1996-1998 Polaris Snowmobile

GENERAL INFORMATION Publication Numbers
1996 Publication Numbers

Model Indy Ute Indy Ute Deluxe Indy l.iteGT 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 RM K Indy Classic Indy Classic Trg. Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy XL T Indy XL SKS T Indy XL RMK T Indy XLT SP Indy XL Touring T Indy 600 XCR Indy 600 XCR SP Indy RXL Indy Ultra SP Indy Ultra SKS Indy Ultra RMK Indy Storm Indy Storm SK S Indy Storm RMK Model No. 0963433 0963431 0963133 0960443 0960143 0960243 0960743 0962760 0961660 0961760 0962061 0962084 0962761 0962262 0962764 0962564 0962964 0963865 0963365 0963774 0962574 0962974 0966756 0960556 0960956 0966676 0963357 0961676 0965677 0966768 0960678 0960578 0960978 0965782 0965582 0965982 Owner 's Manual 9913084 9913084 9913084 9913224 9913224 9913215 9913215 9913107 9913207 9913706 9913092 9913089 9913107 9913465 9913210 991321 0 991321 0 991 3153 9913153 9913617 9913195 9913195 9913103 9913307 9913307 9913103 9913153 9913207 9913322 9913205 9913094 9913094 9913094 9913097 9913097 9913097 Parts Manual 991 3166 9913166 9913308 9913222 9913227 9913222 9913218 991 3174 9913211 9913158 9913162 9913164 9913176 9913176 9913187 9913187 9913187 9913538 991 3362 991361 8 9913198 9913198 9913382 9913181 9913181 9913170 9913192 9913212 9913206 9913203 9913708 9913168 9913168 9913159 9913159 9913159 Parts Microfiche 9913167 9913167 9913309 9913223 9913228 9913223 9913219 9913175 9913213 9913336 9913163 9913165 9913177 9913177 9913188 99131 88 9913188 9913539 9913363 9913619 991 3199 9913199 9913383 9913182 9913182 9913171 9913193 9913214 9913311 9913204 9913707 9913169 9913169 9913160 9913160 99131 60 Assembly Instructions 9913085 9913088 9913087 9913220 9913225 9913221 9913216 9913172 9913208 9913338 9913093 9913090 9913110 9913109 9913185 9913185 9913189 9913184 99131 54 9913196 9913310 9913200 9913178 9913466 9913179 9913105 99131 90 9913209 9913323 9913201 9913194 9913095 9913183 9913098 9913101 9913101
Polaris Industries Inc.
1.1
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GENERAL INFORMATION 1997 Publication Numbers

Mode l Indy Lite Indy Lite Deluxe Indy Lite GT Indy Spo rt Indy TranSport Indy Sport Touring Indy XCF Indy Supe r Sport Indy 440 LC Indy 440 XC Indy 440 XCR 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 S P LTD Indy 600 XC Indy 600 XCR Indy 600 XCR SE Indy RXL Indy Ultra Indy Ultra SP Indy Ultra SPX Indy Ultra SPX SE Indy Ultra Touring Indy 700 SKS Indy 700 RMK Indy 700 XC Indy Storm Indy Sto rm 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 99 13647 9913709 9913841 9913841 99 13845 9913732 9913753 99137 13 9913761 9913761 9913774 9913732 9913658 9913658 9913755 9913795 9913795 9913851 9913804 9913912 991380 1 9913801 9913812 9913856 9913856 9914 180 9913781 9913781 9913786
Pa rts Ma nual 99 13827 9913827 99 13825 9913767 99 13829 9913767 9913861 9913764 9913835 99 13787 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 99 13813 9913857 9913857 9914 181 9913782 99 13782 9913782
Part s Microfiche 9913828 9913828 9913826 9913768 9913830 9913768 9913862 9913765 9913836 9913788 9914472 99138 18 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
As s e mb ly Ins truct ions 99 13749 9913750 99 13742 9913687 99 13697 9913702 9913662 9913766 9913837 9913754 99 13791 9913819 9913824 99 13710 9913704 9913648 99 13735 9913735 99138 44 9913848 9913737 9913751 9913714 9913762 99 13771 9913777 9913733 9913659 9913659 9913758 99 13798 9913798 9913854 9913807 99138 11 9913802 9913802 9913815 9913859 9913859 9914 183 9913784 9913784 9913784
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GENERAL INFORMATION 1998 Publication Numbers

Model Model No. Sup plement to
Owner 's Manual
Part s Book
Part s Microfiche
Assembly Manual Adden dum 9914241 9914188 9914195 9914299 9914284 9914289 9914207 9914279 99 14274 9914592 99 14260 99 14233 99 14223 9914212 99 14364 9914265 99 14250 9914390 9914305 99 14228 99142 18 9914255 9914318 99143 13 9914465 9914374 9914421 9914417 99 14369 9914357 9914342
Indy Lite Indy Lite Deluxe Indy Lite Trg. Indy Spo rt IndyTranSport Indy Super Sport Indy Spo rt Trg. Indy XCF Indy 440 Indy 440 XCR Indy Trail Indy Trail Trg. Indy Tra il RMK Indy500 Indy 500 Classic Indy500 RM K Indy Class ic Trg. Indy XLT LTD Indy XLT Classic Indy XLT SP Indy XLT Trg. Indy 600 XCR Indy 700 XCR Indy600 RMK Indy700 RMK Indy 600 XC Indy700 XC Indy Storm Indy Ultra Indy Ultra Trg.
0983433 0983431 0983133 0980443 0980 143 0980761 0980243 0981643 0982760 0981660 098276 1 0982362 0980961 0982764 0983865 0982964 0983365 0983756 0983857 0985776 0983357 0985677 0985678 0980958 0980966 0981758 098 1766 0985782 0986778 0985378
9914185 9914185 9914185 9914281 9914281 9914281 9914281 9914281 9914257 9914371 9914257 9914257 9914281 9914257 9914257 9914257 9914247 99 14387 9914302 99 14302 9914215 9914302 9914339 9914339 991437 1 991437 1 9914414 9914414 9914339 9914354 9914339
9914186 9914186 9914193 9914205 9914282 9914287 9914205 9914277 9914272 9914590 9914258 9914231 9914221 9914210 9914362 9914263 9914248 9914388 9914303 9914226 9914216 9914253 9914316 99143 11 9914463 9914372 9914419 99144 15 9914367 9914355 9914340
9914187 9914187 9914194 9914206 9914283 9914288 99 14206 9914278 99 14273 991459 1 9914259 9914232 9914222 9914211 9914363 9914264 9914249 9914389 9914304 9914227 9914217 9914254 9914317 9914312 99 14464 9914373 9914420 9914416 9914368 9914356 991434 1
Indy WideTrak LX 0982065
1998 Snowmobile Owner's Ma nua l (All) - P N 99 14617 1998 Snowmobile Dealer Assem bly Ma nua l - PN 99 13911 1998 Snowmobile Dealer Asse mb ly Man ual Update - P N 99 14643
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9/97
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 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 mode ls); Head Gasket Replacement, Fuel Pump Relocation and Carbure tor Main Jet Change on XLT Models Only. 1995 XLT Touring Circuit Breaker Wire may Contact Exhaust Outlet
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-o6
1. 1995 XCR 600 Front Bolt Installed Incorrectly on Steering Drag Link 2. 1995 RXL Exhaust Manifold Flange Angle Incorrect
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 (Additiona l 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 improveme nt kit 1995 Indy 500,500 EFI, 500 EFI SKS, 500 EFI SKS PT, Classic, Wide Trak LX - PTO end crankshaft failu re
Inform ation 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 Mode ls using Reverse Gear Base K~ PN 2871154 or PN 2870861 - Pinion Shaft Diameter XLT and XCR Models with EC58PL02 . 03 and E04 Engines - Coolant Leak at Spar k 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-10 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 Decai 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
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11/95
1.2
GENERAL INFORMATION Bulletin Index - By Number

Service Bulletin s
S-94-03 S-94-04 S-94-05 1994 Storm (EC80PL01) Piston Replacement 1994 XCR 600 Piston Cracking, Fuel Pump Relocation, Carburetor Jetti ng 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 Cylinde r Head O-Rings leaking 1994 XLT SP XTRA,1995 XLT SP, RXL Show Machines - IFS Shock and Rea r 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 Stee ring 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 S96-01 S-96-02 S-96-03 S-96-04 S-96-05 S-96-06 S96-0 7
Bottom Chaincase Sprocke t Washer Replacement (See Models Listed on Bulletin) 1995 XLT Tunnel Wear Strips in Wrong Holes 1995 XCR 600 Steeri ng 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-01 Engines Trail Touring - Wrong Pinion Gear Installed in some Trail Touring Chaincases 1996 Trail Touring Throttle Cabl e 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-Handl ebar Damage When Opening and Closing the Hood 1994 Storm/St orm SKS . Cooling System Update Kit 1995 Storm/Sto rm SKS - Cooling System Update KiVEngine 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). Stor m 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 Touring, Clas sic. Classic Touring. 500. 500 SKS , 500 RMK. 500 EFI. 500 EFI SKS, 500 EFI RMK. Trail, Trail Tou ring, 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
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9/97
GENERAL INFORMATION
Bulletin Index - By Number Service Bulletins, Cant.
S-96-08 S-96-09 --5-96-10 S-96-1 1 S-96-12 S-96- 13 S-96- 14 S-96 -15 S-96- 16 S-96- 17 S96-18 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 Qual ity 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 1997 500 RMK - Incorrect Throt tle Lever 1996 RMK Models - Ski Replacement Prog ram 1997 Lite Dlx.; Trail Trng.; Classic Trng.; XLT Trng.; Ultra Trng.; WideTrak LX - Loose Starter Ring Gear Screws 1997 Ultra Touring - Alumi num Tape On Speedometer Cable May Contact Battery 1997 XLT LTD SP - Incorrect Main Jets Installed In Carbu retors 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 Wit h Reverse Cable 1997 700 RMK - Insufficient Cleara nce Between Exhaust Pipe And Hood 1997 XLT RMK - Rich Condi tion I Poor Fuel Economy 1997 440 XC R - 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 Recoi l Housing 1997 WideTrak LX. GT - Transmission Not Engaging Or Sticking In Gear Safety Alert - 1997 440 XC, XCF - Pitman Arm 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) Pitma n Arm Weld Failure 1997 440 XCR - Engine Update Optio ns 1997 700 XC. SKS, RMK - Durability Improvement Kit For Oil Pump and COl Module
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
9/97
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 lor 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 Ca rburet or 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 2871154 or PN 2870861 - Pinion Shaft Diameter XLT and XCR Models 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-10 Scissor Stop Alignment 1995 RXL and XLT SP - XTRA 12 Suspension Adjustments and General Inform ation 1995 RXL and RXL Touring - Hesitation or Bog when Accelerating All 1995 Mode ls - Loose Rear Suspension Bolts. All 1995 Models Except XCRs - Seat Stain Removal
1,2b
Polaris Industries Inc .
GENERAL INFORMATION Bulletin Index - By Number Information Bulletins, Cant.

