o.ax.ooa 0.7x.00a
N/A
1R 2R 3R 4R 5R 6R 7R
1,25X,012 1.1X.012 1.0X.012 0.9X.010 o.ax.ooa 0.7X.00a

N/A
Stack
o.ax.ow'
0.7X .010'
0.8X.012 0.7X.012
N/A
N/A
N/A
N/A
LIGHT
Shock PN
Compression
HEAVY
704 1585 Rear Track
NJA
7041589 Front Track ac 7C 6C 5C 4C 3C 2C 1C
7041584 Front Track
7041589 Front Track
7041584 Front Track
704 15a5 Rear Track
N/A
0.7X.00a 0.8X.00a 0.9X.00a 1.0X.008 1.1X.0 10 1.25X.010 1.3X.00a 0.075
N/A
1.25x.01O' .9X.010 ' 1.0X.010 1.1X.010 1.3X.010 .9X.00a 1.3X.00a' 0. 075 1.25X.01 0' 1.1x.00a 1.0X. 010' 0.9X.010' 0.8X.010' 0.7X.010
NIA
O.7X.OlO' 0.aX.012 0.9X.012 1.0X.012 1.1X.015 1.25X.012' 1.3X.012' 0.075 1.25X.Ol0' 1.1X.010' 1.0X.012' 0.9X.010' 0.ax.010 0.7X.O l 0
N/A
N/A
1.25x.Ol0' ,9x.012 1.0X.012 1.1X.015 1,3X.012' .9X.006 ' 1,3X,010 0.075 1,25X.012 1.1X.010' 1.0X.010 0.9X.010' 0.aX.010' 0.7X.010
N/A
N/A
1.25X.010' 0.9X.012 1.0X.010 1.1X.015' 1.3X.015' 1,OX.006' 1.3X.0 12 0.Oa6 1,25X.012 1.1X.012' 1.0X.012' 0.9X.012' 0.ax.0 12 0.7X.01 2
Stack 1.25X.010' 0.9X. 010" 1,O 10 X.0 1.1X .012 1.3X.0 10 0.9X.006 1.3X.00a 0.Oa6 1.25X.012' 1.1 X.010 1,OX.OW 0.9X.010 O.aX.OlO 0.7X.O l 0
1R 2R 3R 4R 5R 6R 7R
1.25X.01O' 1.1X.OW' 1.0X.012' 0.9X.010' 0.8X.010' 0.7X.01 0

N/A
N/A
N/A
N/A

8,87b
9/97
SUSPENSION Fox IFP Depth 1992-1995 and Kit Shocks

The foll owin g chart lists all Pre- I 996 Fox' Shock IFP depths by model and part number for quick refcrcncc. Measure
as show n in the illu stration using tFP depth/removal tool PN 287 1351 or vernier caliper.
Typical Shock Shown
c-
For welded dome IFP shocks measure C- D using a di al caliper to center of IFP.
For body style IFP measure fro m point A- B using IFP depth 1001 PN 2871 351 IFS Shocks Model 1992440 XCR
1993/1994 440 XCR; 1993/1994 XLT SP
Part Number 7041266 LH 7041291 RH 7041292 7041346
IFP Depth 2" oil (no IFP) .728" (18.5 mm) .728" (18.5 mm)
Measurement Point
Oil level from top of shock body (C) A-B
1994440 XCR SP & 600 XCR 1994 XLT SP 1995 440 XCR & 600 XCR 1995 RXL & XLT SP 1995440 XCR SP. Model 1992 XCR 1993440 XCR & XLT SP 1994440 XCR 1994440 XCR SP & 600 XCR 1994 XLT SP 1995 440 XCR & 600 XCR 1995440 XCR SP 1995 XLT SP & RXL Model 1992 440 XCR and 1993 XLT SP 1993440 XCR 1994 440 XCR , XLT SP 1994 440 XCR SP & 600 XCR 1995 440 XCR & 600 XCR 1995440 XCR SP 1995 XLT SP & RXL Kit Part Number 1 Model 38 - 41 " Widening Kit 2871711 XTRA-l0 - IFS Shocks 2871401 XTRA- 12 - IFS Shocks. 2871396 XTRA-12 121 / 133.5 Track Shocks 2871399 2871077 2870978 2870979
A-B 7041385 7041401 Front Track Shocks Part Number 7041254 7041294 7041344 1.142"(29.0 mm) 1.139"(28.9 mm) IFP Depth 4.150" (105.40 mm) 4.150" (105.40 mm) 4.150" (105.40 mm) A-B A B
C-D C- D C- D
7041402 7041386 Rear Track Shocks Part Number (sis to 7041267

2870979)
.586"( 14.9 mm) 1.142"(28.9 mm) IFP Depth .835" (21 .2 mm) .835" (21 .2 mm) .835" (21 .2 mm) .835" (21 .2 mm) .795"(20.2 mm) .633"(16.1 mm) IFP Depth 1.000" (25.4mm) 1.139"(28.9mm) 1.142"(29.0mm) 1.142"(2.89cm) .633"( 16.0mm) .835"(21.2mm) 4.150" (105.40 mm) .835" (21 .2mm)
A B A B A- B A- B A- B A- B A- B A-B A-B
Measurement Point
7041295 704 1347 7041345 7041403 7041387
Kit Shocks Shock Part Number 7041612 704140 1 7041385 7041386-(Fr Track) 704148Q-(RrTrack) ITS; XC100; XC10l Rear Track Shock 7041293 ITS; XC100; XC10l Front Track Shock 7041294 1988-1991 Dial Adjust Rear Shock 7041347
A-B A B A- B A- B A-B A B C-D A-B
9/97
8.88
SUSPENSION Fo x Shock Parts

Refer to the appropriate parts manual for a complete listing of Fox shock parts . Fox, Registered Trademark of FOX Shox.
Valve Washer Part Numbers

PgdNQ.
De ~!,;;rigtiQn
1500052 1500050 1500049 1500048 1500053 1500054 1500055 1500030 1500051 1500031 1500032 1500033 1500028 1500029 1500062 1500026 1500027 1500045 1500046 1500047 1500044
. .. . .. .... .. . . .. ... ... ....
. .. . .. . . ... .... .. .. . .. .
1.300 x 0.006 1.250 x 0.006 1.100 x 0.006 1.000 x 0.006 0.900 x 0.006 0.800 x 0.006 0.700 x 0.006 1.300 x 0.008 1.250 x 0.008 1.100xO.008 1.000 x 0.008 0.900 x 0.008 0.800 x 0.008 0.700 x 0.008 1.300 x 0.010 1.250 x 0.010 1.100 x 0.010 1.000xO.Ol0 0.900 x 0.010 0.800 x 0.010 0.700 x 0.010
Part No. 1500079 1500078 1500060 1500059 1500058 1500057 1500056 1500087 1500086 1500085 1500084 1500083 1500082 1500081
Description
. ... ... ... ... ... ... ... . .. ... ... .. . .. . ...
1.300 x 0.012 1.250 x 0.012 1.100xO.012 1.000 x 0.012 0.900 x 0.012 0.800 x 0.012 0.700 x 0.012 1.300 x 0.Q15 1.250 x 0.015 1.100 x 0.015 1.000xO.015 0.900 x 0.015 0.800 x 0.015 0.700xO.015
SHOCK SHAFT (POLARI S PART NUMBER)
SHAFT LENGTH (INCHES)
SHOCK PART NUM BER
1500068 1500076 1500153 1500133 1500140 1500152
9. 125 6.35 5.57 6.85 7.60 7.45
7041385 7041387 7041490 7041402 7041584 7041255 7041545 7041537 7041256 7041295 7041347 7041492 7041588 7041599 7041593 7041612 7041536
7041386 7041480 7041493 7041589 7041403
7041267 7041293 7041444 7041585 7041595 7041540 7041494
1500136
7.73
Shock Travel Limiting Spacer (1/4") - Part Number 5431355 Note: Subtract .029" from IFP depth for each 1/4 inch spacer added to the shock damper rod for limiting. For example: II standard (full shock travel) IFP depth is .835", and 6 spacers are added to reduce shock travel by 1.5 inches, multiply .029 x 6 to calculate the amount to subtract from IFP depth . .835 - .174 =.661 ( .025'1 New IFP Depth
8.89
9/97
SUSPENSION Suspension Troubleshooting - WideTrak Style

Problem Rear suspension bottoms too easily Sol ution -Increase torsion spring preload -Increase rear shock compression valving by turning screw clockwise (if equipped with optional Indy Select / Ryde AFX shock) -Install overload kit PN 2871042 for extreme use -C heck for binding suspension shafts and grease all pivot points -Decrease torsion spring preload adjustments -Decrease rear shock compression valving by turning screw counterclockwise (if equipped with optional Indy Select / Ryde AFX shock) -Check for proper track tension -Make sure skis are aligned properly (straight forward with rider on machine) -Make sure spindles and all steering components are free turning -Make sure skags are straight on skis -Check hi-fax and replace if worn -Reduce ski pressure: -Increase front track spring preload -Reduce IFS spring preload if shims have been added -Reduce rear torsion spring preload -Check for worn skags -Check for binding suspension shafts and grease all pivot points -Increase IFS spring preload by adding shims -Check ski alignment -Check skags and skis for damage -Reduce ski pressure: -Increase front track spring preload -Reduce IFS spring preload if shims have been added -Reduce rear torsion spring preload -Change worn hi-fax -Lower front and rear torque arms (see Performance section at the back of this manual)
Rides too stiff in rear
Machine darts from side to side
Front end pushes
Steering is heavy
Setting up for deep snow operation
9/96
8.90
SUSPENSION Suspension Troubleshooting - Sport Style

Problem Solution
Rear suspension bottoms too easily
-Increase torsion spring preload -Increase rear shock compression valving by turning screw clockwise (if equipped with optional Indy Select / Ryde AFX shock) -Check for binding suspension shafts and grease all pivot points -Decrease torsion spring preload adjustments -Decrease rear shock compression valving by turning sc rew counterclockwise (if equipped with optional Indy Select / Ryde AFX shock) -Make sure skis are aligned properly (straight forward with rider on machine) -Make sure spindles and all steering components are free turning -Make sure skags are straight on skis -Check hi-fax and replace if worn -Reduce ski pressure: -Increase front track spring preload -Reduce IFS spring preload if shims have been added -Reduce rear torsion spring preload -Check for worn skags -Check for binding suspension shafts and grease all pivot points -Increase IFS spring preload by adding shims -Check ski alignment -Check skags and skis for damage -Reduce ski pressure: -Increase front track spring preload -Reduce IFS spring preload if shims have been added -Reduce rear torsion spring preload -Change worn hi-fax -Lower front and rear torque arms (see Performance section at the back of this manual)
Front end pushes
Steering is heavy
8.91
9/96
SUSPENSION Suspension Troubleshooting - XTRA Lite Style

Problem Solution
Rear suspension bottoms too easily Rides too stiff in rear
-Increase to rsion spring preload -I nstall optional torsion springs -Check lor binding suspension shalts and grease all pivot points -Decrease torsion spring preload adjustments -Make sure skis are aligned properly (1/8- 1/4" toe out at ride height) -Make sure spind les and all steeri ng components are free turning -Make su re skags are straight on skis -Check hi-fax and replace if worn -Reduce ski pressure: -I ncrease front track spring preload (requires shims) - Reduce IFS spring preload - Reduce rea r torsion spring preload -Lengthen front limiter strap -Check lor worn skags -Check for binding suspension shalts and grease all pivot points -Increase IFS spring preload by adding washers -Shorten front limiter strap -Check ski alignment -Check skags and skis for damage -Reduce ski pressure: -I ncrease front track spring preload -Reduce IFS spring preload - Reduce rear torsion spring preload -Change worn hi-fax -Increase front limiter strap length -Increase front track spring preload by adding washers
Machine darts lrom side to side
Front end pushes
Steering is heavy
9/97
8.92
SUSPENSION Suspension Troubleshooting - XTRA 10 Style

Problem Rear suspension bottoms too easily Solution -Increase torsion spring preload -Increase rear shock compression valving by turning screw clockwise (if equipped with optional Indy Select / Ryde AFX shock) or refer to optional valving on Suspension Wallchart for Fox equipped models -Change RRSS to highest setting -Install optional torsion springs (stiffer) -Check for binding suspension shafts and grease all pivot points -Decrease torsion spring preload adjustments -Decrease rear shock compression valving by turning screw counterclockwise (if equipped with optional Indy Select / Ryde AFX shock) or refer to optional valving on Suspension Wallchart for Fox equipped models -Set RRSS to lowest position or totally remove -Install optional torsion springs (softer) -Make su re skis are aligned properly (1/8-1/4" toe out at ride height) -Make sure spindles and all steering components are free turn ing -Make sure skags are straight on skis -Check hi-fax and replace if worn -Reduce ski pressure: -Increase front track spring preload (req uires shims) -Reduce IFS spring preload by adj usting cam -Reduce rear torsion spring preload -Lengthen front limiter strap -Check for worn skags -Check for binding suspension shafts and grease all pivot points -Increase IFS spring preload by adjusting cam or adding washers -Shorten front limiter strap -Install optional carbide skags -Check ski alignment -Check skags and skis for damage -Reduce ski pressure: -Increase front track spring preload -Reduce IFS spring preload by adjusting cam -Reduce rear torsion spring preload -Change worn hi-fax -Lower rear torque arm s -Increase front limiter strap length -Based on ri der preference, RRSS may be removed to increase weight transfer -Increase front track spring preload -Move front track shock to upper mounting position
Front end pushes
Steering is heavy
8 .93
9/97
SUSPENSION Suspension Troubleshooting - XTRA 12 Style

Problem Rear suspension bolloms too easily Solution -Check to be sure FRSS block is in highest position -Adjust torsion spring blocks to highest position -Adjust coil over spring on front track shock to increase preload -Install optional (stiffer) torsion springs -Install next heavier coil spring (e.g. 75/125 #/in. to 90/150 #/in. -Increase compression damping on models equipped with Indy Select or Ryde AFX shocks -Check nitrogen pressure in shocks (models equipped with FoxT" shocks) -Change shock valving to heavier selling (models equipped with Fox ,. shocks) -Check for binding suspension shafts and grease all pivot points -Decrease spring preload adjustments -Remove rear track shock spring or reduce rate of spring (refer to wa llchart) -Change front track shock to lighter spring -Change to lighter shock valving on models equipped with FoxT" or Indy Select 1 Ryde AFX shocks (refer to wallchart) -Make sure normal ride -Make sure free turning -Make sure tion skis are aligned properly (1/8- 1/4" toe oul at height) spindles and all steering components are skags are straight on skis and in good condi-
Front end pushes
-Check for worn skags -Check for binding suspension shafts and grease all pivol points -Increase front IFS preload -Change FRSS to low selling or move to forwardmost hole -Install oplional carbide skags -Check ski alignment -Check skags and skis for damage -Change FRSS to high selling -Decrease IFS spring preload -Rotate FRSS to lowest selling. depending upon rider preference -Decrease preload on front track spring -Move FRSS to forwardmost hole -Tighlen limiter strap one hole
Steering is heavy
Selling up for deep snow operation
9/97
8.94
CHAPTER 9 BRAKES I FINAL DRIVE

Specifications ................. . .. ............ .. . . ..... 9.1 - 9.1a Jackshaft Speed vs. MPH Chart ... .... ... . .............. 9.2 - 9.2a Chain / Sprocket Part Numbers ..... .. .... ...... . ... . .... 9.2 - 9.2c Chain / Sprocket Combinations ....... . ..... ... .. . ..... .. 9.2d - 9.2e Track Drive Data .. . .... .. .................. . ...... . .. 9.3 - 9.3c Track Specifications ............. . .. .......... . ........ 9.3d - 9.3f Drive Shaft Sprocket Installation Tips ...... . .. . . .... ..... 9.4 Hydraulic Brake System Operation ........ ................ 9.5 Type 3 Master Cylinder Removal / Inspection / Assembly .. .. 9.6 - 9.9 Brake Bleeding ......................... . .... ........... 9.10-9.12 Type H4 Brake Friction Pad Replacement ........ .. ..... .. 9.13-9 .14 Type H4 Caliper Disassembly . . .. ................ . ..... 9.15 Type H4 Cleaning and Inspection ... . . ... . . . .. . .... .... 9. 16 Type H4 Assembly .. ... ............. . ................... 9. 16-9.17 Type H5LC Brake Friction Pad Replacement ............. .. 9.18-9.19 Type H5LC Caliper Disassembly ....... . .. . .. . .......... . . 9.20 Type H5LC Cleaning and Inspection / Assembly ............ 9.21-9.22 Type M3 Brake Disassembly ................ .... ...... .. . 9.23 Type M3 Assembly to Chaincase ....... .... ...... . .... . 9.24 Type M3 Adjustment .. .. ................................ 9.25 Type WT Brake Disassembly ..................... . ...... 9.26 Type WT Assembly to Transmission / Adjustment ...... . . . .. 9.27 Type 3 Drive System Disassembly ................. . . ... .. 9.28-9.31 Type 3 Drive System Assembly .. .... . . .............. .... . 9.32-9.39 Transmission, Suspension and Track Removal - WideTrak ... 9.40-9.42 Transmission , Suspension and Track Assembly - WideTrak .. 9.43-9.47 Transmission Disassembly 1997 to Current WideTrak .... ... 9.47a - 9.47g Transmission Assembly 1997 to Current WideTrak .. . ...... . 9.47g - 9.47h Track Removal - Two Sprocket Drive Shaft .............. 9.48-9.49 Track Removal - Four Sprocket Drive Shaft ............... 9.50 Series 300 Transmission Overhaul ........................ 9.51-9.55 Reverse Kit Service Tips .............. ... ...... . .... . ... . 9.56 Reverse Kit Maintenance .. ........... . . ... ... ........ ... 9.57-9.58 Traction .................................... . .......... 9.59 - 9.64
BRAKES/FINAL DRIVE
Specifications 1996 Brake Specifi cations
Polaris Chaincase Lube Amoun t 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 11 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 11 II. oz. 11 II. oz. 11 II. oz. 11 II. oz. 9 fl. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 11 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz . 9 II. oz. Chaincase Sprocket! Chain Length
16/39/64 16/39/64 16/39/64 16/35/62 17/35/62 15/39/64 16/39/64 21/39/66 20/39/66 21/39/66 21/39/66 21/39/66 21 /39/66 21/35/64W 18141/66 18/41/66 21/39/66W 20/39/66W 21139/66 18/39/66 20/39/66 21139/66W 20/39/66 18/39/66 21139/66W 20/39/66W 18/39/66W 21139/66W 20/39/66W
,
Reverse Acc Acc Acc Acc Acc Acc Acc Acc SId Acc Acc Acc Acc Acc SId SId Sid SId Acc Acc Acc Acc Acc Acc Acc Ace Ace Ace SId Acc Acc Ace Ace Acc Ace Ace Jackshaft Spline 13 13 13 13 13 13 13 15 15 15 15 15 15 15 Brake Pads Sid Sid SId SId Sid SId Sid Sid SId SId HD
Model Indy Lile Indy Lite Deluxe Indy Lile GT Indy Sport Indy Super Sport Indy TranSport Indy Sport Touring Indy Trail Indy Trail Touring Indy 440 LC Indy 440 XCR Indy 440 XCR SP Indy 600 XCR Indy 600 XCR SP Indy WideTrak GT Indy WideTrak LX Indy Classic Indy Classic Touring Indy 500 Indy 500 RMK Indy 500 SKS Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT SP Indy XLT Touring Indy RXL Indy Ultra SP Indy Ultra SKS .. Indy Ultra RMK Indy Storm Indy Storm SKS Indy Siorm RMK
Brake Ty pe M3 M3 M3 H4 H4 H4 H4 H4 H4 H4 H5LC H5LC H5LC H5LC WT WT H4 H4 H4 H4 H4 H4 H4 H4 H4 H4 H4 H4 H4 H5LC H5LC H4 H5LC H5LC H5LC H5LC
Race*""
HD SId SId Sid Sid SId Std HD SId Sid Sid HD Sid Sid HD Std SId Std Std Std Std Sid Std HD
22 22
15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15
I 20/35/64W
21/35164W 20/35/64W 20/39166W 23/37166W 20135/64W 20139/66W
----....
Brake type 1.0 .. M=Mechanlcal , H=Hydraulic, LC=Liquid Cooled, WT=WideTrak "W" denotes a 13 link wide chain and wide sprocket; others are 11 link wide. Requires 2871296 Installation Tool for 15 tooth. 2870974 Installation Tool for 13 tooth Denotes jackshaHs with pressed on left side bearings (no lock collar) Race pad 440 XCR SP can only be used with special caliper assembly and Magura master cylinder assembly
9.1
9197
BRAKES/FINAL DRIVE Specifications

1997 Brake Specifications
Polaris Chaincase Lube Amount 9 II. oz. 9 II. oz. 911. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 11 II. oz. 11 II. oz. 20 II. oz. 11 II. oz. 11 II. oz . 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz . 11 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz . 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 fl . oz. 9 II. oz . Chaincase Sprocket! Chain Length
16/39/64 17/35/62 16/39/64 15/39/64 20/39/66 21/39/66 21/39/66 22141/70 2 1/39/66 21/39/66 20/39/66 19/40/66 19/41/66 21139/66 19/39/66 21 /39/66 20/39/66 19/40/66 21/39/66 21 /39/66 20/39/66 18/40/66 21 /39/66 21 /39/66 20/40/66 21 /39/66
Model Indy Lile , Deluxe, GT Indy Sport Indy Sport Touring Indy TranSport Indy XCF Indy 440 LC Indy 440 XC Indy 440 XCR Indy Super Sport Indy Trail Indy Trail Touring Indy Trail RMK Indy WideTrak GT 1 LX I ndy Classic Indy Classic Touring Indy 500 Indy 500 SKS Indy 500 RMK Indy 500 EFI Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT SP Indy XLT LT D 1 SP Indy XLT Touring Indy 600 XC Indy 600 XCR Indy RXL Indy Ullra / Ullra SP Indy Ullra SPXlSE Indy Ullra Touring Indy 700 SKS Indy 700 RMK Indy 700 XC Indy Storm / SE Indy Siorm RMK
Brake Type M3 H4 H4 H4 H4 H4 H5LC H5LC H4 H4 H4 H4 WT-2 H4 H4 H4 H4 H4 H4 H4 H4 H4 H4 H4 H4 H5LC H5LC H5LC H5LC H5LC H5LC H5LC H5LC H5LC H5LC H5LC
Sprocket! Chain Width 11 11 11 11 11 11 13

3/4
*
Reverse Acc Acc Acc Acc Acc Acc Acc Acc Acc Acc Sid Acc Sld/LR Sid Sid Acc Acc Acc Ace Ace Acc Ace Acc Acc Sid Acc Aee Ace Acc Acc Sid Acc Aee Acc Ace Acc Jackshaft Spline 13 13 13 13 15 15 15 15 15 15 15 15 19 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 Brake Pads Sid Sid Sid Sid Sid Sid HD HD Sid Sid Sid Sid Sid Sid Sid Sid Sid HD Sid Sid Sid HD Sid Sid Sid HD HD Sid Sid Sid Sid Sid HD HD Sid HD
.../..
11 11 11 11 13 13 13 13 13 13 13 13 13 13 13 15 13 13 13 15 13 13 13 13 13 314 15 15
21 /35/64
20/35/64
21 /35164 21135164
20/35/64
20135166 201391 68 24140/70 23137166

20139/66
Brake type I.D. - M=Mechanical, H=Hydraulic. LC=Liquid Cooled , WT =WideTrak Requires 2871296 Inslallation Tool for 15 tooth . 2870974 Installation Tool for 13 tooth
9(97
9.1a
1998 Chain Case I Brake Specrrications

Polaris Chaincase Lube Model Indy Lite Indy Lite Deluxe Indy Lite Touring Indy Sport Indy Sport Touring
',----,
Amount"
7 fl. oz. 7 fl. oz. 7 fl. oz. 7 fl. oz. 7 fl. oz. 9 fl. oz. 7 fl. oz. 7 fl. oz. 7 fl. oz. 7 fl. oz. 7 fl. oz. 9 fl.oz. 7 fl. oz. 20 fl. oz. 9 fl. oz. 9 fl. oz. 7 fl. oz. 7 fl. oz. 9 fl.oz. 7 fl. oz. 7 fl. oz. 9 fl. oz. 7 fl. oz . 7 fl. oz. 7 fl. oz. 7 fl. oz . 9 fl. oz. 7 fl. oz. 7 fl. oz. 7 fl. oz. 7 fl. oz .
Chaincase Sprocket! Chain Length

16/39/6 4 16/39/6 4 16/39/64 17/35/62 17/4 1/66 15/39/64 19/39/66 22/41/68 21/39/68 22141168 22141/68 20/40/66 18/41/66 19/41/66 22141/68 19/40/66 22141168 17/4 1/66 22/4 1/68 22/41/68 2214 1168 20/40/66 22/40170 23/40/68 19/40/68 23/40/68
Sprocket! Chain Width 13 13 13 13 13 13

314" 314" 314" 3/4" 3/4" 314" 314"
Reverse Opt. Opt. Opt. Opt. Opt. Std. Opt. Opt. Opt. Opt. Opt. Std. Opt. Std.wlH-L Std. Std. Opt. Opt. Std. Opt. Opt. Std. Opt. Opt. Opt. Opt. Std. Opt. Opt. Opt. Opt.
Jackshaft Splines' 13 13 13 13 13 13 15 15 15 15 15 15 15 19 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15
Brake Pads Std Std Std Std Std Std Std Std Std Std Std HD Std Std Std Std HD Std Std Std Std Std HD HD Std Std Std HD HD Std
Brake Type M3 M3 M3 H4 H4 H4 H4 H4 H5LC H4 H4 H4 H4 WT-2 H4 H4 H4 H4 H4 H4 H4 H4 H5LC H5LC H5LC H5LC H5LC H5LC H5LC H5LC H5LC
Indy TranSport Indy XCF Indy 440 LC Indy 440 XCR Indy Super Sport Indy Trail Indy Trail Touring Indy Trail RMK Indy WideTrak LX Indy Classic Indy Classic Touring Indy 500 Indy 500 RM K Indy XLT Classic Indy XLT SP Indy XLT LTD Indy XLT Touring Indy 600 XC Indy 600 XCR Indy 600 RMK Indy Ultra Indy Ultra Touring Indy 700 XC Indy 700 XCR Indy 700 RMK Indy Storm
3/4"
3/4" 314"
3/4"
314" 314" 314" 3/4" 314"
3/4" 3/4" 3/4" 3/4"

3/4" 314"
22140/68
24/40170
24/40/68
21 /41170 25/40170
314" 3/4" 3/4"
Brake type I.D . - M=Mechanical, H=Hydraulic, LC=Liquid Cooled, WT =WideTrak Requires 2871296 Installation Tool lor 15 tooth, 2870974 Installation Tool lor 13 tooth All 1998 Models with PBS Clutch System use HYVO '" Chain and Sprockets (3/4" wide)
711.02. 911.02.
=210ec = 265cc
2011.02. = 590ee
9. 1 b
9/97
INDY JACKSHAFT SPEED VS. MILES PER HOUR SPROCKET COMBINATION/GEAR RATIO/CHAIN PITCH - STD. CHAINCASE
The following chart should be used to setect optimum gearing for special applications. The chart is calculated for models with the
C-1lJ
"
pes drive clutch at a 1 to 1 ratio between drive clutch and driven
clutch Ironl drive sprocket diameter is 7.06 inches. To use the chart, select the jackshalt rpms (equal to engine rpm). MPH is shown to the right of jackshaft rpm . Shown on top is optimum gearing
1lI:c (")l> ~~
Ill(/)
for mph and engine rpm s.
:Tm
-r
Gearing
;:: ......
'01<1 "'3' 1913' , 0' 66
17135
'3137
\.61
20133 12 1135
Rallo
PIlch
Jar;l!Stllllt
RPM
,6fi<X1
6600
"
115.5
I 65
167
I"
82' 183.7
!!!i.O
20135
1"
1.'"
64
''''' '''''' "

1.76
21/39 1 1&'35
1 66 66 11.94
19140
2.11
19/41
1&'3'
16135
2.19
If;V41
1713!I
2.29
15/35
2.33
1714!J
17f41
16139
2,014
16140
14/35
1 64
66
'"
'.06
62
'"
652 66,' 672 68.' 692 702 7\.3 7" 73.3 74.3 75.3 76.3 77.:l
'"
66 63,7 .....7 65.7 66.7 61.6 68.6 69.6 10.6 716
2.17
66
2.28
62
6B
66
62
66
"', '"
66 58.6 59.5 60.4 57.1 58.0
'.SO
66
'SO
62
64
16141
1~39
2.56
2.60
64
..
15140
15/01 1
14139
1<1/40
'67
2.73 66
'.79 64
' ....41
2.03
' .86
"OZ (1) l>
(/)::!!
64
Coo
I/)
(1)
MILES PER HOUR
83'
8n
BS.CI
787 79.9
7<.
76.0 71.1 7,3 79.4 80.6 SI.7
782 79.4
806
740
75.1 76.3 77.4 78.6 79.7 80.8 82.0
70.9
70.6 717 728 73.8 7".9 76.0 77.1 78.2 19.3 90. 61' 82.5 83.6 947 85.6
671 682
69.2
66.B
IOJ.
62. 63.8
GOA
61~
86.
'81
no
TJ. I
6700
I_
6'"
7000 71(). 7200 7,.. 7400
89.
908
87.:l 006 89.8 911 92.' 93.7 95.0 903 97.5
i ~.2 '"
87.5 188.8 90.0 91.3 92.6 87.1
~ 6S.!!
69.9
70.9
921
9JA
".
8"
82.3
81.8
~.o
74.2 75.3
76,4
702 71.:1 72.3 73.3
.,
65,4 67.3 68.3 69.3 70.3 71.2
72.2
64,'
"'.
65.7 687
70.6 71.6
~ 61.0
62.0 62.9
59.1 60.0
56'
57.3 58.1 59.0 59.9 60.7 61.6 62.' 63.'
55.1 55.9 56.7 57.6 58.4 59.3 60.1

61.0
55.1 55.9 56.7 57.6 58.4 59.3 60,1 61.0

61~
53.B 54.6 55.4 56.2 57.1 57.9 58.7 59.6 60.' "2
52.9 53.8 54.6 55.4 562 57.0 57.8 58.6 59.5 60.3 61. 1 61 .9
62.7
5\.6 52.3 53. 1 53.9 M .7

55S
50.4 51 .2 52.0 52.7 53.5

54~
49~
>18.1
47.0 <17.7 48.4 49.\ 49.9 60.6 51.3 52.0 52.'
. <
:r
(')
_ < :c
50.1 50.9 51.6 52.4 53.1 53.9 54.6 55.4
<\8.9 <19.6 SO.3 51.1 51 .8 52.6 53.3 54.0
"0
S:m
62.' 63.2 "'.1 65.0 659
50.'
61.8
62.7
56.'
61.3 62.2
63.1
667 67.7
03.'
64.7
65.7
~ 60.'
61.5
:T
III
84.'
no
73.0 74.0 15.0 78.1 771 16.1
63.'
645
as,
'.1.7
96.0 91.3 98.6 100.0 101 3 102.6 1039 IOS.2 106.5 107.8 IOB2
11 0.5
1118
93.'
'883 840 as,

,OS
920
<D
I\)
lillO
7800 7900
"00 ,7600
"" '6.4
91,6
...
,,,
'G.8
82.'
"4 .6.6
878 89.0
77> 78.6 79.7 60.8 81.9 83.0
74'
75.4 16.>\ 77'
69.6
68.,
61.8 68.7 69.7 70.6 71 .5 72.4 73.4 74,3 75.2 76.2
65.6 61.5 68' 69.4 70.3 7\.2 72.1 13.0 74.0 74.9 75.8 16.7 77.7 78.6
65.. 66.3
....
64. 65.8 86.7 67.6
62.'
63.3 64.1 65.0 65.'
56.3 57.1 57.9 sa.7 59.5 GO.3
55. 1 55.' 56.6 57.4 58.2
'31
642 85.4
61.8 6.., 63.'
12s
73S
"3 87.5 88.6

1 89.8
98.
100.1 10 \
~
'80
100' 101.4
102.7
'"
g.t;!
90.' ,"1 93.2

94A
."
91.4 93.8
~s.o
90'
.as ,...,
.77
88.' 89.9 as.l B6.' 87.3 98,4 89.5 90.6 91.7 9'l,8 93.9 ".0 96.1 97.1
73.2 7<2 75.1 76.1
72.5 73.5 14.5 75.4 70.4 77.4 78.3 79.3 80.3 81.2 82.2 632 84,1 85.1 861 87.0 88.0 89.0
...,
67.3
.<2
66.1
66.0
66~
62.7
78'
795 60.6 81.6 82.6 83.7
74.5 75.5 76.5 77' 78.4 79.4
69.1
70.0
70.9
68.'
60< 70.3 71 .2 72.1 73.0 73.9 74.8 75.7 766
79.2
602 61.2 82.2 83.3
66.' 67.7
G4"
65.2 66.1 66.' 67.8 68.6 69.5
70 .3
....
63. 652 66.1 66.9 67.' 686
G2.
62.'
637 645 65.3 66.' 67.0 67.S 68.7 69.5 70.3 71 .1
76.3
793 80.3 81.3 82.3 83.3 84.3 as.3
n.l
78.1 79.0 60.0 810 82.0 82,9 83.9
71 .S 72.7 73.6
.000
102.7
10~.a
91$.3
811)0
.200
900
975
98.7 99.9 101.1 102.3 103.5 1()I .7 105.9 107 1 108.3 109,5 110.7 111.9 \13,1 114.3 115.5 116.7 117,9 119.1 120.3
'" 922
93,4
86.9
88,0 89.0 901
"'.
68.' 70.3 712 72.0 729 73.8
G7.7 68.6 69" 70.3 71.2 72.0 12.9
G3.'
6U
65.'
66.0 66.!! 676
68.4
".
61.1
58'
59.7 60.' 61 .3 62.1 62.8 63.6 64,4 65.2 65.9 66,7 67.5 68.' 69.0 69.8 70.6 71.4 721 72.9 73.7 74.5 76.2
".
57.7 58.4 59.2 60.0 607 6l.5
56.2
54.' 55.5
56~
53.'
"'2 54.' >S.6
57.0 57.B
56.'
57.1 57.' 58,5
62.1
56.
59.2
GO
".4
105.2 100.5
107.8
104.0
105.2-
8300
8400
18500
'"
.4.7
85.7
.4.3
SO..
81.4 82.3 83.3 94.3 85.3 00.3
100,4 101.6
95.5 86.7 976
94.'
95.6
as.,
86.3
n.l
7a.o 78.9 79.9
74'
75.4
,,.
642 65.0 65.9 66.

67A
62.2
60.7 61.5
62.2
59.3
70,3
106.5 101.8 109.0 1103 111.6 112.9 114.1 1154 110.7 1\7.9 110.2 120.5 121.7
123.0
191.2
ea.
87.8
n'.3
17.2
71.1 720
71 .1 72.0
63.'
653
109. 1 110 4
111 7
102.9
96.'
9"
193.4
'GOO
8700
'600
113.1 114 <I 1157 1171 118.4 1197 121.0 122.3 123.6 1249 126.3 121.6 128.9
104.\ 199.0 IOS.3 1(J7.7 108.9 11 0.1 111 .3 11 25 113.7

11 5.0
101).\
112.9
106 5 1101.3 102.4 103.6 104 7
"'.
97.9
".,
~ 89.9
90.'
"..
89.4 90.5 91.5
87.4
.6.3
87 .3 88.3 89.3 90.3 91.3 82.3
83~
94'
180.
81.7
....
8\.4 83.' ".1 85.1
79.5
79.2
791 80.0
n..
78.4 79.3 902
81.1
'" 75.6
76.4 17.3 78.2 79.1 90.0
73.
14.6 75.5 76.4 17.2 711.1 79.0 79.8 607
69.? 70.0 70.9 71.7 72.5 7>3 74 .1 74.9 75.7 76.6 77.4 7B.2 19.0 79,5 80.6 81.4
..,
68.3 69.8
63,0
GO.o
60.7
62.9
63.7
61.
12.'
73.7 74.5 75.4 76.2 77.1 77.' 78.8 79.'
12.8
73.7 745 75.4
76.2 77.1
68.' 69.0
100.2 10 1 3 102.5 103.6 104.7
9S.6 96.6 97.1
85.'
.68
87.8
n..
73.6
74.'1
72.0
69.'
70.6
11.'1
~ 9000
~
1168 1181 1194 120.8 12UJ 123.2 114.5 125.8 127 1 128.3
a
~ m " to
S" S"
iSS
9100
~1OO
..., ....
993 100.4
lOIS
'"
96.1
930 940 95.0 97.1 98.1
'"
93.5 94.6 95.6 96. 877 98.7 99.7 100.7
101 .6
'"
.27
83.6 64.5
92.3
80.'
81 .8 82.7 83.' "'.5
...
66.0 67.5 69. 1 70.6 71.3 72.1 72.9 73.6
74,4
64.'
652
"'.
83.6 64.3 65.0 65.'
...S
622
88.2
....
66.'
67.4 68.1
89.'
88.'
89.' 90.' 91.7 92.7 93.7 94.7 a5.6 96.6 97.6
82.0
75.3 76.1
n'
73.0 73.8 74.5 75.3 76,1 76.9
IOS.9
1070 1082 109.3 11 0.5 1116
11 2.8
99.'
101.0 102.1
103.2
600O
9400
107.0 IOB.2 109.3 110.4 111 .6

1127
"" ,
00.'
91.2 92.2 931 04.1 ".1 96 1 971
102.6 103.7
",
os.,
96.3
,,~
89.'
90.9
98.'
89.2 90.1
.5.4
87.3
82.'
83.8 84,7 85.6 86.5 87.4 88.3 89.2
80.'
81.7
77.9
860 86.' 81.B 88' 897 90.6 9\ .5 92.5
.5.4
86.3 87,2 862 891 90.0
82.6 83.' 64.3 85.2 98.1 87.0 87.9
81.6
~soo
9600
110.2 1\7.4
118.6
11 9f!
104.8
105.9
107.0
104 .2
99.'
100.2 101 .2 102.3 103.3
'9,. 19
93.8
82.'
83.3
50.'
81 .3 9" 63.0 83,9 847
...
822 83.9
78.8
76.'
79.6
n .
78.6 79.4
....
.. 9
70.3
672 67.9 68.7
81.3
71 .1 71.8 72.6 73.3
69.'
70.1 70.8 7\ .5 72.3
9700
IOS.3
106.4
107.5
'600
9';100
124.3 \25,5 126,8
98.3
94'
95.7 96.7
91.0 91.9
'"
'02
81.1
81,9 82.7
85.0
83.0
84.7
77.7
78.6 79.3
76.0
76.8 77.6
"
t'00
~
131 5
00
121 0
1119 116.1
..
10&.1 1092
'94
100.4
as.9
86.9
75.1 75.9
113.8
108.6
102.8
,8.0
'29
90.'
90. \
74.0
\.
BRAKES/FINAL DRIVE Jackshaft Speed vs. MPH Chart (Long Chain Case)
1997700 XC, 440 XCR; 1998440 XCR, 600 & 700 Domestic Twins (Longer Chain Case)
Top SprOKeC\
2S
41
23 39
1.70
lower Sproke\
"
23
41
1.78
22
22
41
20 39 1.95
21 41
1.95
t9 39
t9 40
16 40
2.22
,.
41
17
41
'0
1.74
40
1.82
Ratio
Chain length
1.64 72
1.86
2.05
68
2."
66
2.28
2.41
70
70
70
70
70
6B
70
66
66
66
JackshaJl
RPM 6000
MILES PER HOUR

76.8
78.1
74.3
72.5
70.7
69.3
70.5
67.6
64.6
64.5 65.6
66.7
81.4
59.9
60.9
6 1.9
56.7
57.7
55.3
523
53.1
6100 6200 6300 6400 6500

6600
75.6
76.8
73.7
74.9
76.\
71.9 73. 1 74.2 75.4

76.6
66.7
69.9
71 ,0
72 . 1
65.7 66.8 67.9
62.4
63.4
58.2
57.2
19.4 80.7
82.0
71.6
58.6
59.5
54.0
5<1.9
55;7
78.0
79.3
726
73.9
75 . 1
67.8
64.S
85,5
62.9
63.9
64.8
56.1
59.0
59.9
77.3
78.5
66.9
70.0
68.9 69..
71.0
72.1
73.2
60,5
61.4
83.2 84.S
85.S
87.1
80.5
73.3
74 .4
66.5
67.5 68.8
69.6
56.6
57.5
81 .8
83.0 84.2
79.7
80.9
77.8
76.2
77.4 78.6 79.7 80.9 82.0 83.2 84.3 S5.5 86.6 87.8 88.9
71 . 1
65.6 66.8
67.8 68.8 69.8 70.8 71.8 72.8 73.8 74.8 75.8 76.8 77.8 78.8 79.8 80.8 81.8
62.4
60.9
SI ,8
6700 6800 6900 7000 7100 7200 7300 7400 7500

7&00
78.9
80.1
75.5
7>,
73.2
&"
64.3
6~.2
56.3
59.2 50. 1 61.0 61.8
82.1 83.3 84.5 SS.7 87.0
76.6
77.8 78.9
62.7 63.6 64.5 65.5 66.4

67.3
88.4
89.5
85.5 85.7
81.3 82.5 83.7 84.8 86.0 87.2 88.4 89.5 90.7
74.3 75.4 75.5
74.2
70.6 71.5 72.7 73.7
75.3
76.4 77.5 78.5 79.6
66.2 67. 1
90.'
879
89.2
800
81.1 82.3 .83.4
845
922
93.5 94.8
n..
78.6 79.7 80.8 81 .9
68.1
62.7
63.6
90..
91.7
882
894 906
91 .8
747
75.7 78.7 77.8 78.8 79.8 80.8 81 .9
89.0
69.9
68.' 89.' 701

71.0 71.9 72.8 73.8 74.7 75.6 76.5
64" 65.3
66.2
96.1
97.3 98,6
929
94. 1
'07
81.8 82.8
709
71 .8
85.7 86.8 87.9 89.0
7700
'5'
96.6 '79 !l9.1 100 3
101.6 t028 104.0 105.3
930 942
95.4
829
84.0
72.8
73.8
671
67.9
7800 7900 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900
9000
99.'
1012 102.5 103.7 105.0
91.9
90.1 913
92,4 93.6 94.7
95.9
63.9
85.0 86.1 87. 1
931
94.3
851 86.' 87 , 88.3 89<

90.5
7<7
75.6 76.S
688 69.7
70.5 71.4 72.3 73.2 74.0 74.9
986 978
99.0 100.2 101.4 102-7 103.9 105.1 106.3 107.5 108.7 109.9 1111 112.3 113.5 li4.7
90.'
91.3
95'
96.6
97.8
829
83.9 84.9 86.0 87.0 88.0 89.0
924 935
94.7 95.8
88.'
89.3
775
78.4
79.'1
106.3
107.6 1089 110.1 11 1.4 112.7 1140 115.3 116.5 117.8 119 , 120A 1217 122..9 1242 125.5 126.8 128. 1
".
83.8
99.0
100.2 101.3 102.5 103.7
97.0 98.2
90..
77.5
78 II 79.3
916 926 937 94.8
.14
92.5 93.6
848
85.8 86.8
80.3
81."3 82.283.2 84.1 85.1 86.0
87.0
1065
1078 109.0 1102 '11 .5 112.7 114 a
993
100.5
96.9 981
80' 911 821

83.0 83.9 84.8
785
76.6
1017 '02_ 8
104.0
99.'
1003
101 .4 1026
103.7
94.7 95.7 96.8 .79 99.0

100.0 101.1 102.2 103.3
104.4
90.0
91 .1
87. 888
89.8
lC)' 9
106.0 1072 108.4 109.6 110.8
111 9
9"
96.9 980 991
100.2 101.2 102.3 103.4 lOti 5 105.6
775
78.4
921
93.1 94.1
9100 9200 9300 9400 9500

9600
105. 1 106.3 1074

108.6
90.8
91.8
79.'
80.1 810
81 .9 82.7 83.6 845
115.2
'1S.4 117.7 118.9 1202 121.4
122.6
'0<18
1OS.9 107 1
952
92.8
93.8
87.9 88.8 89.6
85.8
8S.7
96.'
97.2
98.2
99.3 100.3
109.7 110.9
948
95.8
876 885
115.9
117 1 118.4
119.6
113. 1
108.2
907 917
92.S
936 94.5
9700 9800 9900 10000
1143 115.5 1166

117.8
112
109 3
110,<1
96.8
97.8 98.8
89'
90.4
113.2
1 1~.4
105.4 106.5 107.6
as.)
86.2
87. 1
1116
10M
107.1
101 .3 102.3
.13
92.'
123.9
120.8
115.5
1127
99.8
9.2a
9/97
BRAKES/FINAL DRIVE Chain Case Sprocket Part Numbers Top Sprockets - 13 Spline (Except Large Diameter Jackshaft)
11 L Drive System 13T 14T 15T 16T 17T 18T 19T 20T 21T 3222059 3221036 3221031 3221032 3221033 3221037 3221034 322 1053 3221035 13L Drive System 19T 20T 21T 22T 23T 3221059 3221055 3221054 322 1056 3221057
Top Sprockets -15 So line (Large Diameter) Jackshaft

11 L Drive System 1ST 16T 17T 18T 19T 20T 21T 22T 23T 3221067 3221068 3221069 3221079 3221071 3221065 3221066 3221072 3221073 13L Drive System 17T 18T 19T 20T 21T 22T 23T 15L Drive System 3221080 3222077 3222078 3222079 3221075 20T 3221076 21T 3221060 22T 3221061 3221062 3221063 322 1064 23T
Bottom Sprockets
11 L Drive System 33T 35T 3222039 3222036
11 L Reverse 35T 39T

Steel
13L Drive System 37T 3222056
13L Reverse Gear 1341110 1341114 37T
15L Drive System 35T 37T
15L Reverse 1341173 1341172
1341054 35T 1341053 1341163
3222053 35T
3222073 35T 3222074 37T
39T PM 39T 3222034 40T 1341198 39T 3222052 39T

Stee t
1341111 1341163 1341197
39T
3222075
39T
1341171
39T PM 41T 3222037 41T 1341112 40T 41T 1341117
Drive Chain
11 L Drive System 64P 66P 68P 3224023 3224024 3224025
13L Drive System 64P 66P 3224051
15L Drive System 3224057 3224058 66P
3224052 64P
9/97
9 .2b
BRAKES/FINAL DRIVE HyVo '" Sprocket Part Numbers
HYVO Sprocket Part Numbers