1-95-02
"-
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 Muffle r 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 Requir ed for Reverse Kit Installati on 1996 Ultra RMK - Carburetor Jetting and Fuel Recomm endat ion for Operation Below 6000 ft. (1800 meters), 1996 Ultra RMK - Kinked Coola nt Hose 1996 XLT Touring/Classic Touring - Nut Sarts " 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 ModelsRestricted Coolant Filter 1996 All Models wit h P-85 Driven Clutch - Bogging or Belt Slippage 1996 XLT RMK, Ultra RMK, 500 RMK , 500 EFI RMK - Opt ional Set up for Deep Snow Performance 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 1996 500, 500 SKS (Euro) , 500 RMK , Classic, Classic Touring (Euro) - Hose Clamp Tabs May Damage Coola nt Line 1996600 XCR SP, Ultra RMK - Improved High Elevation Performance 1996600 XCR SP - Improved Low End Performance at Low Elevat ions (0-3000 ft. / 0-900 m) 1996 All Models with XTRA-1a 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 EC58P L Engines 1996 XLT Touring, Class ic Touring - Slide Rail Beam Repair Kit 1996440 and 500Cc Liquid Twins (Except 440 XCR and 440 XCR SP) - Oil In Fuel Pump Impulse Line 1997 XLT RMK - Incorrect Information On Spec ification Deca l All Models With CRC Front Suspension - Stee ring Alignment During Setup 1997 600 XC, XCR, SE; Ultra SPX, SPX SE - Incorrect IFS Shock Spring Pre-load 1997 Super Sport; 600 XC - Nose Cone Decal Placement 1997600 XCR SE; Ultras (All) - Pinched Fuel Line 1997 XLT LTD, LTD SP; RXL; Storm, SE, RMK - 15 Wide Reverse Gear Kit Installation 1997 Class ic Touring - Inco rrect Torsion Bar 1997 Storm (All Including European Mode ls) - Tight Belt-To-Sheave Clearance 1997 600 XCR, SE; Ultra SPX, SPX SE; (And All Euro Models) - Poor PTO Exhaust Pipe Fit 1997 700 RMK ; SKS - Rev ised Oil Injection Pump Bleeding Procedure 1996600 XCR SP; Ultras ; Storms - Recommendations For 1996 High Performance Models 1997 WideTrak LX - Coolant Hose And COl Wire Routing 1997 Ultra SPX (Including SE and Euro Mode ls) - 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 Ca libration Changes
1 -95-03 1 -95-04 1-95-05 1 -95-06 195-07 1 -9508 1 -95-09 1 -95-10
"-
1-96-01 1 -96-02 1-96-03 196-04 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
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9/97
GENERAL INFORMATI ON Bulletin Index -1996 By Model

1996 Model
1996 Indy 5torm
Bulletin #
5 -96-10 5 -96-06 5 -96-04 5 -96-03 5-96-02 5 -95-22 5 -95-19 1 -96-10 1 -96-06 1 -96-04 1-96-0 1 1 -95-13
Type
Service 5a fety Service Service Service Service Service Info Info Info Info Info Service 5a fety
Service
Noles
Improved Clutch Alignment Coolant Tank Expansion Exhaust Pipe support Bracket May Crack Revised Timing and Carburetor Specs . Sharp Edge On Engine Mount False Oil Level Piston Failure At Partial Throttle Loose Wheel Lock Collars Loose Front Torque Arm Bolts Bogging or Belt slippage Main Harn ess/Brake Light Harn ess Position Heavy 5teering Improved Clutch Alignment Coolant Tank Expansion Exhaust Pipe suppo rt Bracket May Crack Revised Timing and Carburetor 5 pecs. 5 harp Edge On Engine Mount False Oil Level Piston Failure At Partial Throttle Loose W heel Lock Collars Bogging or Belt slippage Main Harness/Brake Light Harness Position Heavy 5teering
Aluminum Ski Replacement Program
1996 Indy 5torm 5K5
5-96 -10 5 -96-06 5-96-04 5 -96-03 5 -96-02 5-95 -22 5-9 5-19 1 -96-10 1 -96-04 1-96-01 1-95-13
Service
Service Service
Service
Info Info Info Info Service Service Safely Service Service Service
Service
1996 Indy Storm RMK
5-96-13 5-96-10 5-96-06 S-96-04 S-96-03 S-96-02 S-95-22 S-95-16 1-96-10 1-96-04 1 -96-0 1 1 -95-13
Improved Clutch Alignment Coolant Tank Expansion Exhaust Pipe support Bracket May Crack
R evised Tim ing and Carburetor Specs .
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 Expans.on False Oil Level Exhaust Thermal Sensing 5ystem Low Oil Level In Waler Pump Drive Gearcase Kinked Oil Lines Cracked Exhaust Pipes Loose W heel Lock Collars
Service Info Info Info Info Service Safety

Servi ce
1996 Indy Ultra SP
S-96-10 S-96-06 5 -95-22 S-95-18 S-95- 17 S-95- 10 1 -96- 11 1 -96- 10
Service
Service Serv ice
Info Info
9197
1.2d
GENERAL INFORMATION Bulletin Index - 1996 By Model

1996 Model
1996 Indy Ultra SP, (conI.)
Bulletin #
'96-06 ) 96-04 ) 96 02 )-95-13
Type
Into Into Into Into
Noles
Loose Front Torque Arm Bolts Bogging or Belt slippage Sharp Edge on Mounting Bracket Heavy Steering Improved Clutch Alignm ent Coolant Tank Expansion False Oil Level Exhaust Thermal Sensing System Kinked Oil Lines Cracked Exhaust Pipes Loose Wheel Lock Collars Bogging or Belt slippage Sharp Edge on Mounting Bracket Heavy Stee ring Aluminum Ski Replacement Program Improved Clutch Alignmen t Improved Running Quality & Snowmobility Coolant Tank Expansion False Oil Level Exhaust Thermal Sensing System Kinked Oil Lines Recoil Hub Cracking
Cracked Exha ust Pipes
1996 Indy Ultra SKS
S 96-10 S-96-06 S-9522 S-9518 S-95-10 1 -96-11 196-10 1 96-04 196-02 1 -95 13
Service
Safety
Service Service Service

Into Into Into Into Into
1996 Indy Ultra RMK
S-96-13 S96 10 S9609 S-96-06 S9522 S95 18 S-95- 10 S9507 19611 1 -9610 1 -9608 1 9605 19604 1 -96-02 1 -95-15 1 -95-13 1-95-09 1 -95-08
Service Servi e c Service

Safety
Service Service Service Service

Into Into Into Into Into Into Into Into Into Into Into Into
Service
Loose Wheel Lock Collars Improved High Elevation Pertormance Optional Setup tor Deep Snow Pertormance Bogging or Belt slippage Sharp Edge on Mounting Bracket Improved Snowrnobility In Deep Snow
Heavy Ste ering
Kinked Coolant Hose Carb & Fuel Recommendations for High Alt. Bogging or Belt Slippage Heavy Stee ring Improved Clutch Alignment Coolant Tank Expansion Sharp Edge On Engine Mount False Oil Level Loose Wheel Lock Collars Improved Low End Pertormance-Low All. Improved High All. Pertormance Loose Front Torque Arm Bolts Bogging or Belt slippage
1996 RXL
1 9604 1-95-1 3
1996600 XCR SP
S-96-10 S96-06 S9602 S9522 1-96-10 1 9609 1 9608 1 -96-06 1-96-04
Safety
Service Service
Info Info Info Info Info
1.2e
9/97
GENERAL INFORMATION BUlletin Index -1996 By Model

1996 Model
1996 600 XCR SP (cont.)
Bulletin #
1 -96-02 1 -95-13 1-95-1 1
Type
Info Info Info Info Info Info Info Info Info
Service
Notes
Sharp Edge on Mountin g Bracket Heavy Steeri ng Setup Recomm end ations Extended Warranty on 1996 EC58PL Engines Loose Wheel Lock Collars Loose Front Torqu e Arm Bolts Bogging or Belt slippage Restricted Coolant Filter Heavy Steering Alum inum Ski Replacement Program Snow Skirts Cracking Aroun d Mounting Boss Extended Warranty on 1996 EC58PL Engines Loose Wheel Lock Collars Optional Setup for Deep Snow Performan ce Bogging or Belt slippage Restricted Coolant Filter Heavy Steenng 19 Tooth Top Sproc ket For Reve rse Kit Extended Warranty on 1996 EC58PL Engines Bogging or Bell slippage Restricted Coolant Filter Heavy Steeri ng Wrong Octane Callout on Specification Decal
Snow Skirts Cracking Around M ounting Boss
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
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
Into Info Info Info Info Info Info Info Info Info
Extended Warranty on 1996 EC58PL Engines Loose Wheel Lock Collars Bogg ing or Belt slippage
Restricted Coolant Filte r
Heavy Sleenng Extended Warranty on 1996 EC58PL Engines Bogging or Belt slippage
Restricted Co olant Filter
1996 XLT
1-96-12 1 -96-04 1 -96-03 1-95- 13 1-95-04
Heavy Steenng Fronl Muffler Dampe r Installat ion Location

Increased Rear Ha ndwa rmer Heat
Handl e Bar Welds M issing or Inco mplete
1996 XLT Touring
S-96-08 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
Serv ice
Front Torque Arm Shaft Retention Kit Slide Rail Beam Repair Kit Extended Warranty on 1996 EC58PL Engines Bogging or Belt slip page Restncted Coolant Filte r
Heavy Stee ring Nut Sert ' " Miss inq From Back R est Bracket
Info Info Info Info Info Info
9/97
1.21
Poleris Industries Inc.

1996 Model
1996 Indy Classic
Bulletin #
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 Incomp lete Oil In Fuel Pump Impulse Line Hose Clamp Tab May Damage Coolant Line Bogging or Belt slip page Heavy Steeri ng
1996 Class ic 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
Increased Rear Handwarmer Heat

Handle Bar Welds Missi ng or Incomplete Front Torque Arm Shaft Reten tion Kit Oil In Fuel Pump Impulse Line Slide Rail Beam Repair Kit Hose Clamp Tab May Damage Coo lant Line Bogg ing or Bell slippage Heavy Steering Nut Sert'" Missing From Back Rest Bracket Alum inum Ski Replacement Progra m 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 Bell slippage Heavy Steering 19 Tooth Top Sprocke t Requir ed For Reverse Kit Alum inum Ski Replacement Program Handle Bar Welds Missing or Incomplete Loose Wheel Lock Collars Optional Setup for Deep Snow Performance Bogging or Bell slippage Heavy Steering 1g Tooth Top Sprocket Required For Reverse Kit Handle Bar Welds MIssing or Incomplete Loose Wheel Lock Collars Bogging or Bell slippage Heavy Steering Handle Bar Welds Missing or Incomplete Oil In Fuel Pump Impulse Line Loose Wheel Lock Collars Hose Clamp Tab May Damag e Coolant Line Loose Front Torque Arm Bolls Bogging or Bell slippage Heavy Steeri ng Handle Bar Welds Missing or Incomp lete 0,1In Fuel Pump Imp ulse 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 Inl o Into Info Salety Info
1996 Indy 500 EFI/SKS (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- t 4
Polaris Industries inc.
1.29
9197

1996 Model
1996 Indy 500 SKS (cont.)
Bulletin #
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 Whe el Lock Collars Loose Front Torque Arm Bolts Bogging or Belt slippage Heavy Steering Loose Shock Eyelet On Fox Shocks Loose Wh eel Lock Collars Loose Front Torqu e Arm Bolts Bogg ing or Belt slippa ge Jetting and Clutching For Improved Perf. Heavy Steering Exhaust Pipe May Contact Hood Handle Bar Welds Missing or Incompl ete Loose Wheel Lock Collars Oil In Fuel Pump Impulse Line Loose Front Torque Arm Bolts Boggin g or Belt slippage Heavy Steering Handlebar Damage When Ope ning Hood Bogging or Belt slippage Oil In Fuel Pump Impulse Line Handl e Bar Welds Missing or Incompl ete Loose Wheel Lock Collars Loose Fronf Torqu e Arm Bolts Bogging or Belt slippage Heavy Stee ring Handle Bar Welds Missing or Incomplete Throttle Cable Ends May Be Reversed
Wr ong Pinion Gea r In Ch aincas e
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
Se rvice
1996 Indy 440
S-96-05 1-96- 10 1-96-14 1 -96-06 1 -96-04 1 -95-13
1996 Indy Widetra k GT/LX
S-95-12 1-96-04
Info Info Safety Info Info Info Info Safely
(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 Service
Loose Whe el Lock Collars Bogging or Belt slippage Heavy Steering Loose Wheel Lock Collars
Loose Front Torque Arm Bolts
1996 Indy Super Sport
1 -96-10 1 -96-06 1 -95- t 3
Heavy Stee ring Snow Skirts Cracking Around Mounting Boss Loose Wheel Lock Collars Heavy Steeri ng Heavy Steering
1996 Indy Sport Touring
S-95-11 1 -96-10 \-95-13
Service
Info Info Info
1996 Sport and Lites
1 -95-13
9/9 7
1.2h

1997 Model 1997 Storm I SE 1997 Storm RMK 1997 700 (SKS and RMK) Bulletin # S-96-18 S-96- 18 S-97-05R S-97-05 S-97-02 1-96-24 (RMK Only) All 700s (XCISKSIRMK) S-96-20 1 -96-29 S-97-07 1997 Ultra SPXlSE S-97-05R S-97-05 1997 Ultra SP (Euro) S-97-05R S-97-05 S-96-17 1997 Ultra Touring S-96-19 S-96-15 S-96-14 1997 Ultra (Euro) 1997 RXL 1997 600 XCR I SE S-97-05R S-97-05 1997 600 XC S-97-05R S-97-05 1997 XLT RMK 1997 XLT LTD I LTD SP 1997 XLT Touring 1997 XLT SP 1997 XLT SKS 1997 XLT 1997 500 EFI 1997500 UC 1997 500 RMK S-96-13 S-96-12 1997500 SKS Service Service Aluminum Ski Replacement Program
Incorrect Th rottle Leve r
Type Service Service

Sa fetv Alert
Notes Coolant Check Valve I Filter Assembly Installed Incorrectly Coolant Check Valve I Filter Assembly Installed Incorrectly Pitman Arm Weld Failure and Pitman Arm to Steering Rack Bolt Replacement
Safetv Alert - Refer to S-9 7-05R Service Info Service Info Service Safet y Alert Coolant Hose May Contact Recoil Housing Revised Oil Pump Bleeding Procedure
Insufficient C lea ra nce Between E xhaust Pipe and
Hood Carburetor Calibration Changes Durability Improvement Kit for Oil Pump and COl
Pitman Arm We ld Failure a nd Pitma n Arm to
Steering Rack Bolt Replacement Safety Alert - Refer to S-97-05R Service Pitman Arm Weld Failure and Pitman Arm to Steering Rack Bolt Replacement
Safety Alert - Refer to S-97-05R Service

Service
Oil Supply Line May Kink Below Filter Hood Interfer ence With Reverse Cable Aluminum Tape On Speedo meter Cable May Contact Battery Electric Start - Loose Starter Ring Gear Screws Oil Supply Line May Kink Below Filter
Service Service Service
S-96- 17
Safety Alert
Pitman Arm Weld Failure and Pitman Arm to Steering Rack Bolt Replacement
Safety Alert - Refer to S-97-05R Jiafety Alert Pitman Arm Weld Failure and Pitman Arm to Steenng Rack Bolt Replaceme nt
Safet y Alert - Refer to S-97-05R Service Service Service Rich Condition I Poor Fuel Economy Incorrect Main Jets Installed In Carburetors Electric Start - Loose Starter Ring Gear Screws
S-96-21 S-96-16 S-96-14
Polar is Industries Inc.
1.2i
9197

1997 Model
1997 Classic 1997 Classic Touring 1997 Widetrak GT
Bulleti n #
S-96-14 S-96-14 S-97-03 S-96-23
Type
Service Service Service Service Service Service Service Service Service Service
Notes
Electric Start - Loose Starter Ring Gear Screws Electric Start - Loose Starter Ring Gear Screws Transmiss ion Not Engaging or Sticking In Gear Transmission Oil Leaks I Hard To Shift 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 COl Wires Fuel Line And Water Trap Abrasion Pitman Arm Weld Failure Front Track Shock Reservoir Clamps Installed Incorrectly
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-96-11
Safety Aled
Service
1997440 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
Safety Aled
Service
Pitman Arm Weld Failure Electric Start - Loose Starter Ring Gear Screws
9197
1.2j
GENERAL INFORMATION Bu llet in lndex- 1998 By Model

199 8 M o d el Storm 700 XC 700 XCR S-97-05 R S-97-05 700 RMK S-97-05R S-97-05 Ultra Ultra Touring 600 XC 600 XCR S-97-05 R S-97-05 600 RMK S-97-05R S-97-05 XLT SP S-97-05R S-97-05 XLT Ltd XLT Classic XLT Touring 500 500 RMK Classic Classic Touring Widetrak LX Trail Trail Touring Trail RMK 440 440 XCR XCF Sport Super Sport Spo rt Touring Transport Lite Lite Deluxe Lite Tounng B ulletin # Type N otes
Safelv Afert
Pitman Arm Weld Failure And Pitman Arm to Steering Rack Bolt Replacement
safely Alert - Refe r To S-97-05R Safely Alert

Safely Alert - Refer To S-97-05R
Safely Alert
safely Alert - Refer To S-97-05R Safel y Alert

safely Alert - Refe r To S-97-05R safely Alert

Pitman Arm Weld Failure And Pitman Arm to Stee ring Rack Bolt Replacem ent
safety Alert - Refer To S-97-05R
1.2k
9/9 7
GENERAL IN FORMATI ON Service Videos Service Videos

Part Number Description Advanced Carbu retion Fuel Syste m Diagnostics Polaris Variable Tran smissions Custome r Service Magnu m 4 Stroke Introduction Cha rging System Diagnostics Ignition System Diagnostics Snowmobile Suspe nsion Service
9914394 9912776 9913987 9914171 9912996 9913278 9913533 9913684
1.3
9/97
GENERAL INFORMATION 1996 Modelldentiflcation SERIAL NUMBER IDENTIFICATION

Themachine serial 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 DESI GNATION

YEAR DESIGNATlm-l--1--- -----~ MODE L DESIGNAT ION
O~
~----
ENGIN E DESIGNATION
Referto Engine Sect for ion moredetailedinformation
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 Class ic 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 - EC58PL E05 64 - EC50PL11, PL15, PLE12 65 - EC50PL E11, PL14 68 - EC65PL05 74 - EC50PL13 76 - EC58PL02 77 - EC59PL01 78 - EC68PL01, PL04 82 - EC80PL05, PL04 31 - EC34-2PM E02
MODELNO.
V.t N. NO.
MACE IN U.S.A.
P O L R R IS
U.s. Patents
3,&05,5 11
PATENT NOTICE
PIII*,ted caMC1ll
MId. by PoI.rt. IndUstJ168 ine., In Ro...u, MN underone or more 01 the lo Dow lng patents:
3,813, 810
THIS VEHICLE CONFORMS TO ALL APPUCABLE us. FEDERALAND STATE REQUIREMENTS AND CANADA MOTORVEHICLE SAFETY STAN DARDS IN EFFECT ON THE DATEOF MANUFACTUR E. MFO. DATE:
3,580,&4 7
3,483,7h
3,533,&62 3,545,82 1 3,105,510 3,.&26,412
3.S87,891 4,713,050 5,038.881
5,050,"& 5,G48.503
5,058,482
883,594171
Can~lan
882 ."Vm1
8&4.3i4171
5.0;1 .813
5,074.271
Rd.
34,.&73171
5,172.1175
5,090,3M 5,060 ,564
',191,53 1 3.81U11
34,572171
1.2X1,823/87 7072 133
Th ese 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 mode l and serial numbers be called out. Laser engraved model and serial numbers are located on the crankcase (intake side).
11/95
1.4
GENERA L INFORMATION 1996 Model Identification

Indy L1le
0963433 Engine Type Engine Model Number
Indy Lite Deluxe

096343 1
Indy L1le GT
0963 133
Indy Sport
0960443 Fan Twin EC44-3PM01 432 67.72 x 60
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
Displa cement (ee)

Bore x Stroke (mm) CarburetionfThrottJe Body Oil Injected
2 Mikuni
VM30S S Slide Standard COl 12V 150W 1051266.7 42.51108
2 Mikuni
VM30SS Slide Standard COl 12V 150W 1051266.7 42.51108
2 Mikuni
VM30SS Slide Standard COl 12V 150W 1151292.1 42.51108 481121.9
2 Mikuni
VM34 SS Slide Standard COl 12V 200W 106251269.9 43.51110.5
IgnItion
Alternator Output Length (in.lcm.) Width (in.lern.) Height (in.lern.) Ski Stance (in.lcm.) Track Width (in.lern.) Track Length Ove rall (in.lcm.) Fuel Capacity (U.S. gasJlmp. gal.l liters)
441111.8
37/94 151 38.1 121/307.3
44/111 .8
37/94
44/111.8
38196.5
37/94
15138.1 133.5/339 .1 8/6.7/30 .3 87 Octane Min. Parallel Link Trailing Ann IFS Standard
15/38.1
121/307.3
15138.1
12 1/307.3 10.7/8.9/40.5
816.7/30.3
87 Octa ne Min. Paralle l Link Trailing Arm IFS Standard
8/6.7/30.3 87 Octane Min.
RecommendedFuel
87 Octane Min.
Parallel Link Trailing Arm IFS
Standard
Front Suspension
Rear Suspe nsion
Brake Type Storage
Parallel Link
Trailing Arm IFS Standard
Mechanical Disc Rear of Seat Topol Hood

Standard NIA N/A NIA
Mechanical Disc
Mechanical Disc
Rear of Seat Top of Hood Standard N/A N/A Oil/Ace
Hydraulic Disc
Rear 01 Seat
Asarof Seat
Topol Hood
Toolbox Footrest
Standard
Option Option Oil/Brake Ace High Beam
Option
Speedometer
Standard
NlA NlA Oil/Ace
Tachometer
Electric Fuel Gauge Accessory Lights
Electric Start
Handwarrne~humbwanne r
Option Opticn/Option Standard Lrte Option Option
Standard
Single Heal/S td Standard Lite Option Option
Opt ion Single Heal/Std 2 Up Lite Standard Standard
Single Heal/Std Standard Option
Seat Storage Rack Tow Hrteh
Option
1.5
11/95
GENERAL INFORMATION 1996 Model Identification
Indy TranSport
0960143 Engine Type Fan Twin EC44-3PMOl 432 67.72 x 60
Indy Super Sport

0960743 Fan Twin EC44-3PM02 432 67.72 x 60
Indy Spo rt Touring

0960243 Fan Twin EC44-3PMOl 432 67.72 x 60
Indy 440 LC
0962760 LC Twin EC45PL06 432 67.72 x 60 2 Miku ni VM34SS Slide Standard COl 12V 200W 1081274.3 46.5/ 118.1 46/118.1 41/104.14 15/38 .1 12 1/307.3
EngineModelNumber
Displacement (ee)
Bore x Stroke (mm)
CarburetionIThrottleBody
Oil Injected
2 Mikuni
VM34SS Slide Standard COl 12V 200W 1131287 43.5/110.5 45/114.3 38/96 .5 15/38.1 141/358.1 10.7/8 .9/40.5 87 Octane Min. Paralle l Link Trailing Arm IFS Standa rd
2 Mikuni
VM34SS Slide Standard COl 12V 200W 106.25/269.9 45 .5/115.6 38.5/97.8 41/104 .14 15/38.1 121/307 .3 10.7/8 .9/40.5 88 Octane Min . Parallel Link Trailing Arm IFS XT RA 10
2 Mikuni
VM34SS Slide Standard COl 12V 200W
Ignition
Alternator O utput Length (inJem.) Width (inJem.) Height (inJem.) Ski Stance (in.lem.) Track Width (in.lem.) Track Length Ove rall (in.lcm .) Fuel Capacity (U.S. 9as.ll mp. gal./liters)
1131287
43 .5/110 .5 5011 27 38/96 .5 15/38.1 133.5/339.1 10.7/8.9/40.5
10.718.9/40.5
87 Octa ne Min. Parallel Link
Recommended Fuel Front Suspension
87 Octane Min. Parallel Link