TM
Top Sprockets For 3/4" HYVO

17T 18T 19T 20T 21T 22T 23T 24T 25T 3221084 3221085 3221086 3221087 322 1088 3221089 3221090 3221091 3221092
Drive Systems
HYVO Drive Chain

Chain Length (Pitch) Part Number
66P 68P 70P
3224071 3224070 3224069
Bottom Sprockets For 3/4" HYVO Drive Systems

Standard Bottom Sprockets Reverse Sprockets
39T 40T 41T
3222105 3222094 3222095
40T 41T
1341224 1341225
9. 2c
9/97
BRAKES/FINAL DRIVE Sprocket / Chain Combinations Sprocket / Chain Combinations - 6.625 Chain Case
Acceptable gearing / chain combinations are listed below for the 6.625 (ce nter distance) chaincase. Do not use this chart for 1997 - 1998 models with domestic twin cylinder engines (7.050 chaincase), refer to page 9.2e. Combinations listed as "not recommended " should not be installed. Upper Sprocket (# of Teeth)
16 16 16 16 16
17
Lower Sprocket (# of Teeth)

35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 39 40 41 39 40 41 62 64 64 66 66 62 64 64 66 66 64 64 66 66 66 64 64 66 66 66
64
Chain Length (6 .625 Chain Case)

NOT RECOMMENDED NOT RECOMMENDED
17 17 17 17 18 18 18 18 18 19 19 19 19 19 20 20 20 20 20 21 21 21 21 21 22 22 22 22 22 23 23 23 23 23 24 24 24 25 25 25
NOT RECOMMENDED NOT RECOMMENDED NOT RE COMMENDED
NOT RECOMMENDED
66 66 66 68 64 66 66 68 68 64 66 68 68 68 66 66 68 68 68 68 68 70 68 70 70
NOT RECOMMENDED
NOT RECOMMEN DED NOT RECOMMENDED NOT RECOMMENDED
NOT RECOMMENDED
NOT RECOMMENDED NOT RE COMMENDED NOT RECOMMENDED
9/97
9 .2d
BRAKES/FINAL DRIVE Sprocket / Chain Combinations Sprocket / Chain Combinations - 7.050 Center Distance Chain Case
~
Acceptable gearing / chain combinations are listed below for the 7.050 (center distance) chaincase used on all t997 - t998 models with domestic twin cylinder engines (440 XCR, 600 and 700 XC, SKS, and RMK). Combinations listed as "not recommended" should not be installed. Refer to page 9.2d for 6.625 (center distance) chaincase gearing/chain recommendations. Upper Sprocket (# of Teeth)
16 16 16 16 16
17
Lower Sprocket (# of Teeth)

35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 35 37 39 40 41 39 40 41 39 40 41 64 66 66 68 68 64 66 68 68 68 66 66 68 68 68 66 66 68 68 70 66 68 68 70 70 66 68 70 70 70 68 68 70 70 70 68 68 70 70 70 70 70
72
Chain Length
NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED
17
17
17
17
18 18 18 18 18 19 19 19 19 19 20 20 20 20 20 21 21 21 21 21 22 22 22 22 22 23 23 23 23 23 24 24 24 25 25 25
NOT RECOMMENDED
NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED
NOT RECOMMENDED NOT RECOMMENDEO NOT RECOMMENDED NOT RECOMMENDED
NOT RE COMMENDED
70 72 72
9.2e
9/97

1996 Track Drive Data Model No. of Drive Drive Type Sprockets Drive Shaft Bearing Lock Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Skwez-locT Set Screw Pressed Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Skwez-loc Pressed Pressed Pressed Pressed Pressed Pressed
T
Drive Sprocket Diameter
DRIVE SPROCKET POSITION Reference Page 9.4 A B C D
Indy Lite Indy Lite Deluxe Indy Lite GT Indy Sport Indy Super Sport Indy TranSport Indy Sport Touring Indy Trail Indy Trail Touring Indy 440 LC Indy 440 XCR Indy 440 XCR SP Indy 600 XCR Indy 600 XC R SP Indy WideTrak GT Indy WideTrak LX Indy Classic Indy Classic Touring Indy 500 Indy 500 RMK Indy 500 SKS Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT SP Indy XLT Touring Indy RXL Indy Ultra SP Indy Ultra SKS Indy Ultra RMK Indy Storm Indy Storm SKS Indy Storm RMK
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 2 2 2 2 2 2 4 2 2 4 4 4 4 4 4 4 4 4
3 3 3 3 3 3 3 3 3 3 3 3 3 3' 4 4 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3' 3' 3' 3' 3' 3'
6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.86 6.86 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94
7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 4.41 1.26 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 4.35 7.48 7.48 4.35 4.35 4.35 4.35 4.35 4.35 4.35 4.35 4.35
12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 15.97 4.41 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 7.48 12.32 12.32 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48
All 1996 models, sprocket positions are measured to sprocket hub and not idler center. See page 9.4.
15.97
17.47
12.32
16.32
12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32
16.32 16.32 16.32 16.32 16.32 16.32 16.32 16.32 16.32
Denotes driveshafts with pressed on left side bearings (no lock collar) with welded flangette bolts.
9.3
9/96

1997 Track Drive Data Model No. of Drive Drive Type Sprockets Drive Shaft Bearing Lock Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Pressed Pressed Pressed Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Skwez-loc Pressed Pressed Pressed Pressed Set Screw Set Screw Pressed Pressed Pressed Drive Sprocket Diameter DRIVE SPROCKET POSITION Reference Page 9.4
Indy Lite Indy Lite Deluxe Indy Lite GT Indy Sport Indy XC F Indy TranSport Indy Sport Touring Indy Super Sport Indy Trail Indy Trail Touring Indy Trail RMK Indy 440 LC Indy 440 XC Indy Indy Indy Indy
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 2 2 2 2 4 2 2 4 4 4 4 4 4 4 4 4 4 4 4
3 3 3 3 3 3 3 3 3 3 3 3 3 3 3' 4 4 3 3 3 3 3 3 3 3 3
6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.86 6.86 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94
600 XC 600 XCR WideTrak GT WideTrak LX
Indy Classic Indy Classic Touring Indy 500 Indy 500 RMK Indy 500 SKS Indy 500 EFI Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT SP Indy XLT Touring Indy RXL Indy Ultra Indy Ultra SP Ir,dy Ultra SPX/SE Indy Ultra Touring Indy 700 SKS Indy 700 RMK Indy Storm Indy Storm SKS Indy Storm RMK
A 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 4.41 1.26 7.48 7.48 7.48
7.48 7.48 7.48 4.35 7.48 7.48 4.35 4.35 4.35 4.35 4.35 4.35 4.35 4.35 4.35 4.35 4.35 4.35
12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 15.97 4.41 12.32 12.32 12.32 12.32 12.32 12.32 7.48 12.32 12.32 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48
0 All 1996 models, sprocket positions are measu red to sprocket hub and not idler center. See page 9.4.
C
15.97
17.47
12.32
16.32
3 3
3 3'
12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32 12.32
16.32 16.32 16.32 16.32 16.32 16.32 16.32 16.32 16.32 16.32 16.32 16.32
3'
3" 3' 33" 3" 3" 3"
" Denotes drives hafts with pressed on left side bearings (no lock collar) with welded flangette bolts .
9/96
9.3a
BRAKES/FINAL DRIVE Specifications 1998 Track Drive Data

Model No. of Drive Drive Type Sprockets Drive Shaft Bearing Lock Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Pressed Drive Sprocket Diameter DRIVE SPROCKET POSITION Reference Page 9.4
Indy Lite Indy Lite Deluxe Indy Lite Tou ring Indy Sport Indy XCF Indy TranSport Indy Sport Touring Indy Super Sport Indy Trail Indy Trail Touring Indy Trail RMK Indy 440 LC Indy 440 XCR Indy WideTrak LX Indy Classic Indy Classic Tou ring Indy 500 Indy 500 RMK Indy XLT LTD Indy XLT Classic Indy XLT SP Indy XLT Touring Indy 600 XC Indy 600 XCR Indy 600 RMK Indy Ultra Indy Ultra Touring Indy 700 XC Indy 700 XCR Indy 700 RMK Indy Storm
2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 2 2 2 (wide) 2 (wide) 2 (wide) 4 2 (wide) 4 2 (wide) 4 4 2 (wide) 4 2 (wide) 4
3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 4' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3'
6.94 6.94 6.94 6.94 6.94 6.94 6.94 6.94 6,94 6,94 6,94 6.94 6.94 6.94 6.94 6.94 6.94 6,94 6.94 6,94 6,94 6.94 6,94 6,94 6,94 6.94 6,94 6.94 6,94 6,94 6,94
A
7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 6,95 1.26 7.48 7.48 7.48 7.48 6,95 6,95 6,95 4,35 6,95 4,35 6 ,95 4.35 4.35 6.95 4,35 6.95 4,35
12.32 12.32 12.32 12.32 12.32 12.32 12.32 12,32 12,32 12,32 12.32 11.79 4.41 12.32 12.32 12,32 12.32 11.79 11.79 11.79 7.48 11,79 7.48 11,79 7.48 7.48 11.79 7.48 11 ,79 7.48
All 1998 models, sprocket positions are measured to sprocket hub and not idler center. See page 9.4.
15,97
17.47
12.32 12.32 12,32 12.32 12,32 12.32
16,32 16,32 16,32 16,32 16.32 16,32
Denotes driveshafts with press-fit bearings on left side (no lock collar) and flangette studs (welded).
9.3b
9/97
BRAKES/FINAL DRIVE
Track Specifications 1996 Track Specifications
Model Length x Width Contact Length 35" 41 "
35"
Pattern
Lug Height .66" .82"

.71"
Wheels Bogiel Idler
Wear Strips N/A N/A Acc Ace Acc Acc SId SId Std Std Std Aee Aee Acc Aee Ace N/A Aee Aee N/A Aec Ace Std Aee NIA Aee Std Std N/A Aee Std Aee NIA
Indy Lite/ Deluxe Indy Lile GT Indy Sport Indy Sport Touring Indy TranSport Indy Super Sport Indy 440 XCR Indy 440 XCR SP Indy 600 XCRISP Indy WideT rak GT Indy WideTrak lX Indy Trail Indy Trail Touring Indy 440 lC Indy 500 Indy 500 SKS Indy 500 RMK Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy Classic Indy Classic Touring Indy Xl T/SP Indy XlT SKS Indy XLT RMK Indy Xl T Touring Indy RXl Indy Ultra SP Indy Ultra RMK Indy Ultra SKS Indy Storm Indy Stonm SKS Indy Stonm RMK
121 x 15" 133.5x 15" 121 x 15" 133.5 x 15" 141 x 15" 121 x 15" 121 x 15" 121 x 15" 121 x 15" 141 x20" 156 x 20" 121 x 15" 133.5 x 15" 121 x 15" 121x 15" 133.5x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 133.5 x 15" 133.5 x 15" 121 x 15" 121 x 15" 133.5x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 133.5 x 15"
Block Lightning Block Lightning Wiper Lightning logo logo Lighlning Wiper Bloek Lightning Lightning Lightning lightning Lightning Deep lug Lightning Lightning Deep lug Lightning lightning Lightning Lightning Deep lug Lightning lightning Lightning Deep l ug Lightning Wiper Wiper Deep lug
6/3 6/3 6/3 6/3 8/3 6/3 8/4 6/4 8/4 14 14 6/3 6/3 6/3 6/3 6/3 4/3 6/3 6/3 4/3 6/3 6/3 6/3
61 3 41 3 613 61 4
41 " 45" 35"
.82"
1.13#
.82#
44"
44"
.73# .73"
.82 "
44"
45" 52.5" 44" 50" 44" 44" 50" 50" 35" 50"
41 "
.91 "
.71 "
.82" .82" .82"

.82" 1.0"
1.25" .82"
1.0"
1.25"
.82 "
35"
41 "
.82" 1.0"
1.0"
35/1
41 " 41 "
44"
1.5" .82" 1.0" .82"

1.51/
35" 35"
41 "
8/4 4/4
61 4
41 " 44" 50"

50"
1.0"
.9 1" .9 1" 1.5"
8/4
814
6/4
9.3d
9/97
BRAKES/FINAL DRIVE Track Specifications 1997 Track Specifications

Model Length x Width Part No. Pattern Lug Height
.66"
Whee lsBogiel Idler
Wear Strips
Indy LitelDelu xe Indy Lite GT Indy Sport Indy Sport Touring Indy TranSport Indy XCF Indy Super Sport Indy Trail Indy Trail Touring Indy Trail RMK Indy WideTrak GT Indy WideTrak LX Indy 440 LC Indy 440 XC Indy 500 Indy 500 SKS Indy 500 RMK Indy Classic Indy Classic Touring Indy 500 EFI Indy XLT/LTD Indy XLT Touring Indy XLT SKS Indy XLT RMK Indy XLT SP Indy 600 XC/XCR Indy RXL Indy UltraiSP/S PX Indy Ultra Touring Indy Ultra SPX SE Indy 700 SKS Indy 700 RMK Indy Storm Indy Storm SE Indy Storm RMK
121x15" 133.5 x 15" 121x15" 133.5 x 15" 141 x 15" 121 x 15" 121 x 15" 121 x 15" 133.5 x 15" 133.5x 15" 141 x20" 156 x 20" 121 x 15" 121 x 15" 121 x15" 133.5 x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 121x15" 121 x 15" 133.5 x 15" 133.5 x 15" 133.5 x 15" 121 x 15" 121 x15" 121 x 15" 121 x 15" 133.5 x 15" 121 x 15" 136x 15" 136x 15" 121 x 15" 121 x 15" 133.5 x 15"
5410792 54111 71 5410736 541 11 71 5410801 541 11 83 5411 168 54111 68 541 11 71 541 1021 5410748 5411040 54111 68 5411168 54111 68 54 111 66 5411021 54 111 68 5411091 541 11 68 5411167 54 11 091 541 1166 5410921 5411167 5411167 5411167 5411057 5411176 5411183 5411193 5411194 5411057 5411183 5410921
Block Lightning Block Lightning Wiper Lightning Lightning Li ghtning Lightning Deep Lug Wiper Lightning Lightning Lightning Lightning Lightning Deep Lug Lightning Lightning Lightning Lightning Lightning Lightning Deep Lug Lightnin g Lightning Lightning Lightning Lightning Lightning Lighlning Deep Lug Lightning Lightning Deep Lug
6/2 6/3 6/2 6/3 8/3 6/3 6/3 6/3 6/3 4/3 6/4 6+2/4
6/3 6/4 6/3 6/3 4/3
Aec Acc Ace Acc Acc Std Acc Acc Aec N/A Std Std Acc Std Acc Ace N/A Acc Ace Ace Acc Ace Ace N/A Std Std Std Std Acc Std Acc N/A Std Std N/A
.82#
.71"
.82;1
1.13" .725" .82" .82" .82" 1.25" .91" 1.0"

.82"
.82" .82" 1.0" 1.25"

.82"
6/3
6/3
.82" .82" .82" .82" 1.0" 1.5"

.B2'f
6/3 6/3
6/3 6/3 4/3 6/3 6/4 6/4 6/4
.82" .82" .82"

.821/
.725"
6/4 6/4
6/4 4/4
1.0"
1.5"
.82" .725"
1.5"
6/4 6/4 6/4
9/97
9.3e
BRAKES/FINAL DRIVE Track Specifications 1998 Track

Model
Length x Width Part No. Pattern Lug Height .66" .66"
,82" .71"
WheelsBogiel Idler 4/2
Wear Stri ps
.75/1 Ace
Window
Indy Lite Indy Lite Deluxe Indy Lite Touring Indy Sport Indy XCF Indy TranSport Indy Sport Tou ring Indy Super Sport Indy Trail Indy Trail Touring Indy Trail RMK Indy 440 LC Indy 440 XCR Indy WideTrak LX Indy 500 Indy 500 RMK Indy Classic Indy Classic Tou ring Indy 600 XC Indy 600 XCR Indy XLT LTD Indy XLT Classic Indy XLT SP Indy XLT Touring Indy 600 RMK Indy Ultra Indy Ultra Touring Indy 700 XC Indy 700 XCR Indy 700 RMK Indy Storm
121 "x 15"
5410792 5410792 5411 171 5410736 5411 183 5410801 541 11 71 5411 168 5411168 5411171 5411021 5411168 541 1475 5411040 5411168 5411 021 5411168 5411091 5411 369 541 1344 54 111 67 54111 67 541 1379 5411091 5411237 5411344 5411176 5411369 5411344 5411237 5411344
Block Block Lightning Block Lightning Wiper Lightning Lightning lightning lightning Deep Lug Lightning Lightning Lightning lightning Deep Lu g Lightning lightning New New Lightning Lightning New Lightning Deep Lug New Lightning New New Deep Lug New
1.25" 1.25"
1.5"
1.5"
121 '" x 15"
4/2 6/2 4/2 6/4 8/3 6/2 6/3 6/3 6/3 4/3 6/3 6/4 6+214 6/3 4/3
6/3 6/3 6/4 6/4
.75" Acc .75" Acc 1.05"Acc 1.05"Acc NIA .75" Acc

.75/1 Ace
133.5" x 15" 121 "x 15" 121 "x 15" 141" x 15" 133.5" x 15" 121" x 15"
121 " x 15"
.725" 1.125" .82" .82" .82" .82" 1.25" .82" .82" 1.0" .82"
1 .25/1
1.25" 1.25" 1.5"

1.25#
.75" Acc .75" Acc NIA
1.25"
1.5"
133.5" x 15" 133.5" XIS" 121" x 15" 121 " x 15"

156"
1.25" 1.25" 1.25" 1.25" 1.25"

1.25/1
.75" Ace
Coolers NIA .75" Acc NIA .75" Ace
.75 " Ace
x 20"
121 " xlS"

133.5" x 15"
12 1"
x 15"
.82/1
1.25"
1.5"
133.5" x 15" 121 "x 15"

121 " x 15"
.82" .91" .82" .82"

.82"
Coolers .75" Sid .75" Acc .75" Acc .75" Std .75" Acc N/A .75" Std .75" Acc Coolers .75" Std N/A .75" Std
1.25" 1.25" 1.25" 1.25" 1.25"

1.5"
121 " x 15" 121 "x 15" 121 "x 15" 133.5"x 15" 136"x 15" 121 " x 15" 133.5"x 15" 121"x15"
121 "x 15"
6/3 6/3
6/4 6/3 4/3 6/4 6/3 6/4 6/4 4/3 6/4
.82" .82" 1.75" .82" .82"

.91 "
1.25" 1.25" 1.5" 1.25" 1.25" 1.25" 1.25"
.82" 1.75" .82"
136"x 15"
121 " x 15"
9.31
9/97
BRAKES/FINAL DRIVE Drive Shaft Sprocket Installation Tips

Driveshaft Sprocket Installation
All models, except WideTraks, have a longer spline on the chaincase end of the jacks haft and drive shaft. Sprockets must be started from the end that has a smooth entry onto the hex portion of the shaft (indicated on illustration below by "S"). To ensure proper sprocket tooth alignment, be sure the vendor logos are oriented in the same position on all sprockets. Dri ve shaft sprocket positions are measured to sp rocket hub edge. Not idler center.
Logo orientation
S
2 Drive Sprocket
S
Use straight edge against sprocket hub 4 Drive Sprocket
Square
f - - -- B -------I
A
1--- - - C - - - - I
Coupler WideTrak GT
Left Side WideTrak LX
Coupler
NOTE : When installing drive sprockets , all dimensions are indicated as the shaft is being pressed onto the sprockets. Mark the shaft with a Dykem and a machinist scribe, or a fine line permanent marker for proper sprocket placement. Allow mark to thoroughly dry prior to assembly. Verify proper placement using a straight edge and square on sprocket hub and shaft as shown. On WideTraks, measure from co upler.
9; 97
9.4
BRAKES/FINAL DRIVE Hydraulic Brake System Operation
End View
A \==fI'
F
D-The Polaris snowmobile hydraulic brake system consists of the following components or assemblies: brake lever, master cylinder, hydraulic hose, brake caliper (slave cylinder), brake pads, and a brake disc which is secured to the drive line. NOTE: The Magura master cylinder system used on the 440 XCR SP is similar to this system. It has a see through housing, different piston, and longer lever. Refer to page 9.7 for information on the Magura system. ,,-. When the hand activated brake lever (A) is applied, it contacts a piston (8) within the master cylinder. As the master cylinder piston moves inward it closes a small opening called a compensating port (C) within the cylinder and starts to build pressure within the brake system . As the pressure within the system is increased, the piston (D) located in the brake caliper moves outward and applies pressure to the moveable brake pad. This pad contacts the brake disc, moves the caliper in its floating bracket and pulls the stationary pad into the brake disc. As the lever pressure is increased, the braking effect is increased . The friction applied to the brake pads will cause the pads to wear. As the pads wear, the piston within the caliper self-adjusts and moves further outward. Brake fluid level is critical to proper system operation. A low fluid level allows air to enter the system causing the brakes to feel spongy.
Compensatin g Port
Located within the master cylinder is a small compensating port (C) which is opened and closed by the master cylinder piston assembly. The port is open when the brake lever is released and the piston is outward. As the temperature within the hydraulic system changes, this port compensates for fluid expansion caused by heat, or contraction caused by cooling. During system service, be sure this port is open. Due to the high temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate space to allow for the brake fluid to expand. Master cylinder reservoirs should be filled to the top of the fluid level mark on the inside of the reservoir, 1/4" - 5/ 16" (.6 - .8 cm) below lip of reservoir opening.
'----
WARNING
Never overfill the reservoir. This could alter brake function, resulting in system component damage or sever personal injury or death. This system also incorporates a diaphragm (E) as part of the cover gasket and a vent port (F) located between the gasket and the cover. The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts. Be sure the vent is open and allowed to function . If the reservoir is overfilled or the diaphragm vent is plugged, the expanding flUid may build pressure in the brake system and lead to brake failure. Polaris Industries Inc.
9 .5
11 /95
BRAKES/FINAL DRIVE
Type 3 Master Cylinder Type 3 Master Cylinder
The Type 3 master cylinder assembly is easily re cognized by the longer (centered) brake line mount. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Cover Screw Cover Cover Gasket Cylinder Housing Brake Lever Bushing Brake Lever Park Lever Return Spring Pivot Bolt Nut Park Lever Park Lever Pivot Bolt Park Lever Pivot Bushing Spring Seat Washer Compression Spring U-Pack Seal Piston a-Ring Seal Clamp Bolt Attaching Clamp Lever Pivot Bolt Baffle Baffle Washer
2~
y.----l
/,21
3~~
V~
19
0/
20
17
k 18
/
l-.
I (d/
A"Fl'.;;><:::
12 13
5--~
6 7
Optional at customer request
9 - - IY
' ''' ~5 ~~16

o
COC,
0Ai"'~
IlEl.U!: BEFORE OR BIiM

SYS1 E.\I Fo\I~URE CllfiftE M A'( ~ESULT. III'I'tY
B" ....~E LIVE R

TO AtLO.SE.-
Park Brake Lever Lock
WARNING
Release park brake lock before driving or brake system failure or fire may result. Apply brake lever to release.
Type 3 Master Cylinder Removal

1. Position clean shop cloths to catch spilled fl uid and remove brake hose.
CAUTION:
Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 2. 3. 4. Remove brake clamp attaching bolts (Item 17). Remove park brake lever (Item 9) and brake master cylinder lever (Item 6), noting position of bushing , spring, etc., for proper reassembly. Using the master cylinder service tool, position push rod through small hole in spring seat washer (Item 12) as shown. Remove piston assembly, spring and washer.
Master Cylinder Service Tool Kit
PN 2870962
9/96
9.6
BRAKES/FINAL DRIVE Type 3 Master Cylinder Inspection and Assembly

1996440 XCR SP Brake System Description Component Part Number Difference from Standard Brake System
Magura Master Cylinder Brake Line Caliper Assembly Caliper/ Piston Kit Brake Pads Disc
2050074 1930773 1930772 2200764 2200763 1910197
-5/B"compared to 3/4" -Requires less hand effort for the same braking -Uses a flare fitting instead of threaded fitting -.OBO" shorter castle piston for use with thicker pads and disc -For installing shorter piston into an existing caliper -.060" thick for longer wear -Very aggressive -.250" thick with vents compared to .179" thick without vents -Less runout (.OOB")
The Magura master cylinder must be used with the correct brake line. To upgrade to the Magura master cylinder, order the following : PN 2050074 Master Cylinder PN 1930773 Brake Line The heavier race pads, vented disc, and short piston kit must be used together as a package. To upgrade to the race padslvented disc, order the following: PN 2200763 Race Pads PN 1910197 Vented Disc PN 2200764 Shortened Piston
Inspection
NOTE: Due to the critical nature of these parts and procedures, be sure you have thoroughly read and understand Hydraulic Brake Operation, page 9.5.
(,
.(
1.
Thoroughly clean all brake parts with isopropyl alcohol. Inspect piston for wear, scratches, or corrosion. Check master cylinder bore for scratches, score marks, or corrosion and replace any worn or damaged parts.
)
Assembly
Always replace O-Ring seal, U-pack seal and cover gasket (diaphragm) upon reassembly. Use only genuine Polaris service parts. 2. Apply clean DOT 3 brake fluid on piston, piston seals and cylinder bore. Install seals onto piston positioning U-pack seal lip (A) towards spring. Snap spring into place on piston. 1.
3.
Install piston assembly into master cylinder service tool until U-pack seal is covered by tool as shown. NOTE: This tool is used to guide the seal lip into the cylinder bore without damage.
9.7
11 /95
BRAKES/FINAL DRIVE
Type 3 Master Cylinder Assembly Assembly, Cont.

Install spring seat washer into bore. Insert piston, still installed in tool, into bore. Push piston through special tool. Remove tool. 5. Reinstall brake lever with bushing, bolt and nut. 6. Reinstall master cylinder onto handlebar and reconnect brake line. Partially insert fittings (one to two threads) and apply Loctite T 242 to remaining threads of fittings. Torque brake line fittings to specification. 4.
.'}:1,;:!n . '. Brake Line FltthigTorque -
Master Cylinder End - Finger tight

plus 2 turns
Caliper End.
. .'~
12-14 ~ Ibs. (1.66 - 1.93 kg-m)

".~
'L
7.
Adjust master cylinder to a level position on handlebar. Torque clamp screws to specification.
8.
Bleed brake system. Maintain fluid level in reservoir at 114" - 5/16" (.6 - .8 cm) below lip of reservoir opening while bleeding brakes. Do not allow air into system while bleeding. See bleeding procedure on page 9.10.
Master CyJlnderFI!.\!dLevel
c ,.. ':'" ':'::
1f4"'. 5i'1S''''I.et;.,;a~cm)b;low
topofmilste~,9yllnder
{,.".g
q
_ _, ". ' ~ \:<+r<?::': :ll,
11/95
9.8
BRAKES/FINAL DRIVE Type 3 Master Cylinder Assembly

Assembly, Cont.
9. Field test machine before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2" (1.3 cm) from handlebar.
Brake Lever ReseI'V8 Limit Not leslI ~!i~n~!2)' (1:3 , m) c from handlebar .... >
" " " ''o!,
;;~
"',:,~ .. ,
?>l:,: .~ f.,.,' ,.
r:/&:
:V'~
.:~
1O. Check brake system for fluid leaks.
WARNING
Although snowmobile and ATV master cylinder pistons are very similar, they are not interchangeable. Piston (A) is an ATV piston . Piston (B) is a snowmobile piston. Notice the difference on the lever end of the piston. Using the wrong piston will cause a build up of pressure in the brake system and could result in a fire.
A
440 XCR SP Magura
9.9
111 95
BRAKES/FINAL DRIVE Brake Bleeding - Fluid Change

Brake Bleeding - Fluid Change
This procedure should be used to change fluid or bleed brakes during regular maintenance. If system has been disassembled for repair or parts replacement, follow Bleeding Procedure - System Rebuild, on page 9.11. Brake fluid may damage painted or plastic surfaces. Take care not to spill, and wipe up any spills immediately. Cover parts to avoid damage. 1. Clean reservoir cover thoroughly. 2. 3. 4. Remove screws, cover, and diaphragm from reservoir. Inspect vent slots (A) in cover and remove any debris or blockage. If changing fluid, remove fluid from reservoir with a Mity VacT" pump or similar tool.
~
A
NOTE: Do not remove brake lever when reservoir fluid level is low.
MJty Vae'" PN 2870975
5.
Add brake fluid to within 1/4-5/16" (.6-.8 cm) of reservoir top.
6.
Install a box end wrench on caliper bleeder screw fitting. Attach a clean , clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting.
NOTE: Fluid may be forced from compensation port (B) when brake lever is pumped. Place diaphragm (C) in reservoir to prevent spills. Do not install cover.
7. 8.
9.
Slowly pump lever (D) until pressure builds and holds. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. Do not release lever before bleeder screw is tight or air may be drawn into caliper. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir.
Maintain at least 1/2" (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder. 10. Tighten bleeder screw securely and remove bleeder hose. 11 . Add brake fluid to the proper level. 12. Install diaphragm, cover, and screws. Tighten screws to specification.
Reservoir Cover 'torque -
11/95
9.10
BRAKES/FINAL DRIVE Brake Bleeding - System Rebuild

Brake Bleeding Fluid Change, Cant.
13. Field test machine before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2" (1.3 cm) from handlebar.
No Closer Than 1/2" (1.3 em)
14. Check brake system for fluid leaks.
Brake Bleeding System Rebuild

When the brake system is disassembled for rebuild or component replacement, follow this procedure to ensure all air is quickly and completely purged from system. Maintain level of brake fluid in reservoir while performing bleeding procedure or air may enter system. 1. Add Polaris DOT 3 brake fluid to proper level.
2. Wrap a clean shop towel around master cylinder brake line fitting.
3. 4. 5.
"-
6.
Loosen brake line fitting and tighten lightly. Pump brake lever slowly 2-3 times. Loosen fitting and tighten. Repeat procedure as necessary to bleed master cylinder.
NOTE: If master cylinder will not pump fluid, use the following procedure:
A). Remove brake line. B). Place a finger firmly over end of master cylinder. C). Pump brake lever until pressure forces fluid out end of master cylinder. D). Reinstall brake line and torque to specification.
7.
Bleed caliper as outlined in Fluid Change on page 9.10. It may be necessary to bleed lower line connection at caliper to purge air from brake lines. When all air has been purged from line and caliper, tighten all con nections and add brake fluid to proper level.
8.
9.11
111 95
BRAKES/FINAL DRIVE Brake Bleeding - System Rebuild

Brake Bleeding - Fluid Change, Cont.
9. Install diaphragm, cover, and screws and torque to specification.
ReserllolrColler Torque
10. Field test machine before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2 " (1.3 cm) from handlebar.
'x .
Brake Lever Reserve Limit Not lees than 1[2" (1.3 em)
from handlebl!r~
~:N
11. Check brake system for fluid leaks.
11/95
9.12
BRAKES/FINAL DRIVE Type H4 Brake System

The Type H4 system is a hydraulic brake type. The caliper assembly is mounted on the chaincase, which allows ease of brake pad and caliper service. Measure brake pads from the back of the backing plate to the surface of the friction material as shown in illustration. NOTE: Replace pads when worn beyond service limit.
Brake Pad Thickness - Type H4 Service Limit .250" (El,35mm) Type H4 Friction Pad Replacement
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line Bleeder Screw Caliper Rope Guide WARNING
Minimum Pad Thickness .250" (6.35mm)
The rider's safety depends on correct installation. Follow procedures carefully.
~:\..--2
I
1.
CAUTION: '
8:---'\S..1.k
4
Protect eyes from brake fluid. Clean any dirt from mount bracket and bolts. Brake cleaner may be used to aid in cleaning of components. With a 9/16" socket, remove two 3/8 hex bolts and washers from bracket. Remove rope guide. NOTE: Do not disconnect brake line. Lift bracket and brake assembly off vehicle. Remove all dirt from caliper assembly using brake cleaner and clean shop cloths. Use a drop cloth to protect surfaces from brake fluid spillage. Remove reservoir cover from master cylinder assembly. Using a large hardwood dowel , or a C clamp vise grip on the center of the old pads, apply pressure toward the caliper piston. Compress piston back into caliper assembly. Apply pressure slowly to prevent excessive spillage from master cylinder assembly.
2. 3. 4.
NOTE: Pushing the piston back into the bore will cause the flu id level to rise in the reservoir and possibly overflow. Remove excess fluid and discard.
I .CAUTI;ON: I
Piston must not be forced back into the caliper at an angle or bore damage may occur. 5. Slide caliper and brake pads out of bracket. Discard old pads and clips. NOTE: Pad and holders must be replaced as a set.
9.13
9/96

Type H4 Friction Pad Replacement, Cont.
6. Place new pads with friction material facing each other into housing . Hold in place using clips. See illustration on page 9. 13. Clean brake mount on top of chaincase. Separate pads for installation over disc. If brake assembly does not slide easily overthe disc with loose pads, the piston is not compressed far enough into the caliper. Caliper assembly must fit freely onto disc and chain case. -----./
7. Slide brake assembly into bracket until both clips snap into grooves in bracket. 8. 9.
10. Replace 3/8 bolts, washers, and rope guide. Torque to specification.
11. Actuate brake several times to set brake pads to proper operating position. 12. Check for proper fluid level in master cylinder and replace cover Torque cover bolts to specification.
13. Field test at low speeds and verify proper brake action. If pads drag on disc, check caliper and pad assembly.
11/95
9.14

Type H4 Caliper Disassembly
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line Bleeder Screw Caliper Rope Guide
WARNING
Refer to the exploded view above while performing the following steps. 1. Remove bracket bolts. 2. 3. Disconnect brake line. Drain brake fluid into appropriate container and dispose of properly. Disassemble on a clean bench.
4. Open bleeder screw and drain brake fluid from caliper assembly into appropriate container. Dispose of properly.
Protect eyes from brake fluid at all times. 5. Slide brake assembly out of bracket and remove old pads and clips. 6. Place caliper on bench with piston down. 7. Remove piston from caliper using a caliper piston pliers (commercially available) or by covering the piston with a shop cloth and applying compressed air to the hydraulic in let port.
Use only enough air to remove piston . Too much pressure may damage piston or bore. 8. Using a small wooden or plastic stick, work piston seal out from its groove in the piston bore.
To avoid scratching bore or burring edge of seal groove, do not use a metal tool such as a screwdriver. 9. Discard old seal.
9.15
11/95

Type H4 Cleaning and Inspection
Check all parts for wear or damage and replace as required. Always replace caliper piston seal and dust seal (where applicable) . -----
1.
2. 3.
Clean all parts with denatured alcohol and wipe dry with a clean, lint free cloth. Using compressed air, blowout the drilled passages and piston bore. Be sure piston seal groove is thoroughly clean and free from corrosion or brake fluid build up. Inspect piston bore for scoring, pitting or corrosion. A corroded or deeply scored casting should be replaced. Light scores and stains may be removed by polishing with a crocus cloth only. Use finger pressure and rotate the crocus cloth in the cylinder bore. Do not slide the cloth in and out of the bore under pressure. Do not use any other kind of abrasive cloth. Check piston to see if it is pitted, scored or worn. If so, discard and replace the piston.
4.
CAUT1oN~' 1
Do not attempt to polish or sand piston. 5. Clean piston with denatured alcohol and wipe dry with a clean, lint free cloth. Using compressed air, blow dry. 6. Check inlet and bleeder hole threads for damage. Be sure bleeder screw is clear.
7.
Inspect brake line seat for damage and replace caliper if necessary.
Type H4 Assembly
1. Reassemble by reversing disassembly process. reassembling the unit. Be sure all parts are clean and serviceable before
2. Coat a new piston seal in clean DOT 3 brake fluid and place in groove in the caliper piston bore. Seal should be positioned at one point in groove and then gently worked around the groove by hand until properly seated.
Never reuse an old seal. 3. Coat piston thoroughly with brake fluid and work down into bore by hand carefully until bottomed.
Apply even pressure to avoid cocking the piston in the bore.
11/95
9.1 6

Type H4 Assembly, Cont.
4. Examine pads for wear or damage. If pad thickness is less than 1/32" (.08 cm) install new pad holder assemblies. If pads are not worn or damaged, they may be reused. Be sure pads are reinstalled in their original positions. If pads are replaced, replace in sets and make sure the new pads have the same friction material type code number as the old set. Connect hose or line to caliper. Place new pads with friction material facing each other into housing. Hold in place using clips.
5. 6.
7. Slide brake assembly into bracket until both clips snap into grooves in bracket. 8. 9.
'-.....-
Separate pads for installation over disc. Place brake assembly over disc and push bracket into chaincase.
10. Replace 3/8" bolts, rope guide, and washers. Torque to specification.
11. Perform brake bleeding procedure as outlined after System Rebuild, page 9.11.
9.17
11/95
BRAKES/FINAL DRIVE Type H5LC Brake System

The Type H5LC system, like the Type H4, is a top mounted hydraulic brake system. The difference between the two systems is the the H5LC is equipped with a brake cooler.
NOTE: Replace pads when worn beyond service limit.
Brake
P~d Thlcknei~. Type H5LC

.250 (6.35ilim)
Service Limit
Minimum Pad Thickness .250" (6.35mm)
Type H5LC Friction Pad Replacement
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line Bleeder Screw Caliper (Liquid Cooled) Rope Guide Water Cooler Manifold Screws (Cooler Manifold)
NOTE: 1996440 XC R SP - items 3&7 are unique to this model
WARNING
The rider 's safety depends on correct installation. Follow procedures carefully.
I
1. 2. 3. 4.
CAUTION:
Protect eyes from brake fluid. Clean any dirt from mount bracket and bolts. With a 9/16" socket, remove two 3/8 hex bolts and washers from bracket. Remove rope guide. NOTE: Do not disconnect brake line. Remove hose clamp from engine side of cooler. Twist and remove hose from cooler, catching and disposing of antifreeze properly. Use a drop cloth to protect surfaces from brake fluid spillage . Remove reservoir cover. Using a large hardwood dowel, or a C clamp vise grip on the center of the old pads, apply pressure toward the caliper piston. Compress piston back into caliper assembly. Apply pressure slowly to prevent excessive spillage from master cylinder assembly.
NOTE: Pushing the piston back into the bore will cause the flUid level to rise in the reservoir and possibly overflow. Remove excess fluid and discard.
5.
Lift bracket and brake assembly off vehicle. Raise open end of cooler and pad assembly to trap antifreeze in cooler and plug the opening of both cooler and engine hose open end.
9/96
9.18

Type H5LC Friction Pad Replacement, Cont.
'---6. 7. 8. Place new pads with friction material facing each other into housing. Hold in place using clips. See illustration above. Slide brake assembly into bracket until both clips snap into grooves in bracket. Clean top of chaincase where brake mounts.
9. Separate pads for installation over disc. If brake assembly does not slide easily over the disc with loose pads the piston is not compressed far enough into the caliper. The caliper assembly must fit freely onto the disc and chaincase. 10. Remove plugs. Install coolant hose and clamp on cooler assembly. 11. Replace 3/8" bolts, washers, and rope guide. Torque to specification.
12. Actuate brake several times to set brake pads to proper operating position. 13. Check for proper fluid level in master cylinder and replace cover. Torque to specification.
14. Be sure to bleed coolant system as outlined in Engine section. 15. Field test at low speeds before putting into regular service.
9.19
11/95

Type H5LC Caliper Disassembly
1. Carrier Bracket Attaching Bolts 13
2. Carrier Bracket 3 . Piston

4. 5. 6. Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line Bleeder Screw Caliper (Liquid Cooled) Rope Guide Water Cooler Manifold Screws (Cooler Manifold)
7. 8. 9. 10.
11 .
12
2
12.
13.
NOTE:
WARNING
440 XCR SP items 3&7 are unique to this model
Refer to the exploded view above while performing the following steps. 1. 2. 3. 4. 5. Remove bracket bolts. Disconnect brake line. Drain brake fluid into appropriate container and dispose of properly. Disconnect and plug coolant lines, catching and disposing of antifreeze properly. Disassemble on a clean bench. Open bleed screw. Drain brake fluid into appropriate container and dispose of properly.
I
6. 7. 8.
CA\JTION:! 1 1
Protect eyes from brake flu id. Slide brake assembly out of bracket and remove old pads and clips. Place caliper on bench with piston down . Remove piston from caliper using a caliper piston pliers (commercially available) or by covering the piston with a shop cloth and applying compressed air to the hydraulic in let port.
Use only enough air to remove piston. Too much pressure may damage piston or bore. 9. Using a small wooden or plastic stick, work piston seal out from its groove in the piston bore.
CAOTIOti;wJ
To avoid scratching bore or burring edge of seal groove, do not use a metal tool such as a screwdriver.
10. Discard old seal.

11/95
9.20

Type H5LC Cleaning and Inspection
Check all parts for wear or damage and replace any found to be defective. 1. Clean all parts with denatured alcohol and wipe dry with a clean , lint free cloth. 2. 3. Using compressed air, blowout the drilled passages and bores. Inspect casting cylinder bore for scoring, pitting or corrosion. A corroded or deeply scored casting should be replaced. Light scores and stains may be removed by polishing with a crocus cloth only. Use finger pressure and rotate the crocus cloth in the cylinder bore. Do not slide the cloth in and out of the bore under pressure. Do not use any other kind of abrasive cloth.
4. Check piston to see if it is pitted, scored or worn. If so , discard and replace the piston.
I
5. 6.
CAutION:
Do not attempt to polish or sand piston. Clean piston with denatured alcohol and wipe dry with a clean , lint free cloth. Using compressed air, blow dry. Check inlet and bleeder hole threads for damage.
7. Inspect seat insert for damage and replace if necessary.
Type H5LC Assembly

1. 2. Reassemble by reversing disassembly process. reassembling the unit. Be sure all parts are clean and serviceable before
Coat a new piston seal in clean DOT 3 brake fluid and place in groove in the caliper bore. Seal should be pOSitioned at one point in groove and then gently worked around the groove by hand until properly seated.
r
3.
OAUTION!
Never reuse an old seal. Coat piston thoroughly with brake fluid and work down into bore by hand carefully until bottomed .
I
4.
CAUTIO~:J
Examine pads for wear or damage. If pad thickness is less than 1/32" (.OB em) install new pads and spring clip assemblies. If pads are not worn or damaged, they may be reused. Be sure pads are reinstalled in their original positions. If pads are replaced, replace in sets and make sure the new pads have the same friction material type code number as the old set. Connect hose or line to caliper. Place new pads with friction material facing each other into housing. Hold in place using clips.
Apply even pressure to avoid cocking the piston in the bore.
5. 6.
7. Slide brake assembly into bracket until both clips snap into grooves in bracket. B. 9. Separate pads for installation over disc. Place brake assembly over disc and pusn bracket into chain case.
9.21
11195

Type H5LC Assembly. Cont.
10. Install coolant lines and hose clamps and tighten securely. 11. Replace 3/8" bolts, rope guide, and washers. Torque to specification.
CaIJper Bolt Torque ;~

<,)F ,~,~
25-30 ft.lbs.(3.4s4~1:~1ig:ri1)
~:
n*~Vh+'
:::it
'~>~M ,
'~"
12. Perform brake bleeding procedure as outlined after System Rebuild, page 9.11 .
11/95
9.22
BRAKES/FINAL DRIVE Type M3 Mechanical Brake System

The Type M3 system is the mechanical brake system used only on Indy Lite models. See Maintenance Section for adjustment procedure. 1. Brake Cable and Jam Nuts 2. Bracket, Brake 5 3. Washer 6 4. Washer, Spring Lock 5. Bolt, Top Mount 6. Bracket, Brake Top Mounting 7. Bushing 8. Nut, Bi-Lock 9. Spacer, Alignment 10. Caliper, Stationary, Cast 11 . Pad, Brake 12. Puck, Moveable Brake 13. Spring, Brake Return 14. Nut 15. Bushing, Brake Arm 16. Bolt. Cable Swivel C o B A 24 12 11 17. Clevis, LT 18. Bolt, Caliper 19. Retaining Ring 20. Brake Disc 21. Seal 22. Jackshaft 23. O-Ring 19 24. Adjuster Bolt 20 21 23
NOTE : Replace pads when worn beyond service limit.
.. .
Brake Pad Thickness - Type M3 Service Limit ,250" (6,35mm)

Minimum Pad Thickness .250" (6 .35mm)
Type M3 Brake Disassembly
. cAtmoN :
Whenever inspection reveals worn , damaged or defective parts, replacement is necessary in order to avoid serious damage to the machine or injury to the operator. 1. 2. 3. 4. Open adjuster bolt jam nut locking tab (A). Loosen jam (B) nut and remove adjuster bolt (Item 24). Mark location of actuating lever (C) and worm gear (D). Remove actuating lever (C) and re turn spri ng (13). Do not detach cable from lever arm. Remove top mount bracket and brake assembly mounting bolts (Item 5). Remove washers (Items 3 and 4) and alignment spacers (Item 9). Remove Drake assembly. NOTE: Be prepared to catch brake pads as assembly is lifted out. Remove brake pads and inspect for wear and damage. Replace if necessary.
5.
6. Inspect rotor disc and replace if worn, galled, or warped.

9.23
9/96

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Brake Cable and Jam Nuts Bracket, Brake Washer Washer, Spring Lock Bolt, Top Mount Bracket, Brake Top Mounting Bushing Nut, Bi-Lock Spacer, Alignment Caliper, Stationary, Cast Pad, Brake Puck, Moveable Brake Spring, Brake Return Nut Bushing, Brake Arm Bolt, Cable Swivel Clevis, LT Bolt, Caliper Retaining Ring Brake Disc Seal Jackshaft O-Ring Adjuster Bolt
~1
J
5 6
24
12
11
Type M3 Assembly to Chain case

1. Clip moveable brake pad into position under holder clip. Hold moveable and stationary pads in place with a rubber band while placing assembly over rotor disc and mounting to chalncase. Remove rubber bands once system is bolted into place. Install alignment spacers (Item 9), washers (Items 3 and 4) and bolts (Item 5). specification. Torque assembly to
2.
Caliper Mounting Torque ~

2$30 ft, Ibs. (3.454;14 .kg~ro)
";',:::;:n
,k;.
3. Loosen cable sleeve jam nuts (Item 1) and adjust brake cable sleeve to its shortest position.
11/95
9.24
Type M3 Brake Adjustment
WARNING
The following step is critical for proper positioning of the actuating arm to the caliper helix shaft. Improper pOSitioning will result in minimal resistance and ineffective brakes. 4. With brake lever bottomed on handlebar (as if brakes were applied) and helix shaft (D) bottomed in caliper, install actuating arm, jam nut locking tab, jam nut and adjuster bolt. Release brake arm slightly to index lever for installation on helix shaft. Insert a .015" (.04 cm) feeler gauge between brake disc and moveable brake pad. Release brake lever. Install return spring (Item 13) and finger tighten bolt (Item 24). Set adjuster bolt jam nut, bend locking tab and remove feeler gauge.
~,qAl',:~>
5.
FHctlon Pad Air Gap
: _' _~t }
.015" (.38 mm)
6.
Field test machine for proper braking action before putting into service. If braking action is soft, re-index helix shaft and repeat steps 3. - 6.
9.25
11 /95
BRAKES/FINA L DRIVE Type WT Mechanica l Brake System

The Type WT system is the mechanical brake system used only on Indy WideTrak models. 1. Brake Cable and Jam Nuts 2. Bracket, Brake Cable 3. Washer 4-----4> 4. Washer, Spring Lock 2 ( ! 5. Bolt, Top Mount 3 -- - -6. Bracket, Brake Top Mounting 7. Bushing 8 . Nut, Bi-Lock 9. Adjuster Bolt 10. Caliper, Stationary, Cast 11. Pad, Brake 12. Puck, Moveable Brake 13. Spring, Brake Return 14. Nut 15. Bushing, Brake Arm 16. Bolt, Cable Swivel 17. Clevis, LT 18. Bolt, Caliper 20 11 12 10 19. Brake Disc 21 . Seal 20. Caliper (Moveable Puck) 21. Transmission
5--1
NOTE: Replace pads when worn beyond service limit.