Trailing Arm IFS XTRA 10
Trailing Arm IFS

XTRA 10
Rear Suspension
Brake Type Storage
Hydrau licDisc Rear of Seat

Toolbox Footrest
Hydraulic Disc Rear 01Seat Toolbox Footrest

Standard Standard
Hydraulic Disc Rear of Seat Toolbox Footrest

Standard
Hydraulic Disc
Rear of Seat
Toolbox
Standard
Standard Option OiVBrake Temp High Beam Opt ion Hi-LoIStd Short Option
Speedometer
Standard
Option Option OiVBrake Ace High Beam Option Single HeaVAce 2Up Option Option
Tachometer
Electric Fuel Gauge
Option Option OiUBrake

Ace High Beam
Option
OiVBrake Ace
Accessory Lights
HighBeam
Option Sing le HeaVStd Standard Option Option
Electric Start
Option
Single HeaVAcc 2 Up
HandwarmerslThumbwarmer Seat
Storage Rack
Option
Option
TowHitch
Option
11/95
1.6

Indy 440 XCR
0961660 Engine Type Engine Model Number Displacement (co) Bore x Stroke (mm) CarburetionfThroltl e Body Oil Injected LCTwin EC45P L07 439 68.25 x 60
Indy 440XCRSP
0961760
Indy Trail
096276 1 Fan Twin EC50PM04 488 72 x 60
Indy Trail Touring

09 62262 Fan Twin EC50PME04 488 72 x 60
LCTwin EC45PL08
439 68.25 x 60
2 Mikuni
VM34SS Slide Standard COl 12V 200W 109/276.8
2 Mikuni VM34SS Slide

Standard COl 12V 200W 109/276.8 46.5/118.1 TBA 41/104.14
2 Mikuni
VM34 SS Slide Standard COl 12V 200W
2 Mikun i
VM34 SS Slide Standard COl 12V 200 W 122/309. 8
Igniti n o Alternator Output

Length (inJcm.) Width (inJcm .) Height (inJcm.) Ski Stance (inJcm.) Track Width (inJcm.) Track Length Overall (inJcm.) Fuel Capacit y (U.S. gas.llmp. gal./liters)
11 4/289.5 46.51118.1 46/116.8

41/ 104.14 15/38 .1 121/307.3
46.51118.1 38.5197.8
41/104 .14
46.51 11 8/1
48/1 2 1.9 41/104 .14 15/38.1
15/38.1 121 /307.3

9.5/8.9/40 .5 9 1 Octane Min. CRC XTRA 10 liquid Coole d
15/38.1
121/307.3 9.5/8.9/40.5 91 Octane Min. CRC XTRA 10 TBA
133.5/339.1 10.7/8.9/40.5 87 Octane Min.

Parallel Link Trailing Anm IFS XTRA 10
10.718 .9/40.5 87 Octane Min.

Perallel Link Trailing Arm IFS XTRA 10 Hydraul ic Disc
Recommended Fuel Front SuspensIon Rear Suspension

Brake Type
Hydraulic Disc
Rear 01 Seat Toolbox Standard
Hydraulic Disc
Storage Rear of Seat
Standard Standa rd
Rear of Seat
Optio n Standard
Rear of Seat Toolbox

Standard Standard
Speedometer Tachometer
Electric Fuel Gauge
Option
Option OiVBrake High Beam Standard Hi-LoIStd 2 Up Option Opt ion
N/A OiVBrake
Temp/Ace High Beam
N/A OiUBrake
Temp/Ace
Option
OiVBrake High Beam
Option Hi-LoIStd Long Opt ion Opt ion
AccessoryLights
HighBeam
Option Hi-Lo/Std 2 pc 1 Knee Pad
Electric Start
Option Hi-Lo/Std 2 pc 1Knee Pad Option Option
HandwarmersfThumbwarmer
Seat Storage Rack Tow Hitch
Option
Option
1.7
11/95

Indy Classic
0963865 Engine Type LC Twin EC50P LE11 488 72 x 60
Indy Classic Touring

0963365 LC Twin EC50PL14 488 72 x 60
Indy 500
0962764 LC Twin EC50PL11 488 72 x 60
Indy 500 SKS
Indy 500 RMK

0962564 0962964 LCTwin EC50PL11 EC50PL15 RMK 488 72 x 60
Engine Model Number

Displacement (ce) Bore x Stroke (mm)
CarburetionfThrottle Body
Oil Injected
2 Mikuni 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 87 Octane Min. IFS XTRA 12
2 Mikuni VM34SSSlide
Standard COl 12V 200W 115/292 .1 48/121.9 51.5/ 130.8 42.5/107 .9 15/38.1 133.5/339 .1 10.7/8.9/40.5

COl 12V 200W 108/274 .3 46.5/ 118. 1 46/1I 6.8 4 1/104.14 15/38. I 121/307 .3 10.7/8.9/40 .5 87 Octane Min. Parallel Link Trailing Arm IFS XTRA 10

COl 12V200W 108/274.3 46.5/ 1I 8.1 48/12 1.9 41/ 104.14 15/38 .1 133.5/339 .1 10.7/8.9/40.5
Ignition
Alternator Output
Length (in.lern.) Width (in.lcm.) Height (in.lcm.) Ski Stance (in.lcm .) Track Widt h (in.lcm .) Track Length Overall (in.lcm.) Fuel Capacity (U.S. gas.ll mp. gal./llt ers)
Recommended Fuel Front Suspension

Rear Suspe nsion
Brake Type Storage
87 Octane Min.
Parallel Link Trailing Arm IFS XTRA 12
87 Octane Min. Parallel Link Traiiing Arm IFS

XTRA 10
Hydraulic Disc Rear of Seat Toolbox

Standard
Hydraulic Disc Rear of Seat Toolbox

Standard
Hydraulic Disc
Hydraulic Disc HD Pads RMK Rear of Seat Toolbox

Standard
Rear 01 Seat Toolbox

Standard Standard
Speedometer
Tachometer ElectricFuel Gauge Accessory Lights
Standard
Standar d
Oil/Brake Temp High Beam
Standard Standar d Oil/Brake Temp High Beam Standard

Hi-Lo/Std 2 UplTour
Standard
Option OiVBrake Temp HighBeam
Option Oil/Brake Temp High Beam Option

Hi-La/Std Short
Electric Start
Standard
HI-Lo/Std
Option
Hi-Lo/Std Long Option Option
Seat
Long Option Option
Storage Rack
Tow Hitch
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 WideTrak LX
0962064
LCTwin EC50PLE12
Indy WldeTrakGT
0962061
Engine Type Engine Model Number

Displacement (cc)
LC Twin EC50P113 488 72 x 60 2 Throttle Body 46m m Standard C Ol 12V 250W 1081274.3 481121.9 49.5/ 125.7 42.5/10 7.9 15138.1 121/307.3 10.7/8.9/40.5
Fan Twin
EC50PM03 488 72 x 60
488 72 x 60
Bore x Stroke (mm)
CarburetionfThrottJ Body e
Oil Injected
46 mm
Standard COl t 2V 250W 108/274.3 46.5/ 118.1 48/12 1.9 41/104.14 15/38.1 133.51339.1 10.7/8.9/40.5

COl 12V 200W 1281 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 121.51308.6 43.5/110.5 49/124 .5 38/96.5 20/50.8 141/358.1 10/8.31 37.8
88 Octane Min.
Ignition
Alternator Output Length (in.lcm.) Width (in.lcm.) Height (in.lcm.) Ski Stance (in.lc m.) Track Width (in.lcm.)
Track Length Overall (in.lcm)

Fuel Capacity (U.S. gas.l lmp. gal./liters)
Recommended Fuel
87 Octane Min.
Parallel Link Trailing Arm IFS XTRA1 2
87 Octane Min.
Parallel Link Trailing Arm IFS XTRA 10
87 Octane Min.
Parallel Link Trailing Arm IFS Standard
Frant Suspension
Rear Suspension
Brake Type

Standard
Hydraulic Disc
Rear of Seat
Hydraulic Disc HD Pads RMK Rear of Seat Toolbox

Standard
Standard
Mechanical UnderSeat Storage Rack Standard Standard

N/A OillTemp Rev HighBeam Standa rd Single HeaVStd 2 Up w/Rise r Standard Standard
Mechanical
Under Seat Standard Option N/A
Storage
Speedometer
Toolbox
Standard
Standard Option Oil/BrakelTemp Batt High Beam Option Hi-Lo/Std Long Option Option
Tac hometer
Electric Fuel Gauge
Option
Oil/BrakelTemp Batt High Beam
Accessory Lights
Rev/Ace Oil High Beam

Option Single HeaVStd 2 Upw/Ri ser Standard Standard
Electric Start
H andwanner~humbwarmer
Option
Hi-Lo/Std Short
Option Option
1.9
11/95
GENER AL INFORMATION 1996 Mode l Identification

Indy XLT
0966756 Engine Type EngineModel Number Displacement(oc) Bore x Stroke (mm) CarburetionfThrottie Body Oil Injected LC Triple EC58PL03 597 65 x 60 3 Mikuni VM34SS Standard COl 12V 170W 1081274.3 481121.9 48.5/123.1 42.5/107.9 15/38.1 121/307.3 10.7/8.9/40.5 88 Octane Min. 42.51FS XTRA12 Hydraulic Disc
Rear of Seat Toolbox Footrest
Indy XLTSP
0966676 LC Triple EC58PL02 597 65 x 60 3 Mikuni VM38SS Standard COl 12V 170W 106.251269.9 481121.9 48.51123.1 42.5/107.9 15138.I 121/307.3 10.7/8.9/40.5 91 Octane Min. Non-Parallel Link Trailing Arm IFS XTRA 12
Hydraulic Disc Rear of Seat Toolbox Footrest Standard
Indy XLT SKS

0960556 LC Triple EC58PL03 597 65 x 60
3 Mikun i VM34SS Slide
Indy XLT RMK

0960956 LC Triple EC58PL07 597 65 x60
3 Mikuni
VM34SSSlide Standard COl 12V 170W 1131287 43.51110.4 44/111.8 38196.5 15138.1 133.51339.1 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS XTRA 10 Hydraulic Disc
Standard COl 12V 170W 1131287 46.51118.1 44/111 .8 41/104.14 15/38.1 133.5/339.1 10.7/8.9/40.5
88 Octane Min.
Ignition
AlternatorOutput Length (in.lcm.) Width (in.lcm.) Height (in.lcm.) Ski Stance (in.lcm.) Track Width (in.lcm.)
Track Length Overall (in.lcm.)
Fuel Capacity (U.S. gas.llmp. gal.lliters) Reccmmended Fuel Front Suspension RearSuspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights
Parallel Link Trailing Arm IFS XTRA10 Hydraulic Disc Rear of Seat Toolbox Footrest
Standard
Standard Standard Option OiUBrake Temp/Ace High Beam Option Hi-Lo/Std Standard Option Option
Standard Standard Option Oil/Brake Temp/Ace High Beam

Option
Standard Option OIUBrake Temp/Ace High Beam Option HI-Lo/Std Long Option Option
Standard Option OiU Brake Temp/Ace High Beam

Option
Electric Start
HandwarmenVThu~armer
Hi-Lo/Std Long Option Option
Hi-LoIStd Long Option Option
11/95
1.10
GENERAL INFORMATION
1996 Model Identification
Indy XLTTourlng
0963357 Engine Type Engine Model Number Displacement (ce) LC Triple EC58PLE05 597 65 x 60
Indy 600 XCR

0961676 LC Triple EC56P L02 597 65 x 60
Indy 600XCR SP
0965677 LC Triple EC59PLOI 598 62.5 x 65 3 Mikun i VM38AL Slide Standard Digital COl 12V200W 109/276.8 46/116.8 44/111.7 41/104 .14 15/38.I
Indy RXL
0966768 LC Triple EC65PL05 648 67.72 x 60 3 Throttle Boey
46mm Standard
Borex Stroke (mm)

Carburet ionlThrottie Body Oil Injected

Standard COl 12V200W 1151292.1 48/121 .9 51.5/130 .8 42.5/107.9 15/38.1 133.5/339.1 10.7/B.9/40.5 87 Octane Min.
3 Mikuni VM38ALSJide
Standard COl 12V 170W 109/276 .8 46/116.8 38.5197.7 41/104.14 15/38.I 121/307.3 9.5/8.9/40. 5
Ignition
Alternator Output
Length (inJcm.) Width (inJem.) Height (In.lcm.) Ski Stance (in.lcm.) Track Width (inJcm .) Track Length Overall (In.lem.) Fuel Capacity (U.S. gas.llmp. gal.lliters)
COl 12V 180W 106.251269.9 481121.9 48.5/123.1 42.5/107 .9 15/38.1 12 1/307.3 10.7/8.9/40.5
1211307.3
10.7/8 .9/40 .5 91 Octane Min. Parallel Link Trailing Anm IFS XTRA 10 Liquid Cooled Hydraulic Disc
Recommended Fuel
91 Octane Min. Parallel Link Trailing Anm IFS

XTRA 10 Llquld Cooled
87 Octane Min. Non-Paralle Link l Trailing Arm IFS

XTRA 12 Liquid Coo led HydraulicDisc
Fro Suspension nt Rear Suspension

Brake Type Storage

XTRA 12
Hydr aulic Disc

Rear of Seat Toolbox Under Hood
Standard Standard
Hydraulic Disc
Rear of Seat
Standard Stand ard NlA Oil/Brake Temp/Ace High Beam Option Hi-Lo/Std 2 pc Knee Pad Option Option
Rear or Se~t Toolbox

Stand ard Standard

Standard Standa rd Standard Oil/Brake Temp/Ace High Seam Option Hi-LoiOption Long Option
Speedometer
Tach ometer
Electric Fuel Gauge Aceessory Lights
Standard
Oil/Brake Temp High Beam Standard Hi-Lo/Std 2 Up Touring Option Option
Option
Oil/Brake Temp/Ace High Beam N/A Hi-LoIStd Mid. 1 pc, 121 NlA Option
Electric Start
Handwarmers/Thumbwarmer
Option
1.11
11/95

Indy Ultra SP
0960678 Engine Type Engine ModelNumber Displacement (ce) Sore x Stroke (mm) LC Triple EC68PL01 679 66.6 x 65
Indy Ultra SKS

0960578 LC Triple EC68PLOI 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 x 65
Oil Injected
3 Mikuni VM38 Slide

Standard Digital COl 12V200W 1081274 .3 46.5/118.1 38.5/97.7 41/104 .14 15138.1 1211307 .3 10.7/8.9/40 .5
87 Octane Min.
3 Mikuni
VM38 Slide
3 Mikuni VM38 Slide

Standard Digital COl 12V 200W
3 Mikuni VM38SSSiide
Standard Digital COl 12V 200W 1081274.3 46.51118 .1 44/111.7 41/104 .14 15/38.1 1211307.3 10.7/8.9140.5 91 Octane Min. 4 1 IFS XTRA 10 HP Liquid Cooled
Standard
Digttal CDI 12V200W
Ignition
Alternato r Output Length (inJcm.) Width (inJ cm.) Height (inJcm.) Ski Stance (in./cm.) Track Width (inJcm.) Track Length Overall (inJcm) Fuel Capacity (U.S. gas.nmp . gaL/liters)
1141289.5
41/104 .14 4611 16.8 41/104 .14 15/38.1 133.51339.1 10.7/8.9/40 .5
1141289.5
43.5/110.4 46/116.8 38/96 .5 15138. I 133.51339.1
10.718.9/40.5
87 Octane Min.
Recommended Fuel Front Suspension Rear Suspension

Brake Type
87 Octane Min.
Parallel link XTRA 10
Parallel Link
XTRA 10 liquid Coo led
Parallel Link
XTRA 10 Liquid Cooled Hydraulic Disc
Hydraulic Rearof Seat Toolbox Footrest Standard

Standard Option
Hydraulic Disc
Storage Speedometer Tachometer
Electric Fuel Gauge
Hydraulic Disc
Rear of Seat

Standa rd Standard Option OiVBrake Temp/Ace High Seam NlA Hi-Lo/Std Standard

Standard Standa rd Option
Toolbox
Standard Standard
Option
OiVSrake Temp/Ace High Seam N/A HiLa/Sld Hi-La Sculpt, Mid 121 N/A
Accessory Lights
OiVBrake
Temp/Ace HighBeam NlA Hi-La/SI d Long
OiVBrake Temp/Ace High Seam

N/A Hi-LoIStd Long Option Optio n
Electric Start
Handwanne~humbwanner
Seat
Storage Rack
Tow Hitch
Option
Option
Option
Option
Option
11/95
1,1 2
Polaris Indus tries Inc .
Indy Storm SKS

0965582
Indy Storm RMK

0965982 LC Triple EC80PL04 794 72 x65
Engine Type Engine Model Number

Displacement (cc) Bore x Stroke (mm)
LC Triple ECSOPL05 794 72 x65
CarburetionIThrottJ e Body
Oil Injected

Digital COl 12V 200W 114/289.5 46.5/118.1 44/ 111.8 411104 .14 15/38.1 133.51339.1 10.7/8.9/40 .5

Digital COl 12V200W 114/289.5 46.5/118.1 44/ 111.8 38196.5 15/38.1 133.5/339 .1 10.7/8.9/40.5
Ignitio n
Alternator Output Length (in1cm.) Width (in1cm.) Height (in1cm.) Ski Stance (in1cm.) Track Width (in1cm.) Track Length Overall (in1cm.) Fuel Capacity (U.S. gas.llmp. gal./Illers)
Recommended Fuel Frant Suspension Rear Suspension

Brake Type
91 Octane Min.
41" IFS XTRA 10 H P Liquid Cooled Hydraulic Disc
91 Octane Min.
38" IFS XTRA1 0 Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard Option OiVBrake Temp/Ace High Beam N/A HI-Lo/Std Hi-Lo Sculpt, Mid, 133 N/A
Storage Speedometer Tachometer Elect Fuel Gauge ric

Accessory Lights
Rear of Seat Toolbox

Standa rd Standard Option
OiVBrake Temp/Ace HighBeam

N/A Hi-Lo/Std HI-Lo Sculpt, Mid, 133 N/A Option
Electric Start
H an dwa nne~h umbwa nne r
Seat
Storage Rack
Tow Hitch
Option
Polaris Indu stries Inc.
1.13
11/95
GENERAL INFORMATION 1997 Model Identification SER IAL NUMBER IDENTIFICATION

The machine serial number may be used as an aid in Identifying mach ine model year. Refer to the first digits in the serial number lor proper identification: FIRST DIGITS MODEL YEAR 31 1997
1997 MODEL DESIGNATION

YEAR DESIGNATIONMODEL DESIGNATION -
O~
--,
ENGINE DESIGNATION
Referto Engine Section for more detailed information
1997 MODE L DESIGNATION NUMBERS (Chassis ) 01 - Indy TranSp ort 02 - Indy Sport Touring 04 - Indy Sport 05 - Indy XLT SKS, 700 SKS 06 - Indy Ultra SP 07 - Indy Super Sport, XLT, 09 - Indy Trail RMK, XLT RMK, 700 RMK 16 - Indy XCF, 440 XCR 17 - Indy 440 XC, 600 XC 20 - Indy WideTrak GT/LX 22 - Indy Trail 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 Deluxe 37 -I ndy 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 ENGINE DESIGNATION NUMB ERS 31 - EC34-2PME02 33 - EC34-2 PM02 43 - EC44-3PM02 56 - EC58 PL03, PL05 , PL07 57 - EC58PL09 60 - EC45 PL08, PL09 61 - EC50 PM03, PM04, PM05, PM06 64 - EC50PL1 6, PL17 65 - EC50PL 19, PL20 66 - SN70LCDCSP-01, S P-02 68 - EC65PL05 73 - EC50PL18 76 - EC58PL08, PL12 77 - EC59PL01 78 - EC68PL01, PL03 82 - ECBOPL04 , PL05
MODEL NO.
V.I.N. NO
MADE IN U.S.A.
PDLRRIS
PATENT NOTICE
THIS VEHICLE CONFORMS TO ALL APPLIC ABLE U.S. f EDERAL AND STATE REQUIREMENTS AND
CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFA CTURE.
MFD. DATE:
Mfd. b:t Polaris IndustrIes Inc.. In Roseau, MN under one or more 01 the follo wi ng patents: Palenl ed canada U.S. Pat ents 882,49 1n1 3, 605,511 3,513,810 5.050,559 883,69 4171 3,5 80.647 3,86 1.99 1 5,048,0503 864,394f71 3,483,766 5.056,48 2 4.193,950 Canadian Rd. 3,533,662 5.03 8.88 1 5.099.8 13 34 ,513171 3,545,82 1 5,172,675 5,074,271 34,572/71 3,60 5,510 5,090,3 66 5,191 ,531 1,221 ,823/87 3,525,412 5,050 ,564 3,6 13,811
7072133
These numbers should be referred to in any corresp ondence regarding wa rranty, service or replacement parts. The machine model and serial numb er identification decal is located on the right front side of the tunn el. The serial number is permanently stamped into the tu nnel. The model number is embossed on the decal. Whenever corresponding about an engine it is important that the engine model and serial numbe rs be called out. Laser engraved model and serial numbers are located on the crankcase (intake side).
9/96
1.13a

Indy Lite
0973 433
Indy Lite Deluxe

097343 1
Indy Lite GT
0973 133
Indy Sport
097044 3
Engine Type Engine Model Number Displacement (cc)

Bore x Stroke (mm)
Fan Twin
EC34 -2PM02 339 62 .3 x 55.6
Fan Twin
EC34 -2PM02 339 62.3 x 55.6
Fan Twin
EC3 4-2PM02 339 62 .3 x 55.6
Fan Twin
EC44-3PM Ol 432 67.72 x 60
CarburetionIThrottleBody
Oil Inject ed
2 Mikuni
VM30SS Slide
2 Mikuni
VM30SSSiide
2 Mikuni
VM30SS Slid e
2 Mikuni
VM34SS Slid e
Sta ndard
Standard
CDI 12V 150W 105/266.7 42 .5/108 44 /111.8 37/94
Standard
CD I 12V 150W 105/2 66 .7 42 .5/1 08 44 / 111.8 37/94
Standard
C DI 12V 150 W 115/2 92. t 42 .5/108 48/ 121.9 37/94 15/38. 1
Ignition Alternator Output

Leng th (in.lc m.) W idth (in.lcm .l Hei ght (in.lem. )
CDI 12V 200 W 108/2 74 .3 43.5/ t l 0.5 44/ 111.8
Ski Center Distance (in.lcm.)