)
Brake Pad Thickness Type WT Service Limit .250" (6.35mm)
Minim um Pad Thickness .250" (6.35mm)
Type WT Brake Disassembly
I
1. 2. 3. 4. 5. 6. 7.
CAUTiON:
Whenever inspection reveals worn, damaged or defective parts, replacement is necessary in order to avoid serious damage to the machine or injury to the operator. Open adjuster bolt jam nut locking tab (A). Loosen jam nut (B) and remove adjuster bolt (9). Mark location of actuating lever (C) and worm gear (D). Remove actuating lever (C) and return spring. Do not disconnect lever arm from cable . Remove caliper bolts , spacers, bracket nuts (Items 18, 2, 7, & 8). Remove stationary caliper casting and stationary pad (Items 10 & 11). Remove top mounting bolts and washers (Items 3, 4, & 5). Pull outward on disc with the balance of the caliper assembly. Once disc is free of shaft separate components. Remove brake pads and inspect for wear and damage. Replace if necessary. If stationary pad (Item 11 ) is stuck to siationary casting, tap on the side of the pad with a punch and hammer to break it loose. Inspect rotor disc and replace if worn, galled or warped.
9/96
9.26
BRAKES/FINAL DRIVE Type WT Mechanical Brake System Type WT Assembly and Installation to Transmission
1. Clip moveable brake pad into position under holder clip. Hold moveable and stationary pads in place with a rubber band while placing assembly over rotor disc and mounting to transmission. Remove rubber bands once system is bolted into place. 2. Apply a light coating of RTV silicone to transmission shaft. Position moveable caliper pad assembly along with mounting bracket (Item 6) and brake disc onto transmission as a unit. Slide disc fully over shaft. Assemble bolts, spring washer, and flat washers to transmission and top mounting bracket (Items 3, 4, 5, & 6). Finger tighten. Assemble bolts, spacers, and cable bracket to top mounting bracket and moveable caliper pad assembly (Items 18, 7, 2, 6, & 20). Position stationary caliper pad assembly inside top mounting bracket pushing bolts through stationary assembly. Install spacers and lock nuts on bolts and torque to specification.
C~lIper Solt
,0.'
3.
4.
4,"i(,
<
Torqua
:'< ,}
13,'1
8:ft.Jbs. (1.10 kg-m)
Type WT Adjustment
1. Loosen cable sleeve jam nuts (Item 1) and adjust brake cable sleeve to its shortest position.
WARNING
The following step is critical for proper positioning of the actuating arm to the caliper helix shaft. Improper pOSitioning will result in minimal resistance and ineffective brakes. 2. With brake lever bottomed on handlebar (as if brakes were applied) and helix shaft (0) bottomed in caliper, install actuating arm, jam nut locking tab, jam nut and adjuster bolt. Release brake arm slightly to index lever for installation on helix shaft. Insert a .015" (.04 cm) feeler gauge between brake disc and moveable brake pad. Release brake lever. Install return spring (Item 13) and finger tighten bolt (Item 9). Set adjuster bolt jam nut, bend locking tab and remove feeler gauge.
3.
Friction Pad Air Gap ''''', ::"

'.01.~~ (.38 mill)
Mr
M.>,
4.
Field test machine for proper braking action before putting into service . If braking action is soft, re-index helix shaft and repeat steps 1. - 4.
9.27
11/95
BRAKES/FINAL DRIVE Type 3 Drive System

Type 3 Drive System Disassembly (Except WideTrakj
The Type 3 drive system is used on all models except the WideTrak. This system consists of a right side mounted chaincase wi th right side mounted brake assembly. 1. Mark hood hinges for ease of alignment when reassembling. Remove hood, air silencer, exhaust system and battery, if so equipped. Place drip pan under chaincase and remove drain plug from chaincase. Dispose of used chaincase oil properly.
2. Turn fuel valve off. 3. Remove drive belt and driven clutch . Note position of washers for controlling drive to driven offset (A) and washers to control clutch free floating (B) .
4.
Loosen jackshaft bearing lock set screws.
NOTE: Some models are equipped with set screw or Skwez-loc style jackshaft bearings; Some models are equipped with press-fit bearings which have no locking device.
Loosen screw. Remove collar from bearing Set Screw Style Bearing
. /
Press-Fit Bearing
Skwez-loc Bearing
5.
Remove two upper flangette attaching bolts.
9/97
9.28
BRAKES/FINAL DRIVE
Type 3 Drive System Type 3 Drive System Disassembly, Cant.
6. "-7. 8. 9. Remove three bolts, nuts, and washers securing angle drive (if so equipped) and bearing flangettes. Remove and discard adaptor key if equipped with angle drive. Remove four suspension mounting bolts. Place a protective mat on floor and tip machine onto left side. Remove rear suspension by pulling rear of track outward and sliding suspension forward . Lift out rear of suspension first.
"--
NOTE: On some models it may be necessary to unhook the rear torsion springs to relieve pressure on the torque arm for ease of removal.
1O. Position track as shown and remove third jackshaft flangette attaching bolt (A). Remove bearing . 11. Loosen drive shaft lock set screws and remove bearing. Use emery cloth if necessary to aid in removal of corrosion andlor burrs.
NOTE : Some models are equipped with set screw or Skwezloc style driveshaft bearings; Some models are equipped with pressfit bearings which have no locking device . On these models the bearing must be removed after the drive shaft has been rem oved from the unit. If replacing the bearing only, the drive shaft must be removed from the chaincase entirely to allow bearing puller access.
12. Remove chaincase cover attaching bolts and remove cover. 13. Remove cotter pin and nut. 14. Loosen chai n adjustment bolt and remove chain tensioner assembly. 15. Remove bottom sprocket attaching bolt, chain and sprockets.
16. Note position of top sprocket spacer (A) and sprocket alignment washers (B). Remove spacer and washers. These spacers are used to square the sprockets for true alignment, providing increased chain and sprocket life as well as increasing performance by eliminating drag.
NOTE : The top sprocket spacer (A) is not used with Hyvo top sprockets. Hyvo top sprockets have the spacer Width built in to the sprocket width.
9.29
9/97

Type 3 Drive System Disassembly. Cont.
17. Remove two bolts securing caliper carrier bracket to chaincase (A).
NOTE: Inspect brake pad condition and replace if worn to less than 1/2 the original thickness. See Brake Pad Replacement in this chapter.
18. Remove three chaincase to bulkhead attaching nu1s and bolts.

NOTE: On some machines it may be necessary to remove the rear exhaust bracket prior to lifting chaincase or removing drive shaft assembly. Watch for alignment shims between chaincase and bulkhead. Save for realignment of chaincase and jackshaft assembly to bulkhead during reassembly.
19. Remove chaincase.
20. Remove oil tank attaching bolt (A). On liquid cooled models, remove coolant recovery tank bolt (B). 21. Raise jackshaft assembly as shown. 22. Remove a-Ring, seal sleeve and brake disc by tapping on jackshaft end with a soft face hammer as shown. 23. Remove jackshaft and drive shaft.
NOTE: On models with pressed bearing on jackshaft, shaft will have to be brought through bulkhead slot in order to remove from unit.
11/95
9.30

Type 3 Drive System Disassembly, Cont.
'-...24. For set screw and Skwez-Ioc bearings, inspect drive shaft and jackshaft in bearing contact area. If diameter is .001" (.025 mm) less than non-contact area, shafts should be replaced.
'-
25. After drive shaft has been removed, inspect condition of drive sprockets and replace if required.
NOTE: On models with pressed bearings on jackshaft and drive shaft, if bearings are loose internally or rough they should be replaced. If bearings are loose on the shaft the shaft must be replaced .
26. Remove bearing retaining snap rings. 27. Pry out old seal from back side of chaincase.
28. Press out old bearing from side shown. If bearing appears tight, use heat to expand chaincase bore. Always press bearing toward snap ring side of chaincase when removing. Inspect chaincase for any damage and replace if required.
9.31
11/95
BRAKES/FINAL DRIVE Type 3 Drive System Type 3 Drive System Assembly (Except WideTrak)
1. Apply Loctite 680 to outer race of bearing and press into position.
LoctlteT~, 680
PN~~~,~
2. 3. Reinstall snap rings.
, '[',w
Press new seals in until outer edge is flush with chaincase shoulder. New seals must be installed from outside of case with lip side in. Install drive shaft and jackshaft as shown with new seal sleeves (A) and a-Rings.
4.
NOTE: Recessed area on seal sleeve is positioned outward and a-Ring rests in this recess.
5. Grease seal sleeves and a-Rings.
6.
Install chaincase.
NOTE: On some models, prior to installing the drive shaft it will be necessary to install the chaincase to bulkhead attaching bolts.
7. Install jackshaft alignment tool (8) and secure with castle nut and flat washer. Tighten jackshaft nut securely to ensure positive bearing and jackshaft seating to chaincase. NOTE: The photo shown has a handle added to the retainer nut.
Jackshaft A!!~nment Tool PN 2870399 13 Tooth Jackshafts PN 287153515 Tooth Jackshafts
"'iii,
11/95
9.32

Type 3 Drive System Assembly, Cont.
8. Slide a bearing onto driven clutch end and check shaft alignment to bulkhead opening (A). Models with pressed jackshaft bearings will require the chaincase to be shimmed since the bearings cann ot be moved for alignment. Equal spacing around the bearing is critical.
NOTE: This step is critical to the prevention of bearing preload, which can cause premature bearing and/or jackshaft failure.
9.
If alignment is not correct, shims may be added between any of the chaincase to bulkhead attaching points. Tighten chaincase securely to ensure proper alignment.
NOTE: Use of a standard nut and flat washer forthis alignment process will simplify the process as well as preserve the locking features of the lock nut for reassembly.
. Sl1im . it PN 2200126 K
10. Once corre ct jackshaft alignment has been achieved, install lock nuts on chaincase retention bolts and torque to specification. Remove alignment tool from chaincase.
Cilain case F.'Ietentlon !lolt TorqJe . 28-30 ft. Ibs. (3.86 - 4.14 kg-I11tJ
11. Install track and drive shaft into unit. Pull jacks haft into chaincase and seat in bearing. Install track in proper direction of travel.
9.33
9/96

Type 3 Drive System Assembly. Cont.
12. Install alignment washers and sprocket spacer on drive shaft and jackshaft. Install top and bottom sprockets and secure. Using a straight, flat piece of 1/4" (6mm) bar stock 9" (22.86 cm) long check sprocket alignment. Add or subtract washers to bottom sprocket to achieve alignment.
13. Once alignment has been achieved, install sprockets with chain. Finger tighten nut and turn in bottom sprocket bolt until snug.
NOTE: The bearings on the opposite end must be in place before torquing.
14. Install chain tensioner. Finger tighten adjustment bolt. 15. Install brake caliper assembly in chaincase.
On models with hydraulic brakes, make sure caliper piston is fully retracted into caliper to prevent brake binding from preload of pads. On models equipped with mechanical brakes make sure cam is fully retracted. 16. Torque caliper mounting bolts to specification.
<
,.
>
CalIper
28
11/95
9.34
BRAKES/FINAL DRIVE
Type 3 Drive System

12. Install jackshaft bearing, flangettes, and gasket. Align grease hole (A) in bearing with hole or fitting in flangette (B) to with in .100" to ensure greasability. Torque nuts to specification. Do not lock set screws on retainer ring (if so equipped). NOTE: Ultra, Storm, and 600 XCR SP models do not have set screws. RXL models have a Skwez-loc'M type retaining ring.
Flangette Nut Torque -
15 - 17 fl. Ibs, (2.Q7 - 2.35 kg-m) 13. Install drive shaft bearing, flangettes, a new
speedometer drive key. flangette gasket, and angle drive (if so equipped) to shaft and bulkhead. Torque retaining nuts to specification. Do not lock set screws on retaining ring (if so equipped).
Flangette Nut Torque -
15 - 17 ft. Ibs. (2.01- 2.35 kg-m)

NOTE : On Ultra, Storm, and 600 XCR models with pressed bearings, place inner flangettes with welded bolts inside tunnel, install gasket flangette and angle drive with new adaptor key into assembly. Install Flex Loc' " nuts and torque to specification. Flangette with studs must be assembled on driveshaft prior to pressing bearing on shaft and assembly of driveshaft into unit.
Skwez-locT" Bearing
Flex LocT" Nut Torque -
1517 ft. fbs. (2.07'- 2.35 kg-m)
14. When reinstalling drive shaft flangettes and speedometer angle drive, always replace drive key (A) and install a new gasket (B).
Align holes
9.35
91 96

20. Check cable routing and lubricate with Polaris cable lube.
21. Grease angle drive and bearing with Polaris grease.
22. Torque bottom chalncase sprocket bolt to specification.
23. Torque jackshaft nut to specification. On models with castle nut, if cotter pin does not align, tighten nut until it does. It may be necessary to apply brake to hold jackshaft while torquing.
@ @
24. To obtain correct chain tension, place a slight reverse tension on the chain as indicated in the Illustration at right (A). 25. There should be approximately 1/4-3/8" (.6-.95 cm) total deflection on the chain at point (8). Loosen adjuster bolt locknut and turn adjuster bolt (C) until correct chain deflection is obtained.
11/95
9.36

'---15. Lock adjuster bolt locknut (A) while holding a wrench on the adjuster bolt (B). 16. The illustration at right shows a cross section view of the upper chaincase . Always replace seals and O-Rings. Check seal sleeve for wear and/or nicks. Replace if any are noticed. 17. With unit on its right side. add 9 oz. (11 oz. on models equipped with reverse) of Polaris chaincase oil to the chaincase .
Polaris Synthetic Gearcase Lube PN 2871477 (Gallon) PN 2871478 (12 ounces)
18. Install chain case cover gasket in chaincase with

gap althe top. Install chaincase cover and torque cover bolts to specification.
Chalncase Cover Boll
Torqu ~.-
8 - 10 ft. Ibs. {t.10 - 1.38 kg-ml
19. Torque bearing drives haft and jackshaft set screws to specification (if so equipped).
Drlveshaft and Jackshaft Bearing Set Screw Torque -
80 In. Ibs. (.92 kg-m)
'--"
20. Lubricate bearing with Polaris Premi um All Season grease.
Polaris Premium All Season Grease PN 2871423
9.37
9/96

32. Reinstall clutch offset washers on jackshaft and install driven clutch. Using the clutch alignment tool adjust driven clutch to achieve proper offset.
33. With proper offset achieved, the driven clutch must float on the jackshaft. This is done by adding or subtracting spacer washers (PN 7555734) to the clutch retaining bolt. When properly adjusted, the driven clutch will have .020 - .100" (.5 - 2.5 mm) float.
Incorrect float can cause jackshaft bearings to be side loaded , resulting in premature bearing failure. 34. Torque driven clutch retaining bolt to specification.
35. If only the jackshaft needs service, loosen left rear nosepan to foot rest mounting bolts and slide shaft out left side without removing chaincase. 36. For reassembly, use jacks haft installation tool (A) . Grease tool and guide jackshaft through brake disc hub, seal sleeve, O-Ring and bearing.
NOTE: Jackshaft with tool installed must slide freely. If not, remove brake caliper and disc to access O-ring and reposition O-ring.
11/95
9.38

37. Reinstall suspension and torque to specification.
3/8" SuspensIon Bolt Torque 35-40 ft Ibs {4.83-5.52 kg-m)

<
7/16" Suspension S:o.ltTorque
,p)r. ..
45-50 ft Ibs. (8.21-6.9 kg-m) " "

@'
38. Reinstall air box, adjusting box properly. Route throttle cable through hold down clamp as shown . 39. Reinstall battery (if so equipped) . Always attach ground cable last to prevent sparks. 40. Replace exhaust system sealing ball and socket with high temp RV silicone. 41 . Install hood, aligning with marks made during disassembly. Ensure proper hood closure and readjust if necessary See Hood Alignment, Chapter 7. Torque bolts to specification.
42 . Align track. Chapter 8.
See Track Alignment Procedure,
43. Test ride the unit to ensure all components are functioning properly before putting into service.
9.39
11/95
BRAKES/FINAL DRIVE Transmission, Suspension and Track Removal - WideTrak Models

1. Mark hood hinges for ease of alignment when reassembling unit. Remove hood assembly and set aside to prevent damage. Remove battery (if so equipped). Turn off fuel valve. Move oil tank for access. Remove air intake and coolant recovery bottle from its mounting (WideTrak LX models only - do not remove entirely). Remove drive belt. Remove driven clutch retaining bolt assembly and drive clutch. Note number of spacers which are behind driven clutch for installation during reassembly procedures.
2. 3. 4.
5. 6.
7. Remove muffler springs and muffler from unit. 8. Loosen brake cable jam nut (A) and remove cable bolt, nut and spacer (8). Use care not to loose spacer. Remove cable from transmission.
9.
10. Note location of shift linkage on transmission (A) to assure proper location during reassembly. Remove cotter pin, washers, and pin from transmission arm. 11. Remove brake light wire connector from sensor.
11 /95
9.40
BRAKES/FINAL DRIVE Transmission, Suspension and Track Removal - WideTrak Models

12. Loosen rear idler wheels and bolts. 13. Loosen jam nuts on adjustment bolts on both sides. Back out adjustment bolts to allow rear idler assembly to come forward , relieving track tension. 14. Tighten idler wheel bolts so that spacers on shafts do not rotate and lose alignment.
15. Remove front and rear carrier shaft bolts (A), and front and rear suspension bolts from both sides (B). 16. Place a protective mat on the floor. Tip unit onto right side and remove suspension.
17. Using "T" hand le Allen wrench , loosen set screws on lock collar. 18. Remove (2) bolts, nuts, and flangettes supporting jackshaft bearing. Loosen and slide back lock ring from transmission end of jackshaft. 19. Remove jackshaft by pulling towards driven clutch side and lifting upward through bulkhead . It may be necessary to lightly tap on bearing collar to free coupler of jackshaft from transmission end . 20. Inspect bearing. If loose on the shaft the shaft must be replaced . If bearing is rough when turned, the bearing must be replaced . The bearing is pressed onto the shaft and will require a puller for removal.
9.41
11 /95
BRAKES/FINAL DRIVE Transmission, Suspension and Track Removal - WideTrak Models - 1996
1. Loosen and remove three carriage bolts and nuts retaining angle drive housing and flangettes. Remove angle drive housing , adaptor key, fiangettes, gasket, and bearing from drive shaft and tunnel.
2.
NOTE: It is not necessary to remove speedometer cable from angle drive . Replace adaptor key any time drive train assembly is serviced.
3. Tip machine back onto floo r.
4. 5. 6.
Remove right side bumper plug (A) . Remove bolt retaining rear of bumper to foot rest. Bend muffler mount out of the way to allow transmission removal. Remove three transmission retaining bolts. Note all alignment shim quantities and locations fo r reassembly.
7.
NOTE : Retaining bolts have to be held in place from underside while removing nuts. The lower front bolt cannot be removed at this time. It must be lowered to the drive sprocket.
8. Lift and maneuver transm ission to free drive shaft coupler. Lower drive shaft and remove lower front bolt.
9.
10. Maneuver transmission until it can be removed from the unit. Use care not to damage coolant lines on LX models. 11. With transmission removed, tip unit onto right side. Notice direction of track rotation fo r reassembly. The arrow in the photo at right indicates track bottom, rear of unit. 12. Remove front and rear carrier shafts .. 13. Remove suspension by pulling rear of track out of tunnel. Slide suspension forward to driveshaft. Lift up and out at the rear.
NOTE: On some models it may be necessary to unhook rear torque arm spnngs to allow torque arm to lower.
14. Inspecl transmission. brakes. suspension and track for excessive wear. Cneck bearings for excessive movement or rough feeling. Replace if necessary.
9/96
9.42
Polaris {ndus(rtes Inc.
BRAKES/FINAL DRIVE Transmission, Suspension and Track Assembly - WideTrak Models - 1996 Assembly
1. 2. Tip unit onto right side. Insert track in unit , making sure direction of rotation is correct. Place drive shaft in unit, aligning drive sprockets and track drive lugs. Install lock collar, flangette , bearing , gasket, and flangette on drive shaft, positioning bearing flush with end of drive shaft. Lightly tighten set screws to hold bearing in place. Align flangette holes with tunnel. Replace adaptor key in drive shaft. Install angle drive housing aligning adaptor key with angle drive. Install nuts and finger tighten. Tip machine onto its left side.
3.
4.
5. 6. 7.
8. 9.
10. Replace O-rings on input and output shafts. Apply Polaris All Purpose Grease to drive shaft coupler splines.
Polaris All Purpose G.rease
PN 2871423
11 . Reinstall transmission, using care not to damage coolant hoses on LX models. Be sure transmission shift linkage is properly located. 12. Install lower front mounting bolt (3) before coupling to shaft. Once boll is started into transmission housing, align coupling with drive shaft and jack shaft splines. Keep transmission flat and lower gradually to prevent binding of couplers. t 3. Install remaining transmission mounting bolts. Reinstall shim washers in original positions and tig hten bolts securely. NOTE: Use of a standard nut and flat washer for this alignment process will simplify the process as well as preserve the locking featu res of the lock nut for reassembly. 14 Tip machine onto its right side.
Polans Industries Inc.
9.43
9/96
BRAKES/FINAL DRIVE Transmission, Suspension and Track Assembly - WideTrak Models - 1996 Assemb ly, Cont.
15. Loosen set screws and seat drive shaft in transmission coupler stub shaft. For ease of assembly, make sure track has no pressure against drive shaft.
16. Tighten nuts retaining angle drive housing to tunnel.

Torque to specification.
17. Using "T" handle Allen wrench, torque set screws to

specification.
Set Screw Torque 80 in. lbs. (.92 kgm)
18. Reinstall suspension inside track and align wi th tunne l mounting holes.
19. Install and hand tighten suspension bolts (8).
20. Install front carrier shaft assembly inside track and

mount to tunnel with bolts. Hand tighten bolts.
21. Install rear carrier shaft assembly. Make sure bolts

are not cross threaded and hand tighten (A).
22. Tip machine back onto floor and tighten all suspension
bolts to specification.
Suspensio~
B,olt Torque '
35-40 It. 11;)$ (4,~3~5.?2 kg-m)

' /. :.'~':
91 96
9.44
BRAKES/FINAL DRIVE Transmission, Suspension and Track Assembly - WideTrak Models - 1996
Assembly, Cont. 23 . If jackshaft was removed from unit, grease coupler spline with Polaris Premium All Seaso n Grease and install on transmission.
n
Polaris PremIum All Se<.l.s'?!1.(lrease
:%L
'jMit~i:;,
PN 2871423
':Y~~ili;~
24. Check for bearing to bulkhead alignment and shim transmissi on as required to center jackshaft in bulkhead mount. Shims may be req uired between transmission and bulkhead. Seat jacks haft firmly.
25. Once properly aligned, install flangettes. Align grease holes in bearing and flangette.
26. Replace nuts holding transmission in place with

proper lock nuts and torque to specificatio n.
Transmissl orr .Retainlng
28-30 it.
Ibs. (3.86-4.14 kg-m)
27. Install bolts and nuts securing flangettes to bul khead. Torq ue to specification .
Bearing FllInl1~tte NutTorq'ue 15-1711.
IbS:!(~:07-2.35 k~1ln)
28. Set lock ri ng at transmissio n co upler and torque to specification.

---' II-' ~
~y
Lock Ring Tdn:/u6 T ,

80 In. Ibs. (.92 kg;ro)
T
A
9.45
-- -
--
o
9/96
BRAKES/FI NAL DRIVE Transmission , Suspension and Track Assembly - WideTrak Models - 1996 Assemb ly, Cont.
29. Reattach transmission shift linkage and brake light connector. Check transmission fluid level and fi ll if necessary.
30. Attach brake cable to transmission mou nting with bolt, nut and spacer. 3 1. Install bumper onto footrest bolt and tighten. 32. Reinstall bumper plug. 33. Reinstall and secure muffler. 34. Install battery (if so equipped) , ai r box , oi l tank, and coolant recovery bottle (if so equipped) . 35. Loosen rear idler bolts. 36. Reinstal l driven clutch and spacers onto jackshaft and tighten. 37. Reinstall clutch offset washers on jackshaft and install driven clutch. Using the clutch alignment tool adjust driven clu tch to achieve proper offset.
cluich ~lignment ! <i()I.

P8S - PN 2870426
'~~ .J:F,q?
PB5 Offset 5/8"
38. WideTrak models have no float on driven clutches. Use shim washers (PN 7555734) to create gap between shaft and cover washer only
9/96
9.46
BRAKES/FINAL DRIVE Transmission, Suspension and Track Assembly - WideTrak Models - 1996
39. Torque driven clutch retaining bolt to specification.
W Drlven Clutch Retainin g Bolt Torque 12 ft.lbs. (1 .66 kg-m)
40. Lift and support rear of unit and align track to specifications found in the Maintenance section on page 2.12. Make sure rear idler wheel spacer location is correct before tightening idler wheels. 41 . Reinstall hood.
9.47
9/96
BRAKES/FINAL DRIVE Transmission Disassembly 1997 to Current WideTrak Disassembly/I nspection

1. Drain transmission oil into suitable contai ner.
2.
Remove snap ring , spacer washer, and brake disc.
NOTE : Note position of spacer washers behind disc for proper alignment upon reassembly.
3.
Remove detent spring and ball.
4.
Remove case bolts evenly in a criss-cross pattern.
9/96
g.47a
BRAKES/FINA L DRIVE Transmission Disassembly 1997 to Current WideTrak

5. Tap cases apart with soft faced hammer in the reinforced areas indicated in photo at right. Tap end of brake shaft to be sure It remains in case.
6.
Hold chain tensioner ratchet pawl off ratchet teeth and push tensioner plunger all the way in. Insert a 1/8" diameter rod as shown to hold tensioner in released position. Remove tensioner assembly. Inspect for cracks, chipped, broken, or rounded teeth. Remove shift arm
7.
8.
Remove shaft and gear assembly from case by tapping with a soft faced hammer evenly on end of shafts.
9.
Remove output gear assembly and chain. Mark chain direction for reference during reassembly. Inspect gear teeth for damage. Inspect chain for worn , cracked , or broken link plates.
9.47b
9/96
BRAKES/FINAL DRIVE Transmission Disassembly 1997 to Current WideTrak

10. Remove shift fork shaft from gear cluster. Inspect surface of fork for wear or bendin g.
11. Remove chain from input and reverse shaft. Inspect gear teeth for damage. Inspect chain for worn, cracked, or broken link plates.
_ _-forks
Inspect shift
12. Inspect dog gears and slots in mating gears closely. Rounded edges will cause gears to disengage under load. Replace both dog gear and mating gear if edge of dog and/or slot is rounded. Inspect gears for chipped, cracked , or broken teeth.
9196
g.47e
Polaris industries Inc.

Gear, shaft, and chain cluster assembly shown.
Low gear output power flow...
":;' :
High gear output power flow ...
Reverse output power flow.. .
.Polaris Industries Inc.
9.47d
9196

Low / Reverse Shaft Disassembly
13. Press bearing from end of shaft using a bearing separator.
14. Remove snap ring and spacer washer.
9/96
gA7e

15. Remove low reverse shaft low gear...
LowlReverse dog gear

needle bearing, thrust washer, low/reverse dog gear...
washer
bearing
gear
snap ring, thrust washer (.050"), reverse idler, needle bearing, and thrust washer (.065").
16. Closely inspect drive dogs. Replace gear and mating gear if rounded, chipped or broken . 17. Inspect needle bearings for wear or cracks on cage. Shiny spots on cage indicate wear and the bearing should be replaced. Inspect shaft and thrust washers for galling or wear. Always replace snap rings if removed.
9.471
9/96

Shift Fork Disassembly
1.
Remove the detent cam, spring and shaft. 2. Check condition of key way and key. Inspect indicator, spring legs and detent areas fo r wear. Replace parts as required. NOTE: The spring must be pre-loaded upon installation. Refer to photo and illustration below. Locate spring in retainer slot as shown
Key,--,__'JI.
way Detent area
Hook spring here
Arm of detent plate must be positioned between ends of spring. Install key.
Transmission Assembly
Lubricate all parts before assembly with Premium Synthetic Chaincase Lubricant. 1. Install chain on input and reverse shaft. Photo 1. 2. Add output gear assembly with chain. Photo 2.
Photo 1
Photo 2
3. 4. 5.
6. 7.
8.
Add shiH fork assembly. Install entire assembly in case half. Lock tensioner plunger in retracted position before installation by installing a 1/8" dowel as shown in photo at right (where applicable). If washers were removed upon disassembly, re-install them between tensioner and case. Torque bolts to 10 ft.lbs. (1.38 kg-m) . Apply 3 Bond T" 1215 Sealant to case halves. Install outer case half and replace brake cable bracket. Torque bolts in three steps to 8-10 ft. Ibs. (1.10-1.38 kg -m) using a criss-cross pattern. Remove dowel from tensioner and instali access plug (where applicable). Install transmission. Add 20 oz. Premium Synthetic Chaincase Lubricant. Transmission Case Bolt Torque-
8-10 ft.lbs. (1.10-1.38 kg-m)

9/97
9.479
BRAKES/FINA L DRIVE Transmission Assembly 1997 to Current WideTrak

8.
~
Install seals, shift arm, brake disc and caliper. Install detent ball. spring, and spring guide. Fill with 20 ounces (600cc) Polaris Premium Synthetic Transmission Oil.
Synthetic Chalncase Lubricant Gallon PN2871477 12 oz. PN2871478
Brake Caliper Removal Type WT2

1. Remove brake cable. 2. Remove retaining bolts, making note of location of hex head bolt (with flat washer) and recessed Allen bolt.
NOTE: Before performing next step, note pOSition of two spring clips. 3. Remove upper guide bushing and pads. Remove lower guide bushing. Inspect pads and replace if worn beyond service limit. Brake Pad Thickness Typ.~ WT2 Minimum Pad Thickness .250" (6 .35mm)
Servic!l Limit .250" (6.35mm)
4. 5. 6.
With actuating arm facing up, carefully remove tension from the return spring. Remove the arm using care not to lose the balls, ball spacer, or lifter ramp. Inspect balls , ball spacer, lifter ramp and caliper housing for galling or wear. Replace if necessary.
9.47h
9/96
BRAKES/FINAL DRIVE Transmission Assembly 1997 to Current WideTrak

Assemb ly
1. 2. Apply a light film of grease to balls and bal l spacer. Install in caliper housing. Install lifter ramp. NOTE: Ramp may be installed in any position .
3. 4.
5.
Install spring and arm with arm located in 8:00 position as shown in photo at right. Install lower guide bushing and both spring clips. Place pads against lower bushing spring clip and tip into position . Install upper guide bushing.
Installation
6. Install hex head bolt wi th washer in top guide bushing . Install Allen head bolt in recessed bushing as shown. Reinstall brake actuating cable and adjust as outlined on page 2.2Sa of the Maintenance Section. Tighten cable lock nuts securely. Bracket Lock Nuts
7.
Move cable up or down in bracket to adjust freeplay
9/96
9.47i
BRAKES/FINAL DRIVE Track Removal - Two Sprocket Drive Shaft

1. 2. 3. Remove rear suspension bolts. Remove front suspension bolts. Place a protective mat on the floor and tip the machine on its side.
4. Using an Allen wrench, loosen set screw on lock collar on left side drive shaft bearing.
5.
Tap lock collar with a hammer and punch to loosen it. Rotate lock collar against the normal direction of rotation to loosen, with normal direction of rotation to tighten.
_.
11/95
9.48
BRAKES/FINAL DRIVE Track Removal - Two Sprocket Drive Shaft
\......-
Track Removal - Two Sprocket Drive Shaft

1. 2. 3. Remove three cap screws holding fiangette and bearing in place on left side of machine. Remove bearing and lock collar from drive shaft. Remove chaincase cover. Loosen chain adjuster bolt lock nut and back off adjuster bolt until chain has maximum slack. Remove drive shaft by pulling shaft first from chaincase and then from left side of machine.
4.
5. Remove bottom sprocket in chaincase.

6.
7. Reverse process for reassembly. Be su re to install and torque lower chaincase sprocket before locking lock collar.
NOTE: Cotter pin must be positioned so it will not hit the chaincase cover. Lower Chain case Sprocket Torque50 ft . Ibs (6.9 kg-m)
9.49
9/97
BRAKES/FINAL DRIVE Track Removal - Four Sprocket Drive Shaft

1. Follow steps 1-7 of Two Sprocket Drive Shaft Removal pages 9.48-9.49.
2. Remove handlebar cover. Remove cable tie on steering post securing throttle cable and brake hose. Remove two phill ips screws securing air intake silencer. Taking care not to damage throttle cable, lift silencer out.
3. Remove secondary clutch and loosen jackshaft lock collar set screw. Using a hammer and pu nch, unlock the lock collar. Remove three cap sc rews holding jackshaft left hand bearing and flangettes in place . Remove bearing from jacks haft.
4. Remove chaincase cover, loosen chain adjuster and remove lower sprocket and drive chain. Use care not to damage gasket. Inspect for cracks or damage. Replace gasket if necessary.
5.
Remove three mounting bolts (A, B, C) securing chaincase to chassis. Carefu lly tip machine on its left side onto a mat. Lift chaincase up until drive shaft is out of lower chaincase bearin g. Lift drive shaft up until it clears tunnel on LH side (bottom) and can be pulled out of tunnel. Remove drive shaft and track.
CAUTION:
Whenever inspection reveals worn , damaged or defective parts, replace ment is necessary in orde r to avoid serious damage to the machine or injury to the ope rator. 6. After inspecting all parts, reve rse process fo r reassembly. The lower forwa rd chaincase mount bolt (C) must be in place before installing drive shaft. Drive sprocket interfe rence will not permit installation after drive shaft is installed. The lower chaincase sprocket must be installed and torqued before locking lock collar.
9/97
9 .50
BRAKES/FINAL DRIVE Series 300 Transmission Overhaul

Transmission overhaul should also include drive system overhaul. After removing drive shaft and jacks haft. proceed as indicated below. '1. Remove four caliper carrier attaching bolts (A).
2. Remove two caliper bridge bolts (6). 3. Remove brake caliper and brake disc.
4. 5.
Remove shift linkage (A) and stop light switch wires (6) . Remove exhaust system.
6. Remove three nuts securing transmission to front bulkhead. Remove transmission . NOTE: Note position of transmission shims for reassembly (A) . these shims control jackshaft alignment.
7. Remove transmission drain plug (A) and drain oil.
9.51
11 /95

8. Place transmission as shown and remove shift lever and key (A), neutral light switch (8) , detent set screw, spring, and ball (C). 9. Loosen chain tensioner jam nut and remove tensioner bolt.
10. Remove transmission housing attaching bolts (A).
11. Lift upwards on inner housing and tap with a soft face hammer on input shaft, output shaft, and shift shaft.
12. Remove high range long silent chain (A).
11/95
9 .52
PolarIs Industries Inc.
BRAKES/FINAL DRIVE
Series 300 Transmission Overhaul

13. Remove input cluster and shift cluster as an assembly (A) .
14. Remove output cluster (A). reverse cluster (B) and silent chain as an assembly.
15. Remove low range cluster (A). 16. Thoroughly clean and inspect all parts. Remove old oil seals and replace during reassembly. 17. Assemble transmission in reverse order of disassembly.
18. Be sure the case half mating surfaces are clean and free of any nicks or scratches. Place a small amount of Loctite 515 Gasket Eliminator on one of the case halves.
Loctite'" 515 Gasket ElimInator
" PN2870587 '+.
:,fS,.,
9.53
11/95

6. Assemble case halves using a rubber or plastic mallet to tap halves together. Install cover bolts and torque to specification.
Transmission Case Attaching Bolt Torque&-10 It. Ibs. (1 .10-1.38 kg-m)
7.
Install chain transmission.
adjuster
bolt
and
jam
nut in
8. Turn brake disc in the opposite direction of normal

rotation (counterclockwise) to place a slight reverse tension on chain. Tighten adjuster bolt (B) to specification. Back bolt off 1 1/4 to 1 1/2 turn s. Tighten jam nut while holding adjuster bolt.
9.
Replace detent ball, spring, and set screw in transmission. Apply a small amount of Loctite Primer "T" to threads of case. Apply Loctite 242 Blue to threads of transmission. turn screw in to a depth of .060-.120" (1.5-3 mm) below the casting surface.
NOTE: If the detent is adjusted too tightly the unit will become hard to shift. If the detent is too loose, it will affect the operator's perception of the shift pattern .
.060-.120 (1.5-3 mm)
9/96
9.54

23. Install oil seals. Apply tape to shafts, covering shoulder and splines of shaft to prevent seal damage.
24. Grease inner and outer surfaces of seal as well as shift shaft O-ring. Slide seals over shaft to transmission using bearing installation tool. Tap seals into place.
NOTE: Seal will bottom when properly installed.
'--
25. Install shift lever and cotter key. 26. With transmission installed on unit, fill transmission to correct level. Use only Polaris chaincase oil.
Locknut
Fill Plug
Oil Level Drain Plug
9.55
111 95
BRAKES/FINAL DRIVE Reverse Kit Service Tips

The following illustration indicates sprocket position with the Polaris Reverse Kit in the forward and reverse selection .
Installation Tips (Refer to Illustration on page 9.57)

When installing pinion shaft, be sure the chamfered end of pinion shaft is toward case cover. Install chain, top sprocket, bottom option sprocket and wide face pinion gear into case at the same time. When installing case cover, be sure that shift fork has slipped into fork groove of reverse gear.
Forward Position Top Sprocket - -
i-
Reverse Position
_I
./
~ Top Sprocket
~-Chain Pinion Gear (Wide Face) -----
m
- -
Drive Chain
--~
Chain Pinion Gear
I-f-r-t-l_ (Narrow Face)
Chain Pinion Gear -- (Narrow Face) Chain Pinion Gear (Wide Face)
F=f-'--l=I
Spur Pinion Gear ........... Spur Pinion Gear Shift Fork Groove Reverse Kit Option Sprocket Reverse Kit Option Sprocket Drive Coupler
11/95
9.56

15 tooth jackshaft spacer washer PN 7555917 / 13 tooth jackshaft spacer washer PN 7555876 13 wide top sprocket with 15 tooth jacks haft requires (1) PN 7571620 11 wide top sprocket with 15 tooth jackshaft requires (1) PN 7555864 and (1) PN 7571620 11 wide top sprocket with 13 tooth jackshaft requires (1) PN 7555863 and (1 ) PN 7571620
I/C /
\.!9:q ~ -h!l -a.,~~ :; "" :~'-. ~ IP@
-~ ~ ~ ~r&~_ '~~_
I@
/~\ ~O~~
~ @-~:
,. - - - -
Top ' Sprocket / I "!,' !' r
Chain
,.,
~ ,-~,
'@
~~
l(,(i)'.' ~:;
Bottom Sprocket
Supplied with Options B & C (Top Sprocket, Chain, Bottom Sprocket) Supplied with Options A & D (Bottom Sprocket Only)
Chain Tension
1. Maintain proper chain tension by loosening lock nut and torque adjuster bolt.
'--'
2. 3.
Loosen adjuster bolt 1/2 turn. Hold adjuster bolt in position and tighten locknut.
Oil Level
1. Using Polaris chaincase lubricant, maintain proper oil level. Proper level is checked by removing dipstick.
9.57
9/96

8. Wipe off any metal particles from the dipstick. Small amounts of particles will be common. the dipstick (11 oz.) Do not mix or use other types of lubricant.
9. Add lubricant until the level is in the "safe" zone on
Oil Change
1.
Change annually, prior to off season storage.
Adjustment
Due to break-in or replacement of components, the reverse shift mechanism may require adjustment. Adjust with the shifter in the forward position.
Standard Indy Style

1. Loosen jam nuts on lower end of cable. Adjust cable until endplay movement of cable housing at the handlebar bracket is 1/3 2" (.08 cm). Do not adjust beyond this point. Tighten jam nuts and re-check adjustment.
2.
3.
Reverse Cable End Play H32" (.OB em)
1/32" Adjustment
(.08 cm)
Evolved and Aggressive Style

1.
Lift shift lever slowly while observing shi ft arm on transmissi on.
2.
If adjustment is correct, shift will move 1 - 1 1/2"

before the shift arm begins to move. If adjustment is required. proceed with step 3.
--ti~~
1-1 1/2" (2.5-3.8 cm)
free play Chaincase Cover
Shift Lever
3.
Loosen jam nuts on lower end of cable. Adjust cable end at transmission until the end of the shift lever has 1 - 1 1/2" (2 .5 - 3.8 cm) of freeplay before the cable starts to move the shift arm . Do not
4.
a
5.
Ti
Shift~j
Reverse Shift Lever Freep)aY 1 - 1 1/2" (2.5 - 3.8 em) measured at end of shift lever
Arm
~I<_~o'~~
:?-'fW
. .
9/97
9.58
BRAKES/FINAL DRIVE Traction

The amount of traction required varies depending upon the type of riding and the snowmobile's horsepower. Studs are designed specifically for each riding category. They're made in various lengths, shapes, and materials. Improperly applied studs can cause poor traction and premature wear. Studs which are too long can cause damage to the tunnel and heat exchangers. Stud points fall into two categories: conical and scoopers. Conical studs (or picks) penetrate into the ground for increased traction. Scoopers use a flat surface to hold more ground for traction. Generally, a penetrating point is used for hard ground surfaces and ice. Scoopers are used on softer su rfaces. Material contributes more to stud life and cost than to functi onality. Carbide is the most durable and lasts much longer than steei. Studs should be instal led no closer than 1"from the edges of the track. Avoid the center of the track because there is poor support in this area. The track 's center belt controls acceleration. The two smaller outside track belts contribute to acceleration, but the more studs installed in these belts, the harder it is to corner. The chart on page 9.60 is a guideline for the quantity of studs to install.
Be sure to check allowable clearance between the track and tunnel or heat exchangers, factoring in suspension travel. Do not place studs under the tunnel protector strips (directly above slide rails on underside of tunnel). Tunnel protectors are vital components and must not be subjected to stud damage. V-shaped stud patterns with the least repetition work best. Studs should cover as many different lines in the ice as possible. Studs closest to the slide rails provide the most effectiveness, because the weight of the sled is concentrated in this area.
9.59
9/96
SUSPENSION Traction Polaris Push-Through Stud and Skag Recommendations

Trail Model Lite Lile Deluxe Lile GT Sport Sport Touring TranSport XCF 440 XC Super Sport Trail Trail Touring Trail RMK WideTrak GT WideTrak LX 440 500 500 SKS 500 RMK Classic Classic Touring 500 EFI XLT XLT Touring XLT SKS XLT RMK XLT SP XLT LTD Track Length 121 x 15" 121 x 15" 133.5 x 15' 121 x IS' 133.5 xiS" 141 x IS" 121 x ISH 121 x IS" 121 xIS' 121 xiS" 133.5 x ISH 133.5 x ISH 141 x 20" 156 x 20" 121 x ISH 121 xiS" 133.5 xiS" 133.5xI5" 121 xiS " 133.5x ISH 121 xiS" 121 xiS" 133.5 xiS" 133.5 x IS" 133.5 x ISH 121 x 15" 121 x IS" 121 x IS" 121 Lug Height 0.66 0.66 0.82 0.71 0.82 1.125 0.725 0.82 0.82 0.82 0.82 1.25 0.91 0.91 0.82 0.82 1.00 1.25 0.82 0.82 0.82 0.82 0.82 1.00 1.50 0.82 0.82 0.82 0.725 1.00 1.50 0.82 0.82 0.82 0.725 0.82 0.82 0.725 1.50 Tunnel Protector 2871689 2871689 2871543 2871544 2871543 N/A Sid Sid 2871544 2871544 2871543 N/A Sid Sid 2871544 2871544 2871545 N/A 2871544 2871541 2871544 2871545 2871541 2871542 N/A Sid 2871544 Sid Sid 2871542 N/A Sid Sid Std Sid 2871541 Sid Std N/A 1.000 1.000 1.175 N/A 1.000 1.000 1.000 1.000 1.000 1.175 N/A 1.000 1.000 1.000 0.875 1.175 N/A 1.000 1.000 1.000 0.875 1.000 1.000 0.875 N/A 48 48 53
-
Aggressive Trail Skag' Stud Size 0.750 0.750 1.000 0.750 1.000 Stud Qty. 72 72 80 72 80 Skag' D N D D D
Stud Size 0.750 0.750 1.000 0.750 1.000
Stud Qty. 48 48 53 48 53
B
C D D D D orM
0.875 1.000 1.000 1.000 1.000 N/A
48 48 48 48 53
D R D N N N/A
0.875 1.000 1.000 1.000 1.000 N/A
72 72 72 72 80
D R D N N N/A
J or N J or N
N D D N/A N N N D N D N/A N N D R D N/A N N D R N D R N/A 1.000 1.000 1.175 N/A 1.000 1.000 1.000 1.000 1.000 1.175 N/A 1.000 1.000 1.000 0.875 1.175 N/A 1.000 1.000 1.000 0.875 1.000 1.000 0.875 N/A 72 72 80 N D P N/A N N N P
72 80 72 120 106 106
48 53 48 96 80 80
-
J
P N/A
120 120 120 120 106
96 96 96 96 80
J J
P S P N/A
600 XC/XCR
600 XCR SE 700 SKS 700 RMK RXL
U~ra
x IS"
136x15" 136x15" 121 x iS" 121 x 15" 121 x 15" 121 x IS' 133.5 xiS" 121 x IS" 121 x IS' 133.5 xiS"
96 96 96 96 80 96 96
120 120 120 120 106 120 120
J J
P S
Ullra SP/SPX Ultra SPX SE Ultra Touring Siorm Storm SE Storm RMK
J
P S N/A
Refer to chart on page 9.62.
9/96
9.60
(
a "
~.
0;-
1998 Push-Through Stud & Skag Recommendations