Track Width (in.l em.)
38/96.5 15/38 .1 121/307 .3 10.7/8.9 /40.5

87 Octane Non-Oxygenated
or 89 Oc tane O xygenated
15138.1 121/307 .3 8/6.7/30.3
15/ 38.1 121/307 .3 8/6.7/30.3

Fuel Capacity (U.S. gas .ll mp. gaUliters)
133.5 /339 .1 8/6 .7/30.3

87 O ctane Non -O xygenated
Recomm ended Fuel
87 Octane
Non-Ox yqe nated or 89 Octane
87 Octane
Non-Ox ygenated or 89 Octan e
or 89 Octane
Oxyge nated
Oxygenated Front Suspension Rear Suspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lig hts Parallel Link Trailing Arm IFS X-Lite Mechanical Disc Rear of Seat
Top of Hood Standard N/A N/A N/A
Oxyge nated
Parallel Link Trailing Arm lFS Xd-Lite Mechanical Disc Rear of Seat
Top at Hood Standard N/A NIA Oil/Ace
Parallel Link Trailing Arm IFS Standard Mechanical Disc Rear of Seat
Top of Hood Standard N/A N/A
Parallel Link Trailing Arm IFS X-U te Hydraulic Disc Rear of Seat Toolbox Footrest
Stan dard Option
Option Oil/Brake
Aee
Oil/Ace
High Beam Electric Start HandwarmerslThumbwarmer

Seat
Option Option/Option Standard Lite Option

Option
Standard
Single HeaVStd
Option
Si ngle Hea VStd 2 Up U te
Option Single HeatlStd Standard Option Option
Standard Lite Option

Opti on
Storage Rack Tow Hitch
Standard Standard
1.13b
9/96
GENERAL INFORMATION 1997 Mode l Identification

Indy TranSport
0970143
Indy Super Sport

0970761
Indy Sport Tour ing

0970243
Indy 440 LC
0972760
Engine Type
Engine Model Number

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

43 2 67.72 x 60
Fan Twin EC50PM06

488 72 x 60
Fan Twin
EC44 -3PM02 432 67 .72 x 60
LC Twin EC45PL09
432 67 .72 x 60
Oil Injected

Standard
2 Mikuni
VM34SS Siide
Standard

CO l 12V 2 00W 117/297 .2 43.5/1 10.5 48/ 121 .9 38/96.5 15/38. 1 133.5/339 .1 10.7/8 .9/40.5 87 Octane Non- Oxyqenated
2 Mikun i
VM34 SS Slide Standard COl 12V 200W 2P 108/274.3 46.5/118.1 47.5/120.7 4 1/ 104.14 15/38.1 12 1/307.3 10.7/8.9/40.5

Length (In1cm .) Width (in.lcm .) Height (in.lcm.)
COl 12V 200W 117/2 97.2 43.5/110.5 48/12 1.9 38/96 .5 15/38.1 141/358 .1 10.7/8.9/40.5 87 Octane Non- Oxygenated or 89 Octane Oxygenated
COl 12V 200W 108/274 .3 46 .5/118.1 38.5/97.8 41/104 .14 15/38 .1 121/307.3 10.7/8.9/40.5
Ski Center Distance (inJcm.) Track Width (in.lcm.)

Track Length Overall (in.lcm .) Fuel Capa cit y (U.S. gas .llmp. gal.lli!ers)
Recommended Fuel
87 Octane
Non-Qxygenated or 89 Octane
87 Octane
Non-Oxygenated
or 89 Octane
Oxygenated
or 89 Octane
Oxygenated
IFS XTRA10
Oxygenated Parallel Link
Front Suspension
Parallel link
Trailing Arm IFS Rear Suspension

Brake Type Storage Standard
Trailing Arm IFS

XTRA 10

XTR A 10
Hydraulic Disc Rearof Seat Toolbox Footrest

Standard
Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard

Option
Hydraulic Disc Rearof Seat Toolbox Footrest

Standard
Hydraulic Disc Rear of Seat Toolbox Under

Hood Standard
Speedometer Tachometer ElectricFuel Gauge Accessory Lights
Option Option
Oil/Brake Ace High Beam
Option Option
Oil/Brak e Ace High Beam
Standard Option OiVBrake

Temp
OiVBrake
Ace
HighBeam
Option
HighBeam Option
H,-LoIStd Short Optio n
Electric Start
Option
Single Heal/ Std 2 Up
Option Single Heat'Acc

2 Up
HandwarmersiThumbwarmer
Seat
Single HeatiStd Standard Option Option
Option
Std
Option Option
Option
9/96
1.13c
GENERA L INFORMATION 1997 Mode l Identificat ion

Indy XCF
097 1643 Engine Type
Indy 440 XC
0971760
Indy Trail
097276 1
Indy Trail Touring

0972262
Fan Twin
EC44 -CPM02 432 67.72x60
LC Twin
EC45PL06 438 68.19 x 60
Fan Twin
EC50PM 04 488 72 x 60
Fan TW in
EC50 PME04 48 8 72 x 60
Engine Model Number

Displacement (ee)
Bore x Stroke (mm) CarburetionIThrottle Body

Oil Injected

Standard COl 12V 200W 108/274 .3 46.5/118 .1 38 .51 97.8 4 1/104. 1 15/38 .1 121/307.3 9.5/8.9/40.5 87 Octane Non- Oxygenated
2 Mikuni VM34 SS Slide

Standard COl 12V 20 0W 2P 106/274.3 46.5/118.1 38 .5/97 .8 41/ 104.14 15/38 . 1
2 Mikuni
VM34S S Slide Standard COl 12V 200 W 2P 114/289.6 46 .5/118/1 48/12 1.9 4 1/104 .14
Standard
COl 12V 200W 2P 1081274.3 46.51118. 1 47 .5/120 .7 41/ 104 .14 15138.1 12 1/30 7.3 10.7/8 .9/40 .5 87 Octane
Ignition
Altemator Output Length (inJcm.) Width (inJcm.) Height (in./cm .)
Ski Center Distance (inJcm.)

Track Width (inJcm.) Track LengthOverall (in.lcm.)
Fuel Capacity (U.S. gas .llmp. 9a l.lliters)
15138.1
133.5/33 9.1 10.7/8.9/40 .5
1211307.3
9 .5/8.9 /40 .5
8? Octane
Recommended Fuel
or 89 Octane Oxygenated
Front Suspension
CRC XTR A 10
Non-Oxygenated or 89 Octane
Oxygenated CRC XTRA 10
Oxygenated IFS XTRA 10
87 Octane Non-Oxygenated or 89 O cta ne Oxygenated

IFS XTRA 10
RearSuspension
Brake Type
Vented Hydraulic Disc
Liquid CooledHydraulic Disc
Hydraulic Disc
Hydraulic Disc
Storage
Rear Seat
Rear of Seat
Rear of Seat Toolbox Under

Hood
Rear of Seat Toolbox Under Hood

Standard Option Option OiVBrake HighBeam Standard
Hi-Lo/Sld 2 Up
Speedometer Tachometer Electric Fuel Gauge Accessory Lights
Standard
Standard
Standard N/A Oil/Brak e Temp/Ace
Standard
Sta ndard
Standard Option Oill8rake

Ace
Option OiVBrake
High Beam
High Beam Electric Start HandwarmersIThumbwarmer

Seat
High Beam Option

Hi-Lo/Std 2 pc / Knee Pad Option
Option
Single HeaVSld 2 Pc Option
Option
Hi-Lo/S td Lon g
Option Option
Option Option
Option
Option
1.1 3d
9i96

Indy Trail RMK
097096 1 Engine Type
Indy Classic
09 73865
Indy Classic Tour ing

09 73385
Indy 500
097276 4 LC Twin EC50P L17 488 72 x 60 2 Mikun i VM38SS Sl ide
Engine Moder Number

Displacement (cc)
Bore x Strok e (mm ) Carbu retionlThrottie Bod y Oi l Injected
Fan Twin EC50PM05 488 72x 60 2 Mikuni/ACC S VM34S S Slide Stan dard CO l 12V 200W 2P 114/289.6 43.5/110 .5 46/116 .8 38 /96 .5 15/38 . I
LC Twin
EC50 PL17 488 72 x 60 2 Mikun i VM38SS Slide Sta nd ard CO l 12V 200W 2 P 108/12 1.9 48/ 12 1.9 49 .5/125.7 42.5/107. 9 15/38 . I 121/307.3
LC Twin
EC5 0PL1 9 488 72 x 60
2 Mikuni VM34 SS Slid e

Stan dard C Ol 12V 20 0W 2 P 115/292.1 48/ 121 .9 5 1.5/ 130 .8 42 .5/ 107.9 15/38. I
Standard
C Ol 12V 200W 2P 108/274. 3 46 .5/ 118.1 4 1/1 04 .14 41 / 104. 14 15/38. I 12 11 307.3 10.7/8.9/40.5 87 Oc tane Non-Oxygenated
Ignition
Alternator Out put Length (inJcm.) Width (inJcm.) Height (in./cm.)
Ski Center Distance (mJcm.)

Track W idt h (inJcm.)
Track Length Overall

(inJcm.) Fuel Capaci ty (U.S. gas J lmp . gaL/lite rs)
133.51339.1
10 .7/8.9/40.5 87 Oct ane Non- O xygenated
133.51339.1
10 .7/8 .9/4 0.5 87 Oct ane Non -Oxygen ated
10.718.9/40.5
8? Oc tane Non -Oxygenated o r 89 Octan e Oxygen ated IFS XT RA 12 Hyd raulic Disc Rear of Seat Toolbo x Standard Stan dard Standard OillBrake Temp High Beam Stan dard Hi-L o/Std Lo ng Option Optio n
Recommended Fuel
or 89 Octane
Oxyge nated Fro nt Suspension
or 89 Octane
O xyg enated IFS XTR A1 2
or 89 Octane
O xyge nated IFS XT RA 10 H ydra ulic Disc Rear of Seat Toolb ox Stan dard Standard Optio n Oil/Brake Temp High Bea m Option Hi-Lo/S td Short Option Option

XT RA 10 Hydrauli c Disc
Rear Suspension Brake Type Storage

Spee domet er Tachometer Electric Fue l Gau ge Accessory Lights
Hydraulic Disc
Rear of Seat Toolbo x Stan da rd Stan dard Stand ard Oil/Brake Temp Hig h Beam Standard Hi-Lo /S td 2 Up/Tour Option Option
Rear Seat/Toolbox
Standard Standard Option Oil/Brak e Ace High Beam Option S ingle Hea l/ Std Long/RMK O ptio n Option
Electric Sta rt Handw armer slThumbwarmer Seal Storage Rack Tow Hitch
9196
1.13e

Indy 500 SKS Indy 500 RMK
0972564 0972964 Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) Carburetlon/Throttle Body LC Twin EC50PL17 EC50PL16 RMK 488 72 x 60 2 Mikuni VM38SS Slide 2 MikuniIACCS/RMK VM34SS Slide! RMK
Standard
Indy 500 EFI

0973774
Indy WideTrak LX
0972065 LC Twin EC50PLE12 488 72 x 60 2 Mikuni VM34SSSiide
Indy WideTrakGT
0972061 Fan Twin EC50PM03 488 72 x 60 2 Mikuni VM34SS Slide
LC Twin EC50PL18
488 72 x 60 2 Throttle Body 46 mm
Oil Injected Ignition

Alternator Output
Standard CDI 130 AC/125 DC 2P 108/274.3 481121.9 49.5/125.7 42.51107.9 15/38.1 121/307.3 10.7/8.9/40.5 87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA12 Hydraulic Disc Rear of Seat Toolbox Standard Standard Option Oil/BrakeiTemp Batt High Beam Option Hi-LolStd Long Option Option
Standard COl 12V 200W 1281 325.1 43.5/110.5 49/124.5 38/96.5 20/50.8 156/396.2 10/8.3/38 87 Octane
Non-Oxygenated
Standard
CDI 12V 200W 2P 114/289.6 46.5/118.1 43.5/110.5/RMK 481121.9 38196 .5 15/38.1 133.5/339.I 10.7/8.9140.5 87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA 10 Hydraulic Disc HD Pads RMK Rear of Seat Toolbox Standard Standard Option Oil/Brake Temp High Beam Option
Hl-Lo/Std
CDI 12V200W
Length (inJcm.) Width (inJcm.) Height (in.lcm.)

1221309.9
43.5/110.5 49/124.5 38196 .5 20/50 .8 1411358. I 101 8.3/37.8 87 Octane Non-Oxygenated
or 89 Oc tane Oxygenated
Track Width (inJcm.)

Track Length Overall (in.lcm)
Fuel Capacity (U.S. gas.llmp. gal./liters)

Reco mmended Fuel
or 89 Octane Oxygenated Parallel Link Trailing Arm IFS WideTrak Single Slide Rail Mechanical Under Seat Standard Standard N/A OiliTemp Rev High Beam Standard Single HeaVStd 2 Up w/Riser Standard Standard
Front Suspension Rear Suspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights
Parallel Link Trailing Arm IFS WideTrak Single Slide Rail Mechanical Under Seat Standard Option N/A Rev/Ace Oil High Beam Option Single HeaVStd 2 Up w/Riser Standard Standard
Electric Start HandwarmersIThumbwarmer Seat Storage Rack Tow Hitch
Long Option Option
1.131
9/96
GENERAL INFO RMATION 1997 Model Identification
Indy XLT
0976756
Indy XLTSP
0976676 LC Triple EC58PL12 597 65 x 60
Indy XLT SKS

097 0556 LC Triple EC58PL03 597 65 x 60
Indy XLT RMK

097 0956 LC Tripie EC58PL07 597 65 x 60
Engine Type Engine Model Number Displacement (co)

Bore x Stroke (mm)
LC Triple EC58PL03 597 65 x 60
Carburetion/Throttle Body
3 Mikuni
VM34SS
3 Mikuni VM38SS
Standard
COl 12V 200W 108/274.3 48/12 1.9
48.51123.1
3 Mikuni
VM34SS Slide Standard C Ol 12V 170W 11 4/289.6 46.5/ 118.1 46/116.8 41/ 104 .14 15138.1 133.5/339 .1
10.718.9/4 0.5
3 Mikuni
VM34SS Slide/ACCS Standard COl 12V 170W 114/289 .6 43 .5/110.4 4/116 .8 38/96.5 15/38.1
133 .51339 .1
Oil Inject ed
Standard
COl 12V 170W 1081274.3 46.511 I 8.11 46/ 116.8 4 1/104.14 15/38.1 12 1/307.3 10.7/8.9/40 .5 87 Octane

Lengt h (inJcm .) Width (in.lcm .) Height (in.lcm .)

Track Widlh (in.lcm.)
42.5/10 7.9 15/38.1 12 1/307.3 10.7/8.9/40.5

87 Octane Non-Oxyq enated
Track Length Overall (inJcm.)

Fuel Capacity (U.S. gas .llmp. gal.llilers)
10.7/8.9/40. 5
Recommended Fuel
87 Octane
Non-Qxygenated or 89 Octane Oxygenated

Front Suspension
42.51FS XTRA10
Non-oxygenated or 89 Octane Oxygenated
XTRA 10 Hydraulic Disc
Non-Paral lel Link Trailing ArmIFS

XTRA12
Parallel Link Trail ingArmIFS

XTRA 10
Rear Suspension
Brake Type

Option Oil/Brake Temp/Ace High Beam

Option
Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard Option Oil/Brake
Temp/ Ace
Storage Speedometer Tachometer Electric FuelGauge Accessory Ughts
Rear of Seat Toolbox Footrest Standard

Standard
Option OillBrake TemplAcc HighBeam Option

Hi-LoIStd
OiVBrake
Temp/Ace
HighBeam Option
Hi-LoIStd
High Beam
Op tion Hi-Lo/Sld
Electric Stan HandwarmersIThumbwarmer Seat

Storage Rack
Option
Hi-LoIStd
Standard
Option
Long Option Option
Long
O ption
Long
Option
Tow Hitch
Option
Option
Option
9196
1.13g

Indy XLT Touring
0973357 Engine Type LC Triple EC58PL09 59 7 65 x 60
Indy XLT LTD

0973 756 LC Triple EC58PL09 597 65x60
Indy XLT LTD
Indy 600 XC
0971776 LC Triple EC58PL08 597 65 x 60
SP
0973776 LC Triple EC58 PL12 597 65x60
Engine Model Number Displacement (co) Bore x Stroke (mm) CarburetionfThrottle Body
Oil Injected
3 Mikuni
VM34CS Slide
3 Mikuni
VM38SS
3 Mikuni
VM38S S Siid e
Standard
COl 12V 200W 6P 115/292 .I 48/121.9 51.5/130 .8 42.51 107.9 15/38. I 133. 5/33 9.1 10.7/8 .9/40 .5
Standard
COl 12V 200W 6P 108/274.3 4 8/12 1.9 49.51125.7 42 .5/108 15/38 .1 121/307 .3 10.7/8 .9140.5 87 Octane Non-Oxygenated
Standard
COl 12V 200W 6P 108/274.3 48/121.9 49 .5/125.7 42 .5/ 108 15/38.1 1211307.3 10.7/8 .9/40 .5 87 Octane
Standard
COl 12V 170W 6P 108/274 .3 46 .5/118.11 38 .5/97.7 411104.14 15/38 .1 1211 .3 307 9 .5/8.9140.5 87 Octane Non-Oxygenated or 89 Octane Oxygenated CRC XT RA 10
Ignition
Alternator Output
Length (in.lc m.) Width (in.lcm .) He ight (in.lcm .)

Track Width (inJem.)
--
Track Length Overall (inJem.)

Fuel Capacity (U.S. gas .llmp. gal .llilers)
Recommended Fuel
87 Octane Non-Oxygenated or 89 Octane Oxygenated

IFS XTRA 12
or 89 Octane Oxygenate d
IFS XTRA12
O xygenated
Front Suspension Rear Suspension

Brake Type
IFS XT RA 12
Hydraulic Disc Rear of Seat Toolbox UnderHood Standard Standard Standard OiV Brake Temp
Hydraulic Disc
Hydraulic Disc Rear SeatfToolbox Standard Standard Option OiV8rake

Ace
Liquid Cooled Hydraulic Disc

Rear of Seat
Stora ge Speedometer Tachometer Eleclric FuelGauge Accessory Lights
Rear SeatfToolbox
Stand ard Standard Option
Standard Standard
N/A
Oil/Brake
Ace High Beam
High Beam
Electric Start
Ha ndwarrne~h umbwarrn er
High Beam Option

HI-Lo/Std Long
Oil/Brake Temp/Ace HighBeam Option

Hi-Lo/Std 2 pc Knee Pad Qption Op tton
Standard
HI-La/SId 2 Up Touring Option
Option
Hi-LoISld Lon g Option Option
Option Option
Option
1.13h
9/96
GENERAL INFORMATION
1997 Model Identification

Indy 600 XCR
0975677 Engine Type Engine ModelNumber LC Triple EC59PLOI 597 62.5 x 65
Indy 600 XCR SE

H975677 LCTripie EC59PLOI 597 62.5 x 65
Indy RXL
0976 768 LC Triple EC65PL05 648 67.72 x 60 3 Throttle Body
Indy Ultra
0976778 LC Triple EC68PLOl 679 66.6 x 65
Displacement (cc) Bore x Stroke(mm)

Carburencn/Tnrottle Body
3 Mikuni VM38AL Slide

Standard Digital COl 12V200W 109/276 .8 46.5/118.1I 44/ 1I 1.7
4 1/104 .1~
3 Mikuni VM38AL Slide Standard

Digrtal COl 12V200W 109/276.8 46.51118.11 44/111.7 41/104.14
46mm
Standard COl 12V 180W 106.25 /269 .9 48112 1.9 48 .5/123 .I 42.5/107.9 15138.I 121/307.3 10.7/8.9/40.5 87 Octane Non-Oxygenated or 89 Octane Oxygenated
3 Mikuni VM38ALSiide
Standard Digital COl 12V200W 1081274.3 48/121 .9 48.51123.2 42.5/108 15/38.1 121/307.3 10.7/8.9 /40.5
Oil Injected
Ignition
Alternator Output
Length (in.lem.) Width (in.lem.) Height (in.lem.)

Track Width (inJcm.)
Track Length Overall (inJem) Fuel Capacity (U.S. gas.ll mp. gal.lliters)
15/38.1 121/307 .3 10.7/8.9/40.5
15138. 1
121/307.3 10.7/8.9/40.5
Recommended Fuel
91 Octane Min.
91 Octane Min.
87 Octane Non-Oxygenated or 89 Octane Oxygenated

Parallel Link IFS
XTR A 12 Liquid Cooled Hydraulic Disc
Front Suspension
Rear Suspension Brake Type Storage Speedometer Tachome ter Electric Fuel Gauge Accessory Lights
Parallel Link IFS XT RA 10
Parallel Link IFS

XTRA 10
Non-Parallel Link Trailing Arm IFS

XTR A 12

Rear of Seat Toolbox Standard
Standard
liqUid Cooled Hydraulic Disc Rear of Seat Toolbox Standard Standard Option
OiVBrake Temp/Ace High Beam

Standard
Standard Standard OiVBrake Temp/Ace High Beam
Rear of Seat Toolbox Footrest Standard Standard

Option
Option
Oil/Brake Temp/Ace High Beam
OiVBrake Temp/Ace High Beam
Electric Start HandwarmersfThumbwarmer Seat Stor age Rack
N/A HiLo /Std Mid, 1 pc, 121 N/A Option
N/A Hi Lo/St d Mid, I pc, 121 N/A
Option
Hi Lo/St d
N/A HiLoIStd
Long Option Option
Standar d
Option
Tow Hitch
Optio n
Option
9/96
1.1 3i
GENERAL INFORMATION 1997 Model Identifi cation

Indy Ultra SP
0970678
Indy Ultra SPX

0975678 LC Triple EC68PL03 679 65x60
Indy Ultra SPX SE

H975678 LC Triple EC68PL03 679 65x60
Indy Ultra Touring

0975378 LC Triple EC68PLOI 679 66.6 x 65
EngineType EngineModel Number

Displacement (ce)
LC Triple EC68PL01 679 66.6 x 65
Borex Stroke (mm) CarburetionfThrottle Body
3 Mikuni
VM38AL Slide
3 Mikun;
VM38AL Slide
3 Mikuni
VM38A L Slide
3 Mikuni
VM3BAL Slide
Oli Injected
Standard
Di9ital COl 12V200W 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 109/276 .9 46.5/118.1 441111.8 41/104 .14 15/38.1 121/307 .3 10.7/8.9/40 .5
Standard
Digital COl 12V 170W 109/276 .9 46.5/ 118.1 441111 .8 4 1/104 .14 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 42.51108 15/38 .1 133.5/339 .1 10.7/8.9 /40.5 87 Octane Non-Oxygenated or 89 Octane Oxygenated

Length (in.lcm.)
Width (inlcm.) Height (inlcm.)

Track Width (in./cm .)

Fuel Capacity (U.S. gas.llmp. gal./llters)
Recommended Fuel
87 Octane Non-Qxygenated
91 Octane Min.
91 Octane Min.
or 89 Octane
Oxygenated
Front Suspension Rear Suspension

Brake Type
Parallel Link IFS, CRC XTRA10
CRC XTRA10
CRC XTR A 10
Parallel Link IFS

XTRA1 2 Liquid Cooled
Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard
Option Oil/Brake
Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard
N/A Oil/Brake Temp/Ace High Beam
Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest

Standard
Hydraulic Disc Rear of Seat Standard Standard

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

Indy 700 XC
0971766
Indy 700 SKS

0970566 LC Twin SN70LC DCS P0 1 700 81x68 2 Keihin 238MM 0 Slide Standard Digital COl 12V 280W 116/294 .6 46 .5/1181 46/116 .8 41/1 04 .14 15/38 . 1 136/345.4 10.7/8 .9/40. 5 87 Octane Non-O xygenated
Indy 700 RMK

0970966 LC Twin SN70LC DCSP02 700 81x68 2 Keihin 238MM 0 Slid e Standard Digital CDt 12V 280W 116/294.6 435/110.5 46/11 6 .8 38 /96 .5 15/38 .1 136/345.4 10.7/8.9/40.5 87 Octane Non -Ox ygenated o r 89 Oct ane Oxygenated Pa rallel Link CRC IFS XTRA 10 Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Standard Stand ard Opt ion Oill8rake Temp lAce High Beam Option Hi-LolStd Long Option
Engine Type Engine Model Numbe r