Trail
Model
Track
S-
Aggressive Trail Skag Stud Size
Performance Stud Stud
"
~.
~
f>
Lug
Height
Tunnel
Protector
length
Lite
121
Stud Size
Stud
ety.
Slud aty. 72 72 72 72 72 72
72
Skag
Skag
D
Size
aty
x 15" x 15" x 15" x 15" x 15"

x 15"
0.66 0.66 0.71 0.82 0.82 082 082 0.82 0.82 0.82 0.82 0.82 0.725 0.91 0.82 0.91 0.82 0.82 0.82 0.82 0.82 0.82 0.82 0.82 1.25 1.25
1.75
2871689 2871689 28719 11 287 1544

287 1544
0.750 0.750 0 .750 1.000 1.000 1.000 1.000 1.000 1.000

1.000
48 48 48 48 48 48 48 48 96 96 96 96 48 96 96 96 96 96 48 53 53 53 80 80
0.750 0.750 0.750 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 0.875
1.075
D
N
0.750 0.750 0.750 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 0.875 1.075 1.000 1.075 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000
96 96 96 96 96 96 120 120 144 144 144 144 96 144 144 144 144 144 96 106 106 106 132 132
S-
Lite Deluxe
Sport
121 x 15"
121 121 x 15"
121
J P
P
D
D
D D
N N
D
Super Sport
Trai l
440 500
Classic
121 x 15"
121
2871544
2871544
N N
D N
J J P J
121 x 15'"
121
287 1544 SId

287 1544
72 120 120 120 120 72 120 120 120 120 120 72 80 80 80 t06 106
XLT SP XLT LTD

XLT C lassIc
R
N N N
S
J J J
R
121 x 15"
121
S J
J J
R
287 1544
1.000 1.000 0 .875

1.075
ill
UUra
121 xiS"
12 1 x 15"
SId 2871911 Std SId SId SId SId 2871543 2871543 2871543 2871541 287 1541 2871541
(J)
~
XCF 600 XC 600 XCR 700 XC 700 XCR

Storm
R R R
12 1 xiS"
S S
S S
121
x 15"
1.000 1.075 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1000
1.000 1.075 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000
S
S
121 xiS"
R
R
12.1 x IS"
121
S S
15"
S
J P J S
Lite Tou ring
133.5 xiS"
N
0
Sport Touring
Trail TO Uring
133.5 x 15" 133 .5 x IS"
D
N
N
R S
Classic TOUring XLT Tou ring Ultra Touring Trail RMK
133.5 XIS"
133.5x 15"
133_ 5
R .R
'R
S
S S S S S
x 15"
133.5 x IS" 133.5 x IS"

136 x 15"
136
500 RMK 600 RMK 700 RMK

TranSport
Wide Tl ak LX
\5"
1.75 1.125 1.0
141 x 15 ....
156 x 20'"
N IA N IA N IA N IA N IA N IA
N IA N IA N IA N IA
'R
'R
'R
D or M
J or P
N IA N IA N IA N IA
S 'R
'R 'R
'R
N IA N IA N IA N IA
en en
~ ....
, Sl andard on RMK Models
:I Z
'" z (' en ...) (5' 0
-f"O m "'1
BRAKES/FINAL DRIVE
Traction A WARNING
'-A proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow and ice. Loss of control can result in severe personal injury or death. Track studding will enhance braking control on hard packed snow or ice, but extreme caution is still required on such surfaces. Use extra caution when track studding is employed as steering ability may be reduced on hard packed snow or ice. The addition of carbide skags (if not already installed) is recommended with studded tracks to aid in maintaining proper vehicle steering and control. Proper balance must be maintained between the number of studs and the length and sharpness of carbide on skags.
If you are adding studs to the track of a machine it will probably be advisable to add carbide skags or change to more aggressive skags in order to maintain proper vehicle control while turning on hard packed snow or ice . If the machine is equipped with carbide skags or if you are adding them or changing to more aggressive skags than standard equipment, it may also be necessary to add track studs in order to maintain proper vehicle control while turning on hard packed snow or ice.
As a rule of thumb, the more studs, the longer and sharper the carbide on the skags should be. The recommendations in the chart on page 9.60 should be used as guidelines in achieving a proper balance of ski and track traction products on Polaris snowmobiles.
..
,J
9.61
9/96
SUSPENSION
Traction
Polaris Push-Through Stud and Skag Recommendations
B C D
7/16 x 3" 120,2870693 7/16 x 3" 120 EZ, 2870997 7/16 x 4" 60 ,2871288
7/16x6" 600 EZ.2871416
Stud Kits 2871112 Traction Master Carbide Push Through .75 (Pkg of 24 w/backers) *2871404 Traction Master Carbide Push Through .875 (Pkg of 24 w/backers) *2871405 Tractio n Master Carbide Push Through 1.0 (Pkg of 24 w/backers) *2871414 Traction Master Carbide Push Through 1.075 (Pkg of 24 w/backers) *2871649 Traction Master Carbide Push Through 1.175 (Pkg of 24 w/backers) 2871243 Traction Master Carbide Push Through. 75 (Pkg of 96 no backers, use 7mm washer) "2871244 Traction Master Carbide Push Through .875 (Pkg of 96 no backers, use 7mm washer) *2871245 Traction Master Carbide Push Through 1.0 (Pkg of 96 no backers, use 7mm washer) *2871415 Traction Master Carbide Push Through 1.075 (Pkg of 96 no backers, use 5/16 washer) *2871650 Traction Master Carbide Push Through 1.175 (Pkg of 96 no backers, use 5/16 washer) 2871598 Traction Master Push Through Carbide Wedge .875 (Pkg of 24 w/backers) 2871599 Traction Master Push Through Carbide Wedgel.0 (Pkg of 24 w/backers) 2871241 Traction Master Backer Plates, Aluminum, 7mm (Pkg of 48) 2871242 Traction Master Backer Plates, Steel, 7mm (Pkg of 48) 2871430 Traction Master Backer Plates, Aluminum, 5/16" (Pkg of 48) 2871431 Traction Master Backer Plates , Steel, 5/16" (Pkg of 48) 2871374 Drill Bits, Track Studding , 7mm and 5/16" 2870768 Track Studding Kit (T Nut Puller)
J
N P
7/16 x 4" 60 EZ, 2871603

1/2 x 6" 60 , 2871601 1/2 x 8" 60, 2871602
Polaris Composite Ski
R 7/16 x 4" 60 , 2871688

S 1/2 x 6" 60, 2871687
SLP Ski
7/16 x 4" 60 , 2871717

1/2
x 6" 60 , 2871718
Wear Strip Kits** 2871540 2871541 2871544 2871542 2871543 2871545 2871689 1 piece tunnel SKS .625 1 piece tunnel SKS ,75 121" .75 2 piece tunnel SKS .625 2 piece tunnel SKS .75 121" .625 .75 Indy lite
* Patent Pending Carbide 60 Point ** Production set up of wear strips will be located over the windows of the track. An optional position is available for using hooker plates. Only the outer end holes are punched in the tunnel. The wear strip will serve as the template for drilling the remaining holes.
9196
9.62
BRAKES/FINAL DRIVE Traction

Stud Installation
1. Mark the stud pattern on the track. 2. 3. Drill stud holes with a 1/4" (or 7mm) hollow-core drill bit. Make sure the drill is sharp for a clean hole. Spin the non-cutting portion of the drill shank in the hole at high speed to melt the cords together, or melt them with a 1/4-9/32" heated probe. This will prolong track life.
T-nut Studs
1. Push a T-nut tool through the hole from the outside of the track. 2. With the barrel end of the T-nut toward the track, spin a T-nut onto the tool. Pull the T-nut into the track until the head is flush with the track. 3. Remove the tool and put a drop of Loctite T 262 or 271 on the nut threads and stud threads . 4. Secure the T-nut, slide a support washer onto the stud, and screw the stud into the T-nut 5. Torque to BO-100 in. Ibs. and let dry for 24 hours at room temperature . 6. Check for loose studs after each event.
Push Through Studs

1. 2. 3. Push stud through track hole from inside track. Hand tighten domed support plale and Nyloc nut on the exposed stUd. TIghten with a socket on the nut and a 5.32" Allen wrench on the stud head. Tighten nut until the domed washer bottoms out on the stud shoulder. If tightened beyond this point, the threads will be stripped. Inspect for loose nuts after each event.
Refer to the diagrams below for stud length recommendations. Penetration A = Stud Height B = Washer Thickness C = Track Lug Height A + B - C = Penetration Maximum
Stud Length Penetration

Maximum Stud Length
Standard Low Profile Track
31B"
'\J It''\J
Deep Lug Track
.750"
______flL~IL-___
l
Backer Plates Steel .195 Aluminum .220 Stud Mate .14B Hooker ~ Washer .025 ~
31 B"
.B75"
Steel Cleated Track
=
c==:=
'C
31 B"
JOO"
,,==:=:f?
Alum.
~ Shim .055
9.63
9/96
SUSPENSION Traction
Ideally when going through a turn, the vehicle should be kept as flat as possible without the skis or track losing contact with the surface. When entering a corner and turning the skis the rest of the snowmobile will want to continue straight ahead. If the skis do not bite into the surface they will slip, and the turn will not be as tight as desired. This is called pushing. If the skis bite well and the track starts to slide out, the vehicle is said to be loose. Both ski and track traction must be balanced to maintain a good li ne through the corn er. Too few studs will allow the track to spin, resulting in excessive wear or damage to the studs. A loose condition can result from too many dull studs. Front end pushing can result from too many sharp studs. After studs are installed, it's important to install carbide skags to ensure maximum steering control. See the diagrams below. Loose - not enough rear traction or too much carbide Pushing - too much rear traction or not enough carbide
Correct balance
Carbide Placement
50%
50%
60%
40%
91 96
9.64
CHAPTER 10
ELECTRICAL
Lighting Specifications .. . . . . . . . . . . . . . . . . . . . . . . . . . .. 10.1 - 10.1a Ignition Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10.2 - 10.2d Coil Resistance Specifications. . . . . . . . . . . . . . . . . . . . . .. 10.3 Routing Diagram - Indicator Lights . . . . . . . . . . . . . . . . . .. 10.4 - 10.7 Multimeter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 - 10.10 Timing Advance Curves I Verifying liming Marks . .. . ... 10.11 Conversion Chart - Degrees to Piston Position . . .... . .. 10.12 Ignition System Exploded Views . . . . . . . . . . . . . . . . . . . . . . 10.13 - 10.16 Ignition liming Inspection I Adjustment ........ ... ... . 10.17 High RPM liming Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10.18 Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 - 10.20 Dynamic Testing of Electric Starter System. . . . . . . . . . . . . 10.21 Static Electric Starter System Testing. . . . . . . . . . . . . . . . . . 10.22 Electric Starter Assembly .. .. . . . . . . . . . . . . . . . . . . . . . . .. 10.23 Starter Installation . ... .. . ... . ... . ... . .. .... . . . . . ... 10.24 Lighting System Output Test . . . .. . .. .. . . . . . . ... .. . 10.25 Alternator Output Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26 Typical Exciter, Pulser or Lighting Coil Replacement . ... 10.27 Electrical Testing . ... .. ... .. ... .... . . .... .. ... . . . . .. 10.28 - 10.30 Coolant High Temperature Indicator Testing . . . . . . . . . . .. 10.31 Speed Control Assurance Operation . ... ..... . . . . .... 10.32 Speed Control Assurance Testing. . . . . . . . . . . . . . . . . . . .. 10.33 Electric Fuel Gauge Testing . . . . . . . . . . . . . . . . . . . . . . . . .. 10.34 Handlebar Warmer Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35 Exhaust Thermal Sensing System (ETSS) .... .. . ... . . 10.35a - 10.35b Ignition System Troubleshooting . . . . . . . . . . . . . . . . . . . . .. 10.36
'-
1996 Wiring Diagrams .. . ... . ...... . ........... ..... 10.37 -10.48 1997 Wiring Diagrams . . . . . .. . ..... .. . ...... . . . ... .. 10.49 - 10.62b 1998 Wiring Diagrams .. . . ... . ..... . .. . ......... . .. . 10.63 - 10.72
ELECTRICAL Lighting Specifications

1996 Models
Model Type Indy Lite/Deluxe Indy Lite GT Indy Sport Headlight Watls Hil Low Taillight
Watts
Brake Light
Handwarmer
Watls HIILow
Voltage Reg.
Watts
13.3 23.0 13.3 13.3 13.3 13.3 13.3 13.3 13.3 26.9 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3
Incan Incan Incan Incan Incan Incan

Halogen
60/60 60/60 60/60 60/60 60/60 60/60 601 55 60/55 2x601 2x55 60/55
2x37.5 2x37.5 2x37.5 2x37.5 2x37.5
2@2.7 1@8.3 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 1 @8.3 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7
Ace
IS
LR9 LR9 LR9 LR9 LR9 LR9 LR9 LR9 LR7 LR9 LR9 LR7 LR9 LR9 LR9 LR9 LR9 LR7 LR7
15 15 15 15
Indy TranSport
Indy Super Sport Indy Sport Touring Indy 440 XCR/600 XCR Indy 440 XCR SP Indy 600 XCR SP Indy WideTrak LXlGT
15/7.5 15/7.5 15/7.5 15/7.5 15/7.5 1517.5 1517.5 1517.5 1517.5 15/7.5 15/7.5 15/7.5 15/7.5
Halogen Dual Halogen

Halogen Halogen
Indy TrailfTouring Indy 440 LC

Indy XLT Touring Indy 500/SKS/RMK Indy 500 EFI/SKS/RMK
Halogen Halogen Halogen

Halogen Halogen
Indy CJassicITouring
Indy XLT/SP/SKS/RMK Indy RXL Indy Ultra SP/SKS/RMK Indy StormiSKS/ RMK
601 55 60/55 60/55 2x601 2x55
Halogen Halogen Dual Halogen
10.1
9196
ELECTRICAL Lighting Specifications

1997 Models
Model Type Headlight Watts HI/Low 60160 60160 60160 60160 60160 60160 60155 60155 2x601 2x55 60155 2,37.5160 2,37.5160 2x37.5160 2x37.5160 2x37.5160 2x37.5160 60155 60155 60155 601 55 2x451 2x45 60155 2x601 2x55 Taillight Brake Light Watts 13.3 23.0 13.3 13.3 13.3 13.3 13.3 13.3 13.3 26.9 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 2@18 13.3 13.3
Handwarmer
Watts
Voltage Reg .
Watts
2@2.7 1@8.3 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 1 @8.3 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@2.7 2@9 2@2.7 2@2.7
Hi/Low
Indy Lite/Deluxe
Indy Lite GT Indy Sport
Incan lncan lncan

Incan
Ace
15 15 15 15 15 1517.5 1517.5 1517.5 1517.5 1517.5 15/7.5 15/7.5 1517.5 1517.5 1517.5 15/7.5 1517.5 1517.5 1517.5 1517.5 1517.5 1517.5
LR9 LR9 LR9 LR9 LR9 LR9 LR9 LR9 LR7 LR9 LR9 LR9 LR7 LR9 LR9 LR9 LR9 LR7 LR9 LR7 LR7 LR7 LR7
Indy TranSport
Indy Super Sport
Incan
Incan
Indy Sport Touring

Indy 440 XCI600 XC Indy XCF Indy 600 XCR/SE Indy WideTrak LXIGT
Halogen
Incan Dual Halogen
Halogen
Halogen Incan Halogen
Halogen
Indy TrailfTouring
Indy 440 LC Indy Trail RMK Indy XLT Touring Indy 500lSKSI RMK Indy 500 EFI
Halogen Halogen Halogen Halogen

Halogen
Indy ClassicITouring
Indy XLTISPI LTDISP LTDI SKSIRMK Indy 700 SKSIRMK Indy RXL Indy UltraiSP
Halogen Dual Halogen Dual Halogen Dual Halogen
Indy Ultra Touring

Indy Ultra SPXI SPX SE Indy StormiSElRMK
9196
10.1 a
ENGINES I ELECTRICAL Lighting Specifications

1998 Models
Model Type Indy Lite Indy Lite Deluxe Incandescent Headlight Watts Hi/Low
60/60
Taillight
Brake Light
Watts
Watts
18 1S 29 18 1S 29 1S 18 18 18 18 18 18 29 18 18 18 2 x 18 2 x 18 18 2 x 18 1S 2 x 18 18 2 x 18 18 2 x 18 2 x 18 2 x 18 1S 2 x 1S
Alternato r Output (In Watts) @ 4000RPM

150 150 150 200 200 200 200 200 280 200 200 200 200 200 200 200 200 200 280 280 280 280 280 280 280 280 280 280 280 2S0 200
Voltage Reg.
x 3 Watts
8 Watts
LR9 LR9 (LR2) LR9 LR9 LR9 LR9 LR9 LR9 LR7 LR9 LR9 (LR2) LR9 LR9 LR9 (LR2) LR9 LR9 (LR2) LR9 LR9 (LR2) LR7 LR7 LR7 (LR2) LR7 LR7 LA7 LR7 LR7 (LR56) LR7 (LR2 & LR56 ) LR7 LR7 LR7 LA7
Incandescent Incandescent
Incandescent
60/60 60/60 60/60 60/60 60/60 60/60 2x38 / 1 x60

601 55
2 x 3 Watts
Indy Lite Touring

Indy Sport Indy Sport Touring
2 x 3 Watts 2 x 3 Watts 8 Watts
Incandescent Incandescent Incandescent Halogen Halogen

Halogen
Indy Transport
Indy XCF Indy 440 UC Indy 440 XCR Indy Trail
2 x 3 Watts 2 x 3 Watts 2 x 3 Watts

2 x 3 Watts 2 x 3 Watts 2 x 3 Watts 2 x3 Watts 8 Watts
2x38 / 1x60 2x38 / 1 x60 60/60 60/60

60/55 2x38 / 1 x60
Indy Trail Touring

Indy Trail RMK Indy SuperSport Indy WideTrak LX Indy 500 Indy 500 Classic Indy 500 RMK
Halogen
Incandescent
Incandescent
Halogen Halogen Halogen Halogen Halogen Halogen
Halogen Halogen
2 x 3 Watts
2 x 3 Watts
2 x 38 / 1 x 60 2 x 381 1 x 60
2x38 / 1x60 2x60/2x55 2x38 / 1x60 2x38 /1 x60 2x38 / 1x60
x 3 Watts

Indy XLT SP Indy XLT LTD Indy XLT Touring Indy XLT Classic Indy 600 XC Indy 600 AMK Indy 600 XCR Indy Ultra
2 x 9 Watts 2 x 9 Watts
2 x 3 Watts
2 x g Watts 2 x 3 Watts 2 x 9 Watts 2 x 3 Watts 2 x 9 Watts 2 x 3 Watts 2 x 9 Watts
Halogen
Halogen
60/55
60/55 2x60 / 2x55
Halogen
Halogen Halogen
Halogen
60/55 2 x 45 / 2 x 45 60/55
2x60 / 2x55
Indy Utlra Touring

Indy 700 XC Indy 700 XCR Indy 700 AMK Indy Storm
Halogen
Halogen
2 x 9 Watts
2 x 9 Watts 2 x 3 Watts 2 x g Watts
Halogen Halogen
60155 2 x 60 / 2 x 55
LR7: Full Wave Voltage Regulator LR9: 1/2 Wave Voltage Regulator LR2: Rectifier Only, For Battery Charging LR56: For Exhaust Thermal Sensing System (ETSS)
10.1 b
9197
ELECTRICAL Ignition Specifications

1996 Models
Machine Model Engine Model EC34-2PM02lE02 EC44-3PM01/02 EC5OPM04/E04 EC5OPM03 EC45PL06 EC45PL07 EC45PL08 EC50PLE1 1111 /14/15 EC50P LE 12 EC50PL 13 EC58PL02l03/07 EC58PLE05 EC5802 EC59PLol EC65PL05 EC68PLo 1/04 EC8oPL04105 Alternator Wattage 150 200 200 200 200 200 200 200 200 250 170 200 170 200 180 200 200 Spark Plug NGK Plup, Gap MMI nches COl Box Identification Number CU6409 CU6416 CU6413 CU6413 CU6417 CU6417 CU6418 CU6417 CU6417 CU6417 CU2J94 CU2194 CU2 194 CU7303 CU2193 CU7301 CU7302 Flywheel 1 # 0 FP5439 FP5446 FP5441 FP5441 FP5445 FP551 0 FP5517 FP5445 FP5445 FP5508 FP8312 FP8314 FP8312 FP9306 FP6392 FP9304 FP9305
Champion
RN-3C RN-3C RN-3C RN-3C RN-3C RN-2C RN-2C RN-3C RN-3C RN-3C RN-3C RN-3C RN-2C RN-2C RN-2C RN-2C RN-2C
Indy Lite Models Indy Sport Models Indy Trail Models
BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR9ES BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR9ES BR9ES BR9ES BR9ES
0.71.028 0.71.028 0.71.028 0.71.028

0.7/.028 0.7/.028 0.71.028 0.71.028
Indy Wide Trak GT

Indy 440 LC Indy 440 XCR Indy 440 XCR SP Indy 500/SKSIRMKlCIassic
Indy WideTrak LX
Indy 500 EFI
0.71.028
0.71.028
Indy XLT (Except Touring) Indy XLT Touring

Indy XCR 600 IXLT SP Indy 600 XC R SP Indy RXL Indy Ultra SP/SKS/RMK
0.71.028 0.71.028 0 .71.028 0.71.028 0.71.028 0 .71.028 0. 71.028
Indy StormfSKSfRMK
Runn ing Ignition Timing at 3000 RPM

Engine Model
Freratln~
Acceptable Variances
Tim n,rBT C R M
MM
BTDC
Inches BTDC
D8rees B DC
MM
EC34-2P M02/E02 EC44 3PM01/02 EC50PM04/E04 EC50PM03 EC45PL06/07 EC45PL08 EC50PLE11111 i E12/ 14/15 EC50PL13 EC58PL02l03/ E05/07 EC65PL05 3.67 3.81 3.81 4.71 4.40 5.69 4.40 4.71 4.40 3.53 .145 .150 .150 .185 .173 .224 .173 .185 .173 .139 26.51.5 261.5 3.28-4.08 3.39-4 .25 3.39-4 .25 4.25-5.20 3.91-4.87 5.18-6.22 3.91-4.87 4.25-5.20 3.9 1-4.87 3.13-4.01
Inches .129.161 .133-.167 .133.167 .167-.204 .156'.191 .217' .242 .1 56' .1 91 .167-.204 .156' .191 .123' .156 15.5' @7000 16' @6500 16' @6500 19'@7500 16' @750o 16' @7500 16' @7500 17' @7500 20' @ 7500 19' @7500
261.5 291.5
281.5
321.5
281.5
291.5
281.5
25.1:1.5
Running Ignition Timing at 3500
RPM '
Engine
Model
MM
BTOC
Inches BTOC
D8rees B DC
Tim na,' BT C R M
Freratin~
MM
EC59PL01 EC68PLOl EC68PL04 EC80PL04 EC8oPL05
4.74
Inches
.168- .200 .144-.180
.144-,180
.187 .162 .162 .162 .162
281.5
26.1:1.5 26.1:1 .5 26.1:1.5 26.1:1,5
4.26-5.24 3.66-4.57 3.66-4 .57 3.664.57 3.66-4.57
10' @8500 16' @8000 16' @8000 16' @8ooo 16' @8000
4.10 4.10 4.10 4.10
.144-. 180 .144-.180
Engine at room temperature

10.2
9/96
ELECTRICAL Ignition Specifications 1997 Models

Machine Model Engine Model
EC34-2PM02(-S) EC44-3PM02 EC44-3PM02 EC50PM03 EC50PM04(-S) EC50PM05 EC50PM06 EC45PL06 SN44LCOCSP-Ol EC45PL09 EC50P116 EC50PLE17 EC50PL 11 EC50P118 EC50P119 EC50PL20 EC58PL03 EC58PL07 EC58PL08
EC5BPL09
Alternator
Wattage
Spark Plug NGK
Champion
AN-3C RN-3C AN-3C AN-3C RN-3C AN-3C AN-3C AN-2C AN-2C RN-3C AN-3C AN-3C AN-3C RN-3C AN-3C AN-3C
AN3C
Plug Gap MMllnches 0_7/_028 0.7/. 028 0_7/. 028 0.7/. 028 0.7/_028 0.7/.028 0.7/.028
COl Box Identification
Number
CU6409 CU6416 CU6416 CU6413 CU6413 CU6413 CU64 13 CU6418
Fl ywheel 10 # FP5439 FP5446 FP5446 FP5441 FP5441 FP5441 FP5441
Indy lite Models
150 200 200 200 200 200 200 200 200 200 200 200 200 250 200 200 170 170 170 200 170 200 180 200 200 200 200 280 280 280
BA8ES BA8ES BA8ES BA8ES BA8ES BA8ES BA8ES BA9ES BA9ES BA8ES BA8ES BA8ES BA8ES BA8ES BA8ES BA8ES BA8ES BA8ES BA9ES BA8ES BA9ES BA9ES BA9ES BA9ES BA9ES BA9ES BA9ES BA9ES BA9ES BA9ES
Indy SportrrranSport/Spon Touring

Indy XCF
Indy WideTrak GT
Indy Trailrrrail Touring

Indy Trall RMK
Indy Super Sport

Indy 440 XC
Indy 440 XCA
0.71.028
0.7/_028
fP5517
406014 '1
4060163
CU6417 CU6417 CU6417
Indy 440 LC
Indy 500 AMK Indy 500/SKS
0.71.028
0.7/.028 0.7/.028 0.7/.028
FP5445
FP5445
FP5445
Indy Classic
Indy 500 EFI Indy Classic Touring
CU6417
CU6417 CU6417
FP5445
FP5508
FP5445
0.71.028 0.71.028 0.71.028

0.7/. 028 0_7/.028 0.7/.028 0.7/.028 0_7/.028 0.7/.028
Indy WideTrak LX
Indy XLT/SKS Indy XLT AMK Indy 600 XC Indy XLT Touring/LTD Indy XLT SP Indy 600 XCA/SE Indy AXL
CU6417 CU2194 CU2194 CU2194 CU2194 CU2194 CU7303 CU2193 CU730 1 CU7307 CF7302 CF7302 4060144
FP5445 FP8312 FP8312 FP8312 FP8314 FP8312 FP9306 FP6392 FP9304

FP9104
AN-3C AN-2C AN-3C AN-2C AN-2C AN-2C AN-2C AN-2C AN-2C AN-2C AN-2C AN-2C AN-2C
EC5BP112 EC59PLOl EC65PL05 EC68PLOl EC68PL03 EC80PL05 EC80PL04 SN70LCOCSP-Ol SN70LCOCSP-02 SN70LCOCSP-Ol
0.71.028
0.7/.028
Indy UltralSPfTouring
Indy Ultra SPX/SPX SE
0_7/. 028
0.7/.028
Indy StormJSE
Indy Storm AMK Indy 700 SKS Indy 700 AMK Indy 700 XC
FP9305 FP9305
4060141
0.71.028 0.71.028 0.71.028

0.7/.028
4060144
4060144
4060141 4060141
9/97
10.2a
Polaris Industries In c_

1997 Models
Runn ing Ignilion Timing al 3000 Engine Model
RPM '
MM
BTDC
Inches
BTDC
Derees
B DC
rreralln% Tim npp' BT C R M
MM
EC34-2PM02(-S) EC44-3PM02 EC50PM03 EC50PM04(-S) EC50PM05 EC50PM06 EC45PL08 EC45PL09 EC50P116 EC50PL17 EC50P118 EC50P119 EC50Pl20 EC58PL03 EC58PL07 EC58PL08 EC58PL09 EC58P112 EC65PL05 3.67
3.81
4.71
Inches
.145 .150 .185 .150 .150 .150 .211 .173 .173 .173 .185 .173 .173 .173 .173 .173 .173 .173 .139
26.S.:1.5
3.28-4.08 3.39-4.25 4.25-5.20 3.39-4.25 3.39-4.25 3.39-4.25 4.87-5.86 3.91-4.87 3.91-4.87 3.91-4.87 4.25-5.20 3.91-4.87 3.91-4.87 3.91-4.87 3.91-4.87 3.9H.87 3.91-4.87 3.91-4.87 3.13-4.01
.1 29- .1 61 .133-.167 .167-.204 .133-.167 .133-.167 .133-.167 .192-.231 .156-.191 .156-. 191 .156-.191 .167-.204 .156-.191 .156-.191 .156-.191 .156-.191 .156-.191 .156-. 191 .156-.191 .123-.156
15.5' @7000 16"@6500 19'@7500 16' @6500 16' @6500 16' @6500 13.5' @7500 16' @ 7500 16' @7500 16' @7500 17' @7500 16' @7500 16' @7500 20'@7500 20'@7500 20' @7500 20' @7500 20' @7500 19' @7500
26.tl.5
291 .5
26.1.S
26. 1.5
3.81 3.81
3.Bl
261 .5
311.S
5.36
4.40
281.5
2B.1.S
4.40 4.40 4.71 4.40 4.40 4.40 4.40 4.40 4.40 4.40 3.53
281.5
291.5
281.5
2B1.5
281.5 281.5
2B1.S
281.5
2B.1 .S
251 .5
Runn ing Ignition Timing al 3500

Engine Model
RPM '
MM
BTDC
Inches BTDC
Cerees
B DC
rreratln% Tim ng ' BT C
RPM
MM
EC59PL01 EC68PL01 EC68PL03 EC80PL04 EC80PL05 SN70LCOCSP-01 SN70LCOCSP'()2 4.74
4.10
Inches
.187 .162 .070 .162 .1 62 .0365 .0365
2B1.5 261.5 171.5 261.5 261.5 121.5

121.S
4.26-5.24 3 .66-4.57
1. 492.1'
.1 68.200 .144-.180 .059.087 .144-.180 .144-.180 .028-.046 .028-.046
13'@8000
16 @7500
1.78 4.10 4.10 .9268 .9268
18' @8000 14' @8000 14' @8000 16' @8000 16' @8000
3.66-4.57 3.66-4.57 .71-1.17

.71-1.17
Engine at room temperature
10.2b
9/96
FUEL SYSTEM/CARBURETION Ignition Specifications
1998 Engine Electrical

Ma chin e Model
Engin e M odel Alternator Wattage Spark Plug
PIU9 Gap
MMllnches
NGK Lite Models SportfTranSporV Sport Touring/XCF Super Sport TraillTrail Touring Trail RMK 440 XCR 440 LC 500 RMK 500 EC34-2PM02A EC44-3PM024 EC50PM061 EC50PM043 EC50PM051 SN44-44LCDCSP-Ol EC45PL091 EC50PL 161 EC50PL171 EC50PL 171 EC50PL 191 EC50PL201 EC58PL140 EC58PL 130 EC58PL130 EC58PL150 SN60-70LCDCSP-Ol SN6070LCDCSP-02 EC59PL020 EC68PL050 EC68PL060 SN70-70LCDCSP-02 SN70-70LCDCSP-Ol EC80PL052 150 200 200 200 200 200 200 200 200 200 200 200 280 280 280 280 280 280 280 280 280 280 280 200 BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR8ES BR8ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES
Champion
COl Box Identifica ti on Number
Fl yw heel
10 #
RN-3C RN -3C RN-3C RN-3C RN-3C RN-2C RN-3C RN -3C RN-3C RN-3C RN-3C RN-3C RN-2C RN -3C RN -3C RN -2C RN-2C RN -2C RN-2C RN-2C RN-2C RN-2C RN-2C RN-2C
0.71.028
0.7/.028
CU6409 CU6416 CU6413 CU6413 CU6413 4060190 CU6417 CU6417 CU6417 CU6417 CU6417 CU6417 CU2552 CU2552 CU2194 CU2552 4060186 4060186 CU7308 CU7306 CU7307 4060181 4060189 CU7302
FP5439 FP5446 FP5441 FP5441 FP5441 4060 141 FP5445 FP5445 FP5445 FP5445 FP5445 FP5445 FP9102 FP9102 FP8314 FP9 102 4060141 4060141
0.7/.028 0.7/.028
0.7/. 028
0.7/.028 0.7/.028 0.71.028 0.71.028 0.7/.028 0.7/.028

0.7/.028
Classic Classic Touring

WideTrak LX XLT SP XLT LTD XLT Touring XLT Classic 600 XC 600 RMK 600 XCR Ultra/Touring 700 XCR 700 XC 700 RMK Storm
0.71.028 0.71.028 0.71.028 0.7/.028 0.71.028 0.7/.028 0 .7/.028 0.71.028 0.71.028 0.7/.028 0.71.028
0.7/.028
FP9103 FP9104 4060141 406014 1 FP9305
9/97
10.2c
1998 Ignition Timing Specifications

Running Ignition Timing at 3000 RPM '
Engine Model
Operating Timing "BTDC RPM
BTDC
3 .67 3.81 3.81 3.81 3.81 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40
MM
Inches
BlOC
.145 .150 .150 .150 .150 .173 .173 .173 .173 .173 .173 .173 .173
Defrees
B DC
MM
EC34-2PM02A EC44-3PM024 EC50PM043 EC50PM051 EC50PM061 EC45PL091 EC50PL 16 1 EC50PL 171 EC50PL 191 EC50PL201 EC58PL130 EC58P L140 EC58P L150 26.51.5 261.5 261.5 261.5 261.5 281.5 281.5 281.5 281.5 281.5 281.5 281 .5 281.5 3.28-4.08 3.39-4.25 3.39-4.25 3.39-4.25 3.39-4.25 3.91-4.87 3.91-4.87 3.91-4.87 3.91-4.87 3.91-4.87 3.91-4.87 3.91-4.87 3.91-4 .87
Inches
.129-.161 .133-. 167 .133-.167 .133-.1 67 .133-.167 .156-.191 .156-.191 .156-. 19 1 .156-.191 .156-.19 1 .156-.191 .156-.191 .156-.191
15.5'
7000
16 ' @ 6500 16' 16' 16' 16' 16 ' 16 ' 16' 16 ' 20' 20' 20'
@ @ @ @
@
6500 6500 6500 7500 7500 7000 7500 7500 7500 7500 7500
@ @ @ @ @ @
Running Ignition Timing at 3500 RPM *

Engine Model
Operating
Timing "BTOC RPM
MM BTDC
3.72 4 .74 4.10 1.78 4.10 .93
Inches
BTDC
.146 .187 .162 .070 .162 .037
Degrees
BlOC
MM
Inches
SN44LCDCSP-01 EC59PL020 EC68PL050 EC68PL060 EC80PL052 SN70-70LCDCSP-02
251.5 281.5 261.5 171.5 261.5 121.5
3.29-4. 16 4.26-5.24 3.66-4.57 1.49-2. 11 3.66-4.57 .71-1 .17
.130-.164 .168-.200 .144-.180 .059- .087 .1 44-.180 .028-.045 13 ' 16' 18' 14' 16'
@ @ @ @ @
8000 7500 8000 8000 8000
Running Ignition Timing at 1500 RPM'

Engine Model
Operating Timmg "BTOC RPM Operating Timing "BTDC RPM
BTDC
.22 .22
MM
Inches
Degrees
BTDC
.009 .009
BlOC
SN60-70LCDCSP-01/02 SN70-70LCDCSP-01
61.5 61.5
.13-.34 .13-.34
.005-.014 .005-.014
11 ' 15'
@ @
8000 8000
Engine at ro om temperature
10.2d
9/97
ELECTRICAL Coil Resistance Specifications

Ignition system components can be individually tested by measuring their internal resistance and insulation to ground. These checks must be done with a digital volt/ohm meter. Compare the readings obtained to the values listed on the chart. Actual values may vary upto 10% between like components. Any readings outside the span should be considered questionable.
NOTE:
'--
The stator coils can be checked without removing them from the engine. Simply disconnect the connector, plug in the stator-to-CDI wire, and check the resistance values between the wire colors listed below. For further information, consult the wiring diagrams at the end of this chapter.
Model 1996 Exciter Coli Wire Color BrnMi to BlklR BrnMi to BlklR BrnMi 10 BlklR BrnMi to BlklR BrnMi 10 Blk R Brnrw to BlklR Ohms Trigger Coli Wire Color Ohms Light Coil Wire Color Y to Brn Y to Ohms Charge Coil Wire Color Ohms Ignition Coil Primary Secondary
..
EC34PM EC44PM EC50PM EC45PL EC50PL11,12,14,15 EC50PL13
164 164 164 164 164 164
0.3-0.6 0.2-0.5 0.2-0.5 0.2-0.5 0.2-0.5 0.2-0.5
5700' 5700' 5700' 5700' 5700' 5700'
Y/R Y/R
0.4-0.8
&
Ylo Y 10 Y 10
Y/R
Gry to GryMi & BrnMi 10 Gryl W
Y/R Y/R
Ylo
0.2-0.4
EC58PL02,03,07 EC58PL05 EC65PL05
BlklR to R BlklR to R BlklR to Grn & Rio Grn Grn 10 BlklR & Grn to R Grn to BlklR & Grn to R
4.6 4.6 288

&
Wto
100 100 96
W/R
Wlo
Y to
Y/R Y/R
0.2-0.5 0.2-0.5 0.2-0.4
Gry 10 GryMi & Brnrw 10 Gryl W
0.4--0.8
&
0.4 0.4 0.4
4000 4000 7500
Y 10 Y 10 Brn
W/R
W lo
W/R
20
0.3-0.5
EC68PL01,04
500
&
W/R
Wto
100
Ylo
Y/R
0.17
0.34
7900
15.5
EC80PL04,05
500
&
Wlo
100
Y 10
W/R
Y/R
0.17
0.34
7900
15.5
Resistance should be checked with the coil at room temperature COils must be isolated from the system to check resistance Plug cap resistance is 3700-6300 Ohms (measured separately) 'Measure resistance from Mag plug lead to PTa plug lead "Secondary coil resistance is measured with the plug cap off
10.3
11/95
ELECTRICAL Routing Diagram - Indicator Lights

1996 RXU440 XCR/600 XCR/XLT/XLT SKS/XLT RMK Models
YELLOW BLACKIWHITE
PURPLE
BROWN
ORANGE
YELLOW/RED
WHITE/BLUE
11/95
10.4
ELECTRICAL Routing Diagram - Indicator Lights

1996 WideTrak LXlSportlTranSport/Super Sport/Sport Touring Models
PURPLE
BROWN
YELLOW/RED
WHITE/BLACK
10.5
11/95
ELECTRICAL Routing Diagram Indicator Lights

1996 WideTrak GT Models
WHITE
-- -
:::::::.------BROWN
PURPLE
YELLOW/RED
WHITE/BLUE
11/95
10.6
ELECTRICAL Routing Diagram - Indicator Lights 1996 Lite GT Models
Rocker Switch and Indicator Lights
BLACKlR ~ ~
~ " .x"i ~ ~~
/'
I~ ~
~ Cc
BLACKl~
(l/YELLOW
/r~
,, :::::S
"
BROWN
Blue~"'--.
~ a::Y Yellow
~,'~
-/'
I"''''
~
1998 Lite Deluxe
~ BIU~ / ~~ ~ '-,J
. ~
AC
Brown
~ purple
B / 7
10.7
9/97
ELECTRICAL Multimeter Usage

Multimeter Usage
The easiest and most accurate method for testing modern electrical components is with a digital multitester. Any good quality muititester will work. However, due to ease of operation and durability, Polaris recommends the Fluke Model 73 (PN 2870659), or Tektronix DMM155. See photo at right. This Instrument will provide a digital readout Of the measured value of the test being performed . Listed below are the dial symbols, their meaning and what the dial setting can be used for. Off = Instrument Off
RED LEAD HERE
FOR AMPS COMMON
(BLACK LEAD)
v - = Volts AC - measuring alternator output

Used to measure AC voltage in an electrical system. AC voltage is produced from every coil on the stator plate when a magnet is passed by it. Test Method 1. Connect black lead to Com (-) meter terminal . 2. Connect red lead to Vo. (+) meter terminal. 3. Turn selector dial to V setting. 4. Connect test leads parallel with test component. The polarity of the leads is not important.
!.l.sage
Test unregulated voltage output of a stator coil Test regulated voltage to the lights and handwarmers
V -::-:-:
=Volts DC - measuring battery voltage, volt drop, etc.
Used to measure DC voltage produced by a battery or rectifier. Test Method 1. Connect black lead to Com (-) meter terminal 2. 3. 4. Connect red lead to Vo. (+) meter terminal. Turn selector dial to V -::-:-: setting. Connect test leads parallel with test component. Observe polarity. Test battery voltage Test DC regulator Test voltage drop for bad connections Test supply voltage to electric fuel gauge EFI electrical testing
11/95
10.8

Q
= Ohms, resistance - measuring component resistance values - testing coils, wiring, etc.
Used to test resistance to the flow of electricity in a circuit or component. A reading of OL means an open circuit or infinite resistance. Sometimes the leads themselves will have some resistance. Touch the leads together and subtract this resistance from the component reading to achieve the actual reading. Test Method 1. 2. 3. 4. "--Connect black lead to Com (-) meter terminal Connect red lead to VQ (+) meter terminal. Turn selector dial to n setting.
Isolate test component from the rest of the electrical circuit by disconnecting wires from harness. 5. Connect test leads to the circuit to be tested. Usage Testing coil resistance Testing switch operation Testing wire continuity
A - = Amps AC - used to test lighting coil output Used to test the power of an alternator coil. Test Method 1. Discconnect engine harness from system. 2. Connect red lead to lOA (+) meter terminal. 3. Connect black lead to Com (-) meter terminal. 4. Start engine and let it idle. 5. Observe and record the meter reading. 150 Watt Alternators: The reading should exceed 8 amps. 200 Watt Alternators: The reading should exceed 12 amps. NOTE: Amperage readings are not dependent upon engine RPM. The reading you obtain at idle is essentially the same as the reading that would be obtained at higher RPMs. NOTE: Although the meter connection is labeled lOA it will correctly read higher AC amperage (without damage to your meter) for periods of time not exceeding 10 seconds,
''-...-
10,9
91 97

A -:-:-:
= Amps DC used to check battery charge rate, system draws, etc.
Used to check the current flow to and from the battery. Test Method 1. Make sure red lead is in the 1OA terminal of the meter and the black lead is in the Com (-) terminal olthe meter. 2. Disconnect battery ground wire(s) from battery (-) terminal. 3. Connect red meter lead to battery (-) terminal. 4. Connect black meter lead to harness ground wires and cable.
Do not operate electric starter (if equipped) or meter damage may occur.
~
Testing key off current draw Testing key on current draw Testing charging system break even RPM
'-""
Testing DC current flow (direction), is battery charging? NOTE: When using the DC Amp settings, the red test lead must be moved to the 10A socket on the front of the instrument.
11/95
10.1 0
ELECTRICAL Typical Timing Advance Curves

Ignition Timing
Maximum Advance (Depending on Model)
Operating RPM (Depending On Engine) See Data
1000
2000
3000
4000 RPM
5000
6000
7000
8000
NOTE: Always verify timing of engine at room temperature only (68" F 1200 C) and at the proper RPM. To obtain the best ignition timing accuracy and reduce the chance of error, the ignition timing specification is given at a "flaf' portion of the advance curve. This flat portion on the curve is at 1500, 3000 or 3500 RPM on all current style ignition systems. Ignition timing must be checked at the specified RPM, or inaccurate timing will result. Refer to timing specifications at the beginning of this chapter. If engine damage has occurred due to a suspected ignition related problem, verify the ignition timing is correct at the specified operating RPM as outlined on page 10.18.
Dial Indicating The Timing Marks

Due to differences between engines, it is necessary to dial indicate the timing marks on all engines before attempt ing to adjust the ignition timing. To indicate the marks: Remove the mag cylinder spark plug and install the dial indicator. Rotate the crankshaft by hand while observing the dial indicator. As the piston touches the indicator plunger, the dial will begin to rotate. Find the point where the pointer stops rotating and reverses direction. This will be TDC (Top Dead Center). 3. While holding the crankshaft with the piston at TDC , zero the indicator by rotating the bezel until the 0 on the dial and the pointer align. 4. Rotate the crankshaft opposite the direction of rotation about .250 BTDC (2 1/2 pointer revolutions). 5. Determine the correct ignition timing position from the ignition data charts and rotate the crankshaft in the normal direction of rotation to that position. (Example: If engine timing is .150 BTDC, the crankshaft must be rotated in the normal direction of rotation so that the dial indicator pointer does one complete revolution and stops on 50 . This should be 1 1/2 pointer revolutions before top center, or .150 BTDC. While holding the crankshaft at the correct timing position, mark the flywheel (with chalk or a white marker) directly inline with the stationary pointer (or line) on the fan or recoil housi ng through the timing inspection window.
'.
1. 2.
6.
10.11
9/97
ENGINE Timing Curves Timing Curve 1998 Domestic 600 Twins
20
18
16 14 12 10
8
~.
.' ~,
,,
,,
,,
6 4
;-
. . . . .. .. .
.' -
J.
,
'4
1000
2000
3000
4000
5000
6000
7000
8000
Timing Table 1998 600 Twin RPM

Degrees
600 2000 4500 5000 6000 7500 8000 8500
6 6 12 17 19 13 11 6
9/97
10.1 1a
ENGINE Timing Curves Timing Curve 1998 700 XC
20 18 16 14
12
10
8
6
4 2
;-
. .. .. . .
. .. .
.'
J.
..
. . ~ .. . . ..
-..
,,
o o
1000 2000 3000 4000 5000 6000 7000 8000
Timing Table 1998700 XC
RPM
600 2000 4500 5000 6000 7500 8000 8500
Degrees
6 6 12 17 19 16 15
11
10.11 b
9/97
ENGINE Timing Curves Timing Curve 1998 700 RMK
20 15
10
~.
... _-
---
.. ' e

...
#I
--~- -
--- .-
o o
:
1000 2000 3000 4000 5000 6000 7000 8000
9000
Timing Table 1998700 RMK
RPM
500 2700 3500 4800 5500 8000 8400 9000
Degrees
6 12 12 18.so 23 16 15.5 5.5
9/97
10.11 c
ENGINE Timing Curve Template

20 ~===+====+===~====~,====+===~====~====+=~ 18r-----+------r-----+------r-----+_-----r-----+------r-~
16r-----+------r-----+------r-----+_-----r-----+------~~
14~----r-----+_----+-----~----~----_+----_+----_4--~ 1 2r------r----~------+_----_r------r_----_r----~------+_~
10 ~----r-----+_----+-----~----~----_+----_+----_4--~
8 r-----+------r-----+------r_----+------r-----+------r_~
6 r------r----~------+_----_r------r_----_r----~------+_~
4 ~----~----_+------+_----~------~----~----_+------+_~
2 r------r----~------+_----_r------r_----_r----~------+_~
OL-____- L_ _ _ _ _ _ _ _ _ _ _ _ _ _ 2000 4000 o 1000 3000

~ ~
_ L_ __ _ _ _L __ _ _ __ L_ _ _ _~_ _ _ __ _~~
5000
6000
7000
8000
Timing Table RPM
Degrees
10.11 d
9/97
ELECTRICAL Conversion Chart - Degrees to Piston Position - B.T.D.C.

Engine
Model DEG. BTDC
EC443PM EC45PL EC50PL
EC50PM EC58PL EC65PL
EC59PL EC68PL EC80PL 125 MM ROD 65 MM STROKE

MM
EC342PM
SN44LCDCSpOl SN4444LCDCSpOl 128 MM ROD 64 MM STROKE

MM
SN70LCDCSP-Ol102 SN6().7OLCDCSPOl102 SN7()' 7OLCDCSP0I/o2 136 MM ROD 68 MM STROKE
112 MM ROD 60 MM STROKE

MM
103 MM ROD 55.6 MM STROKE MM 0.0054 0.0215 0.0484 0.0860 0. 1343 0.1933 0.2630 0.3432 0.4341 0.5355 0.6474 0.7698 0.9025 1.0456 1.1989 1.3624 1.5359 1.7 195 1.9130 2.1163 2.3294 2.5521 2.7843 3.0260 3.2769 3.5370 3.8062 4.0843 4.3712 4.6667 4.9708 5.2832 5.6039 5.9326 6.2693 6.6138 6.9658 7.3253 7.6920 8.0659 INCHES 0.0002 0.0008 0.0019 0.0034 0.0053 0.0076 0.0104 0.0135 0.0171 0.0211 0.0255 0 .0303 0.0355 0.0412 0.0472 0.0536 0.0605 0.0677 0.0753 0.0833 0.0917 0.1005 0.1096 0.1191 0.1290 0.1393 0 .1498 0.1608 0.1721 0 .1837 0.1957 0.2080 0.2206 0.2336 0 .2468 0.2604 0.2742 0.2884 0.3028 0.3176
INCHES 0.0002 0.0009 0.0021 0.0036 0.0057 0.0082 0.0112 0.01 46 0.0184 0.0227 0.0275 0.0327 0.0383 0.0444 0.0509 0.0578 0.0652 0.0729 0 .0811 0.0898 0.0988 0.1083 0.1181 0.1284 0.1390 0.1500 0.1615 0.1733 0.1854 0.1980 0.2 109 0.2241 0.2377 0.2517 0.2660 0.2806 0.2955 0.3108 0.3263 0.3422
INCHES 0.0002 0.0010 0.0022 0.0039 0.0061 0.0088 0.0120 0.0157 0.0198 0.0245 0.0296 0.0352 0.0412 0.0478 0.0548 0.0622 0.070 1
0.D785
INCHES 0.0002 0.0010 0.0022 0.0038 0.0060 0.0086 0 .0117 0 .0 153 0.0194 0 .0239 0 .0289 0.0343 0.0403 0.0466 0.0535 0.0608 0.0685 0.0767 0.0854 0.0944 0. 1039 0.1139 0.1243 0.1350 0 .1462 0.1579 0.1699 0.1823 0.1951 0.2083 0.22 19 0.2359 0.2502 0.2649 0.2799 0.2953 0.3111 0.3271 0.3435 0.3602
MM
0.0065 0.0259 0.0582 0.1035 0.1617 0.2327 0.3166 0.4132 0.5226 0.6448 0.7795 0.9268 1.0867 1.2589 1.4435 1.6404 1.8494 2.0705 2.3036 2.5485 2.8052 3.0735 3 .3532 3.6444 3.9467 4.2602 4.5846 4.9197 5.2655 5.6218 5.9884 6.3651 6.7518 7 .1482 7.5543 7.9698 8.3945 8 .8282 9.2708 9.7220
INCHES 0.0003 0.0010 0.0023 00041 0.0064 0.0092 0.0125 0.0 163 0.0206 0.0254 0.0307 0.0365 0.0428 0.0496 0.0568 0.0646 0.0728 0.0815 0.0907 0.1003 0. 1104 0.1210 0.1320 0.1435 0.1554 0.1677 0.1805 0 .1937 0.2073 0.2213 0.2358 0.2506 0.2658 0.2814 0.2974 0 .3138 0.3305 0.3476 0.3650 0.3828
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
0.0058 0.0232 0.0521 0.0926 0.1447 0.2083 0.2833 0.3698 0.4677 0.5770 0 .6976 0.8294 0.9724 1.1265 1.29 17 1.4678 1.6548 1.8526 2.0611 2.2802 2.5098 2.7497 3.0000 3.2603 3.5307 3.8110 4.1010 4.4007 4.7098 5.0282 5.3559 5.6926 6.0381 6.3924 6.7552 7.1263 7.5057 7.8931 8.2883 8.6912
0.0062 0.0249 0.0561 0.0997 0.1558 0.2242 0.3050 0.3981 0.5036 0.6212 0.7510 0.8930 1.0470 1.2129 1.3908 1.5804 1.7818 1.9948 2.2 193 2.4552 2.7024 2.9608 3.2303 3.5107 3.8019 4.1038 4.4161 4.7389 5.0719 5.4149 5.7679 6.1306 6.5028 6.8845 7.2754 7.6753 8.0840 8 .5015 8.9274 9.3616
0.0061 0.0244 0.0548 0.0974 0.1522 0.2190 0.2979 0.3889 0.4919 0.6068 0.7336 0.8723 1.0227 1.1849 1.3586 1.5439 1.7406 1.9487 2.1681 2.3986 2.6402 2.8927 3.1560 3.4300 3.7146 4.0096 4.3149 4.6303 4.9558 5.2911 5.6361 5.9907 6.3546 6.7278 7.1099 7.5010 7.9007 8.3089 8.7254 9.1501
0.0874 0.0967 0.1064 0.1166 0.1272 0.1382 0 .1497 0 .1616 0.1739 0.1866 0.1997 0.2132 0.2271 0.2414 0.2560 0.2710 0.2864 0.3022 0.3183 0.3347 0.3515 0.3686
9/97
10.12
ELECTRICAL Twin Cylinder Fan COl Ignition (Adjustable) - Exploded View - Timing
l.~
LIGHTING COl L
EX CITER
~""""' RFICAP
(
0
Fon
COl Control
Unll
/
...
150 and 200 Watt Pulse less
VIb ration
Dam per
@..
....' - Torque to 9 in. Ibs. (. 103 kgm)
120 Watt Pulse Type
NOTE: Always verify timing of engine at room temperature on ly (68 0 F/20 C).
Refer to ignition timing procedu re on page 10.17.
Blower Housing Stationary Lines
NOTE: Acceptable variance is usual ly one line on either side of the dial indicated blower housing stationary li ne.
Flywheel Mark
10.13
9/97
ELECTRICAL Twin Cylinder Liquid CDI Ignition (Pulse, Pulseless) - Exploded View - Timing Timing Procedure
Excller Coil
Trl9ger Coli
~ ' %-4ir!
" . '" "
~>.1 /
I
~ S TATOR PLA T E
jp:ft.J ' ..,

I.
If
:1 .
~~ " i'-' "".' ~:9l
~'> LIGHTING COIL
r ' ..... '
"
.
EXCITER "<) I
I ,
,~ lIghl~g ~Oi~/ ;'

> ' ,
. (It
.
"d. '
"
"
/dJ
",
RFI Spa'" PI" C'P
~.
/'/ '
d rRF'CAP
Flywheel
120 Watt Pulse Type CDI NOTE: Always verify timing of engine at room temperature only (68 0 F/20 0 C). Refer to ignition timing procedure on page 10.17.
200 Watt Pulseless CDI
Acceptable Variance Flywheel Rotation Flywheel Lines Stationary Pointers
NOTE: Acceptable variance is usually one line on either side of the dial indicated timing mark.
9/97
10.14
ELECTRICAL Three Cylinder COl Ignition Timing - Exploded View (Typical)
Lighting Coil
Flywheel
Charging Coli
Secondary Colis
NOTE: Always verify timing of engine at room temperature only (68 0 F/200 C). Refer to ign ition timing procedure on page 10.17.
Acceptab l~
Variance
Flywheel Rotation
\~
W
-
Flywheel Lines Stationary POinters
10.15
9/97
ELECTRICAL Three Cylinder COl Ignition - Exploded View
Pulser Coil --/7!~"",~
.'-. <W".....
[JJ//.';::i'"--- = - - - Stator Plate "!iI--_--'L1ghting/Exciter
" - - Flywheel
COl Control Box
- .1----,7'''---- RFI Spark Plug Cap
Secondary Cable Secondary Coils 170 Watt The Exciter Coil can be identified by wire color, and smaller windings. NOTE: Always verify timing of engine at room temperature only (68 0 F/20 C). Refer to ignition timing procedure on page 10.17.
Acceptabl{l Variance Flywheel \ Rotation
W
-
Flywheel Lines Stationary Pointers
9/97
10.16
ELECTRICAL COl Ignition Timing
Timing Procedure - All Models

NOTE: Always verify timing of engine at room temperature only (20 C/68 F).
1. Refer to the timing specification charts at the beginning of this section to determine the proper ignition timing for the engine you are working on. 2. 3. Use a dial indicator to place the piston in the proper timing position and mark the flywheel at this point (follow procedure on page 10.11).
Connect an accurate tachometer and a good quality timing light to the engine according to manufacturer's instructions. 4. Start engine and increase RPM to the point Acceptable Variance specified in the timing specification charts (1500, 3000, or 3500). Hold the throttle or set idle screws Flywheel to maintain specifieed timing RPM. Rotation 5. Point the timing light at the timing inspection hole. Stationary 6. With your head positioned so there is a straight Pointers line between your eye, the stationary pointer and the crankshaft center line, note the relative position between the marked flywheel line and the NOTE: Acceptable variance is usually stationary pointer. If the stationary pointer is one line on either side of the dial indicated aligned with the mark made in Step 2, (or within timing mark. the acceptable variance) the timing is correct. 7. If the pointer is outside the variance, the stator will Liquid Cooled have to be rotated either with crankshaft rotation (to retard the timing) or against rotation to advancei!. NOTE:Rotate stator plate approximately the same distance as the marks must move. Blower Housing NOTE:ln most cases, the recoil starter housing, recoil Station a drive hub, and flywheel must be removed to loosen Lines the stator bolts and change the timing. On some engines, the stator plate retaining screws can be accessed through the flywheel. Flywheel 8. Torque stator plate screws and flywheel nut to Mark specified torque. Apply Loctite 262 (red) to crankshaft flywhee l taper if required. Refer to the Engine section for torque specifications and Fan Cooled flywheel installation procedure for engine type.
10.17
9/97
ELECTRICAL Operating RPM Timing Check - All Models
Due to the high RPM necessary and the possible danger involved, special care must be observed whenever performing an operating RPM timing check to avoid serious personal injury. This check need not be performed unless symptoms leading to poor performance and possible engine damage are present. Never operate the engine with the clutch guard open or removed. Do not stand over or around the clutch while performing this test. Perform the test as quickly as possible. Avoid prolonged periods of engine free-rev.
Operating RPM Timing Test Procedure

1. 2. 3. Using the charts at the beginning of this unit, determine the ignition advance BTDC at the operating RPM. Remove the mag side spark plug and install a dial indicator in that cylinder. Zero the dial indicator as explained on page 10.11.
4. Turn the crankshaft in the opposite direction of rotation to a pOint approximately .100" (2.5 mm) before the operating ignition timing point. 5. Turn the crankshaft in the proper direction of rotation until the dial indicator shows the proper piston position BTDC for operating RPM ignition timing. NOTE: The charts only indicate degrees BTDC . This figure must be converted using the tables on page 10.12. Example: The operating timing and RPM for an engine is 16 at 7500 RPM. Using the chart, 16 on this engine is .058 BTDC at 7500 RPM. Using a properly Instal led and zeroed dial indicator, back the engine up to approximately .150 BTDC. Then rotate the crank in the proper direction of rotation to .058 BTDC. 6. While holding the crankshaft at the operating RPM ignition timing point, make some timing marks on the flywheel or blower housing using a piece of chalk or marker. Remove the dial indicator and reinstall spark plug. Start the engine. Advance and hold the throttle at the operating RPM specified on the charts. View the timing mark with the timing light. The marks should be between the allowable +/- variance indicated on the operating RPM timing specification. If the operating RPM timing greatly varies from the specification, but the 3000 or 3500 RPM ignition is correct, refer to the ignition troubleshooting section in this unit for corrective action.
7. 8.
9.
11/95
10.18
ELECTRICAL
Battery Service
Preparing a New Battery for Service
'--" To ensure maximum service life and performance from a battery, it must have proper initial servicing . To service a new battery, the followi ng steps must be taken. NOTE: Do not service the battery unless it will be put into regular service within 30 days. 1. 2. 3. Remove vent plug from vent fitting. Fill battery with electrolyte to the upper level marks on the case. Set battery aside and allow it to cool and stabilize for 30 minutes. electrolyte should be added. If the level becomes low after this point, add only distilled water. 5. Charge battery at 1I I 0 of its ampl hour rating. Example:l /1 0 of 9 amp battery = .9 amps, 1/10 of 14 amp battery = 1.4 amps, 1I I 0 of 18 amp battery = 1.8 amps (recommended charging rates). Check specific gravity of each cell with a hydrometer to ensure each has a reading of.l.270 or higher.
4. Add electrolyte to bring the level back to the upper level mark on the case. NOTE: This is the last time that
'--
6.
Battery Testing
There are three easy tests which can determine battery condition . Whenever the complaint is related to either the starting or charging systems, the battery should be checked first. Lead-acid batteries should be kept at or as near full charge as possible. If the battery is stored or used in a partially charged condition, hard crystal sulfation will form on the plates, reducing their efficiency and possibly ruining the battery.
Open Circuit Voltage Test (OCV)

Battery voltage should be checked with a digital multitester. Readings of 12.6 or less require further battery testing and charging.
Specific Gravity Test

A tool such as the battery hydrometer (PN 2870836) can be used to measure electrolyte strength or specific gravity. As the battery goes through the chargeldischarge cycle, the electrolyte goes from a heavy, more acidic state at full charge to a light, more water state when discharged . The hydrometer can measure state of charge and differences between cells in a multi-cell battery. Readings of 1.270 or greater should be observed in a fully charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery.
State Of Charge 100% Charged 75% Charged 50% Charged 25% Charged 0% Charged Conventional Lead-acid 12.60V 12.40V 12.10V II.S0V Less Than 11.80V Conventional Lead-acid 1.265 1.210 1.160 1.120 Less Than 1.100 Yumacron Type 12.70V 12.50V 12.20V 12.0V Less Than 11.9V Yumacron Type 1.275 1.225 1.175 1.135 Less Than 1.115
Detail A
.. II
State Of Charge" 100% Charged 75% Charged 50% Charged 25% Charged 0% Charged
"at 80 F NOTE: Subtract .01 from the specific gravity for electrolyte at 40 F and compare these values to the chart.
10.19
11 /95
ELECTRICAL
Battery Service
Load Test
NOTE: This test can only be performed on machines equipped with electric start. This test cannot be performed if the engine or starting system is not working properly.
A battery may indicate a fully charge condition on the OCV test and the specific gravity test, but still not have the storage capacity necessary to properly function in the electrical system. For this reason , a battery capacity or load test should be conducted whenever poor battery performance is encountered. To perform the test, hook a multitester to the battery in the same manner as in the OCV test. The reading should be 12.6 volts or greater. Engage the electric starter and view the registered battery voltage while cranking the engine. Continue the test for 15 seconds. During this cranking period, the observed voltage should not drop below 9.5 volts. If the beginning voltage is 12.6 or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery. '---'"
Refilling a Low Battery

The normal charge/discharge cycle of a battery causes the cells to give off gases. These gases, hydrogen and oxygen, are the components of water. Because of the loss of these gases and the lowering of the electrolyte level, it will be necessary to add pure, clean distilled water to bring the fluid to the proper level. After filling, charge the battery to raise the specific gravity to the fully charged position (1.270 or greater). '---'"
Off Season Storage

To prevent battery damage during extended periods of non-use, the following basic maintenance items must be performed. 1. Remove battery from machine and wash the case and battery tray with a mild solution of baking soda and water. Rinse with lots of fresh water after cleaning. CAUTION: Do not allow any of the baking soda solution to enter the battery or the acid will be neutralized. Using a wire brush or knife, remove any corrosion from the cables and terminals. Make sure the electrolyte is at the proper level. Add distilled water if necessary. Charge at a rate no greater than 1/10 of the battery's amp/hr capacity until the electrolyte's specific gravity reaches 1.270 or greater.
2. 3. 4.
5. The battery may be stored either in the machine with the cables disconnected, or on a piece of wood in a cool place. NOTE: Stored batteries lose their charge at the rate of 1% per day. They should be fully recharged every 30 to 60 days during a non-use period. If stored during winter months, the electrolyte will freeze at higher temperatures as the battery discharges. The chart indicates freezing points by specific gravity. Specific Gravity of Electrolyte 1.265 1.225 1.200 1.150 1.100 1.050 Freezing Point -75 0 F -35 0 F _17 0 F +50 F +180 F +27" F
A WARNING
Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes. or clothing. ANTIDOTE: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician Immediately. EYES: Flush with water for 15 minutes and get prompt
medical attention.
Charging Procedure
Charge battery with a charger no larger than 1/10 of the battery's amp/hr rating for as many hours as needed to raise the specific gravity to 1.270 or greater.
WARNING
The gases given off by a battery are explosive. Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it. If battery acid gets on anyone, wash the affected area with large quantities of cooi water and seek immediate medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in closed space. Always shield eyes when
working near batteries .
KEEP OUT OF REACH OF CHILDREN .
11 /95
10.20
ELECTRICAL Dynamic Testing of Electric Starter System

Condition: Starter fails to turn motor or motor turns slowly.
NOTE: Be sure the engine crankshaft is free to turn before proceeding. For this test a digital multitester must be used.
With tester on VDC, place tester black lead on battery negative (-) terminal and tester red lead on battery positive (+) terminal. Reading should be 12.6V or greater. Is it? No_ Yes! (A) Page 10.22 Disconnect re d engagement coil wire from start solenoid. Connect black tester wire to an appropriate ground and red lead to red harness wire at solenoid. Rotate ignition key to the start position. Meter should read battery voltage. Does it? No_ Yes! Reconnect solenoid, connect tester black lead to battery positive terminal and red tester lead to solenoid end of battery to solenoid cable. Turn key to start position. The reading must be less than .1 V DC. Is it? NoYes! (B) Page 10.22 Connect black tester lead to solenoid end of battery to solenoid cable and red tester lead to solenoid end of solenoid to starter cable. Turn key to start position . The reading must be less than .1 V DC. Is it? No_ Yes! (C) Page 10.22
Remove battery, test and/or service. Install a fully charged shop battery to continue the test. (Continue with left column)
With black tester lead on ground, check for voltage at large relay in terminal" circuit breaker in and out terminals, and across both sides (red and red/white) of the ignition switch with switch on start. Repair or replace any defective parts.
Clean battery to solenoid cable ends or replace cable.
Replace starter solenoid.
Connect black tester lead to solenoid end of solenoid Clean solenoid to starter cable ends or replace to starter cable and red tester lead to starter end of cable. same cable. Turn key to start position . The reading must be less than .1 V DC. Is it? NoYes! (D) Page 10.22 Connect black tester lead to starter frame. Connect red tester lead to battery negative (-) terminal. Turn key to start position. The reading should be less than .1 V DC. Is it? NoYes! (E) Page 10.22 If all these tests indicate a good condition, yet the starter still fails to turn, or turns slowly, the starter must be remove for static testing and inspection. Clean ends of engine to battery negative cable or replace cable.
10.21
11 /95
ELECTRICAL Electric Starter System Testing (Static)

Starter Motor Static Testing
IGNITION
SWITCH
IG TION SWITCH NI
eRN -
SYSTEM
GROUND
ALTEAN .... TOR
IGNIT ION WIRE COLORS G TERM J N~L - BROWN - GROUND e TERM INAL - REP - BATTERY M TERMI NAL ' aLACK - IGNITION 5 T EAMI NA~ - AEO/wHITE - STARTER
~Df"F ~ RUN START

R
I
: -=I -:-
R L - - - - R' . _ __ _~
RECTIfiER
(e)
e
S
CIRCU IT 6REN<EA
18 .... W l
Rro
IGNI TI O SWI TCH N

COLOR CODE
R : RED eAN : BROWN
,. ___ , ",(A).. ,/ STARTER RELAY : rt'~---'"::J'" - - - - - - - - - (8) CHASS I S GNO ~,-'...1 I lZV~TTDn' .----------(E) _________ ! _
el l( : !)LACK y ~ YELLOW R/ W : RED WI TH WHITE TA .... CER
I ,
BATTERY :
I
ENGINE GNO
-= -
~_g~JfiE_~Q.
_______ J
A-E See page 10.21 1. 2. 3. 4. 5. 6. Remove starter motor and disassemble. Mark end covers and housing for proper reassembly. Remove pinion retaining snap ring, spring and pinion gear. Remove brush end bushing dust cover. Remove housing through bolts. Slide brush end frame off end of starter. NOTE: The electrical input post must stay with the field coil housing. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate.
7. Clean and inspect starter components. NOTE: Some cleaning solvents may damage the insulation in the starter. Care should be exercised when selecting an appropriate solvent. The brushes must slide freely in their holders. If the commutator needs cleaning, use only an electrical contact cleaner and/or a non-metallic grit sandpaper. Replace brush assembly when worn to 5/16" (.8 cm) or less.
Starter Housing and Field Coil Inspection

1. 2. 3. Using a digital multitester, measure resistance between starter input terminal and insulated brushes. The reading should be .3 ohms or less. Measure resistance between insulated brushes and field coil housing. The reading should be infinite. Inspect insulated brush wire and field coil insulation for damage. Repair or replace components as required.
Armature Testing
1. 2. 3. Using a digital multitester, measure resistance between each of the segments of the commutator. The reading should indicate .3 ohms or less. Measure resistance between commutator and armature shaft. Reading should be infinity. Place armature in a growler. With the growler on, position a hacksaw blade lengthwise 1/8" (.03 cm) above armature coil laminates. Rotate armature 360. If hacksaw blade is drawn to the armature on any pole, the armature is shorted and must be replaced .
11 /95
10.22
ELECTRICAL Electric Starter Assembly Starter Assembly

Ring Gear Brush and Spring
Armature
1. Slide armature into field coil housing. 2. Lightly grease drive end bushing and install drive end frame on armature. 3. Mount starter vertically in a vice with brush end up.
4. While holding negative brushes out against their

springs, slide brush plate down onto the commutator.
5. While holding positive brush springs to the side, slide
'-....-.-
positive brushes into their holders and correctly position the springs on top of the brushes.
6. Using a non-petroleum grease, lubricate brush end

bushing and slide it onto end of armature.
7. Align threaded holes in brush plate and install dust

cover and screws.
8. Reinstall through bolts and properly tighten all

screws.
9. Lightly grease pinion shaft and install pinion, spring

stopper and snap ring.
10.23
11 /95
ELECTRICAL Starter Installation

Starter Solenoid Bench Test It is difficult to test the high amp side of the solenoid accurately on the bench. The only test which can be done on the bench is the pull in coil resistance, which should read 3.4 ohms .
Starter Installation
1. Position starter motor so there is no less than .100" clearance between the ring gear and the starter motor pinion gear. Torque Bmm drive end mount bolts to specification. Torque 6mm brush end mount bracket to engine bolts to specification.
.100 Ring Gear
2. 3.
Starter Pinion Gear
4.
Torque through specification.
bolt mount bracket nuts to
11/95
10.24
ELECTRICAL lighting System Output

Unregulated Voltage
1. Turn the multitester dial to the Volts AC (V~) position. 2. Disconnect the alternator to main harness connector at engine. 3. Connect one of the tester leads to the yellow alternator wire and the other lead to the brown alternator wire. 4. Start the engine . While observing the voltage reading, increase the engine speed to about 3000 RPM. Readings of between 15 and 45 VAC are considered normal. NOTE: Higher readings may occur on Ultra models.
"-A - = Amps AC - used to test lighting coli output Test Method 1. Discconnect engine harness from system. 2. Connect red lead to lOA (+) meter terminal. 3. Connect black lead to Com H meter terminal. 4. Start engine and let it idle. 5. Observe and record the meter reading. 150 Watt Alternators: The reading should exceed 8 amps. 200 Walt Alternators: The reading should exceed 12 amps. NOTE: Amperage readings are not dependent upon engine RPM . The reading you obtain at idle is essentially the same as the reading that would be obtained at higher RPMs. NOTE: Although the meter connection is labeled lOA it will correctly read higher AC amperage (without damage to your meter) for periods of time not exceeding 10 seconds.
',,----,
Regulated Voltage
Due to the internal construction of the LR modules and the way they function, it is not possible to accurately measure regulated voltage with most VOMs. There are two possible problems that can occur with voltage regulators: Not enough output or too much output. Not enough output would show itself because of low output from the lights. t . Disconnect the yellow wire from the regulator. 2. Start the engine and observe the headlight at idle. 3. Slowly increase engine RPM a slight amount. 4. If the light output increases above what you observed when the regulator was con nected , the regu lator or regulator ground Is probably at fault. 5. If the light output does not change when the regulator is not connected (and the lights excessively dim), this would indicate excessive system loads, poor flywheel magnets, lighting coil problems, or wiring harness problems. 6. The other possibility is too much voltage . Light bulbs that continually burn out would be an indication of too much voltage reaching the headlights. 7. Before you change the regulator due to too much voltage reaching the lights, make sure that you inspect all connections and grounds. Poor connections can cause volt age spikes which could damage the lights. NOTE: Fuel injected models have two regulators; one for lighting and one for charging the battery. Battery charging is discussed on page 10.20.
"--
10.25
91 97
ELECTRICAL Alternator Output Test - Open Circuit

Lighting System Identification - Test between labeled wires.
150 Watt Twins 200 Watt Twins 180 Watt 3 Cyl. (Carb.) 170 Watt 3 Cyl. (Carb.)
Yellow
Yellow/Red
250 Watt Twin - 500 EFI
Brown
Gray/ White Gray BrownlWhite Check Lighting Coil Between Yellow and Brown. Check Battery Charging Between Gray and BrownlWhite and GrayIWhite and BrownlWhite.
NOTE: Gray, GrayIWhite, BrownlWhite
are Bullet Type Connectors
11/95
10.26
ELECTRICAL Typical Exciter, Pulser or Lighting Coil Replacement

1. 2. Remove coil retaining screws and spacers. Using a pliers, remove epoxy from solder jOints (A) on the coil to be replaced.
3. Unsolder connection from coil.
4.
Clean solder terminals (8) on the replacement coil and re-solder to their proper wires. NOTE: Always position with numbers towards the outside.
5. 6.
Reinstall retaining screws and spacers. Using a moisture-proof sealant, seal solder joints as shown . NOTE: All soldering must be done using rosin core solder.
7.
Test resistance of each coil prior to stator plate installation. NOTE: Lighting and pulseless coils are replaced in a similar manner.
IMPORTANT: After the stator plate is reinstalled on the engine, check placement of all coil leads to prevent possible contact with the flywheel. Polaris Industries Inc.
10.27
11/95
ELECTRICAL Electrical Testing

Headlight Bulb Filament Continuity Test
1. Turn the Multitester dial to the ohms (Q) position. 2. Disconnect the wire harness from the headlight bulb. 3. Viewing the end of the bulb with the terminal blades at the 9, 12 and 3 o'clock position, connect the black multitester lead to the 9 o'clock blade. Touch the red tester lead to the 12 o'clock terminal and then to the 3 o'clock terminal, noting the resistance value of each. A reading of between 2 and 5 ohms is good. An open reading indicates a bad element.
4.
HilLo Beam Switch Testing

1. 2. Set the multitester dial to the ohms (Q) position . If the Hillo switch has not been removed from the machine, disconnect the switch to harness plug in connector. With the Hillo switch in the La beam position, checkthe resistance between the yellow and the green switch wires. The reading should be less than .4 ohms. Turn the Hillo switch to the Hi beam position and the multitester should indicate an open ci rcuit (Ol) reading . Move one of the tester leads from the green to the red switch wire. The multitester should now read less than .4 ohms.
Grn
Yel
3.
4.
5.
Low
H'IgT h
6. Turn the Hill o Switch back to the La beam position and the meter should again read an open circuit (Ol).
Yel/Rd
Seat Harness Troubleshooting

1. 2. 3. 4. Remove the taillight lens. Remove the two taillight bulbs and the brakelight bulb. Separate the seat harness from the main harness by unplugging the connector at the right rear of the tank.
HighlLow Switch
With the multitester dial set on ohms (Q) connect either meter test lead to the brown seat harness wire. 5. Touch the other tester lead to first the yellow wire and then the orange wire . Observe the readings. Readings other than an open circuit indicate a shorted harness or bulb socket. NOTE: The bulb socket tangs sometimes short to ground with the bulb removed. 6. Check between the yellow and orange wires in the same manner to check for a short between the brake and running lights. If damaged wiring is found. remove the seat. 7. Tip the seat over and remove the right side seat cover staples. locate and repair the harness problem. 8. Reinstall the staples and re-check the seat harness.
111 95
10.28
ELECTRICAL Electrical Testing Ignition Switch Testing (Non-Electric Start)

Set the multitester dial to the ohms (Q) position. Connect one of the tester leads to either of the switch terminals and the other tester lead to the other switch terminal. 2. With the switch off, the reading should be less than .4 ohms. With the switch on, the reading must be an open circuit (OL) . 3. Check the resistance between each of the switch terminals and the switch body. With the switch still in the on position , there must be an open circuit (OL) reading. Readings other than those listed indicate a defective switch. 1.
Off
On
I
Igniti on Switch
Ignition Switch Testing (Electric Start Models)

NOTE: Refer to the appropriate model and year wiring diagram for ignition switch wire colors and connections.
1.
Disconnect wires. Set the multitester dial to the ohms (Q) position.
2. With the key in the off position , check the resistance between the G (Ground, brown) terminal and the M (Mag, black) terminal. This reading must be less than .4 ohms. 3. Turn the key to the on position. The multitester should now read an open circuit (OL) .
Brn
Off
On
Start
4. Move the tester lead from the G terminal to the switch housing and re-check the reading. It should also be an open circuit (OL) . 5. Place one of the tester leads on the B (Battery, red) terminal and the other tester lead on the S (Starter, blue) terminal. With the key in the on position, there must be an open circuit (OL) reading. Turn the key to the start position. The reading should be less than .4 ohms. Readings other than the ones listed indicate a defective switch.
Blk
6.
R/W
Ignition Switch - Electric Start
10.29
11 /95
ELECTRICAL Electrical Testing

Ignition Switch Testing (Fuel InJected Models)
1. Disconnect wires. Set the multitester dial to the ohms (Q) position. With the key in the off position, connect one of the tester leads to the G terminal. Randomly connect the other tester lead to the other terminals. The only terminal that should show other than an open circuit (Ol) is the M terminal. The M terminal should read less than .4 ohms.
R/Grn
2.
3.
Off
On
Start
Y/Grn
4. Turn the key switch to the run position. Check the resistance between the M terminal and each of the other terminals, and the M terminal and the switch housing. All of these readings must be an open circuit (Ol). 5. 6. Return the key to the off position. Connect a tester lead to the B terminal. Randomly connect the other tester lead to each terminal. The readings must be an open circuit (Ol ). Turn the key tothe run position and repeatthe test. All of the readings must be an open circuit (Ol), except between the Band l terminals. This reading must be less than .4 ohms. With one tester lead connected to the B terminal and the otherto the S terminal and with the switch in any position except start, the reading should be an open circuit (Ol). In the start position, the reading must be less than .4 ohms.
Brn
Blk
RIW
7.
RlBlu
8.
R/BLU R/GRN
ISOLENOIDI
*-+-R/W
Y-GRN BRN BLK WIRE CONNECTS TO TAB ON IGN. SWITCH
11/95
10.30
ELECTRICAL Coolant High Temperature Indicator Testing
Circuit Power In - Yel
-----,1
BlkIW----. Temp
Ground the BlacklWhite wire here (with the engine runn ing) to test the light.
II
II
Engine Ground
The indicator light is controlled by a temperature/warning switch installed into the engine cooling system. When engine coolant temperature reaches approximately 205 0 F, the switch closes, completing the circuit through the indicator light to ground. The system should be tested periodically for proper operation.
Lamp Circuit Test

1. 2. Remove wire from temperature sensing switch located under thermostat housing. With engine idling, ground wire to engine. The temperature warning lamp on the console should light. If not, replace the lamp assembly or inspect wiring for shorts or open circuit.
Temp Light Temperature Sensor Test

The temperature/warning switch is normally open. 1. 2. 3. Set the multitester on the ohms (Q) scale. Disconnect the lamp wire. Connect one test probe to the switch terminal and the otherto engine ground. The meter should show an open circuit (O l ). This indicates a normally open switch . If the switch were heated to approximately 205 0 F, the contact in the switch would close and the reading would be less than .4 ohms.
If attempting to heat the sensor to close the contacts, heat only in a water bath. Never subject the sensor to an open flame to attempt to close the contacts as sensor damage will result.
10.31
11/95
ELECTRICAL Speed Control Assurance Operation

Auxiliary Kill Switch Contacts Off Idle Switch Insulator
Ignition Primary Plungers Outward Idle SwitC , : - - \ h Engine Ground
~ ![J--9~
Throttle Control Cutaway
The speed control assurance consists of two series connected switches. If one or both switch plungers are positioned inward, the circuit is open and the engine will run. At idle, with the throttle lever properly adjusted, the bottom switch circuit is open and the plunger is inward. The top switch circuit is closed, and the plunger is outward. The speed control circuit is open, allowing the engine to run . As the throttle lever is actuated to an off idle position, the top switch circuit is opened (plunger in) and the bottom switch circuit is closed (plunger out). The speed control circuit is still open, allowing the engine to run. In the event the carburetor or controls malfunction and allow the throttle cable to become slack, the circuit will close (both SWitch plungers out), grounding the ignition system and causing the engine to stop. '-'"
Speed Control Assurance Adjustment

Throttle lever free play must always provide a specified clearance between throttle lever (A) and throttle block (8). Th is clearance is controlled by the throttle cable sleeve(s) and the idle speed screw(s). Throttle Lever Freeplay.
'hM:
~::~' :" >4~\
Regular Throttle-.cli0 .030' (.25 .8 mm) EZ Tbrqttl~ . 050 17 .~~~(i.27 !;,1,5 mm) If the idle speed screw(s) is adjusted inward and the cable sleeve(s) is not adjusted to take up the throttle lever to throttle block clearance, the engine may misfire or kill upon initial throttle opening.
oiir.IQN,,~
After any idle speed adjustments are made. the throttle lever to throttle block clearance and oil pump adjustment must be checked and adjusted. NOTE: When adjustments are made on models which have more than one carburetor. refer to Section 6, Carburetion, for proper carburetor synchronization adjustments.
11 /95
10.32
ELECTRICAL Speed Control Assurance Testing

1. Set the multitester in the ohms (Q) position.
'-.....-
2.
Disconnect the switch harness from the main wire harness.
3. Connect the two multitester test leads to the two switch wires.
Test 1 - Open Circuit - Run
With the auxiliary shut-off switch in the ON position, the multitester should read an open circuit (Ol). As the throttle lever is moved from idle to off idle, the tester should continue to read an open circuit. If the tester fluctuates and the throttle lever to throttle block clearance is adjusted properly, the switch assembly must be replaced.
Test 2 - Closed Circuit - Kill
The two speed control switches must make a complete circuit to kill the engine. To check the switches, pull the throttle lever out away from the throttle block. With the switch plungers outward and the auxiliary shut-off switch in the ON position , the multitester must read less than .4 ohms resistance. Inspect wires and repair if damaged, or replace switch assembly.
Test 3 - Auxiliary Shut-Off
The multitester should read less than .4 ohms in the OFF position and an open circuit in the the ON position. Inspect wires and repair if damaged, or replace switch assembly.
Speed Control Assurance Replacement

Auxiliary shut-off and speed control assurance switches are connected and replaced as a unit from the back side of the throttle block. 1. Remove the handlebar pad andlor throttle block backing plate.
2. Slide out the auxiliary shut-off portion of the switch. 3. 4. 5. Remove the two screws securing the two speed control assurance switches. Remove the switches noting their placement in the throttle block. Replace the assembly and check its operation.
10.33
11 /95
ELECTRICAL Electric Fuel Gauge Testing

1996 RXL Model
Use the multitester's ohmmeter to test the resistance of the fuel sender. Position Empty Full Ohms 00 900 Range 030 85.594.50
The supply voltage on the RedlWhite sender wire should be higher than 2 VDG, and less than 5 VDG.
All Other Models

Use the multitester ohmmeter to test the resistance of the fuel sender.
-...../.
Position Empty Full
Ohms 950 70
Range 9097.50 4.5130
The supply voltage to the gauge should be 13.5 VAG.
Fuel Gauge
Diode Fuse (0.2A)
PurlWh
8rn
Yel
11/95
10.34
ELECTRICAL Handlebar Warmer Testing

High-Low Handwarmer Toggle Switch
'---Below are the correct wire to PIN numbers:
1. 2. 3. 4. 5. 6. 7.
Blue Yellow Blue/Red Blank Blank Blank Brown 8. Blank
High Circuit Regulated Power (A.C.) Low Circuit
HANDLEBAR HARNESS WIRE CONN. BLUE

B
=7
BROWN
Ground Circuit
YELLOW
~ 1. Disconnect handwarmer handwarmer.
BLUE/RED connector at the
2,
Measure the low range resistance between the Blue and Brown wires. The resistance should be 19.2 Q. Measure the high range resistance between the Brown and Blue/Red. The resistance should be 9.6Q,
SWITCH - HANDWARMER HI-LOW
3.
Thumbwarmer Toggle Switch

Below are the correct wi re to PIN numbers:
"-
1 White/Gray 2. Yellow 3. White/Gray 4. Blank 5. Blank 6. Blank 7. Brown 8. Blank

Testing
To Thumbwarmer Regulated Power (A.C.) To Thumbwarmer
WHITE/GRAY YELLOW
f;~~~L7 4
BROWN
Ground Circuit
Disconnect handwarmer and check resistance at handwarmef. The resistance between the Blue/ Red and Brown wires is 9.6 Q.
WHITE/GRA SWITCH - THUMBWARMER
10.35
9/96
ELECT RICAL Exhaust Thermal Sensing System (ETSS) Ultra ETSS Diagnostic Chart
Condition: Engine misfire, weak yellow or no spark at plug wires. Test Procedure: Check all ETSS system electrical connections. NOTE : The exhaust stop system module must have wires properly connected to the exhaust probe molded connector. White/Red wire to RW indicated female position and WhiteNeliow wire connected to YW indicated female position.
Disconnect black wire from stop system module. Re-test spark condition. Is proper spark being generated? Yes
No
Failure is not with ETSS system . Reference ignition system troubleshooting.
Disconnect temperature probe from stop system module and check continuity between probe wires. NOTE: Probe does not have to be removed from exhaust silencer. They should have continuity. Check continuity between probe wire and ground. Must be open. Set meter at 300 mv scale. Connect red meter lead to YW, and black meter lead to RW. Use a soldering iron to warm probe at exhaust end. Voltage should rise when heat is applied to the exhaust probe end. Does it? Yes
Replace exhaust probe. No
Replace exhaust stop system module.
Test for normal operation by starting engine and accelerating to 3500 RPM. Disconnect probe from module wires and lower rpms to 3000 200 rpm). The engine shOuld stop. Reconnect probe to module. Engine should start and idle normally. For system to operate properly there must be voltage (AC) to yellow module wire. the module must be grounded, and the black wire connected to the COl box black kill Wire.
Polarts Industnes Inc.
9/96
10.35a
ELECTRICAL Exhaust Thermal Sensing System (ETSS)

Exhaust The rmal Sensing System (ETSS)
Indy Ultra models come equipped with a thermal sensing device. This device will preve nt engine operation below 3000 RPM if the exhaust system's internal temperature is too high. When the exhaust temperature is high at low RPM, the potential exists for an exhaust flame being emitted from the exhaust outlet. The condi tion, which causes the engi ne to stop operating, is rare and generally results after prolonged wide open th rottle operation with a rapid return to idle. '-In the event that the device is activated, the engine will restart immediately, but may not continue to idle until the exhaust system cools down. the exhaust system usually cools down within one minute of shut down.
I . ~l.mPN : I
Disconnect black wire for testing purposes only. Do not operate the snowmobile with the ETSS system disconnected.
'--...
--L -_ _
~
__
~~
_________ __ __ _ ,
~'
10.35b
9/96
ELECTRICAL Ignition System Troubleshooting

Condition: No Spark
Disconnect the single black (black/white) wire from the COl Module to the ignition kill circuit. Does it have a spark?
Check the ignition switch, wire harness, throttle safety switches and kill switch for proper adjustment or short to ground. Repair or replace as necessary.
Yes-" No)
Disconnect the stator to COl module wires. Test the resistance values of the stalor coils as per the charts on page 10.3. Are the resistance values within specs?
Ves-
NOl
Isolate which component's resistance is not within specs. Remove the flywheel and stator. Recheck the resistances; look for pinched or bare harness wires: or replace the coil. Refer to page 10.27 for coil replacement procedures.
All except 3 cylinders: If the parts of the ignition system under the flywheel check OK. the only remaining component is the coil/COl module assembly. Replace the module with another with the same CU number. (See ignition data) All 3 cylinders: Disconnect and check the secondary ignition coil resistances. Reier 10 the resistance values listed on page 10.3. II the coil resistance values are within specs, replace the COl module.
Condition: Incorrect Advance/Retard

Follow the engine timing procedure for checking running tim ing at
3000 RPM. Is the timing within limits ? N<>Yes 1

Follow the engine timing procedure for checking operating RPM timing from page 10.1 B. Is the timing within limits? Ves-
Adjust the ignition timing by rotating the stator plate to correct the timing. After adjusting the 3000 RPM timing, continue with operating RPM timing if poor performance exists. (Continue on with lett column.) See ignition timing page 10.11 . If the 3000 and operating RPM timing are within limits, no other testing is necessary.
N01
Remove the ignition kill circuit by disconnecting the single black wire between the COl module and the machine hamess. Is the timing now correct? YesCheck the ignition switch, throttle safety switches. kill switch and harness lor damage which can cause intermittent shorting problems. Correct the problem .
Nol
Verify the correct CO l module by com paring the CU code on the box to the information listed in the ignition data charts at the beginning of this section. Is it the right module? Replace the modu le with the correct part and readjust the ignition timing.
NoYes l
Check the resistance of the coils under the flywheel. Compare these values to the charts on page 10.3. Are they within limits? Check the wiring connecting the coils and/or replace the coils as necessary.
NoYes l
" the 3000 RPM timi ng is within limits butlhe operating RPM timing is not acceptable, replace the COl module.
NOTE: 3 cylinder engines fire three times per revolution. At 7500 RPM the ignition is firing 21,500 times per minute. Use of a timing light not capabl e of handling these RPMs may provide an inco rrect operating RPM timing reading. Use timing light PN 2870630 or equivalent.
I
9/96
Timing Light PN 2870630
10.36
PolariS Industnes Inc.
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INDEX
A
ACCS System . ............... _.. . .. . 5.325.34 Adjusting Belt Deflection ... . 6.43 5.25 Air/Fuel Mixture Ratio ,. "."., . Alignment Bar Specifications . .. 7.10 Alignment Bar, Ski, Snow ...... . 1.28 Alignment Kit, Crankshaft. Snow ... . 1.22 Alignment Tool, Clutch Offset, 5/ 8" , Snow ....... '" 1.25 Alignment Tool , Jackshaft ............ . 1.28 Alignment Tool, P90 Clutch Offset, Snow 1.25 4_8 Alternator Controlled Switch (ACS) Testing .. , . 10.26 Alternator Output Test ... . Amp Draw Test ......... . 4.11
B
2.19 4.26 10.20 ............... 4.5 ......... 4.4 ........ 10.19-10.20 4.4 Battery Tender ..... , ...... . .. . 4.4 Battery Testing _. 10.19 6_42 Belt Deflection .... Belt Inspection . . ........................ 2.18 Belt Wear I Bum Diagnosis ................... . .. . .. 6.63 6.46 Belt to Sheave Clearance Inspection .. . ............ 2.24 Bleeding, Brake .... ' Bleeding, Brake, Fluid Change ..... . 9.109.1 1 Bleeding, Brake, System Rebuild ...... ...... . 9.11 .. .. 2.11 . Bleeding, Cooling System ..... . 3.56-3.57.3.91 3.92 Bleeding. Oil Pump ............................. ...... 3.89 Block. Fox Shock Body. Snow . . . . . . . . . . .. 1.29 Brake Adjustment 2.25 9.25 Brake Adjustment. Type M3 . .... . . .. . ... 9.27 Brake Adjustment , Type WT ........... 9.24 Brake Assembly to Chaincase. Type M3 .. . 9.169.17 Brake Assembly. Type H4 Brake Assembly. Type H5LC . . . . . . . . . . . . . . . . 9.21-9.22 .. .. .. .. .. .. 9.27 Brake Assembly. Type WT . . .. Brake Bleeding ..... _. . . . . . 2.24 .... . .... .. 9.10-9.11 Brake Bleeding, Fluid Change. .... Brake Bleeding, System Rebuild. . 9.11-9.12 Brake Cleaning and Inspection. Type H4 . . . . . . . . . . . 9.16 9.21 Brake Cleaning and Inspection, Type H5LC ............. Brake Disassembly. Type M3 .. .... . ... .. 9.23 Brake Disassembly, Type WT 9.26 2.24 Brake Fluid Replenishment . . . . . .. . . Brake Specifications, 1996 . . . .... , . . . . . . 9.1 ........... . .. . 9.1a Brake Specifications, 1997 ... Brake System, 440 XCR SP . .. ............... .. .......... 9.7 Bulietin Index By Model ............. _........ 1.2d 1.2k Bushing End Play. Oil Pump ......................... 3.54 -3.55 Backrest Adjustment .. Barometric Pressure Sensor Battery Charging . ....... . Battery Charging System Testing Battery Maintenance , EFI . Battery Service .... , . . Battery Service, EFI ... .. , .. .
Carburetor Assembly. Keihin ... . . . . . . ... 5.38d 5.28 Carburetor Component Effect vs. Throttle Opening . .. 5.25-5.27 Carburetor Component Function. . . . 5.24 Carburetor Function .................. ,. . Carburetor Leak Testing Needle and Seat. 5.38 .... 5.355.37 Carburetor Service Carburetor Service, Keihin . . . . . .......... 5.38a-5.38e . . ... . _.. , .. . . 5.355.37 Carburetor Service, Mikuni . ... Chaincase Oil Level ............ 2.7-2.8 Charge Coil Test Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.1 1.29 Charging Needle Replacement, Snow .. , . . . . . . . . . . Choke Adjustment . . . .. .. .. ... .. ... .. . 5.40 Choke and Cable Lubrication .. . . . . . . . . . 2.6 Clutch Alignment . . ... .. . . ... . ..... .... . .. 6.31 Clutch Alignment Adjustment ....... , . . . 6.45 Clutch Alignment Inspection ... . .... . . .. .. , . . . . . . 6.45 1.26 Clutch Bushing Replacement Tool Kit. Snow ......... Clutch Offset. .... ..... .... .. .. . 6.31 Clutch Offset Adjustment 6.44 6.44 Clutch Offset Inspection . ......... Clutch Service Data , t 996 .... ... . 6.2 Clutch SpeCifications, 1996 ......... . . ... 6.3-6 .5 Clutch Specifications, 1997 6.6-6.8 Clutch Specifications. 1998 . .... , . . .. . ... , .. 6.8a*b Clutch Spider Button Removal Tool, Snow .......... 1.24 Coil Replacement . .... . .... . .......... . . ,........ . . 10.27 .. .. . .. .. .. .. . .. ... 4.8 Cold Starting, EFI ............. Compression Adjustable Shocks . . . . . . . . . . . . . . .. 8.62 Compression Tool. Clutch. Snow . . . . . . . . . . . .. 1.26 Compression Tool. Shock Spring, Snow ..... . . . . . . . . . . 1.29 . . . . . . . . .. 3.82 Connecting Rod (Big End) Inspection .... Connecting Rod (Small End) Inspection . .. ... . .. 3.82 10.12 Conversion Chart, Degrees to Piston Position BTDC Conversion Table. . . . . . . . . . . . . . . . .. , . . .. 1.18 10.31 Coolant High Temperature Indicator Testing Coolant Level ......... . . . . . . . 2. 11 Cooling System . . .. 2.11 Cooling System Diagrams .......... . ... ... .. 3.91 3.99b Crankcase Inspection. . ........... .. .......... 3.81 Crankcase Temperature Sensor ....... . ................. 4.25 .......... 3.81 Crankshaft Bearing Inspection Crankshaft Indexing ... ........ . ...... 3.84-3.85 Crankshaft Straightening 3.83 Crankshaft Truing .. . .......... 3.48 . ............. , . . 3.80 Cylinder Cleaning , .. .... Cylind er Head Inspection ........ , . . . . . . 3.86 . . . . .. . . . .. . . . 3.79 Cylinder Honing ... Cylinder Measurement ................. 3.86
o
Decal Installation .......... , , . .. ......... 7.33 Decal Removal ... . .. ............... 7.33 Decimal Equivalent Chart ... . 1.17 Deglazing . . ...... . ................ . 3.79 1.32 Dial Indicator, Ignition TIming. Snow ... . . .. ........ Drive Clutch Weight Identification . ... 6.9-6.12 Drive Belt . ........... . 6.40 Drive Belt Adj ustment .................. . 6.29 Drive 8el1 Deflection ........ , .... . 6.32 Drive Be lt Installation ................ . 2.18 Drive Belt Part Numbers .......... . . 6.29 Drive 8elt Removal ... 2.18 ..... ...... .. ...... .. . 2.7-2.8 Drive Chain Tension Drive Clutch Assembly 6.29 ... ............. 6.54-6.55 Drive Clutch Bushing Service 6.24 Drive Clutch Disassembly ......... , . .. 6.23 Drive Clutch Jdentificalion . . . . . . . . . . . . . .. . . . . . . . Drive Clutch Installation 6.30 ... 6.20-6.21 Drive Clutch Operation
c
Caliper Disassembly. Type H4 9.15 9.20 Calipe r Disassembly, Type H5LC Camber Adjustment , AIlIFS 7.9d Camber Adjustment- (Travel Bar Method) XC10IXtra10CRC . 7.18a 7.12 Camber I Toe Specifications Quick Reference .. ,... ... ............. 5.2-5.3 Carburetion Condensed Data. 1996 Carburetion Condensed Data, 1997 ........ .. . . . . . . . 5.3a-5.3b Carburetor Adjustment ...... , ..... , , ... , , , . . . . . 5.38-5.39c 5.38 Carburetor Adjustment, Mikuni ... ,.
INDEX
Drive Clutch Removal . . . . . . . . . . 6.23 Drive Clutch Service Tools. . . . . . . . . . . ......... 6.1 Drive Clutch Spring Compression Rate Chart. . . . . . . . . . . . . 6.13 Drive Clutch Spring Data .................. 6. 14 Drive Clutch Spring Rate Chart. . . . . . . . . . . . . . . . . . . . . . . . 6.15 . . . . . . . . . . . . 6.13 Drive Clutch Spring Rates Drive Clutch Weight Identification . ....... . .......... S.6-6.9 Drive Gear End Play, Oil Pump ... .. .... . .... . ...... 3.893.90 Drive System Assembly, Type 3 .. 9.329.37 Drive System Disassembly, Type 3 ... 9.28-9 .3 1 Driven Clutch Assembly . . .. . . . . . . . 6.36 Driven Clutch Di sasse mbly . . .. . . . . . . . . . . . . 6.34 Driven Clutch Installation 6.39 Fluke Meter, Snow . . . . . . . .... . . . . . . . . . . . . . . '.20 Flushing the Cooling System ................ .. ..... . ..... 2.11 Fox Remote Shock Assembly .. . ..... , . . 8.81 Fox Remote Shock Disassembly . . . .... . ... . 8.79-8.80 Fox Remote Shock Recharging . . ... . , . . . . .. 8.82 Fox Shock Assembly .. 8.748.78 '--./. Fox Shock Data . .. .. .. .. .. .. . . .. . . .. . .. .. .... 8.68 Fox Shock Disassembly .. _... . ... .. ............ . 8.70-8.71 Fox Shock Hardware ......... . ............... .. 8.88-8 .89 . . .. 8.69 Fox Shock Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . Fox Shock Seal Replacement .. . ... . ....... . ... 8.72-8 .73 9.13 Friction Pad Replacement, Type H4 '" Friction Pad Replacement. Type H5LC 9.18 Front Rear Scissor Stop (FRSS) XTRA 10 Style. 8.45 Front Rear Scissor Stop (FRSS), XTRA 12 Style 8.56 Front Shock Spring Preload Adjustment 8. 11 Front Shock Spring Preload Adjustment XTRA 7.15 8.56 Front Track Shock Spring. XTRA 12 Style . . . . . . . . . 5.18 Fuel Delivery System , Typical . .. . Fuel Injectors .... .... . . . . . .... ............ 4.29 Fuel Pressure Test ... 4.11 ""Fuel Pump Exploded View . . . ... 5.43-5.45 Fuel Pump Maintenance. . . . . . . . . . . ......... 5.42 Fuet Pump Operation . . . ......... _. . . . . . . . . .. 5.42 Fuel Pump. EFI .. . .. .. .. .. .. .. 4. t 0 Fuel Rall .... .. . ........ .... . ... . 4.12 Fuel Recommendation 3.6-3.8 Fuel Recommendation-199b EFt Mode ls 3.9 Fuel System . . . .......... 2.20 Fuel System Deicers ............ 3.9,5.3 .. . ....... 7.21-7.22 Fuel Tank/Seat Removal Fuse Unk ... ........ . 4.7
Driven Clutch Operation Driven Clutch Removal

Driven Clutch Springs . . . . . . . Driver, Transmission Seal/Bearing, Snow Driveshaft Sprocket Installation . . . . . . . Dropping ReSistor . ... .. .... . .........
.. .. .... .. . . .,.......
6.22 6.33 6. 15
1.32 9.4 4.29
E
ECU Diagnostics . . ... ... ............................... 4.30 EFt Accessory Note . ........... ..... 4.2 EFt Electronics . . . .......... 4.28-4.32 EFI Fuel System Maintenance ...... 4.10-4.14 EFt Fuel System Testing. .. . . . . .................. 4.10-4.15 EFt Operation . . . . . . ........... 4.1-4.3 . .. 4.9 EFI System II Operation. . EFI Troubleshooting .. ... ... ,.... . .. 4.22 . . . . . . . . . . . . . . 10.34 Electric Fuel Gauge Testing Electric Starter Assembly ....... ,.. . . ... . .. .. 10 .23 Electric Starter System Testing . . .. . 10.21- 10.22 Electronic Control Unit . . . . .. 4.19 Electronics Operation , EFI System III . . . ...... . ...... 4.1B-4.17 .. 4.18-4 .27 Electronics Testing . EFI System III . . . ... 3. 41 -3. 44 Eng ine Assembly, 3 Cylinder Monoblock . . . .. .. . . . 3.66-3.71 Engine Assembly, BOOnOa Case Reed Engine Assembly, 800 Case Reed .. . . . .. . . . 3.75-3.78 ...... 3.24-3.27 Engine Assembly, Fan Cooled Twin Cylinder . . 3.32-3.34 Engine Assembly, Liquid Twin Cylinder ..... Engine Assembly, Monoblock EC58PL . ..... . .... . 3.19-3.21 Engine Assembly. PL Series Reed Valve ...... 3.32-3.35 Engine Assembly. PL Three Cylinder. _. , ... _, ......... 3.25-3.28 . ....... . .... 3.14 -3. 16 Engine Assembly, PL Twin Cylinder. . Engine Assembly, RXL . .. . ...... . .... . . 3.483.51 Engine Disassembly, 3 Cylinder Monoblock . .. 3.35-3.40 Engine Disassembly, 600nOO Case Reed . . . .. 3.60-3.65 Engine Disassembly, BOO Case Reed . . ........ .. 3.72-3.74 Engine Disassembly. EC59PUEC68PL . . . . . . . . . . . . .. 3.363.59 EngIne Disassembly. Fan Cooled Twin Cylinder ... 3.19-3.23 Engine Disassembly, liquid Twin Cylinder ... 3.28-3.31 . .. .. 3.17-3.18 Engine Disassembly. Monoblock EC58PL . . .. . .. .. 3.29-3.3 1 Engine Disassembly. PL Series Reed Valve . . ... 3.223.24 Engine Di sassembly. PL Three Cylinder . ,. Engine Disassembly. PL Twin Cylinder.. . . .. . .... 3.10-3.13 Engine Disassembly. PM Twin Cyllnder . . . . . . . ..... 3.8-3.9 . . . 3.45-3.47 Engine Disassembty. RXL .. . ... . .... 3. 14-3.18 Engine Installation, Typical. . . .. 3.10-3. 13 Engine Removal. Typical ...................... 2.25 Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . Exhaust Thermal Sensing System (ETSS) ...... . ........ 10.35a
G
Gasoline Volatility ..... .... . .. .... . 5.16 . . . . . . . .. 1.22 Gauge, Cylinder Compression. Snow ...... . . Gauge, Pressure, Snow . 1.31 Gearing Chart . . . . . . . . . . . . . . . ..... _..... . , . . . . . . . . .. 6.1 Glossary of Terms . .. . .. . ... _. . ... , .33-1.35 Greasing Driveshaft Bearing . .... .. ......... ,. . ... 2.5 Greasing Jackshaft Bearing . . . . . . . . .. . . . . . . . . . . .. . . . . .. 2.5
H
Handlebar Adjustment 2.23 7.13 Handlebar Centering. . . . . . . . . . . . .............. Handlebar Centering XTRA . 7.16 Handlebar Centering-CAC . ..... . .. . ............. . 7.18c . . ... . .. . 7.20 ,. Handlebar Torque - Aggressive Style. . . 7.20 Handlebar Torque - Evolved Style .. . .. . . . .. . .. . ... Handlebar Torque - Indy Style 7.20 10.35 Handlebar Warmer Testing . Headlight Adjustment . .... . ... _...... . . ... 2.202.22 Headlight Bulb Filament Continuity Test . .. . . . .. .. to.28 Headlight Bulb Installation . ....... _........ . .. 2.202.22 Headlight Bulb Removal . . . . _............ . . . .... . . .. 2.202.22 Helix Angles and Effects .... .. . . 6.28 Helix Ramps . .. _............... . .. ............ 6.37 10.28 Hi La Beam Switch Testing .... . .. ......... 8. 168.17 Hi- Fax Replacement . .. . .... . ... . 1 ~4 Holding Fixture. Orive Clutch. Snow .. . 1.24 Holding Tabs. Replace ment. Snow ... . . . ........... . Hone Selection. 3.79 1.21 _ Hone. Cylinde r. Snow Hone, Replacement Set, Snow . . ... . .. . Honing Oil, Snow ..... ...... .. . Honing Procedure Honing to Oversize
F
Final Toe Adjustment (Exce pt CRC) ... .. . __ . , . . . . . Float Chamber Venting . . . Float Level Adjustment .. Float System .. .. . ........ . .
7.15 5. t7 5.38 5.24
1.22 1.22 3.80 3.79
INDEX
Hood Adjustment - Evolved Style Hydraulic Brake System Operation Hydrometer, Battery, Snow .... 7 .317.32 .. 9.5 . ... 1.32
Nosecone Alignment Indy Style .... . Nosepan Replacement - Evolved Style Nosepan Replacement Indy Style .......... .
7.30 7.29 7.28
o
IFS Adjustment XTRA 10 Style .. . 8.44 IFS Adjustment, XTRA 12 Style ...... ........... . 8.53 lFS Specifications. 1996 ." .. _. . . . . . .. . ........ 8.1 IFS Specifications. 1997 . .. .. . . ...... . .. _. _... B.2 IFS Specifications. 1998 __ ....... " ..... , ... _. 8.2a Ignition Switch Testing .... . , . . . . . _..... . 10.29-1 0.30 .. ... . ............... 8.43,8.62 Indy Select Shock . .... _,_ 1.2-1.29 Information Bulletins . ...... _. Injector. . . . . . . _... _...... .. . _.... _ 4.14 Installation Tool. Clutch Spider Rolier, Snow . . . . . . . . . . . . . . . 1.24 Installation Tool, Jackshaft, Snow . ...... _... , . _. . . .. 1.28
Oil Pump Adjustment . .. ....... . ..... . . . ...... Oil Pump Bleeding . . . . . . . . . . . . . . .
3.89 3.89
011 Pump Bushing End Play Adjustment
..... 3.543.55
Oil Pump Drive Gear End Play Adjustment . 3.89-3.90 . . . . . . . . . . . . . . .. 3.88 Oil Pump Operation . . . . . . . . . . . . . . . . . . Open Circuit Voltage Test ............... . .... 10.19 Operating RPM Timing Check. . ......... 10.18 Operation, Rear Suspension .............. . .. 8.8B_9 Output Volume Test ........... . . . . . .. 4.11 Oxygenated Fuel . . .. .... .... .. . . . . . . .. 3_9 Oxygenated Fuel Carbureted Models ........... .. 5_ 30
Oxygenated Fuel EFI Models .. .. .. .. . 5.31
Installation Tool , Piston CClip. Snow. Installing the Center Bulb , . . ... , .. _. . . Installing the Side Bulbs ...... . . . . . . Inlake Air Temperature Sensor ....... "... . ......... ,.
1.21 2.21 2.21 4.25
Oxygenated FuelCarbureted Models . ... ....
. ..... , 3.8
p
J
Jackshaft Speed vs. MPH Chart.
Jet Needle .. .. .. .. P85 Clutch Bushings .. .... .. . . . . .. . . 6 .476.52
. ........ . .... .. ... 9.2

.. .. . .. .. . . .. .. .... 5.26
Jet NeedleJNeedle Jet . ................................. 5.22 Jet Part Numbers. . . . . . . . . . . . . . . . .. . . . . . . 5.1 Jet Part Numbers, Keihin .. . . . . . . . .. . . . .. . . . . . 5.1 a 5.1 Jet Part Numbers. Mikuni .. . . . . . . . . . Jetting Compensation Charts, 1996 ., .... ,.. . ....... 5.8-5.15 Jetting Compensation Charts, 1997 ,... . S.lSa-S.1Sj Jetting Compensation Charts. 1998 . S.lSk-5.1So "-.,., Jetting Guidelines ..... .. ,. " ..... ,.... . ... .. .......... . 5.29
P85 Dri ve Clutch Exploded View. . . . . . . . . . . .. 6.16 P-85 Drive Clutch Movable Sheave Bushing Installation ..... 6.50 P-85 Drive Clutch Movable Sheave Bushing Removal 6.49 P-85 Driven Clutch Cover Bushing Installation ..... .... , . . .. 6.48 P-85 Driven Clutch Cover Bushing Removal _.......... 6.476.48 P85 Driven Clutch Exploded View. ..... . .... . .. 6.13-6.17 P85 Driven Clutch Movable Sheave Large Bushing Installation 6.52 P85 Driven Clutch Movable Sheave Large Bushing Removal 6.51 P85 Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . .. 6.27
P90 Clutch Bushings ..... . . . ............... 6 .536.60
L
Lighting System OUlput Load Test ..... . Lubrication , .. Lubrication, Suspension ... ,
... 10.25 10.20 .. 2.52.10 ... . .................... 2.92.10
M
Main Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5.27 Main System. . . 5.23 Maintenance Inspection, 1000 Mile 2.2 Maintenance Inspection, 150 Mile. 2.1 Maintenance Inspection, 2000 Mile 2.3 Maintenance Products . . . . . .. . . . .. . . .. . 2.4 Master Cylinder Assembly. Type 3 ...... .... 9.79.9 Master Cylinder inspection, Type 3 . . . . . . . . . . . . . .. , . . .. 9.7 Master Cylinder Removal, Type 3 . ........... . . . 9.6 Master Cylinder Service Tool Kit, Snow. . ... .. 1.31 Measuring Belt Deflection ...... , . . . . . 6.43 . .. 1.41 .13 Model ldentlfication. 1996 ..... . .... .... . Modelldenlification, 1997 ................. 1.13a-1.131 MR Adjustments .. .......... . . .. .. .......... . .... 4.27 Multi meter Usage 10,810. 10 MuHitester, Snow. . ... .. ... .. .. 1.20
P90 Drive Clutch Exploded View . . 6.18 P9Q Driven Clutch Exploded View ............. . .. 6.19 P90 Driven Clutch Service ... . ... . 6,30 Paint Codes, 1996 . 1.14 Paint Codes, 1997 . . . . . . . . . . ... , . . . . 1.14a PUot Ai r Screw . . . _. . . . . . . . . . . . . . . . . . . . . . .. . . . . . 5.25 Pilot Jet .. . . . . . . . . . . . . . ........... ... .. .. .. 5.25 . . . . . . . .. . ... . ...... " 5.20 Pilot System .......... Piston Inspection/Measurement ... .. .... . . 3.87 Piston Pin Inspection . . . . . . . . . .. .. . . . . . . . 3.82 Pi ston Ring End Gap, Installed . ... . ..... 3.2-3.4 ......... . , . . . . . . . . . . . . .. 3.87 Piston Ring Installation . . .. .......... '" 3.87 Piston Ring Installed Gap . . Piston/Cylinder Clearance Measurement 3.7 Port Chamfering ... , . . . . . . . . . . . .. .. .... .. . 3.80 Power Up Component Testing. 4.7 Power Up Testing ..... ........ 4.6 Powering Up, EFI .. . . . ... . .. .... . . 4.2 7.10b Preliminary Toe Adjustment ......... . ... . .. . ... Pressure Regulator .. . .. , . . . . . . . . . . . . . . . . . . 4.12 ..... .. _. .. . . . . . . .. 1.1 Publication Numbers, 1996 Publication Numbers. 1997 ...... .. ..... ....... .... 1.1 a Puller, Drive Clutch. THandle , Snow 1.24 Puller, Driven Clutch , Snow. . . . . . .. ...... ...... . 1.26 Pull er, Flywheel, Snow .. , .. ,. . . . . . . . . . .. . . . . 1.23 1.21 Puller. Piston Pin. Snow ...................... _. . . . . Pump Kit. Vacuum, Snow ............... . . . .. . . , . . . . . . 1.32
R
Reamer. Tapered, Drive Clutch Bore. Snow ......... 1.25
8.46 8.56 ... 8 .568.57 8. 13 Rear Rear Scissor Stop (RRSS) . XTRA 10 Style .. . Rear Rear Scissor Stop (RRSS), XTRA 12 Style .. .
"---
N
Needle Bearing Inspection Needle Jet ........ .
3.82 5.26
Rear Suspension Adjustments, XTRA 12 Style Rear Suspension OpefBtion . . . . ...... , .
INDEX
Rear Suspension Specifications, 1996 .. .... . ....... 8.2-8 .3 Rear Suspension Specifications, 1997 . .......... , .... 8.4-8.5 Rear Suspension Tuning ......... 8.10 Rear Torsion Spring , XTRA 12 Style ... _. . . . . . . .. 8.57 Rear Track Shock Spring. XTRA 12 Style ................. 8.56 Recharging Kit, Gas Shock , Snow ..... 1.29 Recoil Assembly ..... . 3.97-3.100
Recoil Disassembly ............... , . .

Recoil Starter Spring Replacement . . . . .
. . . . . . . . . .. 3.96
. . 3.96-3.100
Reed Valve Inspection 3.77 Relay Coils. . . . ... ...... 4.7 Removal Tool, Clutch Spider, Snow .. 1.25 Removing the Center Bulb. . 2.21 Return Hose ... . .............. ,. _. 4.12 Reverse Kit Maintenance.. .. . 9.579.58 Reverse Kit Service llps .... . . . . . . . . . . . .. 9.56 Rivet Tool , Tunnel. Snow .. . . . . . . . . . . . . . . 1.30 Removing the Side Bulbs . . . . _..... _. 2.21 ROM Chip Removal _.. _.. . .. ... .. _.. . 4.20 . . . . . . . . . . . . . . . . .. . . . . . . .. 4.1 ROM Identification . . . . . . . . . . . . . . .. .. 2.59-2.66 Routing - Carburetor Vent line .. Routing - Fuel line .... . . . .................. 2.41-2.44 . .. .... ...... . ..... 2.45-2.47 Routing - Handlebar Harness . . ............... 1004-10.7 Routing - Indicator lights Routing - Miscellaneous. . ... 2.67-2.70 . . . . . . . . . .. . . . .. . . . . .. .. . 2.48-2.49 Routing - Oil line . .. 2.50-2.51 Routing - Oil Vent line .,........ . .. , 2.292.30 Routing - Speedometer Cable .. ... . .... , . . . . . Routing - Vent Lines .... . .. 2.52-2.58 . .. 2.36-2.40 Routing - Wire Harness/Fuel Line. . . . . Routing Wire Harness/Speedometer Cable ... 2.31-2.35 RPM Sensor ... ' . .. 4.23 8.10 Rubber Track Clip Replacement
s
Seal Cover Replacement ........ ........... . . 7.237.25 ." 7.27-7.27a Seat Length Matrix ..... Seat Removal .... .. ... . ,... . ..... ,. 7.217.22 Select Monitor Scrolling . .. ... , . . . . .. . ................... 4.22 Select Monitor, Snow ......... . . . . . . . . . . . . . . . . . . .. 1.20 . .. 1.21 .29 Service Bulletins .............. .. 1.37-1.38 ServIce Tips ... . ......... ,. Service Videos . . . . . . . . . . . . . . . . . .. . . . . . . . . 1.3 Set Up Width, Maximum. .. . . ........ 7.10a Set Up Width-CRC .. _.. .. .. 7. t 8a Shock Installation. XTRA 12 Style 8.64 Shock Removal. XTRA 12 Style _..... _.. 8.63 Shock Tuning .. 8.10 Shock Valving . . . . . .......... 8.83 Shop Supplies/Accessories 1.16 Ski Alignment - XTRA .. 7.17 Ski Installation 7.14 SkiSkagRemoval-IFS .. .. ..... 7.19 Ski Skin Installation. . 7.19a Ski Spindle Bushing Replacement 7.18e-7. 18f Slide Cutaway ..... 5.21 Socket, Drive Clutch Spider Nut. Snow 1.25 Spark Plug Selection. . . . . . . . . . . . ...... " .... 2.17 Specific Gravity Test ............. 10.19 ....... 7.10 Specifications. Alignment Bar Specifications, Brake, 1996 . ... . ...... . ....... 9.1 Specifications, Brake, 1997 . .... ... ...... . .... 9.1a Specifications, Charge Coil Test .. , . .. , ....... , ..... . 4.1 Specifications. Clutch, 1996 . . . . . . .... 6.3-6 .8 Specifications, Coil Resistance . . .. 10.3 .... .... .. .. . . .. ,. 3.1 -304b Specifications, Engine. Specifications. IFS. 1997 ... __ ... _. 8.2 .. 10.2- 10.2b Specifications, Ignition, 1996 , . Specifications, Lighting, 1996 ... ..... ......... 10.110.1a Specifications, Rear Suspension. 1996 . . . . . . . . . . . ... 8.2-8.3
Specifications, Rear Suspension, 1997 ................. 8.4-8.5 ..... , . . .... . ......... 8.84-8.87 Specifications, Shock Valving . 7.2-7.2b Specifications, Steering .. .......... ,. Specifications, Torque. .......... . .. . .. . .. 1.15-1 .16 Specifications, Torque. Body and Steering 7.1 Specifications, Torque, Engine . 3.3-3.6 .... 8.14-8.15. 9.3b Specifications, Torque, Suspension . .. 9.3-9.3b Specifications, Track Drive Data, ..... Specifications, Track, ... ...... 9.3d-f Speed Control Assurance Adjustment . . . 10.32 10.32 Speed Control Assurance Operation .... Speed Control Assurance Replacement ,.. 10.33 10.33 Speed Control Assurance Testing . . . . . . . Spider Assembly .. .... ... .. ... ... . 6.22-6.24 Spider Button Shimming . . . . 6.27 Spider Indexing . , . . . ..... ......... . . .. 6.32 Spider Roller Installation ... . . . .... .. .... 6.26 Spider Roller Removal . .... . .................. _.. . _.. , 6.26 Spindle Centering, IFS . ................ . .... . ... . .... . 7.10a Spindle to Chassis Centering - CRG ..... , . .. 7.18a Spring Tension, Rear, XTRA 10 Style . .......... 8.46 "'Springs, Accessory. XTRA Ute ............... 8.26 Springs, Coil. XTRA Ute . . . . . . . . 8.26 Springs. Optional. Sport Style .. . _.. . __ ..... 8.21 Springs, Optional, WideTrak Style 8.37 .. ..... ... 8.59 Springs. Optional. XTRA 10 Style . _ Springs. Optional. XTRA 12 Style 8.58 Starter Installation . .. . ......... 10.24 Starter Solenoid Bench Test 10.24 5.19 Starter System . . . . . ...... , . . Steering - Standard IFS . ... . .... . ..... 7.10-7.14 Steering-XTRA 10and 12 .. . . ... 7.15-7.17 7.18g Steering Arm Installation .,..... Steering Assembly Exploded View .... ,. . . . .... " 7.4a-7.9a Sleering Inspection - Standard IFS .......... . .. . .. . 7.10 Steering Inspection, - All Models.. ........ . ... ... .. . . . . . 7.10 ".. Steering Rod End Orientation ....... ,.. . ... . .... . . .. 7.3 Steering Specifications . . ....... ... , ............... 7.2-7.2b ....-/ Steering Stop Adjustment . . . . 7.16 Steering Slop Adjustment - Standard IFS .............. 7.14 Steering Stop Adjustment - XTRA . .. . ....... _...... ... 7.16 Storage ................ .. _.. .. .... .. _.. . .. .. .... 2.26-2.28 Stud Installation . . . . . . . . . . . .. . . . . . . . . . . . . . . 9.63 Support Block. Piston. Snow . . . . . . . . . . .......... 1.21 Suspension Adjustment .. ..................... 8.24 Suspension Adjustment Sport Style 8.20 Suspension Adjustment - Standard Indy Style ... . . 8.35-8.36 8.13-8. 14 Suspension Adjustment WldeTrak Style Suspension Adjustment - XTAA 10 Style 8.42-8.43 8.24 Suspension Adjustment Features. . . . . . . 8.21 Suspension Adjustment. Sport Style Suspension Adjustment. XTRA 12 Style 8.55 SuspenSion Adjustment, XTRA Lite Style .. 8.25-8.27 ... SuspenSion Adjustments , Rear . . . . 8.25 . . . . 8.19 ~ Suspension Components - Sport Style .... Suspension Components WideTrak Style ... 8.12 Suspension Components. XTRA 10 Style ....... . ..... 8.39-8.41 Suspension Components, XTRA 12 Style . .... . ........ 8.51-8.52 Suspension Exploded View, Sport Style ,.... 8.18 Suspension Exploded View, Standard Indy Style ... . . 8 .338.34 Suspension Exploded View, WideTrak Style . ........... 8.28-8.29 Suspension Exploded Vtew, XTRA 10 Style 8.38 Suspension Exploded View. XTRA 12 Style, 8.28. 8.49. 8.50 SuspenSion Exploded View. Xtra Ule Style. 8.22 Suspension Lubrication. 2.9, 2.10, 8.27 Suspension Set Up, Rear. XTRA 12 Style, 8.36. 8.60 Suspension, Rear Components, Xlra Ute Style, 8.23
INDEX
Track Removal, Two Sprocket Driveshaft ... . .. 9.489.49 Track Tension .. ., ........ ,.. .. ,. 2.132.16 Track TenSion Data . ........... . . . . . . . . . . . . . . .... 2.13 Traction . . ... 9.599.64 Transmission Overhaul, Series 300 .... . . .. . ... 9.51 9.55 Transmission , Suspension / Track Assembly, WideTrak .. 9.439.47 Transmission. Suspension / Track Removal , WideTrak ,. 9.409.42 Troubleshooting, Body and Sleering . . . . . . . . . . . . . . . . . . . . 7.34 . ... 5.475.48 Troubleshooting . Carburetion .. ... . ....... . Troubleshooting , Clutch. . . . ... . . . . . . ... 6.616.62 Troubleshooting. EFI ......... ' .. , ........ 4.22 Troubleshooting, Engine . . . . . . . . . . 3.101-3.102 Troubleshooting, Ignition System . ... .... 10.36 Troubleshooting, Oil Pump , . . .. . .... . _ . . ..... .. , ,. 3.88 10.28 Troubleshooting, Seat Harness , Troubleshooting. Suspension ,_ .. ,. .. . ...... ' , . . 8,908,94 Tunnel Mounting Positions, .. , ... .. ...... ".. 8.14
T
Taillight Assembly Replacement - Indy Style . . . . . . . . . . . . . . 7.26 Taillight Bulb Replacement ......... 2.22 Tap Drill Chart ... . .. . . .. . . .. . . 1.19 Throttle Body ... .. . .. .. .. 4.15 Throttle Cable Lubrication . ..................... 2.6 Throttle Opening vs. Fuel Flow . . . . . . . . . 5,26 Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . .. 4.24 Throttle Synchronization . . . . . . . . . . . . . . . . . . . .. 5.39 Throttle Synchronlzation-Keihin ...... .. ... ... .. S.39c Throttle Synchronizatior'\Mikuni .. ..... ..... 5.39b 5.27 Throttle Valve . . . . . . . . . . . . . .. . . . nming Advance Curves, Typical. . ...... .... . 10.11
v
VM30SS VM34SS VM34SS VM38SS Exploded Exploded Exploded Exploded View . . . .. . .. .. . .. .. . ~ew . . . . .. . .. .. . .. .. .. View with ACCS .... ...... , .. ,. View, ... . "...... . .. . .. ' , , , 5.4 5.5 5.7a 5.6a
liming Ught, Snow .. . ...
...........
1.20
Timing Procedure . Three Cylinder COl. . . . .. 10 .15-10.17 Timing Procedure , Twin Cylinder Fan COl . . . . . . . . . . . . . 10.13 Timing Procedure, TwIn Cylinder Liquid COl . . . . . . . 10.14 Toe AdJustment Standard IFS ,." ..... . , ... _. , . _, . .. . . 7.13 Toe Adjustment, Finat (Except CRG) ................... . 7.15 . ... , . . . . . . . . . . . .. 7.1 Ob Toe Adjustment, Preliminary .. ... Toe AlignmentCRC . ..... , .... , .... ,........... 7.18c 6.45 Torque Stop Adjustment . . . . . . TorsIon Bar . . . . ...... . . . 8.6 Torsion Bar Instailation . . . . . . .. . . , . . _. . . .. 8.7 .. . ...... . .... .. . ... . , . . . . . . . 8.7 Torsion Bar Removal . .. ... . 2.12 Track Alignment . TrackClipRemoval. . .. . . . ..... 8.17 1.27 Track Clip Removal Tool , Snow. . 8.17 Track Clip Replacement .... . . . . 1.27 Track Clip Tool. Camoplasl, Snow 1.27 Track Clip- Tool, IOl, Snow . . . .. ....... . .. . . . ....... 2.12 Track Maintenance .. Track Maintenance/Alignment . .. .. 2.122.16 Track Removal. Four Sprocket Oriveshatt . 9.50
w
Warranty Policy ... , .. , .. , . . ... ' .. , .. 1.36 Water Pump Rebuild ' ,..... 3.533.55 WaterTrapService . . , ' """,., 5.46 Wheel Kits .. .. . . .. . .. .. .. .. .. .. . ..... 8.658.67 Width , Maximum Set Up , . , , .. , . ' . , , , , , , , , .. 7,1Oa Wiring Diagram. 1995500 EFI I SKS I RMK . 4.34-4.35 Wiring Diagrams. 1996 .. . 10.39-10 ,44 Wiring Diagram. 1997 . ....... _...... ,. 10.54 -10.62a Wiring Diagram. 1998 .. . ....................... , 10.6310.72 Wrench, Spanner, Snow. . . ...... , . 1.30 Wrench, Strap, Snow .. . . , . . . . . . . . . . . . . . 1.31
XLT SP Model #099AB6AS Rev. 02
1999
PARTS MANUAL PN 9914839 and MICROFICHE PN 9915650 3/99
TABLE OF CONTENTS
XLT SP 099AB6AS Parts Manual
B
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . D2
C
CARBURETOR . . . . . . . . . . . . . . . . . . . . . CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . CONSOLE and WIRE HARNESS . . . . . CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . C12-13 B8 A10 B4 C1 C8 C9 B1 C2 B9 C3
N
NOSEPAN . . . . . . . . . . . . . . . . . . . . . . . . . A7-8 NOSEPAN FOIL . . . . . . . . . . . . . . . . . . . . A9
O
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . D1 OIL TANK/AIR BOX . . . . . . . . . . . . . . . . . C7
D
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . .
P
PART NUMBER INDEX . . . . . . . . . . . . . . D5-10 PISTON and CRANKSHAFT . . . . . . . . . C10
R
RAIL MOUNTING (SUSPENSION) . . . . B10 REAR TORQUE ARM . . . . . . . . . . . . . . . B13 RECOIL STARTER . . . . . . . . . . . . . . . . . . D3
E
ENGINE MOUNTING . . . . . . . . . . . . . . . . C5-6 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . C4
F
FOX SHOCK - REAR TRACK . . . . . . . . FRONT SUSPENSION and SKI . . . . . . FRONT TORQUE ARM . . . . . . . . . . . . . . FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . B14 B5-6 B12 C14
S
SEAT and GAS TANK . . . . . . . . . . . . . . . STEERING . . . . . . . . . . . . . . . . . . . . . . . . . STEERING - HANDLEBAR . . . . . . . . . . SUSPENSION . . . . . . . . . . . . . . . . . . . . . A6 B2 B3 B11
H
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-14 HOOD - FOAM/FOIL . . . . . . . . . . . . . . . . A11
T
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . D4 TUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
I
INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . A12
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . C11
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
1999 XLT SP SPECIFICATIONS

BRAKES
Type Hydraulic Disc/3/4 Piston
GRAPHICS
Backrest Pad Color Belly Pan Color Front Shock Color Front Springs Color Grab Bar Color Handlebar Cover Headlight Pod Color Hood Color Hood Accent Colors Snow Flap Color Nosecone, Top/Bottom Color Rear Rack (Cargo) Color Rear Idler Wheel Color Ski Color Tunnel Color Tunnel Stripe Color Windshield (Size/Color) Windshield Base Color N/A Black Black Bright Red N/A Black Molded N/A Black Metallic New Purple C/Bright Silver/Regal Teal/Violet C/Medium Blue Black/Silver Logo Black Metallic/Black N/A Bright Red Black Composite Black New Purple C/Violet C/Regal Teal/Bright Silver/White Standard/Clear Black Dots
CAPACITIES
Coolant Capacity (qts.) Chaincase Oil Capacity (oz.) Dry Weight (lbs.) Fuel Tank Capacity (US/lmp. Gal.) Gearcase Oil Capacity (oz.) Height (in.) Length (Incl. skis) Oil Capacity (qts.) Ski Center Distance (in.) Ski Length (in.) Ski Width (in.) Width (in.) 3 9 503 11.8/9.7 N/A 46.5 108 2 41 40 5.5 46.5
CHAINCASE
Drive Chain Length Drive Shaft Sprocket Reverse Transmission Sprocket Ratio 68 (3/4) 9T-2W Accessory 22:41
ELECTRICAL
Headlight Type Headlight (watts) Indicator Light Thumbwarmer Handwarmers Dual Halogen 2 X High 60/Low 55 X 2 Oil/Brake/Acc/Hi Beam/Temp Standard Hi/Low
DRIVE CLUTCH
Center Distance (in.) Clutch Offset (in.) Clutch Type Clutch Weight Ring Gear Spider Spring Color 12 5/8 P-85 10M Bushed Accessory Cast Dark Blue
TRACK
Track Construction Track Length Overall Track Pattern/Lug Height Track Width Polyester-C 121 New Block/.82 15
DRIVEN CLUTCH
Covers Diameter (in.) Helix Angle Spring Position Spring Type Yes 10.75 R32 2 Silver
SUSPENSION
Front Type Front Travel (in.) Radius Rods IFS Shocks/Spring Adjustment Torsion Bar Rear Type Front/Rear Torque Arm Limiter Rear Travel (in.) (Rear Idler) Shock: Front Track Rear Track Springs: Front Torque Arm Rear Torque Arm Rear Torque Arm Spring Dia. X-10 CRC 9 Adjustable Select w/Thread Adjustment 5/8 X-10 XTRA-10 121 Quick Adjustable 10.2 Ryde FX FOX IFP Position Sensitive Coil/Variable Torsion/Coil/Variable Rate .359/77
ENGINE SPECS
Engine Model Number Alternator Output Bore X Stroke (mm) Displacement (ccs) Carburetion/Throttle Body Carburetor Model Cooling Cylinders Cylinder Plating Electric Start Ignition Timing Dynamic Deg. BTDC Ignition Type Oil Injection Spark Plug Type (RFI) EC58PL160 12V 280W 65x60 597 3 Mikuni TM 38 Flat Slide Liquid 3 Iron Liner Accessory 28_@ 3000 RPM CDI Yes RN2C Champion
Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.
1999 POLARIS SNOWMOBILE PUBLICATION NUMBERS

MODEL XLT SP MODEL # 099AB6AS OWNERS MANUAL & SUPPLEMENT 9914668 & 9914857 PARTS MANUAL 9914839 PARTS ASSEMBLY MICROFICHE INSTRUCTIONS 9915650 9914784
TUNNEL
XLT SP 099AB6AS
6
3 2 1 4
17 32 17 17
25 9
9 24 23 15 16 5 21 17 18 19 17 19 17 20 14 13 12 11 22 10 5
31
17 26 30 29 28 27
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1012281 5242493-067 7512057 1012703-067 7661840 5432149 7621418 5241053-067 7661841 2670169 5811263-070 5431995-070 7558301 7552801 7515159 7661850 5242492-067 7661638
Qty. Description 1 1 2 1 70 1 5 1 25 1 AR 2 4 4 4 2 1 110 Footrest, RH Mount, Console, RH Screw Tunnel (Incl. 8,17,22,25) Rivet Flap, Snow Rivet Panel, Tunnel Back Rivet Bumper, Rear Bumper Strip, Vinyl Cap, Bumper Washer Washer Bolt Rivet Mount, Console, LH Rivet
Ref. Part No. 18 5241320-067 5241321-067 19 1012280 20 1012812-067 1012813-067 21 1012441 22 5241268-067 5241269-067 23 7621222 24 7080227 25 5241303-067 5241304-067 26 7621452 27 5222857 28 7080416 29 7080398 30 1012615-067 31 5222687-067 32 5431385
Qty. Description 1 1 1 1 1 1 1 1 2 2 1 1 4 1 2 4 1 1 1 Bracket, Corner Brace, LH Bracket, Corner Brace, RH Footrest, LH Support, Tunnel, LH Support, Tunnel, RH Plate, Clutch Guard Pad, Rear Suspension, LH Pad, Rear Suspension, RH Rivet Snap, Male Pad, Front Susp. Mounting, LH Pad, Front Susp. Mounting, RH Rivet Guard Adaptor, Drive Plug, Hole Plug, Hole Bulkhead Bracket, Rope Guide Guide, Rope 8/98
A5
SEAT and GAS TANK

XLT SP 099AB6AS
5 2 1 3 4 7 6
9 8
10
32 30 31
12 13 14 11 10 15 16 17 20
29 28 27 26 25
Ref. Part No. 1 2682381 2682382 2 2511248 5810513 3 5410815 4 7080550 5 7080549 6 7621337 7 7080548 8 7546908 9 5432008 10 7522004 11 1012643-067 12 7555746 13 7661046 14 5432002 5432003 15 4030045 Qty. Description 1 Asm., Seat (Incl. 1,4-20,22-26,30-32) 1 Asm., Seat Cover 1 Cap, Fuel w/Gauge 1 Gasket 1 Grommet, Fuel Tank 2 Grommet, Relatch, 1 Bottom 2 Grommet, Relatch, 1 Top 4 Rivet 2 Twist Lock, Relatch, 1 w/Hole 8 Nut, Nylon 1 Reflector, Seat, Center 4 Screw 1 Bracket, Mount, Seat 7 Washer 6 Rivet 1 Housing, Lens, LH 1 Housing, Lens, RH 2 Bulb, Brakelight
19 18
21 22 23
12
24
Ref. Part No. 16 4032084 17 5432031 5432032 18 7512054 19 7511954 20 7541901 21 7515159 22 7052037 23 7080402 24 8450003-1525 25 7541925 26 7052023 27 7080003 28 8450040-153 29 8450061-600 30 7080559 31 7052095 32 2460541
Qty. Description 2 1 1 14 2 2 2 1 2 AR 1 1 1 AR AR 1 1 1 Bulb, Taillight Lens, LH Lens, RH Screw Screw Nut, Well Bolt Fuel Pickup w/Strainer Ring, Compression Line, Fuel Nut, Nylok Fitting, Outlet, Double, 90 Degree Clamp, Hose Line, Fuel Line, Fuel Cable, Tank Retention Fitting, 90 Degree Harness, Taillight 8/98
A6
NOSEPAN
XLT SP 099AB6AS
14 15 13 12 1 11 2 10 9 3 4 10 19 12 18
16 17
7 5
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 7621334 5811263-070 5431782-177 5224585 5431824-070 7512078 7515178 7558212 5240834 7621402
Qty. Description 2 1 1 1 1 12 4 8 1 8 Rivet, Bulbex Bumper Strip, Front, Vinyl Nosecone, Upper, Black Metallic Bumper, Front Nosecone, Lower, Black Screw Screw Washer Bracket, Hinge Rivet
Ref. Part No. 11 12 13 14 15 16 17 18 19 5210728 7621330 7078009 5222769 7075350 7080523 5431928 5222903 7621429
Qty. Description 1 8 1 2 1 1 1 1 4 Hinge, Clutch Guard Rivet Decal - Troubleshooting Clip, Belt Retainer Decal - Engine and Clutch Knob, Clutch Guard Bumper, Clutch Knob Guard, Clutch Rivet 8/98
A7
NOSEPAN
XLT SP 099AB6AS
6 4 3 2 1 5 7 8 9 10 11 8
12 31 10 29 26 20 27 28 30 32 17 16 16 18 14 19 20 21 22 24 23 13
25
15
Ref. Part No. 1 7621318 2 5220984 3 2670162 2670163 4 5811264-070 5 7515166 6 5431913 5431914 7 7542103 8 7621601 9 5224590-067 5224591-067 10 7661638 11 5410370 12 7621472 13 5432668-067 14 2670071 15 5410344 16 7621418
Qty. Description 4 2 1 1 2 2 1 1 2 2 1 1 5 2 2 1 2 1 8 Rivet Guide, Hood Bumper Extrusion, LH Bumper Extrusion, RH Bumper Strip, Vinyl, Side Screw Cap, Bumper End, LH Cap, Bumper End, RH Nut, FLEXLOC Rivet Trim, Rear Pan, LH Trim, Rear Pan, RH Rivet Strap, Hood Latch Rivet Nosepan Reflector, Amber Plug, Hole Rivet
Ref. Part No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 7621467 5242763-067 7661643 7515177 7558221 7621507 2670165 2670166 7542122 5131070 7552604 2670167 7512024 5240698 7621484 5240785 5240786 7621425
Qty. Description 32 1 3 8 4 8 1 1 2 1 4 2 2 1 4 1 1 8 Rivet Brace, Nosepan, Black Rivet Screw Washer Rivet Corner Brace, LH Corner Brace, RH Nut, Nylok Brace, Pan, Drilled Washer, External Tooth Hinge, Lower Screw Support, Pan Brace, Upper Rivet Guide, Hood, LH Guide, Hood, RH Rivet 8/98
A8
NOSEPAN FOIL
XLT SP 099AB6AS
3 2 1
5 6
9 10
Ref. Part No. 1 2 3 4 5 5811157 5811159 5811134 5811132 5811136
Qty. Description 1 1 1 1 1 Foil - Tape, Pan, RH Foil - Tape, Pan, RH Foil - Tape, Pan, RH Foil - Tape, Pan, RH Foil - Tape, Pan, RH
Ref. Part No. 6 7 8 9 10 5810496 5810465 5810838 5811129 5811130
Qty. Description 1 1 1 1 1 Foil - Tape, Pan, RH Foil - Tape, Pan, RH Foil - Tape, Pan, RH Foil - Tape, Pan, RH Foil - Tape, Pan, Center 8/98
A9
CONSOLE and WIRE HARNESS

XLT SP 099AB6AS
4 5 6 8
9 10
2 3 1
7 11
12
11
12
14 20 19 17 18 21 13 15 16
Ref. Part No. 1 5410611
Qty. Description 1 Key, Ignition w/Cap NOTE: When ordering ignition key PN 5410611 be sure to specify if for an A, B, C, D or E switch. Letter code will be labeled on underside of switch body behind console. Key dot code found on key cap (i.e. one dot = A, two dots = B, etc.). 1 Nut, Switch, Ignition 1 Nut, Choke Control 1 Kit - Ignition Switch (Incl. 1) 1 Washer 1 Kit - Choke Lever 1 Cable, Choke Control 1 Console
Ref. Part No. 9 10 11 12 13 14 15 16 17 18 19 20 21 7512069 7555792 7558301 7512252 2460506 7541925 4060123 5210650 7512031 4020153 4020057 4020133 2460517
Qty. Description 2 2 4 4 1 2 1 1 2 2 1 1 1 Screw Washer Washer Screw Harness, Wire, Handlebar Nut, Nylok Regulator, LR7 Sink, Heat Screw Housing, 1 Circuit Housing, 5 Circuit Housing, Socket Harness, Wire, Main 9/98
2 3 4 5 6 7 8
7547035 5432944 2200357 7571610 2201439 7080734 5431781
A10
HOOD - FOAM/FOIL
XLT SP 099AB6AS
4 3 5 6
9 13 12
11
10
Ref. Part No. 1 2 3 4 5 6 7 5811125 5811123 5811119 5811121 5811118 5811122 5811124
Qty. Description 1 1 1 2 1 1 1 Foil, Tape, Side, Outer, RH Foil, Tape, Side, Inner, RH Foil, Tape, Center, Top, RH Foil, Tape, Center Louver Foil, Tape, Center, Top, LH Foil, Tape, Side, Inner, LH Foil, Tape, Side, Outer, LH
Ref. Part No. 8 9 10 11 12 13 5811115 5811116 5811127 5811117 5811128 5811126
Qty. Description 1 1 1 1 1 1 Foam, Hood, Center Foam, Hood, LH Foil, Tape, Rear Vent, RH Foam, Hood, RH Foil, Tape, Side, RH Foil, Tape, Vent, RH 8/98
A11
INSTRUMENTS
XLT SP 099AB6AS
5 4 6 3 1 2 7 8
10 11
13
12
14
18 16 15
17
Ref. Part No. 1 2 3 4 5 6 7 8 9 3280243 4030050 4030052 3280244 5811250 7516303 3280201 5432292 7522024 2460568
Qty. Description 1 3 4 1 1 4 1 1 1 1 Speedometer, MPH Bulb, Dash Bulb, Warning Drive, Angle Gasket, Drive, Angle Screw Cable, Speedometer Clamp, Harness, Wire Screw Harness, Wire, Low Level
Ref. Part No. 10 11 12 13 14 15 16 17 18 7516304 7516305 2652163 3280242 2652164 2652162 7555904 7512026 3280196
Qty. Description 2 2 1 1 1 1 4 6 1 Screw Screw Case, Low Level Tachometer Panel, Reflector Lens Washer Screw Asm., Instrument Cluster 8/98
A12
HOOD
XLT SP 099AB6AS
3 4 2 5
6 14 13 8 7 12
15
16 18 19
17
20 21 5 10 11 22
28 30 29 33 31 31 32 27 32 34 35 39 38 26 34 37 36 35 27 21 21 33 25
23 24
28
A13
HOOD
XLT SP 099AB6AS
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 5431780-070 5410970 5432267 5432573-177 7621509 5811094 5431901 7541925 2431009 2870448 4032063 7542122 7558301 7512222 5020811 7041397 5333296 7621485 5432614 4032072 5240757-067 Qty. Description 1 4 1 1 8 1 1 1 1 2 2 2 2 2 1 1 1 2 1 1 1 Housing, Instrument Retainer, Windshield Windshield, Standard, Clear Retainer, Windshield, Black Rivet Foam, Headlight Nut, Pivot, Headlamp Nut, Nylok Headlight (Incl. Bulbs) Bulb, Headlight, Halogen Retainer, Bulb Nut, Nylok Washer Bolt Washer, Shoulder Spring, Adjustment, Headlight Spacer, Tube Rivet Plenum, Air Intake Screw, Adjustment, Headlight Bracket, Headlight Ref. Part No. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 7555904 7512026 2631895-177 5430733 7621334 7080372 7080569 7670082 5241146-067 5411075 5241142-067 5241140-067 5241138-067 5241144-067 5211536-067 1012246-067 1012247-067 7555734 5431884 7661644 7621433 Qty. Description 6 6 1 2 4 1 1 28 2 1 2 2 1 2 2 1 1 2 2 2 8 Washer Screw Hood, Black (Incl. Foil and Foam) Cup, Hood Latch Rivet Clamp, Retainer Cable, Hood Retainer Clip, Speed Screen, Louver, Side, Upper, RH Retainer, Tab Screen, Louver, Center, Upper, RH Screen, Louver, Center, Middle, RH Screen, Louver, Center, Lower Screen, Louver, Side, Lower, RH Plate, Hinge Hinge, Upper, LH Hinge, Upper, RH Washer Bushing, Hinge Pin, Hitch Rivet 8/98
A14
DECALS
XLT SP 099AB6AS
3 2 1 4
10
RH
9 8 7 6 5
11
18 8
12 14 13 15 16 17
19
10 22 20 5
Ref. Part No. 2201339 1 7076360 2 7076876 2200891 3 7077382 4 7077585 5 7076596 6 7077362 7 7077388 8 7077386 9 7077364 10 7077792 11 7075369 Qty. Description 1 Kit - 99 XLT SP Hood Decals (Incl. 3,4,7,8,11,18,19,21) 1 Decal - Track/Seat, English/French 2 Decal - POLARIS, Flags, Seat 1 Kit - Decal Application (Seat Decals) 1 Decal - Hood Top, RH 1 Decal - Hood Center, INDY, Flags 2 Decal - CRC 1 Decal - IFS XTRA, RH 1 Decal - Hood Side, XLT, RH 2 Decal - SPECIAL 1 Decal - Tunnel, RH 2 Decal - Position Sensitive 1 Decal - Warning, Dash, English, LH Ref. Part No. 12 7075371 13 7075373 14 15 16 17 18 19 20 21 22 7077530 7074202 7075372 7075374 7075370 7077381 7077361 7077387 7077363 Qty. Description 1 Decal - Caution, English, LH 1 Decal - NO PASSENGER, Warning, English 1 Decal - POLARIS, Domed 1 Decal - Ignition 1 Decal - Caution, French, RH 1 Decal - NO PASSENGER, Warning, French 1 Decal - Warning, Dash, French, RH 1 Decal - Hood Top, LH 1 Decal - IFS XTRA, LH 1 Decal - Hood Side, XLT, LH 1 Decal - Tunnel, LH 8/98
21
LH
B1
STEERING
XLT SP 099AB6AS
19 20 16 5 4 3 2 1 6 7 8 9 10 4 2 1 15 5 6 7 4 12 11 8 9 40 14 13 18 4 17 22 23 24 21
25
44 43 42 38 41
39 14 38 37
23 30 26 29 28 27
12 36 35
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 5411220 5010384 1820579 7542403 7542503 7555721 3563907 7080433 5010385 1822562 7060174 7542401 5333411 7542424 7512404 7060164 7080424 7542303 1822432-067 7517377 7080804 1012604-067 Qty. Description 2 2 1 4 2 2 4 2 2 1 3 3 1 3 1 1 3 4 1 2 2 1 O-Ring, Teflon Tube, Spacer Asm., Idler Arm (Incl. 7,8) Nut, FLEXLOC Nut, FLEXLOC Washer Bushing Fitting, Lubrication Spacer Arm, Pitman (Incl. 7,8) Rod End, RH Nut Rod, Drag Link Nut, LH Bolt Rod End, LH Fitting, Lubrication Nut, Nylok Post, Steering Screw Cable Tie Hoop, Steering
11
31 32
34 33
Ref. Part No. 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 7542103 7661638 7512275 1012618 7661643 7542404 3021081 7517428 5411249 5211796-067 7621323 4020139 7512564 7558702 5020857-067 7556053 7060166 7542411 7515434 7515415 7555893 1822408 Qty. Description 6 1 4 1 7 1 1 4 2 2 8 2 2 2 2 2 2 2 2 2 2 1 Nut, FLEXLOC Rivet Bolt, Carriage Stop, Torque Rivet Nut Stop, Rubber Bolt, Carriage Boot, Tie Rod Plate, Boot Rivet Clip, Rosebud Bolt Washer Tie Rod Washer Rod End, LH Nut, FLEXLOC Bolt Bolt Washer Rack, Steering 8/98
B2
STEERING - HANDLEBAR
XLT SP 099AB6AS
1 2 17 15 14 16 1 3 4 5
13 6
12 11
7 8
10
Ref. Part No. 1 2 3 4 5 6 7 8 9 7621509 5431620 1823169-067 5431096 5432634 2460311 7542122 5630382-067 5630187-067
Qty. Description 8 1 1 2 2 2 4 2 1 Rivet Cover, Handlebar, Top Handlebar, Adjustable Plug Grip, Handlebar, Black Heater, Grip, Hi/Lo Nut, Nylok Block, Handlebar, Upper Block, Handlebar
Ref. Part No. 10 11 12 13 14 15 16 17 7517238 7511840 5431491 5431530 7515197 5431490 4110175 4032081
Qty. Description 4 4 1 1 4 1 2 2 Bolt Screw Cover, Handlebar, Lower Cover, Reverse Lever Screw Cover, Handlebar, Upper Switch, Handwarmer, Hi/Lo Cap, Switch 8/98
B3
CONTROLS
XLT SP 099AB6AS
1 2 3 4 5 6 14 7 8 9 10 8 13 12 11 8 15 32 20 26 21 22 23 25 24 27 19 33 31 30 29 28 18 16 17 38 37 36
35 34
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7661624 7710503 7555730 2010180 5432970 5431592 4110106 7555727 7511848 7512465 7710401 7511858 5432261 4110136 5430604 2050083
Qty. Description 1 1 2 1 1 1 1 1 6 1 1 2 1 1 1 1 Pin, Retaining Ring, Retaining Washer Lever, Thumb w/Connector Lever, Throttle Block, Throttle/Brake Switch, Auxiliary Shut-Off Washer Screw Screw Ring, Retaining Screw Wire Holder Switch, Headlight, Hi/Lo Adaptor, Block Asm., Master Cylinder (Incl. 16-19,26-38) 2 Screw 1 Cover, Master Cylinder 1 Gasket, Master Cylinder
Ref. Part No. 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 7512287 7041229 5240809 5020670 7511866 5431389 7080447 7542122 5630847 5410163 5020679 5410164 7041311 5332931 7555708 5630342 7512290 5130955 1930673 1930662
Qty. Description 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Bolt, Brake Lever Spring, Lever, Park Brake Lever, Park Brake Bushing, Lever, Park Brake Screw Tag, Warning, Park Brake Strap, Tag, Park Brake Nut, Nylok Lever, Brake O-Ring Piston, Master Cylinder Seal, U-Packing Spring, Master Cylinder Bushing Washer Clamp, Master Cylinder Bolt Housing, Master Cylinder Baffle, Master Cylinder Washer, Baffle, Master Cylinder 8/98
16 7512050 17 5630338 18 5410527
B4
FRONT SUSPENSION and SKI

XLT SP 099AB6AS
2 1
5 4 6
48 58 59 2 57 56 55 44 43 42 41 40 45 54 53 52 51 50 49 48 47
9 6 10 6 11
12 13
60 61
14 12 15
6 47 28 50
16 17 19 18 20 21 22 23 6
47 46
39 38 37 34 35 33 28 32 28 31 36 28
24 25 26
27 28 29 30
B5
FRONT SUSPENSION and SKI

XLT SP 099AB6AS
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 5241641-067 5211345 7542703 7558702 7512551 7542439 5224742-067 5432038 7621477 5241660-067 5241661-067 7661643 7555721 5010310 5410872 7512557 1822517 1822518 5432561 5241777-067 5241778-067 3573909 7556509 3574208 6230102-067 7080306 1820610-070 7542324 7555843 2871815 7555832 7512596 7515514 Qty. Description 1 2 2 2 2 10 1 2 6 1 1 2 4 2 2 2 1 1 2 1 1 2 2 2 2 2 2 6 6 1 8 2 2 Brace, Bulkhead, Front Strap, Spacer, Bottom Nut, FLEXLOC Washer Bolt Nut, FLEXLOC Bar, Sway Bushing Rivet Arm, Steering, LH Arm, Steering, RH Rivet Washer Bushing Pivot, Rubber Bolt Arm, Trailing, LH (Incl. 13,14) Arm, Trailing, RH (Incl. 13,14) Slide, Sway Bar Stop, Steering, LH Stop, Steering, RH Bushing, Flanged Bushing Bushing, Flanged Spindle Fitting, Lubrication Ski, Plastic Nut Washer Skag, Carbide, 3, 120 Degree Washer Bolt Bolt Ref. Part No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 7515307 7542452 7542321 5432209 7661209 7542438 5241912-067 5243127 5411094 1500063 5431734 7041551-067 5630580 7041523 5010158 7080433 7517583 7515415 5010127 5431486 1822375-067 1822377-067 7542711 7061011 7512684 7621452 5240699-067 7661638 7542503 7061010 7542520 Qty. Description 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 8 2 2 2 2 2 4 1 4 2 2 2 Bolt Nut Nut Toe, Ski, Plastic Pin, Cotter Nut Support, Ski, Rubber Retainer, Ski, Rubber Stop, Rubber Retainer, Spring Slotted Ring, Spring Preload Spring, Compression Retainer, Slotted Shock, Gas, IFS, Select Bushing Fitting, Lubrication Bolt Bolt Bushing Bushing, Radius Rod, Outer Radius Rod, Upper Radius Rod, Lower Nut, Rod End Bolt Rivet Brace, Pan, Lower Rivet Nut, FLEXLOC Rod End Nut 8/98
B6
BRAKE
XLT SP 099AB6AS
1 2 3
13 4 5 6 12 11 8 10 9 7
Ref. Part No. 1 2 3 4 5 6 7 8 7515521 7552603 7555806 1930733 1930734 2200466 2200467 4110135
Qty. Description 2 2 2 1 1 1 1 1 Bolt Washer Washer Bracket, Caliper Piston and Seal (Incl. 6) Kit - Seal, Piston, Caliper Kit - Clip, Spring (Qty. 2) Switch, Stoplight
Ref. Part No. 9 2201019 2201020 10 11 12 13 1930825 1930737 1930755 1930735
Qty. Description 1 Kit - Brake Pad, Type 69 (Incl. 7) 1 Kit - Brake Pad, Heavy Duty (Incl. 7) 1 Asm., Brake Caliper (Incl. 4-11,13) 1 Kit - Caliper (Incl. 5,6,13) 1 Line, Brake 1 Bleeder 8/98
B7
CHAINCASE
XLT SP 099AB6AS
1 2 3 4 5 6 7 2 22 18 21 5 6 16 15 19 20 14 17 9 10 11 12 8
13
Ref. Part No. 1 2 3 4 5 6 7 8 3610030 7515551 7542404 3514309 7718406 3221098 1332096 3553002 5630122 5630123 7558702 7662210 9 7571620
Qty. Description 1 Jackshaft (See Drive Train Pg. B9, Ref. 16) 2 Seal, Oil 1 Screw 1 Nut 2 Bearing 2 Ring, Retaining 1 Sprocket, 22T, 3/4W 1 Tightener 1 Bearing, Chaincase Idler 1 Block, Tightener 1 Wheel, Idler 2 Washer, Thrust 1 Pin, Chain Tightener 1 Washer
Ref. Part No. 10 11 12 13 14 15 16 17 18 19 20 21 22 7661401 5410277 5630413 7512242 7542811 7515350 7571618 3224070 7542451 3222101 7052115 5131568 7515477
Qty. Description 1 1 1 4 1 1 1 1 1 1 1 1 1 Pin, Cotter Gasket, Chaincase Cover, Chaincase, Cast Bolt Nut, FLEXLOC Bolt Washer Chain, 68P, 3/4W Nut, Nylok Sprocket, 41T, 3/4W Plug Chaincase w/Ratchet Mount Screw 8/98
B8
DRIVE TRAIN
XLT SP 099AB6AS
4 5
8 9 10 11 7 6
12
13 14 15 17 18 21 20 16
19 29
28 27 26 25 22
15 33 32 31 30 19 23 20
Qty. Description 1 2 2 1 2 3 1 3 1 1 1 1 1 1 1 1
23 24
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 7515369 7555701 7555734 5020913 3211070 7512377 7556509 5020837 5241359 5811095 7721116 3514525 5222751 7542324 1332207 7710422
Qty. Description 1 1 AR 1 1 1 3 AR 1 1 1 1 1 1 6 1 1 Bolt Washer Washer Spacer, Input Shaft Driven Clutch, 36 Degree Adj. (See Driven Clutch Pg. C3, Ref. 16) Belt, Drive Bolt, Carriage Bushing Spacer Flangette w/Grease Zerk Gasket, Jackshaft Key Bearing, 1 Jackshaft Flangette Nut, Nylok Jackshaft (Incl. 13,17) Ring, Retaining
Ref. Part No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 1910276 5020588 5410613 5431419 5410675 7542423 7515428 1590269 1012434 3514526 3280019 5241178 3280017 5830012 3280116
Disc, Brake, Slotted Sleeve, Seal O-Ring Dipstick O-Ring Nut, Flange Cover, Chaincase, Cast (See Chaincase Pg. B8, Ref. 12) Bolt, Carriage Drive Shaft (Incl. 27,28,29) Flangette w/Screws Bearing, Drive Shaft Bushing, Speedometer, Metal Flangette Key, Speedometer, Square Gasket, Drive Adaptor Adaptor, Drive w/ Zerk 9/98
B9
RAIL MOUNTING (SUSPENSION)

XLT SP 099AB6AS
14 15 1 16 17 21 2 13 3 4 2 11 12 9 10 8 5 7 6 25 38 27 24 28 30 31 33 29 32 34 35 34 37 23 22 26 25 23 1 10 18 20 19
32 36
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1594082-243 5431531 3514305 7718407 7621435 5433005 7542122 5810554 5222629 7542439 7542411 7542525 5211790 5811097 5222629 7515545 5131113 5410925 7515455 5020943 5130530
Qty. Description 4 8 4 4 2 2 2 2 4 4 6 2 2 2 4 4 4 4 2 2 2 Asm., Bogie Wheel (Incl. 2-4) Insert, Bearing (2 per Wheel) Bearing, Roller (1 per Wheel) Ring, Retaining (1 per Wheel) Rivet Cover, Rail Tip Nut, Nylok Bumper, Suspension Angle, Reinforcement Nut, Nylok Nut, FLEXLOC Nut, Nylok Bracket, Rail Reinforcement Bumper, Suspension Angle, Reinforcement Screw Mount, Bumper Bumper, Pivot Arm Bolt Nut Block, Idler Bolt Adjusting
Ref. Part No. 20 1541336 1541337 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 7621501 7512538 7555852 5333116 7621476 5630399 5432982 5332787 5130570 7555806 7555976 7555804 7515433 7512404 7553201 7512659 5332786 7515175
Qty. Description 1 Asm., Rail, Xtra-10, LH (Incl. 6,8,13,19) 1 Asm., Rail, Xtra-10, RH (Incl. 6,8,13,19) 4 Rivet 2 Bolt 4 Washer 2 Bushing 8 Rivet 2 Spacer, Bogie Wheel 2 Roller, Spring 2 Spacer 2 Bracket, Bogie Wheel 2 Washer 2 Washer 4 Washer 2 Screw 4 Bolt 2 Washer 2 Screw 2 Spacer 2 Screw 8/98
B10
SUSPENSION
XLT SP 099AB6AS
7 8
9 10 10 12 11 13 14
5 1 2 4 1 23 53
6 6 21 20 19 6
11 10
10
9 8
22 23
19 18 3 4 2 15 1
6 7 15
12 16 17
24
2 1
Ref. Part No. 7517247 7552603 7555806 5241443 7542411 7555893 7515526 7571629 1594083-243 7718407 3514012 10 5432535 11 7555918 12 1594087 1 2 3 4 5 6 7 8 9
Qty. Description 4 4 4 2 3 4 2 2 2 2 2 4 2 2 Screw Washer Washer Bracket, Shaft Support Nut, FLEXLOC Washer Bolt Washer Asm., Idler Wheel Ring, Retaining Bearing Spacer, Idler Bushing Wheel, Idler
Ref. Part No. 13 14 15 16 17 18 19 20 21 22 23 24 5333283 5020744 7517353 3514012 7710444 5521405 5333404 1540982-067 7080433 5020724 5020723 5411379 5222839 5222840
Qty. Description 1 Spacer, Idler, Center 1 Shaft 2 Screw Bearing (1 Per Wheel) Ring, Retaining (1 Per Wheel) 2 Hi-Fax 2 Shaft 1 Arm, Pivot, Rear 2 Fitting, Lubrication 1 Shaft 1 Shaft, Arm, Pivot 1 Track 48 Clip, Slide 48 Clip, Guide 8/98
B11
FRONT TORQUE ARM

XLT SP 099AB6AS
12 13 14 18 15 2 3 4 5 11 6 7 8 10 9 6 8 8 24 18 34 7 29 7 30 29 28 31 27 26 18 25 22 23 16 19 20 20 1 17 19 21
33
27
32
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 7517247 7552603 7555893 5020908 1541203-067 7542324 7555716 7080433 7010050 5241276-067 5430671 7041693 5630580 7041253-067 7542403 5333028 5020561 7542411 7555795
Qty. Description 2 2 2 1 1 2 6 2 2 1 1 1 1 1 1 1 1 3 2 Screw Washer Washer Shaft Arm, Torque, Front Nut Washer Fitting, Lubrication Bolt, Eye Retainer, Spring Shield, Spring Shock, Track, Front Retainer, Spring, Slotted Spring, Compression Nut, FLEXLOC Spacer Bushing Nut, FLEXLOC Washer
Ref. Part No. 20 21 22 23 24 7555957 7515472 1540942-067 7515438
Qty. Description 2 1 1 1 1 1 2 4 2 2 2 2 1 2 2 Washer Screw Arm, Shock Screw Shaft (See Suspension Pg. B11, Ref. 19) Shaft (See Suspension Pg. B11, Ref. 22) Spacer Bushing Asm., Bogie Wheel (See Rail Mounting Pg. B10, Ref. 1) Screw Screw Strap, Limiter, Front Shaft, Arm, Pivot (See Suspension Pg. B11, Ref. 23) Nut, Nylok Bolt, Carriage 8/98
25 26 5332784 27 7556301 28 29 30 31 32 7515433 7517313 5411498
33 7542344 34 7512377
B12
REAR TORQUE ARM

XLT SP 099AB6AS
23 4 5
7 6 8 9 10 11
31 30 6 29 28 26 25 24 10 11 21 23 12 11 14 22 25 6 27 20 18 24 19 17 16 15 21 13
24
Ref. Part No. 7517247 7552603 7555893 5131910 1541290-067 7542411 7512377 5333536 7010050 7080433 7542324 7517232 7080394 5432983 7512257 5131911 1543023 3514305 7718407 18 7555787 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Qty. Description 2 2 2 1 1 3 1 1 1 2 3 1 2 1 2 2 2 2 2 2 Screw Washer Washer Shaft, Arm, Torque, Rear, Upper Arm, Torque, Rear Nut, FLEXLOC Bolt, Carriage Shaft, Arm, Torque, Rear, Lower Bolt, Eye Fitting, Lubrication Nut, Nylok Screw Clip, Push-On Roller, Spring Screw, Set Collar, Bearing Lock Wheel, Carrier Bearing (1 Per Wheel) Ring, Retaining (1 Per Wheel) Washer
Ref. Part No. 19 7041627-067 7041628-067 7041629-067 7041630-067 7041631-067 7041632-067 20 21 22 23 24 25 26 27 28 29 5433007 7555716 5411061 7512310 5020561 7555795 5333559 1541015-067 7515472
Qty. Description 1 Spring, Torsion, LH, Optional (.347/77 Degree) 1 Spring, Torsion, RH, Optional (.347/77 Degree) 1 Spring, Torsion, LH, Standard (.359/77 Degree) 1 Spring, Torsion, RH, Standard (.359/77 Degree) 1 Spring, Torsion, LH, Optional (.375/77 Degree) 1 Spring, Torsion, RH, Optional (.375/77 Degree) 2 Sleeve, Spring, Torsion 3 Washer 1 Strap, Limiter, Rear 1 Bolt 4 Bushing 2 Washer 1 Spacer 2 Rod, Shock 1 Bolt 1 Shock, Track, Rear (Fox Position Sensitive)(See Fox Shock-Rear Track Pg. B14) 1 Bushing 1 Bolt 8/98
30 5010422 31 7512410
B13
FOX SHOCK - REAR TRACK

XLT SP 099AB6AS
17 16 15 1 2 14
18 15
13 12 11 10 9 1 3 8 7 6 19 5 20 24
23 21 4 22
Ref. Part No. 7041728 1 1500193 2 1500187 1500018 1500022 3 1500186 4 1500148 5 1500152 6 1500017 7 1500191 8 1500002 9 1500015 10 1500016 11 1500192 12 1500190
Qty. Description 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 Shock, Track, Rear O-Ring Piston, IFP Screw O-Ring Asm., Bearing Eyelet Shaft Plate, Top-Out Collar Ring, Piston Bushing, Backup Nut, Lock Sleeve, Bypass Ring, Rebound, Blue
Ref. Part No. 13 1500188 14 1500004 15 1500072 1500019 1500023 16 1500189 17 5020657 18 5432040 19 1500021 20 1500020 21 1500025 22 1500024 23 1500070 24 1500071
Qty. Description 1 1 1 1 1 1 2 2 1 1 1 1 1 1 Body O-Ring Asm., Air Valve Screw O-Ring Body Cap Sleeve Bushing O-Ring O-Ring Wiper, Inner Wiper, Outer Screw Ball 8/98
B14
COOLING SYSTEM
XLT SP 099AB6AS
3 1 2 4 5 2 6
28 28 29 28 14 15 14 10 26 22 21 25 24 11 23 11 19 20 18 17 27 30 31
30 7 8
10 28
30 32 28 33
28 9
11 10
8 16 15
14
12 15 10 13 8
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 7542122 7558302 5430743 5431096 5810279 7512240 5431733 7661638 2511239 7080562 7080564 2511257 5222863 7041079 5521242 5410350 5410673 Qty. Description 1 2 1 1 1 1 1 60 1 5 4 1 2 3 3 1 1 Nut, Nylok Washer Cap, Bottle, Overflow, Drilled Plug, Cap, Overflow Gasket, Cap, Overflow Bolt Bottle, Overflow w/Fittings Rivet Extrusion, Cooling, Center Clamp, Hose, Silver Clamp, Hose, Grey Extrusion, Cooling, Side, LH Guard, Cooling Extrusion Spring, Hose Retainer Tubing, Convoluted Hose, Side to Center, LH Hose, Center to Pump Ref. Part No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 5411396 5431931 5241334 2511256 5411010 7042041 8360012 7080563 5410557 5411011 7080307 5810831 8450003-1525 7052038 2530024 2511258 Qty. Description 1 1 2 1 1 1 1 1 1 1 8 1 AR 1 1 1 Tubing, Convoluted Filler, Remote Coolant Bracket, Oil Tank Cap, Pressure Hose, Engine Out/Filler Spring, Hose Retainer Trim, Edge Clamp, Hose Hose, Crossover Hose, Filler Out, RH Clamp, Hose, Green, Large Foil, Tape Line, Coolant Valve, Check Filter, Coolant Extrusion, Cooling, Side, RH 8/98
C1
DRIVE CLUTCH
XLT SP 099AB6AS
3 4 5 6 9 11 12 10 16 9 17 13 14 15 18 7 8
Ref. Part No. 2200386 1 2 3 4 5 6 7 8 9 7512265 7552801 3576516 7710417 7041526 5020425 5430945 1321457 5430445
Qty. Description 1 Kit - Clutch Update (Incl. 7-8,12,16,17) 6 Bolt 6 Washer 1 Cover, Bearing, Garmax 1 Ring, Retaining, Cover 1 Spring, Clutch, Dark Blue 1 Nut 6 Washer 3 Roller and Bushing 6 Button, Guide
Ref. Part No. 10 5210754 5210753 5242981 5210752 11 1321528 12 7515105 13 3576502 14 5010188 15 7541906 16 5020422 17 2200387 18 1321733
Qty. Description AR AR AR AR 3 3 1 1 3 3 1 1 Spacer (.050) Spacer (.032) Spacer (.025) Spacer (.020) Weight/Bushing (10M) Pin, Weight, Hardened Bearing, Sleeve Insert, Moveable Nut, FLEXLOC Pin, Roller Kit - Shim, Drive Clutch Asm., Drive Clutch, Basic, 84 (Less 5,11) 8/98
C2
DRIVEN CLUTCH
XLT SP 099AB6AS
3 4
9 10
11 12
13
14
15
16
Ref. Part No. 1 2 3 4 5 6 7 8 9 7512048 5210749 7714804 7556804 5630853 7721103 7041499 3569803 7555898 7556076
Qty. Description 14 1 1 3 1 1 1 1 AR AR Screw Plate, Driven Ring, Retaining Washer (.03) Ramp, Driven, 32 Degree Key Spring, Clutch, Silver Bushing, Driven, Large DU Washer (.02) Washer (.025)
Ref. Part No. 10 11 12 13 14 15 16 7555865 5020653 5222878 7515133 5230101 5430466 1322192
Qty. Description 1 3 1 3 1 3 1 Washer Pin, Driven, Adjustable Cam, Driven, Adjustable Bolt Cap, Driven Button, Ramp Asm., Driven Clutch, R-32 (Incl. 1-14)
8/98
C3
EXHAUST SYSTEM
XLT SP 099AB6AS
1
16
3 7 4 6 5 8
16 12 11 17 16 6 5 13 14 10
15
Ref. Part No. 1 2 3 4 5 6 7 8 9 1260678-029 7042029 1260885-067 7621467 7555788 5410467 5242913 7621433
Qty. Description 1 1 1 4 AR 2 1 4 3 Resonator Spring, Exhaust Stinger, Outlet Rivet Washer, Thrust Dampener, Vibration Bracket, Resonator, Rear Rivet Gasket, Exhaust (See Cylinder Pg. C9, Ref. 19)
Ref. Part No. 10 11 12 13 14 15 16 17 1260649-029 7661643 7661638 1012233-067 7041687 1260780-029
Qty. Description 6 Washer (See Cylinder Pg. C9, Ref. 20) 6 Nut (See Cylinder Pg. C9, Ref 21) 1 Manifold, Short 2 Rivet 3 Rivet 1 Support, Muffler 4 Spring, Exhaust 1 Muffler 8/98
C4
ENGINE MOUNTING
XLT SP 099AB6AS
4 5 6
36
29
25
35 33 34
28 32 28 29 29 25 24 25 30 29 31 25 27 21 14 18 20 15 26 22 23 9 10 11
28
13
12
19 18
16 17
C5
ENGINE MOUNTING
XLT SP 099AB6AS
Ref. Part No. 1 2 3 4 5 6 7 8 7512565 7575202 5010287 5410507 5020513 4010051 3070165 3085649 Qty. Description 1 1 1 2 1 3 3 1 Bolt Washer Washer, Clutch Retainer, Short O-Ring, Clutch Bolt Spacer, Clutch Bolt Conduit, Convoluted Spark Plug, RN2C Champion Engine, EC58PL160 Short Block NOTE: The Short Block Engine assembly contains a crankcase assembly, cylinder and cylinder head assembly, and a piston & crankshaft assembly. Prior authorization required for warranty consideration. Nut, Well Washer Asm., Fuel Pump (See Fuel Pump Pg. C14, Ref. 2) Nut, Flange Washer Mount, Engine, Rubber Plate, Engine, LH Plate, Engine, RH Ref. Part No. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 7553101 7512575 7547008 3110062 7555823 5332778 7512222 7552604 5431499 7080534 5431893 7512530 8450040-600 7080003 8360049-153 8450045-153 2530030 7052060 8450079-1525 7080138 7080770 Qty. Description 4 4 4 2 2 2 2 2 1 12 3 2 AR 6 AR AR 1 1 AR 2 1 Washer Bolt Nut, FLEXLOC Mount, Engine Washer Spacer Bolt Washer Handle, Recoil Clamp, Hose Plug, Trap Screw Line, Fuel Clamp, Hose, Red Conduit, Convoluted Line, Fuel Filter, Fuel Valve, Fuel Shut-Off Hose Cable Tie Cable, Throttle 8/98
9 7541923 10 7555843 11 12 13 14 15 7542503 7555740 5410390 5241038 5241039
2 2 1 2 4 4 1 1
C6
OIL TANK/AIR BOX

XLT SP 099AB6AS
17 18 21 16 2 3 5 4 15 20 17 18 19 4 14 13 25 24 26 24 23 21 22 27 28
29 30 31
6 9 7 8 7 13 16 12 10 11 21 32 34 33 35 18 17
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 4040040 5430779 5810141 7558302 7512240 5431437 8450003-1525 2530009 7080236 7080307 7052042 5241334 7661638 7542122 7052095 8450061-600 7512222 7552604
Qty. Description 1 1 1 2 1 1 AR 1 1 3 1 1 6 1 1 AR 5 5 Sensor, Oil Level w/Connector Cap, Oil Tank Gasket, Oil Cap Washer Bolt Oil Tank w/Sending Unit Hole Line, Fuel Filter Clamp, Hose, Yellow Clamp, Hose, Green, Large Fitting, Outlet, Single Bracket, Oil/Tank, Coined Rivet Nut, Nylok Fitting, 90 Degree Hose, Fuel Line Bolt Washer
Ref. Part No. 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 5240824-067 7072151 7541923 5850102 7075359 4020139 2620057 5431879 7075351 7073820 7073426 1253124 7670055 5241080-067 5433031 5411424 7052077
Qty. Description 1 1 5 1 1 2 1 1 1 1 1 1 10 1 1 3 3 Bracket, Air Silencer Decal - Fuel Shut-Off Nut, Well Plate, Silencer, Air Decal - Cooling System Clip, Rosebud Asm., Air Duct Silencer, Air, Upper, Drilled Decal - Air Box Caution Decal - Adjustable Driven Clutch Decal - Greasing Asm., Baffle Clip, Silencer Bracket, Air Silencer, LH Silencer, Intake, Drilled Boot, Air Silencer Fitting, 90 8/98
C7
CRANKCASE
XLT SP 099AB6AS
1 2
9 8 7
4 9 12 10
11 10
Ref. Part No. 1 2 3 4 3085462 3084119 3082875 3085586
Qty. Description 1 8 1 1 Nipple, Elbow Stud Grommet Asm., Crankcase (Incl. 1,2,5,6,10-12) 1 Pipe, Pulse 2 Pin, Dowel
Ref. Part No. 7 8 9 10 11 12 3082758 3083568 3083045 3082097 3084670 3084671
Qty. Description 3 3 2 8 12 2 Gasket, Aluminum Bolt, Flange Seal, Oil Bolt and Washer Bolt and Washer Bolt and Washer 8/98
5 3083798 6 3080103
C8
CYLINDER
XLT SP 099AB6AS
1
4 5
3 6 7 8 9
26 25 26 24 23
22
20 10 18 17 16 19
21
15 11 12 13 14
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 3084437 3084435 3086101 3084722 3085192 3085419 3085418 3085613 3086099 3084428 3084593 3083166 3081497
Qty. Description 8 18 1 3 3 1 1 1 1 3 1 3 3 Bolt, Flange Bolt, Flange Switch, Thermostat (105 C) Spacer O-Ring, Head Cylinder Head (PTO) Cylinder Head (Center) Gasket, Head Cylinder (Incl. 10,18) Plug Gasket, Cylinder Asm., Band (Incl. 13) Screw, Pan Head
Ref. Part No. 14 15 16 17 18 19 20 21 22 23 24 25 26 3081330 3085619 3086102 3082911 3085326 3084439 3080530 3080285 3085417 3084434 3086100 3083452 3084721
Qty. Description 6 3 3 8 6 3 6 6 1 1 1 1 3 Bolt, Socket Head O-Ring Adapter (Incl. 15) Nut, Flange Stud Gasket, Exhaust Washer Nut Cylinder Head (MAG) O-Ring, Head Cover Cover, Head (Incl. 25) Pipe, Water Pin, Dowel 8/98
C9
PISTON and CRANKSHAFT

XLT SP 099AB6AS
1 4 2 3 4 9 6 7 8 9 5 6 7 10 9 5 16 14 15 6 7 10 9 2 3 4 5 2 3 4 1 1
17 18 19
14 13 12
11
17 20
Ref. Part No. 1 3083349 3083358 3083359 2 3085873 3085874 3085020 3 3085021 4 3084456 5 3080998 6 3085627 7 3085628 8 3083254 9 3083277 10 3084447 11 3080130 Qty. Description 6 6 6 3 3 3 3 6 3 3 3 1 6 2 1 Ring, Piston (Standard) Ring, Piston (0.25mm O/S) Ring, Piston (0.50mm O/S) Asm., Piston (Standard) Asm., Piston (0.25mm O/S) Asm., Piston (0.50mm O/S) Pin, Piston Clip, Piston Pin Bearing, Small End Rod, Connecting Bearing, Large End Pin 2, Crank Spacer, Pin, Crank Pin 1, Crank Key, Woodruff Ref. Part No. 12 3085437 3084441 13 3085438 14 15 16 17 18 19 20 21 3084443 3084586 3084444 3085439 3084681 3080447 3084599 3084457 3083093
21
Qty. Description 1 Asm., Crankshaft (Incl. 6-10,12-17) 1 Crankshaft 1 (MAG Side) 1 Crankshaft (Center) (Incl. 6-10,13,15) 1 Crankshaft (MAG Side) (Incl. 10) 4 Bearing, Ball 1 Crankshaft (PTO Side) (Incl. 8) 1 Crankshaft 3 (PTO Side) 2 Bearing, Ball 1 Spacer 1 Bearing, Ball 1 Washer 1 Nut 8/98
C10
WATER PUMP
XLT SP 099AB6AS
1 2 3
4 8 5
6 7
Ref. Part No. 1 2 3 4 3084461 3084460 3083370 3084459
Qty. Description 1 1 2 1 O-Ring Casing 2, Pump Bolt and Washer O-Ring
Ref. Part No. 5 6 7 8 3084458 3082747 3084462 3084221
Qty. Description 1 1 1 5 Asm., Water Pump (Incl. 1,2,4,8) Belt Pulley, Drive Screw and Washer 8/98
C11
CARBURETOR
XLT SP 099AB6AS
1
2 3 4 5 10 9 8 7 1 6 2 25 11 12 13 14 15 17 18 16 24 1 19 2
27
PTO Side
24 26 Center 25 23 22 20
21 MAG Side
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 3130968 3130833 3130832 3130969 3130816 3130817 3130809 3130810 3130815 3130811 3130812 3130814 3130853 3130982
Qty. Description 1 5 3 1 1 1 1 1 1 1 1 1 1 1 Asm., Carburetor Screw Lever Asm., Mixing Body Screw Spring Screw Screw Bracket Spring Screw, Adjust Spring Ring Asm., Shaft w/Throttle Lever
Ref. Part No. 14 15 16 17 18 19 20 21 22 23 24 25 26 27 3130989 3130990 3130988 3130841 3130819 3130985 3130821 3130971 3130992 3130991 3130978 3130984 3130970 3130983
Qty. Description 1 1 3 1 1 1 2 1 1 1 4 2 1 2 Shaft E-Ring Packing Spring Lever, Starter Bracket Screw Asm., Mixing Body Asm., Lever Screw Ring Asm., Nipple Asm., Mixing Body Bolt 8/98
C12
CARBURETOR
XLT SP 099AB6AS
6 5 4 3 2 1 44 43 24 40 39 38 42 41 37 28 27 26 25 12 13 15 14 13 23 10 9 11 12 7 8 18 9 10 11 16 17 19 20 21 22
29 30 31
32 33 36 35
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 3130828 3130829 3130830 3130831 3130951 3130976 3130871 3130980 3130857 3130856 3130981 3130845 3130850 3130854 3130848 3130849 3130855 3140032 3130868 3130844 3130843 3130974 Qty. Description 1 Asm., Mixing Body (See Carburetor Pg. C12, Ref. 21) 3 Asm., Plunger 3 Spring 3 Holder, Guide 3 Cap 6 Screw 3 Cap, Top 3 Gasket 6 E-Ring 6 Plate 6 Clip 6 Washer 12 Ring 2 Screw (Center and MAG Side) 1 Screw (PTO Side) 2 Ring (Center and MAG Side) 2 Asm., Lever (Center and MAG Side) 1 Asm., Lever (PTO Side) 1 Ring (PTO Side Only) 3 E-Ring 3 Screw 3 Plate 3 Packing
34
Ref. Part No. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 3130972 3130973 3130836 3130986 3130987 3130837 3130835 3130066 3130771 3130977 3130861 3130858 3130824 3130862 3130863 3130860 3130139 3130949 3130993 3130994 3130825 3130975 3130870
Qty. Description 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6 3 3 3 3 12 3 3 Needle, Jet (9DH3-54-4) Asm., Piston Valve Spring Cap Adjuster Washer Packing Jet, Pilot (#35) Jet, Main (#155) Asm., Float O-Ring Body, Float Screw Nipple O-Ring Screw Jet, Main (#360) Washer Jet Hose Screw Asm., Funnel O-Ring 10/98
C13
FUEL PUMP
XLT SP 099AB6AS
Ref. Part No. 1 3084222 2 3086103 3 3084223 8/98
Qty. Description 1 Diaphragm, Gasket Set 1 Asm., Fuel Pump (Incl. 1,3) 6 Screw and Washer
2 1
C14
OIL PUMP
XLT SP 099AB6AS
1 1 5
7 1 6
3 2 4
9 1 1 10
21 19 17 16 11 2 12 13 15
Ref. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 3083141 3240234 3086106 3085172 3085157 3083125 3083447 3083126 3086104 3084467 3083131 3083130 Qty. Description 8 2 1 1 2 1 1 1 1 1 1 1 Clamp, Hose Bushing, Linkage Pipe, Vinyl Pipe 1, Vinyl (290mm) Pipe 2, Vinyl (120mm) Screw, Air Vent Band, Wire Packing Asm., Oil Pump (Incl. 6,8,9,15-21) Pipe 1, Vinyl (210mm) Gear, Small Spacer
20
22
18
14
Ref. Part No. 13 3083353 14 3083671 3083672 3083673 15 3083127 16 3086105 17 3083120 18 3083121 19 3086109 20 3083445 21 3086110 22 3083783 Qty. Description 1 AR AR AR 1 1 1 1 1 1 1 2 Bushing Spacer 1 (.15mm) Spacer 2 (.3mm) Spacer 3 (.6mm) O-Ring Rod Nut Washer Lever, Control Collar, Cam Shaft Spring and Lever Set Screw and Washer 8/98
D1
MAGNETO
XLT SP 099AB6AS
5 4 2 3 1 7 8 6
17
15 16
10 11
14
13
12
Ref. Part No. 1 2 3 4 5 6 7 8 9 3084512 3081256 3081146 3084976 3085629 3085877 3083866 3085604 3085615 Qty. Description 1 3 1 2 1 1 3 3 1 Band, Wire Screw and Washer Clamp Screw and Washer Plate, Coil Asm., Plate (Incl. 1-4,8) Screw and Washer Screw and Washer Asm., Flywheel Ref. Part No. 10 11 12 13 14 15 16 17 3085589 4020129 3084516 3083730 3085208 3083150 3081513 3082969 Qty. Description 1 3 1 3 3 1 1 1 C.D.I. System Cap, Spark Plug Code Bolt and Washer Ignition Coil Coupler, 3P Coupler, 6P Grommet 8/98
D2
RECOIL STARTER
XLT SP 099AB6AS
1 2
3 4 5 6 7 8
9 10
16
11 15 12 13 14
Ref. Part No. 1 2 3 4 5 6 7 8 9 3083312 3084224 3083381 3083464 3083379 3083378 3083463 3083377 2870621
Qty. Description 1 3 1 1 1 1 1 1 1 Pulley, Starting Bolt and Washer Nut, Flange Plate, Friction Spring, Friction Ratchet Spring, Return Reel Rope, Starter
Ref. Part No. 10 11 12 13 14 15 16 3083376 3083107 3084773 3080530 3080119 3083078 3085444 3085445
Qty. Description 1 1 1 1 1 3 1 1 Spring, Spiral Guide, Rope Bolt Washer Nut Bolt and Washer Starter, Recoil (Incl. 3-11,16) Case, Starter 8/98
D3
TOOL KIT
XLT SP 099AB6AS
9 8 1 10 11
12
13
3 6
Ref. Part No. 1 2 3 4 5 6 2870463 2871845 2872012 9914668 9914857
Qty. Description 1 1 1 1 1 1 1 Kit - Tool (Incl. 1-3) Screwdriver Wrench, 10-12 Spanner Wrench, Box, Special Screwdriver, Flat Wrench, Scissor Stop Manual, Owners, 99 Snowmobile Supplement, Owners Manual, 99 XLT SP
Ref. Part No. 7 8 9 10 11 12 13 2690016 7080287 5430719 5811051 7512017 5430716 5240921-067
Qty. Description 1 1 1 1 4 1 1 Pouch, Tool Kit Strap, Emergency Starter Cover, Tool Box Foam, Tool Box Screw Box, Tool Bracket, Tool Box
8/98
D4
PART NUMBER INDEX

XLT SP 099AB6AS
Part No. Ref. No. Grid No. Part No. Ref. No. Grid No. Part No. 2872012 3021081 3070165 3080103 3080119 3080130 3080285 3080447 3080530 3080998 3081146 3081256 3081330 3081497 3081513 3082097 3082747 3082758 3082875 3082911 3082969 3083045 3083078 3083093 3083107 3083120 3083121 3083125 3083126 3083127 3083130 3083131 3083141 3083150 3083166 3083254 3083277 3083312 3083349 3083353 3083358 3083359 3083370 3083376 3083377 3083378 3083379 3083381 3083445 3083447 3083452 3083463 3083464 3083568 3083671 3083672 3083673 3083730 3083783 3083798 3083866 3084119 3084221 3084222 Ref. No. ....... 5 . . . . . . 29 ....... 7 ....... 6 . . . . . . 14 . . . . . . 11 . . . . . . 21 . . . . . . 18 . . . . . . . 20 13 ....... 5 ....... 3 ....... 2 . . . . . . 14 . . . . . . 13 . . . . . . 16 . . . . . . 10 ....... 6 ....... 7 ....... 3 . . . . . . 17 . . . . . . 17 ....... 9 . . . . . . 15 . . . . . . 21 . . . . . . 11 . . . . . . 17 . . . . . . 18 ....... 6 ....... 8 . . . . . . 15 . . . . . . 12 . . . . . . 11 ....... 1 . . . . . . 15 . . . . . . 12 ....... 8 ....... 9 ....... 1 ....... 1 . . . . . . 13 ....... 1 ....... 1 ....... 3 . . . . . . 10 ....... 8 ....... 6 ....... 5 ....... 3 . . . . . . 20 ....... 7 . . . . . . 25 ....... 7 ....... 4 ....... 8 . . . . . . 14 . . . . . . 14 . . . . . . 14 . . . . . . 13 . . . . . . 22 ....... 5 ....... 7 ....... 2 ....... 8 ....... 1 Grid No.
1012233-067 . . 15 1012246-067 . . 35 1012247-067 . . 35 1012280 . . . . . . 19 1012281 . . . . . . . 1 1012434 . . . . . . 27 1012441 . . . . . . 21 1012604-067 . . 22 1012615-067 . . 30 1012618 . . . . . . 26 1012643-067 . . 11 1012703-067 . . . 4 1012812-067 . . 20 1012813-067 . . 20 1253124 . . . . . . 30 1260649-029 . . 12 1260678-029 . . . 1 1260780-029 . . 17 1260885-067 . . . 3 1321457 . . . . . . . 8 1321528 . . . . . . 11 1321733 . . . . . . 18 1322192 . . . . . . 16 1332096 . . . . . . . 8 1332207 . . . . . . 16 1500002 . . . . . . . 8 1500004 . . . . . . 14 1500015 . . . . . . . 9 1500016 . . . . . . 10 1500017 . . . . . . . 6 1500018 . . . . . . . 2 1500019 . . . . . . 15 1500020 . . . . . . 20 1500021 . . . . . . 19 1500022 . . . . . . . 2 1500023 . . . . . . 15 1500024 . . . . . . 22 1500025 . . . . . . 21 1500063 . . . . . . 40 1500070 . . . . . . 23 1500071 . . . . . . 24 1500072 . . . . . . 15 1500148 . . . . . . . 4 1500152 . . . . . . . 5 1500186 . . . . . . . 3 1500187 . . . . . . . 2 1500188 . . . . . . 13 1500189 . . . . . . 16 1500190 . . . . . . 12 1500191 . . . . . . . 7 1500192 . . . . . . 11 1500193 . . . . . . . 1 1540942-067 . . 22 1540982-067 . . 20 1541015-067 . . 27 1541203-067 . . . 5 1541290-067 . . . 5 1541336 . . . . . . 20 1541337 . . . . . . 20 1543023 . . . . . . 17 1590269 . . . . . . 26 1594082-243 . . . 1 1594083-243 . . . 9 1594087 . . . . . . 12
. . . C4 . . A14 . . A14 . . . A5 . . . A5 . . . B9 . . . A5 . . . B2 . . . A5 . . . B2 . . . A6 . . . A5 . . . A5 . . . A5 . . . C7 . . . C4 . . . C4 . . . C4 . . . C4 . . . C2 . . . C2 . . . C2 . . . C3 . . . B8 . . . B9 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . . B6 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B14 . . B12 . . B11 . . B13 . . B12 . . B13 . . B10 . . B10 . . B13 . . . B9 . . B10 . . B11 . . B11
1820579 . . . . . . . 3 . . . B2 1820610-070 . . 24 . . . B6 1822375-067 . . 51 . . . B6 1822377-067 . . 52 . . . B6 1822408 . . . . . . 44 . . . B2 1822432-067 . . 19 . . . B2 1822517 . . . . . . 16 . . . B6 1822518 . . . . . . 16 . . . B6 1822562 . . . . . . 10 . . . B2 1823169-067 . . . 3 . . . B3 1910276 . . . . . . 18 . . . B9 1930662 . . . . . . 38 . . . B4 1930673 . . . . . . 37 . . . B4 1930733 . . . . . . . 4 . . . B7 1930734 . . . . . . . 5 . . . B7 1930735 . . . . . . 13 . . . B7 1930737 . . . . . . 11 . . . B7 1930755 . . . . . . 12 . . . B7 1930825 . . . . . . 10 . . . B7 2010180 . . . . . . . 4 . . . B4 2050083 . . . . . . 15 . . . B4 2200357 . . . . . . . 4 . . A10 2200386 . . . . . . . . . . . . . C2 2200387 . . . . . . 17 . . . C2 2200466 . . . . . . . 6 . . . B7 2200467 . . . . . . . 7 . . . B7 2200891 . . . . . . . 2 . . . B1 2201019 . . . . . . . 9 . . . B7 2201339 . . . . . . . . . . . . . B1 2201439 . . . . . . . 6 . . A10 2431009 . . . . . . . 9 . . A14 2460311 . . . . . . . 6 . . . B3 2460506 . . . . . . 13 . . A10 2460517 . . . . . . 21 . . A10 2460541 . . . . . . 32 . . . A6 2460568 . . . . . . . 9 . . A12 2511239 . . . . . . . 9 . . . C1 2511248 . . . . . . . 2 . . . A6 2511256 . . . . . . 21 . . . C1 2511257 . . . . . . 12 . . . C1 2511258 . . . . . . 33 . . . C1 2530009 . . . . . . . 8 . . . C7 2530024 . . . . . . 32 . . . C1 2530030 . . . . . . 32 . . . C6 2620057 . . . . . . 25 . . . C7 2631895-177 . . 22 . . A14 2652162 . . . . . . 15 . . A12 2652163 . . . . . . 12 . . A12 2652164 . . . . . . 14 . . A12 2670071 . . . . . . 14 . . . A8 2670162 . . . . . . . 3 . . . A8 2670163 . . . . . . . 3 . . . A8 2670165 . . . . . . 23 . . . A8 2670166 . . . . . . 23 . . . A8 2670167 . . . . . . 27 . . . A8 2670169 . . . . . . 10 . . . A5 2682381 . . . . . . . 1 . . . A6 2682382 . . . . . . . 1 . . . A6 2690016 . . . . . . . 7 . . . D4 2870448 . . . . . . . 9 . . A14 2870463 . . . . . . . . . . . . . D4 2870621 . . . . . . . 9 . . . D3 2871815 . . . . . . 27 . . . B6 2871845 . . . . . . . 4 . . . D4
. . . D4 . . . B2 . . . C6 . . . C8 . . . D3 . . C10 . . . C9 . . C10 . . . C9 . . . D3 . . C10 . . . D2 . . . D2 . . . C9 . . . C9 . . . D2 . . . C8 . . C11 . . . C8 . . . C8 . . . C9 . . . D2 . . . C8 . . . D3 . . C10 . . . D3 . . . D1 . . . D1 . . . D1 . . . D1 . . . D1 . . . D1 . . . D1 . . . D1 . . . D2 . . . C9 . . C10 . . C10 . . . D3 . . C10 . . . D1 . . C10 . . C10 . . C11 . . . D3 . . . D3 . . . D3 . . . D3 . . . D3 . . . D1 . . . D1 . . . C9 . . . D3 . . . D3 . . . C8 . . . D1 . . . D1 . . . D1 . . . D2 . . . D1 . . . C8 . . . D2 . . . C8 . . C11 . . C14
D5
PART NUMBER INDEX

XLT SP 099AB6AS
Part No. 3084223 3084224 3084428 3084434 3084435 3084437 3084439 3084441 3084443 3084444 3084447 3084456 3084457 3084458 3084459 3084460 3084461 3084462 3084467 3084512 3084516 3084586 3084593 3084599 3084670 3084671 3084681 3084721 3084722 3084773 3084976 3085020 3085021 3085157 3085172 3085192 3085208 3085326 3085417 3085418 3085419 3085437 3085438 3085439 3085444 3085445 3085462 3085586 3085589 3085604 3085613 3085615 3085619 3085627 3085628 3085629 3085649 3085873 3085874 3085877 3086099 3086100 3086101 3086102 Ref. No. ....... 3 ....... 2 . . . . . . 10 . . . . . . 23 ....... 2 ....... 1 . . . . . . 19 . . . . . . 12 . . . . . . 13 . . . . . . 15 . . . . . . 10 ....... 4 . . . . . . 20 ....... 5 ....... 4 ....... 2 ....... 1 ....... 7 . . . . . . 10 ....... 1 . . . . . . 12 . . . . . . 14 . . . . . . 11 . . . . . . 19 . . . . . . 11 . . . . . . 12 . . . . . . 17 . . . . . . 26 ....... 4 . . . . . . 12 ....... 4 ....... 2 ....... 3 ....... 5 ....... 4 ....... 5 . . . . . . 14 . . . . . . 18 . . . . . . 22 ....... 7 ....... 6 . . . . . . 12 . . . . . . 13 . . . . . . 16 . . . . . . 16 . . . . . . 16 ....... 1 ....... 4 . . . . . . 10 ....... 8 ....... 8 ....... 9 . . . . . . 15 ....... 6 ....... 7 ....... 5 ....... 8 ....... 2 ....... 2 ....... 6 ....... 9 . . . . . . 24 ....... 3 . . . . . . 16 Grid No. Part No. 3086103 3086104 3086105 3086106 3086109 3086110 3110062 3130066 3130139 3130771 3130809 3130810 3130811 3130812 3130814 3130815 3130816 3130817 3130819 3130821 3130824 3130825 3130828 3130829 3130830 3130831 3130832 3130833 3130835 3130836 3130837 3130841 3130843 3130844 3130845 3130848 3130849 3130850 3130853 3130854 3130855 3130856 3130857 3130858 3130860 3130861 3130862 3130863 3130868 3130870 3130871 3130949 3130951 3130968 3130969 3130970 3130971 3130972 3130973 3130974 3130975 3130976 3130977 3130978 Ref. No. Grid No. Part No. 3130980 3130981 3130982 3130983 3130984 3130985 3130986 3130987 3130988 3130989 3130990 3130991 3130992 3130993 3130994 3140032 3211070 3221098 3222101 3224070 3240234 3280017 3280019 3280116 3280196 3280201 3280242 3280243 3280244 3514012 3514305 3514309 3514525 3514526 3553002 3563907 3569803 3573909 3574208 3576502 3576516 3610030 4010051 4020057 4020129 4020133 4020139 4020153 4030045 4030050 4030052 4032063 4032072 4032081 4032084 4040040 4060123 4110106 4110135 4110136 4110175 5010127 Ref. No. ....... 9 . . . . . . 12 . . . . . . 13 . . . . . . 27 . . . . . . 25 . . . . . . 19 . . . . . . 25 . . . . . . 26 . . . . . . 16 . . . . . . 14 . . . . . . 15 . . . . . . 23 . . . . . . 22 . . . . . . 40 . . . . . . 41 . . . . . . 17 ....... 6 ....... 7 . . . . . . 19 . . . . . . 17 ....... 2 . . . . . . 31 . . . . . . 29 . . . . . . 33 . . . . . . 18 ....... 6 . . . . . . 13 ....... 1 ....... 4 ........ 9 16 ........ 3 17 ....... 5 . . . . . . 13 . . . . . . 28 ....... 8 ....... 7 ....... 8 . . . . . . 19 . . . . . . 21 . . . . . . 13 ....... 3 ....... 2 ....... 6 . . . . . . 19 . . . . . . 11 . . . . . . 20 . . . . . . . 34 24 . . . . . . 18 . . . . . . 15 ....... 2 ....... 3 ....... 9 . . . . . . 18 . . . . . . 17 . . . . . . 16 ....... 1 . . . . . . 15 ....... 6 ....... 8 . . . . . . 13 . . . . . . 16 . . . . . . 49 Grid No.
. . C14 . . . D3 . . . C9 . . . C9 . . . C9 . . . C9 . . . C9 . . C10 . . C10 . . C10 . . C10 . . C10 . . C10 . . C11 . . C11 . . C11 . . C11 . . C11 . . . D1 . . . D2 . . . D2 . . C10 . . . C9 . . C10 . . . C8 . . . C8 . . C10 . . . C9 . . . C9 . . . D3 . . . D2 . . C10 . . C10 . . . D1 . . . D1 . . . C9 . . . D2 . . . C9 . . . C9 . . . C9 . . . C9 . . C10 . . C10 . . C10 . . . D3 . . . D3 . . . C8 . . . C8 . . . D2 . . . D2 . . . C9 . . . D2 . . . C9 . . C10 . . C10 . . . D2 . . . C6 . . C10 . . C10 . . . D2 . . . C9 . . . C9 . . . C9 . . . C9
. . . . . . . 2 . . C14 . . . . . . . 9 . . . D1 . . . . . . 16 . . . D1 . . . . . . . 3 . . . D1 . . . . . . 19 . . . D1 . . . . . . 21 . . . D1 . . . . . . 19 . . . C6 . . . . . . 29 . . C13 . . . . . . 38 . . C13 . . . . . . 30 . . C13 . . . . . . . 6 . . C12 . . . . . . . 7 . . C12 . . . . . . . 9 . . C12 . . . . . . 10 . . C12 . . . . . . 11 . . C12 . . . . . . . 8 . . C12 . . . . . . . 4 . . C12 . . . . . . . 5 . . C12 . . . . . . 18 . . C12 . . . . . . 20 . . C12 . . . . . . 34 . . C13 . . . . . . 42 . . C13 . . . . . . . 2 . . C13 . . . . . . . 3 . . C13 . . . . . . . 4 . . C13 . . . . . . . 5 . . C13 . . . . . . . 2 . . C12 . . . . . . . 1 . . C12 . . . . . . 28 . . C13 . . . . . . 24 . . C13 . . . . . . 27 . . C13 . . . . . . 17 . . C12 . . . . . . 20 . . C13 . . . . . . 19 . . C13 . . . . . . 13 . . C13 . . . . . . 15 . . C13 . . . . . . 16 . . C13 . . . . . . 14 . . C13 . . . . . . 12 . . C12 . . . . . . 14 . . C13 . . . . . . 16 . . C13 . . . . . . 11 . . C13 . . . . . . 10 . . C13 . . . . . . 33 . . C13 . . . . . . 37 . . C13 . . . . . . 32 . . C13 . . . . . . 35 . . C13 . . . . . . 36 . . C13 . . . . . . 18 . . C13 . . . . . . 44 . . C13 . . . . . . . 8 . . C13 . . . . . . 39 . . C13 . . . . . . . 6 . . C13 . . . . . . . . . . . . C12 . . . . . . . 3 . . C12 . . . . . . 26 . . C12 . . . . . . 21 . . C12 . . . . . . 22 . . C13 . . . . . . 23 . . C13 . . . . . . 21 . . C13 . . . . . . 43 . . C13 . . . . . . . 7 . . C13 . . . . . . 31 . . C13 . . . . . . 24 . . C12
. . C13 . . C13 . . C12 . . C12 . . C12 . . C12 . . C13 . . C13 . . C12 . . C12 . . C12 . . C12 . . C12 . . C13 . . C13 . . C13 . . . B9 . . . B8 . . . B8 . . . B8 . . . D1 . . . B9 . . . B9 . . . B9 . . A12 . . A12 . . A12 . . A12 . . A12 . . B11 . . B11 . . B10 . . B13 . . . B8 . . . B9 . . . B9 . . . B8 . . . B2 . . . C3 . . . B6 . . . B6 . . . C2 . . . C2 . . . B8 . . . C6 . . A10 . . . D2 . . A10 . . . B2 . . . C7 . . A10 . . . A6 . . A12 . . A12 . . A14 . . A14 . . . B3 . . . A6 . . . C7 . . A10 . . . B4 . . . B7 . . . B4 . . . B3 . . . B6
D6
PART NUMBER INDEX

XLT SP 099AB6AS
Part No. 5010158 5010188 5010287 5010310 5010384 5010385 5010422 5020422 5020425 5020513 5020561 Ref. No. Grid No. Part No. Ref. No. Grid No. . . . A8 . . . A8 . . . B4 . . . C7 . . . A7 . . . D4 . . . C6 . . . C6 . . . A5 . . . C7 . . A14 . . A14 . . A14 . . A14 . . A14 . . . B9 . . . A5 . . . A5 . . B12 . . . A5 . . . A5 . . . A5 . . . A5 . . . C1 . . . C7 . . . B9 . . B11 . . . B6 . . . B6 . . . B6 . . . B6 . . . B6 . . . B6 . . . A5 . . . A5 . . . A8 . . . C4 . . . C2 . . . B6 . . . C6 . . B12 . . B10 . . B10 . . . B4 . . B12 . . B10 . . B11 . . A14 . . B11 . . . B2 . . B13 . . B13 . . . B4 . . . B4 . . . B8 . . . A8 . . . C1 . . . A8 . . . C6 . . . C4 . . . C6 . . . B4 . . . C1 . . A10 Part No. Ref. No. Grid No.
. . . . . . 45 . . . . . . 14 ....... 3 . . . . . . 13 ....... 2 ....... 9 . . . . . . 30 . . . . . . 16 ....... 6 ....... 5 . . . . . . . 17 24 5020588 . . . . . . 19 5020653 . . . . . . 11 5020657 . . . . . . 17 5020670 . . . . . . 22 5020679 . . . . . . 29 5020723 . . . . . . 23 5020724 . . . . . . 22 5020744 . . . . . . 14 5020811 . . . . . . 13 5020837 . . . . . . . 9 5020857-067 . . 37 5020908 . . . . . . . 4 5020913 . . . . . . . 4 5020943 . . . . . . 18 5130530 . . . . . . 19 5130570 . . . . . . 29 5130955 . . . . . . 36 5131070 . . . . . . 25 5131113 . . . . . . . 15 5131568 . . . . . . 21 5131910 . . . . . . . 4 5131911 . . . . . . 16 5210650 . . . . . . 16 5210728 . . . . . . 11 5210749 . . . . . . . 2 5210752 . . . . . . 10 5210753 . . . . . . 10 5210754 . . . . . . 10 5211345 . . . . . . . 2 5211536-067 . . 34 5211790 . . . . . . 12 5211796-067 . . 32 5220984 . . . . . . . 2 5222629 . . . . . . . . 8 13 5222687-067 . . 31 5222751 . . . . . . 14 5222769 . . . . . . 14 5222839 . . . . . . 24 5222840 . . . . . . 24 5222857 . . . . . . 27 5222863 . . . . . . 13 5222878 . . . . . . 12 5222903 . . . . . . 18 5224585 . . . . . . . 4 5224590-067 . . . 9 5224591-067 . . . 9 5224742-067 . . . 7 5230101 . . . . . . 14 5240698 . . . . . . 29 5240699-067 . . 57 5240757-067 . . 19
. . . B6 . . . C2 . . . C6 . . . B6 . . . B2 . . . B2 . . B13 . . . C2 . . . C2 . . . C6 . . B12 . . B13 . . . B9 . . . C3 . . B14 . . . B4 . . . B4 . . B11 . . B11 . . B11 . . A14 . . . B9 . . . B2 . . B12 . . . B9 . . B10 . . B10 . . B10 . . . B4 . . . A8 . . B10 . . . B8 . . B13 . . B13 . . A10 . . . A7 . . . C3 . . . C2 . . . C2 . . . C2 . . . B6 . . A14 . . B10 . . . B2 . . . A8 . . B10 . . B10 . . . A5 . . . B9 . . . A7 . . B11 . . B11 . . . A5 . . . C1 . . . C3 . . . A7 . . . A7 . . . A8 . . . A8 . . . B6 . . . C3 . . . A8 . . . B6 . . A14
5240785 . . . . . . 31 5240786 . . . . . . 31 5240809 . . . . . . 21 5240824-067 . . 19 5240834 . . . . . . . 9 5240921-067 . . 13 5241038 . . . . . . 15 5241039 . . . . . . 15 5241053-067 . . . 8 5241080-067 . . 32 5241138-067 . . 32 5241140-067 . . 31 5241142-067 . . 30 5241144-067 . . 33 5241146-067 . . 28 5241178 . . . . . . 30 5241268-067 . . 22 5241269-067 . . 22 5241276-067 . . 10 5241303-067 . . 25 5241304-067 . . 25 5241320-067 . . 18 5241321-067 . . 18 5241334 . . . . . . . 20 12 5241359 . . . . . . 10 5241443 . . . . . . . 4 5241641-067 . . . 1 5241660-067 . . 10 5241661-067 . . 10 5241777-067 . . 18 5241778-067 . . 18 5241912-067 . . 37 5242492-067 . . 16 5242493-067 . . . 2 5242763-067 . . 18 5242913 . . . . . . . 7 5242981 . . . . . . 10 5243127 . . . . . . 38 5332778 . . . . . . 21 5332784 . . . . . . 26 5332786 . . . . . . 37 5332787 . . . . . . 28 5332931 . . . . . . 32 5333028 . . . . . . 16 5333116 . . . . . . 24 5333283 . . . . . . 13 5333296 . . . . . . 15 5333404 . . . . . . 19 5333411 . . . . . . 13 5333536 . . . . . . . 8 5333559 . . . . . . 26 5410163 . . . . . . 28 5410164 . . . . . . 30 5410277 . . . . . . 11 5410344 . . . . . . 15 5410350 . . . . . . 16 5410370 . . . . . . 11 5410390 . . . . . . 14 5410467 . . . . . . . 6 5410507 . . . . . . . 4 5410527 . . . . . . 18 5410557 . . . . . . 26 5410611 . . . . . . . 1
5410613 . . . . . . 20 5410673 . . . . . . 17 5410675 . . . . . . 22 5410815 . . . . . . . 3 5410872 . . . . . . 14 5410925 . . . . . . 16 5410970 . . . . . . . 2 5411010 . . . . . . 22 5411011 . . . . . . . 27 5411061 . . . . . . 22 5411075 . . . . . . 29 5411094 . . . . . . 39 5411220 . . . . . . . 1 5411249 . . . . . . 31 5411379 . . . . . . 24 5411396 . . . . . . 18 5411424 . . . . . . 34 5411498 . . . . . . 31 5430445 . . . . . . . 9 5430466 . . . . . . 15 5430604 . . . . . . 14 5430671 . . . . . . 11 5430716 . . . . . . 12 5430719 . . . . . . . 9 5430733 . . . . . . 23 5430743 . . . . . . . 3 5430779 . . . . . . . 2 5430945 . . . . . . . 7 5431096 . . . . . . . 4 4 5431385 . . . . . . 32 5431389 . . . . . . 24 5431419 . . . . . . 21 5431437 . . . . . . . 6 5431486 . . . . . . 50 5431490 . . . . . . 15 5431491 . . . . . . 12 5431499 . . . . . . 24 5431530 . . . . . . 13 5431531 . . . . . . . 2 5431592 . . . . . . . 5 5431620 . . . . . . . 2 5431733 . . . . . . . 7 5431734 . . . . . . 41 5431780-070 . . . 1 5431781 . . . . . . . 8 5431782-177 . . . 3 5431824-070 . . . 5 5431879 . . . . . . 26 5431884 . . . . . . 37 5431893 . . . . . . 26 5431901 . . . . . . . 7 5431913 . . . . . . . 6 5431914 . . . . . . . 6 5431928 . . . . . . 17 5431931 . . . . . . 19 5431995-070 . . 11 5432002 . . . . . . 14 5432003 . . . . . . 14 5432008 . . . . . . . 9 5432031 . . . . . . 17 5432032 . . . . . . 17 5432038 . . . . . . . 8 5432040 . . . . . . 18 5432149 . . . . . . . 6
. . . B9 . . . C1 . . . B9 . . . A6 . . . B6 . . B10 . . A14 . . . C1 . . . C1 . . B13 . . A14 . . . B6 . . . B2 . . . B2 . . B11 . . . C1 . . . C7 . . B12 . . . C2 . . . C3 . . . B4 . . B12 . . . D4 . . . D4 . . A14 . . . C1 . . . C7 . . . C2 . . . B3 . . . C1 . . . A5 . . . B4 . . . B9 . . . C7 . . . B6 . . . B3 . . . B3 . . . C6 . . . B3 . . B10 . . . B4 . . . B3 . . . C1 . . . B6 . . A14 . . A10 . . . A7 . . . A7 . . . C7 . . A14 . . . C6 . . A14 . . . A8 . . . A8 . . . A7 . . . C1 . . . A5 . . . A6 . . . A6 . . . A6 . . . A6 . . . A6 . . . B6 . . B14 . . . A5
D7
PART NUMBER INDEX

XLT SP 099AB6AS
Part No. Ref. No. Grid No. Part No. Ref. No. Grid No. Part No. 7077386 7077387 7077388 7077530 7077585 7077792 7078009 7080003 7080138 7080227 7080236 7080287 7080306 7080307 7080372 7080394 7080398 7080402 7080416 7080424 7080433 Ref. No. ....... 8 . . . . . . 21 ....... 7 . . . . . . 14 ....... 4 . . . . . . 10 . . . . . . 13 . . . . . . . 27 29 . . . . . . 35 . . . . . . 24 ....... 9 ....... 8 . . . . . . 23 . . . . . . . 28 10 . . . . . . 25 . . . . . . 13 . . . . . . 29 . . . . . . 23 . . . . . . 28 . . . . . . 17 ........ 8 46 21 8 10 . . . . . . 25 . . . . . . 16 . . . . . . 25 ....... 7 ....... 5 ....... 4 . . . . . . 30 . . . . . . 10 . . . . . . 25 . . . . . . 11 . . . . . . 26 ....... 7 . . . . . . 36 . . . . . . 21 . . . . . . 11 ....... 8 . . . . . . 11 . . . . . . 23 . . . . . . 19 . . . . . . 11 . . . . . . 28 . . . . . . . 17 21 . . . . . . 17 ....... 1 . . . . . . 16 . . . . . . 18 ....... 3 ....... 9 ....... 6 . . . . . . . 12 22 17 ........ 6 5 . . . . . . 13 . . . . . . 12 Grid No.
5432209 . . . . . . 34 5432261 . . . . . . 12 5432267 . . . . . . . 3 5432292 . . . . . . . 7 5432535 . . . . . . 10 5432561 . . . . . . 17 5432573-177 . . . 4 5432614 . . . . . . 17 5432634 . . . . . . . 5 5432668-067 . . 13 5432944 . . . . . . . 3 5432970 . . . . . . . 4 5432982 . . . . . . 27 5432983 . . . . . . 14 5433005 . . . . . . . 6 5433007 . . . . . . 20 5433031 . . . . . . 33 5521242 . . . . . . 15 5521405 . . . . . . 18 5630122 . . . . . . . 8 5630123 . . . . . . . 8 5630187-067 . . . 9 5630338 . . . . . . 17 5630342 . . . . . . 34 5630382-067 . . . 8 5630399 . . . . . . 26 5630413 . . . . . . 12 5630580 . . . . . . . 43 13 5630847 . . . . . . 27 5630853 . . . . . . . 5 5810141 . . . . . . . 3 5810279 . . . . . . . 5 5810465 . . . . . . . 7 5810496 . . . . . . . 6 5810513 . . . . . . . 2 5810554 . . . . . . . 8 5810831 . . . . . . 29 5810838 . . . . . . . 8 5811051 . . . . . . 10 5811094 . . . . . . . 6 5811095 . . . . . . 11 5811097 . . . . . . 13 5811115 . . . . . . . . 8 5811116 . . . . . . . . 9 5811117 . . . . . . . 11 5811118 . . . . . . . . 5 5811119 . . . . . . . . 3 5811121 . . . . . . . . 4 5811122 . . . . . . . . 6 5811123 . . . . . . . . 2 5811124 . . . . . . . . 7 5811125 . . . . . . . . 1 5811126 . . . . . . . 13 5811127 . . . . . . . 10 5811128 . . . . . . . 12 5811129 . . . . . . . . 9 5811130 . . . . . . . 10 5811132 . . . . . . . . 4 5811134 . . . . . . . . 3 5811136 . . . . . . . . 5 5811157 . . . . . . . . 1 5811159 . . . . . . . . 2 5811250 . . . . . . . 4
. . . B6 . . . B4 . . A14 . . A12 . . B11 . . . B6 . . A14 . . A14 . . . B3 . . . A8 . . A10 . . . B4 . . B10 . . B13 . . B10 . . B13 . . . C7 . . . C1 . . B11 . . . B8 . . . B8 . . . B3 . . . B4 . . . B4 . . . B3 . . B10 . . . B8 . . . B6 . . B12 . . . B4 . . . C3 . . . C7 . . . C1 . . . A9 . . . A9 . . . A6 . . B10 . . . C1 . . . A9 . . . D4 . . A14 . . . B9 . . B10 . . A11 . . A11 . . A11 . . A11 . . A11 . . A11 . . A11 . . A11 . . A11 . . A11 . . A11 . . A11 . . A11 . . . A9 . . . A9 . . . A9 . . . A9 . . . A9 . . . A9 . . . A9 . . A12
5811263-070 . . . 10 . . . A5 2 . . . A7 5811264-070 . . . 4 . . . A8 5830012 . . . . . . 32 . . . B9 5850102 . . . . . . 22 . . . C7 6230102-067 . . 22 . . . B6 7010050 . . . . . . . 9 . . B12 9 . . B13 7041079 . . . . . . 14 . . . C1 7041229 . . . . . . 20 . . . B4 7041253-067 . . 14 . . B12 7041311 . . . . . . 31 . . . B4 7041397 . . . . . . 14 . . A14 7041499 . . . . . . . 7 . . . C3 7041523 . . . . . . 44 . . . B6 7041526 . . . . . . . 5 . . . C2 7041551-067 . . 42 . . . B6 7041627-067 . . 19 . . B13 7041628-067 . . 19 . . B13 7041629-067 . . 19 . . B13 7041630-067 . . 19 . . B13 7041631-067 . . 19 . . B13 7041632-067 . . 19 . . B13 7041687 . . . . . . 16 . . . C4 7041693 . . . . . . 12 . . B12 7041728 . . . . . . . . . . . . B14 7042029 . . . . . . . 2 . . . C4 7042041 . . . . . . 23 . . . C1 7052023 . . . . . . 26 . . . A6 7052037 . . . . . . 22 . . . A6 7052038 . . . . . . 31 . . . C1 7052042 . . . . . . 11 . . . C7 7052060 . . . . . . 33 . . . C6 7052077 . . . . . . 35 . . . C7 7052095 . . . . . . . 31 . . . A6 15 . . . C7 7052115 . . . . . . 20 . . . B8 7060164 . . . . . . 16 . . . B2 7060166 . . . . . . 39 . . . B2 7060174 . . . . . . 11 . . . B2 7061010 . . . . . . 60 . . . B6 7061011 . . . . . . 54 . . . B6 7072151 . . . . . . 20 . . . C7 7073426 . . . . . . 29 . . . C7 7073820 . . . . . . 28 . . . C7 7074202 . . . . . . 15 . . . B1 7075350 . . . . . . 15 . . . A7 7075351 . . . . . . 27 . . . C7 7075359 . . . . . . 23 . . . C7 7075369 . . . . . . 11 . . . B1 7075370 . . . . . . 18 . . . B1 7075371 . . . . . . 12 . . . B1 7075372 . . . . . . 16 . . . B1 7075373 . . . . . . 13 . . . B1 7075374 . . . . . . 17 . . . B1 7076360 . . . . . . . 1 . . . B1 7076596 . . . . . . . 5 . . . B1 7076876 . . . . . . . 2 . . . B1 7077361 . . . . . . 20 . . . B1 7077362 . . . . . . . 6 . . . B1 7077363 . . . . . . 22 . . . B1 7077364 . . . . . . . 9 . . . B1 7077381 . . . . . . 19 . . . B1 7077382 . . . . . . . 3 . . . B1
7080447 7080523 7080534 7080548 7080549 7080550 7080559 7080562 7080563 7080564 7080569 7080734 7080770 7080804 7511840 7511848 7511858 7511866 7511954 7512017 7512024 7512026 7512031 7512048 7512050 7512054 7512057 7512069 7512078 7512222
7512240 7512242 7512252
. . . B1 . . . B1 . . . B1 . . . B1 . . . B1 . . . B1 . . . A7 . . . A6 . . . C6 . . . C6 . . . A5 . . . C7 . . . D4 . . . B6 . . . C1 . . . C7 . . A14 . . B13 . . . A5 . . . A6 . . . A5 . . . B2 . . . B2 . . . B6 . . B11 . . B12 . . B13 . . . B4 . . . A7 . . . C6 . . . A6 . . . A6 . . . A6 . . . A6 . . . C1 . . . C1 . . . C1 . . A14 . . A10 . . . C6 . . . B2 . . . B3 . . . B4 . . . B4 . . . B4 . . . A6 . . . D4 . . . A8 . . A12 . . A14 . . A10 . . . C3 . . . B4 . . . A6 . . . A5 . . A10 . . . A7 . . A14 . . . C6 . . . C7 . . . C1 . . . C7 . . . B8 . . A10
D8
PART NUMBER INDEX

XLT SP 099AB6AS
Part No. 7512257 7512265 7512275 7512287 7512290 7512310 7512377 Ref. No. . . . . . . 15 ....... 1 . . . . . . 25 . . . . . . 19 . . . . . . 35 . . . . . . 23 ........ 7 34 7 . . . . . . . 15 34 . . . . . . 31 ....... 9 . . . . . . 27 . . . . . . 22 ....... 5 . . . . . . 15 . . . . . . 35 ....... 1 . . . . . . 17 . . . . . . 29 . . . . . . 36 . . . . . . 55 . . . . . . 12 . . . . . . 13 . . . . . . . 14 21 ....... 5 . . . . . . 38 . . . . . . 20 ....... 7 . . . . . . 14 . . . . . . 31 . . . . . . 15 ....... 1 . . . . . . . 42 48 . . . . . . 25 . . . . . . . 33 29 . . . . . . 41 . . . . . . 23 . . . . . . 17 . . . . . . . 21 28 . . . . . . 22 . . . . . . 30 ....... 1 ....... 7 . . . . . . 14 ....... 3 ....... 5 . . . . . . 10 . . . . . . 11 . . . . . . 12 . . . . . . 10 ....... 1 1 1 . . . . . . 30 . . . . . . 15 . . . . . . 20 . . . . . . 30 . . . . . . 47 Grid No. Part No. 7522004 7522024 7541901 7541906 7541923 7541925 Ref. No. . . . . . . 10 ....... 8 . . . . . . 20 . . . . . . 15 ........ 9 21 . . . . . . . 25 14 8 ........ 7 23 . . . . . . . 24 10 7 26 7 1 14 . . . . . . 18 . . . . . . 33 . . . . . . . 25 15 6 11 . . . . . . 33 . . . . . . 12 ........ 4 15 . . . . . . . 28 4 . . . . . . . 40 10 5 18 6 . . . . . . 23 . . . . . . 14 . . . . . . 36 ........ 6 9 . . . . . . 18 . . . . . . 32 ........ 5 59 12 . . . . . . 61 . . . . . . 11 ....... 3 . . . . . . 53 . . . . . . 14 ....... 8 . . . . . . 18 ....... 2 ....... 2 2 2 2 . . . . . . . 26 23 18 . . . . . . . 13 2 . . . . . . 16 Grid No. . . . A6 . . A12 . . . A6 . . . C2 . . . C6 . . . C7 . . . A6 . . A10 . . A14 . . . A8 . . . B2 . . . A8 . . A14 . . . B3 . . . B4 . . B10 . . . C1 . . . C7 . . . B2 . . . B6 . . . B6 . . . B9 . . B12 . . B13 . . B12 . . . B2 . . . B2 . . B12 . . . B2 . . . B8 . . . B2 . . B10 . . B11 . . B12 . . B13 . . . B9 . . . B2 . . . B6 . . . B6 . . B10 . . . B8 . . . B6 . . . B2 . . . B6 . . . C6 . . . B6 . . B10 . . . B6 . . . B6 . . . B8 . . . A6 . . . C6 . . A10 . . . B7 . . B11 . . B12 . . B13 . . . A8 . . . C6 . . . C7 . . . A5 . . . C2 . . . C6 Part No. 7553201 7555701 7555708 7555716 7555721 7555727 7555730 7555734 7555740 7555746 7555787 7555788 7555792 7555795 7555804 7555806 7555823 7555832 7555843 7555852 7555865 7555893 Ref. No. . . . . . . 35 ....... 2 . . . . . . 33 ........ 7 21 ........ 6 12 ....... 7 ....... 3 . . . . . . . 36 3 . . . . . . 13 . . . . . . 12 . . . . . . 18 ....... 5 . . . . . . 10 . . . . . . . 19 25 . . . . . . 32 ........ 3 30 3 . . . . . . 20 . . . . . . 28 . . . . . . . 26 10 . . . . . . 23 . . . . . . 10 . . . . . . . 43 6 3 3 ....... 9 . . . . . . . 16 20 . . . . . . 11 . . . . . . 20 . . . . . . 31 . . . . . . 38 ....... 9 . . . . . . 27 . . . . . . . 20 8 ....... 4 ....... 8 . . . . . . 21 . . . . . . . 12 11 11 ........ 2 4 . . . . . . . 36 4 8 ....... 5 . . . . . . 16 ....... 9 ....... 8 ....... 2 . . . . . . 23 ....... 1 . . . . . . 33 . . . . . . 12 ........ 1 24 Grid No.
7512404 7512410 7512465 7512530 7512538 7512551 7512557 7512564 7512565 7512575 7512596 7512659 7512684 7515105 7515133 7515159 7515166 7515175 7515177 7515178 7515197 7515307 7515350 7515369 7515415 7515428 7515433 7515434 7515438 7515455 7515472 7515477 7515514 7515521 7515526 7515545 7515551 7516303 7516304 7516305 7517232 7517238 7517247
7517313 7517353 7517377 7517428 7517583
. . B13 . . . C2 . . . B2 . . . B4 . . . B4 . . B13 . . . B9 . . B12 . . B13 . . . B2 . . B10 . . B13 . . . B4 . . . C6 . . B10 . . . B6 . . . B6 . . . B2 . . . C6 . . . C6 . . . B6 . . B10 . . . B6 . . . C2 . . . C3 . . . A5 . . . A6 . . . A8 . . B10 . . . A8 . . . A7 . . . B3 . . . B6 . . . B8 . . . B9 . . . B2 . . . B6 . . . B9 . . B10 . . B12 . . . B2 . . B12 . . B10 . . B12 . . B13 . . . B8 . . . B6 . . . B7 . . B11 . . B10 . . . B8 . . A12 . . A12 . . A12 . . B13 . . . B3 . . B11 . . B12 . . B13 . . B12 . . B11 . . . B2 . . . B2 . . . B6
7542103 7542122
7542303 7542321 7542324
7542344 7542401 7542403 7542404 7542411
7555898 7555904 7555918 7555957 7555976 7556053 7556076 7556301 7556509 7556804 7558212 7558221 7558301 7558302 7558702 7571610 7571618 7571620 7571629 7575202 7621222 7621318 7621323 7621330 7621334
7542423 7542424 7542438 7542439 7542451 7542452 7542503
7542520 7542525 7542703 7542711 7542811 7546908 7547008 7547035 7552603
7552604
7552801 7553101
. . B10 . . . B9 . . . B4 . . B12 . . B13 . . . B2 . . . B6 . . . B4 . . . B4 . . A14 . . . B9 . . . C6 . . . A6 . . B13 . . . C4 . . A10 . . B12 . . B13 . . B10 . . . B7 . . B10 . . B11 . . . C6 . . . B6 . . . B6 . . . C6 . . B10 . . . C3 . . . B2 . . B11 . . B12 . . B13 . . . C3 . . A12 . . A14 . . B11 . . B12 . . B10 . . . B2 . . . C3 . . B12 . . . B6 . . . B9 . . . C3 . . . A7 . . . A8 . . . A5 . . A10 . . A14 . . . C1 . . . C7 . . . B2 . . . B6 . . . B8 . . A10 . . . B8 . . . B8 . . B11 . . . C6 . . . A5 . . . A8 . . . B2 . . . A7 . . . A7 . . A14
D9
PART NUMBER INDEX

XLT SP 099AB6AS
Part No. Ref. No. Grid No. Part No. 7661209 7661401 7661624 7661638 Ref. No. . . . . . . 35 . . . . . . 10 ....... 1 . . . . . . . 17 10 24 58 14 8 13 . . . . . . . 19 27 11 13 . . . . . . 38 ....... 5 ....... 9 . . . . . . 15 ....... 8 . . . . . . 31 . . . . . . 27 . . . . . . 10 ....... 4 Grid No. . . . B6 . . . B8 . . . B4 . . . A5 . . . A8 . . . B2 . . . B6 . . . C4 . . . C1 . . . C7 . . . A8 . . . B2 . . . B6 . . . C4 . . A14 . . . A5 . . . A5 . . . A5 . . . B8 . . . C7 . . A14 . . . B4 . . . C2 Part No. 7710422 7710444 7710503 7714804 7718406 7718407 Ref. No. Grid No.
7621337 . . . . . . . 6 7621402 . . . . . . 10 7621418 . . . . . . . . 7 16 7621425 . . . . . . 32 7621429 . . . . . . 19 7621433 . . . . . . . 39 8 7621435 . . . . . . . 5 7621452 . . . . . . . 26 56 7621467 . . . . . . . 17 4 7621472 . . . . . . 12 7621476 . . . . . . 25 7621477 . . . . . . . 9 7621484 . . . . . . 30 7621485 . . . . . . 16 7621501 . . . . . . 21 7621507 . . . . . . 22 7621509 . . . . . . . . 5 1 7621601 . . . . . . . 8 7661046 . . . . . . 13
. . . A6 . . . A7 . . . A5 . . . A8 . . . A8 . . . A7 . . A14 . . . C4 . . B10 . . . A5 . . . B6 . . . A8 . . . C4 . . . A8 . . B10 . . . B6 . . . A8 . . A14 . . B10 . . . A8 . . A14 . . . B3 . . . A8 . . . A6
7661643
7661644 7661840 7661841 7661850 7662210 7670055 7670082 7710401 7710417
. . . . . . 17 . . . . . . 17 ....... 2 ....... 3 ....... 6 ........ 4 9 17 7721103 . . . . . . . 6 7721116 . . . . . . . 12 8360012 . . . . . . 24 8360049-153 . . 30 8450003-1525 . . 24 30 7 8450040-153 . . 28 8450040-600 . . 28 8450045-153 . . 31 8450061-600 . . . 29 16 8450079-1525 . 34 9914668 . . . . . . . 6 9914857 . . . . . . . 6
. . . B9 . . B11 . . . B4 . . . C3 . . . B8 . . B10 . . B11 . . B13 . . . C3 . . . B9 . . . C1 . . . C6 . . . A6 . . . C1 . . . C7 . . . A6 . . . C6 . . . C6 . . . A6 . . . C7 . . . C6 . . . D4 . . . D4
D10
In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication.
or FAX your report to: 218-463-4580
POLARIS PUBLICATIONS REPORT

Publication No. Machine Publ. Date Page - Report of Error - Suggestion
Name Company Address City, State, Zip Phone No. ( ) Date Thank you for your help!
Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge.
4/94 Rev. 04 9912263
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FIRST CLASS PERMIT NO. 22 ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE
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4/94 Rev. 04 9912263
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4/94 Rev. 04 9912263
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PRINTED IN THE USA
PARTS MANUAL PN 9914839 and MICROFICHE PN 9915650 3/99

10653282-Polaris Download 1996 1997 1998 Snowmobile Service Manual Repair

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CHAPTER 1 GENERAL INFORMATION

GENERAL INFORMATION Publication Numbers

Polaris Industries Inc.

GENERAL INFORMATION 1997 Publication Numbers 1997 Publication Numbers

Polaris Industries Inc.

GENERAL INFORMATION 1998 Publication Numbers 1998 Publication Numbers

Indy WideTrak LX 0982065

Polaris Industries Inc .

Polaris Industries Inc.

GENERAL INFORMATION Bulletin Index - By Number

Polaris Industries Inc.

GENERAL INFORMATION Bulletin Index - By Number

Polaris Industries Inc.

GENERAL INFORMATION Bu lletin Index - By Number Information Bulletins, Cont.

1-95-03 1-95-04 1-95-05 1-95-06 1-95-07 1-95-08 1-95-09 1-95-10

1-96-01 1-96-02 1-96-03 1-96-04 1-96-05 1-96-06 1-96-07

Polaris Industries Inc.

GENERAL INFORMATION Bulletin Index - 1996 By Model

Service Service Service

1996 Indy 8torm 8K8

Info Info Info Info

1996 Indy 8torm RMK

Service Service Service

1996 Indy Ultra 8P

5 -96-10 8-96-06 8-95-22 8 -95-18 5-95-1 7 5-95- 10 1-96-11 1-96- 10

Polaris Industries Inc.

GENERAL INFORMATION Bulletin Index - 1996 By Model

1996 Indy Ultra SKS

Service Service Service

1996 Indy Ultra RMK

Service Service Service

Service Service Service Service

S-96-10 S-96-06 S-96-02 S-95-22 1-96-10 1-96-09 1 -96-08 1-96-06 1-96-04

Polaris Industries Inc.

GENERAL INFORMATION Bulletin Index -1996 By Model

1-96-12 1-96-10 1-96-06 1-96-04 1-96-03 1 -95-13

1996 Indy XLT RMK

1-96-12 1-96-04 1 -96-03 1-95-13 1-95-03

1996 XLT SKS

S-95- 11 1-96-12 1 -96-10 1-96-04 1-96-03 1-95-13

1-96-12 1-96-04 1-96-03 1-95-13 1-95-04

1996 XLT Touring

S-96-0B S-96;05 S-96-01 1-96- 13 1 -96-12 1-96-04 1 -96-03 1 -95-13 1-95- 10

Increased Rear Handwarmer Heat

GENERAL INFORMATION Bulletin Index - 1996 By Model

1996 Classic Touring

S-96-08 S-96-05 S-96-01 1-96-14 1-96-13 1-96-07 1-96-04 1-95-13 1-95-10

1996 Indy 500 RMK

S-96-13 S-96-05 1-96-14 1-96-10 1-96-07 1-96-05 1-96-04 1-95-13 1-95-07

1996 Indy 500 EFI RMK

S-96-13 S-96-05 1-96-10 1-96-05 1-96-04 1 -95-13 1-95-07

1996 Indy 500 EFIISKS (SKS Only)

S-96-05 1-96-10 1-96-04 1-95-13

1996 Indy 500

S-96-05 1-96-14 1-96-10 1-96-07 1-96-06 1-96-04 1-95-13

1996 Indy 500 SKS

Polaris Industries Inc.

GENERAL INFORMATION Bulletin Index - 1996 By Model

1996 Indy 440 XCR

1-96-10 1-96-06 1 -96-04 1-95-13

1996 Indy 440 XCR SP

S-95-20 1-96-10 1-96-06 1-96-04 1-95-14 1-95-13 1-95-12

1996 Indy 440

S-96-05 1-96-10 1-96-14 1 -96-06 1-96-04 1-95-1 3