Displacement (ee) Bore x Stroke (mm) CarburetionIThrottle Body
LC Twin
SN70LC DCS p01 700 6 1x68 2 Keihin 238M M 0 Slide Standard
Oil Injec ted Ignition Alternator Output Leng th (in.lcm .) Width (in.lc m .) Height (in.lcm .) Ski Center Distance (in.lcm .) Track Width (in.lcm. ) Track Len gth Overall (in ./cm.) Fuel Capacity (U.S. gas .Jlmp . gal.lhters ) Recommended Fuel
Digital COl
12V280W 109/276 .9 4 6.5/118 .1 38.5/97 .8
41 /10 4.14
15/38.1
1211307 .3
9.517.9/35 .9 87 Octane Non-O xygenated o r 89 Octane Ox ygena ted XCl 0 C RC IFS XT RA 10 Liquid Coo led Hydr aulic Disc Rear of Seat Toolbox Standard Standard Op tion OiUBrake TemplAce High Beam Option HiLo/Sld Long Op tion Opt ion
or 89 Octane
Oxygenated Parallel Link CRC IFS XTRA 10 liqUId Cooled Hydraulic Disc Rear of Seat Toolb ox Standard Standard Opnon Oil /Brake TemplAce High Beam Option Hi-Lo/S ld Long Option Opti on
Fron t Sus pe nsion Rea r Suspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights
ElectriC Start Handwarmers/Thumbwarrner
Seal
Op non
9;9 7
1.13k

Indy Storm
0975782
Indy Storm SE
H975782 LC Tnple EC80PL 05 794 72 x 65
Indy Storm RMK

0975982 LC Triple EC80PL04 794 72 x 65
Indy 440 XCR

0971660
Engine Type Engine Model Number Displacement (ee) Bore x Stroke (mm) CarburetionfThrottle Body
LC Triple EC80PL 05
794 72 x 65
LC Twin SN44 LCDCSP-Ol

439 68 .25 x 60

Digital COl 12V200W 109/276.9 46.5/118.1 441111.7 4 11104.14 15/38 .1 121/30 7.3 10.71 8.9/40.5
91 Oclane Min.

Standard
Digital COl 12V 200W 109/276.9 46.5/118 .I 44/111.7 4 1/104 .14 15138.1 12 1/3 07.3 10.7/8 .9/40 .5
91 Octane Min.

Digital COl 12V 200W 115/292 .1 46.5/118 .1 49/12 4.5 38/96.5 15/38 .1 133.5/339.1 10.7/8.9/40.5

Digilal COl 12V 200W 2P 109/276.9 46.5/118.1 38.5/9 7.8 4 111 04_14 15/38 .1 121/307 .3
9.517.9/35.9
Oil Injected Ignition

Alternator Output
Length (in1cm.) Width (in1cm.)
Height (inJcm.) Ski Center Distance (in.lcm.)
Track Width (in.lcm.)

Track LengthOverall (in.lcm.)
Fuel Capa city (U.S. gas.llmp. gal.lliters)
Recommended Fuel
91 Octane Minimum
38"IFS XTRA 10 LWT
91 Octane Minimum
XC-l0 CRC XTRA 10
FrontSuspension
Rear Suspension Brake Type
4 1" IFS XTRA 10 HP
41" IFS XTRA 10 HP
Lrqtnd Coole d Hydraulic Disc

Rear of Seat Toolbox Standard Standard Option OillBrake Temp/Ace High Beam
N/A
Liquid Cooled
Hydraulic Disc Rear of Seal Toolbox Standard Standard Option Oil/Brake Temp/Ace High Beam
Liquid Cooled Hydraulic Disc Rear of Seat Toolb ox Standard Standard Option OiV8rake Temp/Ace High Beam
N/A
Liquid CooledHydraulic Disc 518 Piston (Mast Cyl) Rear of Seat Standard Standard
N/A
Storage Speedometer Tachometer Electric Fuel Gauge Accessory lights
OiVBrake Temp/Ace High Beam Option

Hi-Lo/Std
Electric Start
Ha ndwarmers/Thumbwarmer
N/A
HiLo/Std -n-t.o
Sculpt, Mid 121 N/A
HiLa/Sld -u-t,o SCUlpt, Mid t21

NIA
HiLo/Std Hi-Lo
Sculpt. Mid, 133 N/A
2 pc / Knee Pad
NIA
Option
Option
Option
NfA
Poleris Industries Inc.
1.131
9/97
GENERAL INFORMATION 1998 Model Identification SERIAL NUMBER IDENTIFICATION

The machine serial number may be used as an aid in identifying machine model year. Refer to Ihe first digits in the serial number tor proper identification: FIRST DIGITS MODEL YEAR 33 1998
---/
1998 MODEL DESIGNATION

YEAR DESIGNATION- - - - -E=European Model MODEL / CHASSIS DESIGNATION -
O~
--,
ENGINE DESIGNATION
Refer to Engine Section for more detailed information
1998 MODEL DESIGNATION NUMB ERS (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 ENGINE DESIGNATI ON NUMBER S 3 1 - EC34 -2PM0 2A 33 - EC34-2PM02A 43 - EC44 -3PM0 24 56 - EC58P L130 57 - EC58PL130, EC58PL1 50 58 - SN60-70LCDCS P-Ol / 02 60 - SN44-44LCDCSP-Ol / EC45PL091 61 - EC50PM04 3, EC50PM0 51, EC50PM 061 62 - EC50PM04 3 (-S) 64 - EC50PL161, EC50PL 171 65 - EC50PL171, EC50PL 191, EC50PL201 66 - SN70-70LCDCSP-Ol / SN70-70 LCDCSP-02 68 - SN60-70LCDCSP-Ol 76 - EC58 PL140 77 - EC59PL020 78 - EC68PL050 , EC68PL060 82 . EC80PL052
M ODELNO
V,IN ,NO
MADE IN US.A
POLRRIS
PATENT NOTICE
VEHICLE CONFOAMS TO A.LL APPUCA BLE US FEDER AL AND STATE REQU IREMENTS AND CANAD A MOTOR VEHICLE SAFETY STAND ARDS
noons
IN EFFECT 0:'' THE DATEOF

MFO. DATE.
M:..NU~ AC TU RE
MI d. by Polaris Indus tries Inc. In ROSNU, MN under one or mo re of the followi ng paten ts : Patented canaca U.S. Palents 882.491n1 3,60 5.5 11 5.050,559 3.6 13.810 883 .69.v7 1 5,048 ,503 3,580 .S47 3,867,99 1 86 4.39 4n1 5.056,482 3.483.76 6 4.793.950 Canadian Rd. 3,53 3,662 5.038 ,$81 5,099 ,8 13
3.545 .821 3.605 ,510 3.52 5.412
5,172,675 5.09 0.386 5,050,564
5 .014 .21 1
5.19 1,531 3.613 ,811
34.573171 34.572/71
1.22 7.823187
7072133
These numbe rs should be referred to in any correspondence rega rding war ranty, service or replacement pa rts. Th e machine model and serial number Identification deca l is located on the right front side ot the tunnel. The serial number is permanently stamped into the tunnel. The mode l numbe r is embossed on the deca l. W heneve r corresponding about an engine it is important that the engine model and se rial numbers be called out. Laser engraved model and serial numbe rs a re located on the crankcase (intake side).
9/9 7
1,13 m
GENERAL INFORM ATION 1998 Model Identificati on

1998 Model Indy Lite
0983433 Engine Ty pe Engine Model Numbe r Dis pla cement (ee) Bore x Stro ke (mm )
In dy Li te Delu xe
098343 1
Indy Lite Touring

0983 133
Indy Sp ort
0980443
Fan Twin
EC342 PM02A 339 62 .3 x 55 .6 2 Mikun i V M30SS Sli de Sta ndard CDI 12V 150W 105/266 .7 42 .5/108 44/1 11.8 37/94 15/38.1 121/307.3 8.817.3/33 .3 87 Oc tane Non-Oxygenated or 89 Octane Oxygenated IFS-38 XTR AU te Me cha nical Disc Rear of Seat Top of Ho od Standard N/A Accessory N/A N/A
Fan Twin
EC34-2PM 02A 339 62 .3 x 55.6 2 Mi kun i V M30SS Slide Standard CD I 12V 150W 105/266.7 42 .5/ 108 44/111.8 37/94 15/38.1 12 1/307 .3 8 .817.3/33 .3 87 Octane Non-Oxygenated
Fan Twin
EC3 42PM02A 339 62 .3 x 55 .6 2 Miku ni VM30SS Slide Standard CD I 12V 150W 115/292. 1 42 .5/108 48/12 1.9 37 /94 15/38 .1 133 .5/339 .1 8. 817.3/33 .3 87 Oc tane Ncn-Oxyqenated or 89 Oc tan e Oxygenated IFS 38 XTRAUte Mechanical Disc Rear of Seat Top of Hood Standard N/A Acce ssory N/A Oil/Ace
Fan Twin
EC443PM024 432 67.72 x 60 2 Mikuni VM34SS Sl ide Standard CDI 12V 200W 108 /274 .3 43.5/110 .5 44/11 1.8 38 /96 .5 15/38 .1 121/3 07 .3 10 .7/8. 9/40. 5 87 Oc ta ne Non-Oxygenated or 89 Octane Oxygenated IF S-38 XTRA-Lite Hy drauli c Di sc Rear of Seat Toolbox Footr est Stan da rd Option Accessory Op tion Oil/Brake Ace High Beam Opt ion Sing le Hea t/Std Standard
CarburetionlThrotll e Body
Oi l Injected Ignition
Alternator Output
Length (inlcm.) Wid th (in./cm.) Height (in./ cm.) Ski Center Dis tan ce (in.lcm.) Tra ck Width (in.lcm.) Track Length Ove rall (in .lcm.) Fuel Capa city (U.S . gas.llm p. gal.lllte rs) Recommended Fuel
or 89 Octane
Oxygenated IFS-38 XT AAUte Mechanical Disc Rear of Seat Top of Hood Standard N/A Accessory N/A Oil /Ace
Front Suspension Rear Suspension Bra ke Type Storage Speedometer Tach om eter Reverse Electric Fuel Gauge Accessory Lights
Electr ic Start Han dwarmersffhum bwa rmer Seat Stor age Rack Tow Hit ch
Opti on Option /Option Standard Lite Opti on Opti on
Standard Single Heal/SId Standard Ute O ption Opti on
Opt ion Single Heat/Std 2 Up Ute Standard Standard
Opnon
Option
Polaris Indus tries Inc.
1.13n
9/97
GENERAL INFORMATION 1998 Model Ident ificat ion

1998 Model Indy TranSport
0980 143 Engine Type Engine Mode l Number Displa cement (cc ) Bo re x Stroke (m m )
Indy Sport Touring

098 0243
Indy XCF
0981643
Fan Tw in EC4 43PM024
432 67 .72x 60 2 Mikun i V M3 4SS Sli de
Indy 440 LC
0982760
LCTwin EC45PL09 1 432 67.72 x 60
Fan Twin EC443PM024

432 67 .72 x 60
Fan Twin EC443PM 024

432 67.72 x 60 2 Mikuni VM34SS Slide Stand ard C Ol 12V 200 W 117/2 97 .2 43 .5/110.5 48/ 12 1.9 38/ 96 .5 15/ 38 .1 133 .5/33 9. 1 11.8/ 9.8/44.7 87 Oc tane Non-Ox ygenated or 89 Oc tane O xygenated IFS -38 XTR A Lit e Hydrau lic Disc Rear of Seat Toolb ox Footrest Standard Op tion O ption O ption Oil/Brake Ace Hig h Beam O ptio n Sing le HeaVAcc 2 Up Opti on O ption
CarburetionlT hrottle Bo dy
O il Injected Ignition Alt ernator Ou tput Leng lh (in.lcm.) W idlh (in.lem .)
2 Mikuni V M34 SS Slide

Sta ndard COl 12V 200 W 117/2 97 .2
2 Mikun i VM3 4SS Slide Stan dard

COl 12V 200W 2 P
Standard
C Ol 12V 200 W
108/274 .3
46.5/118 .1 38 .5/97.8
108/274 .3
4 6.5/1 18.1
43.5/11 0 .5
48 / 121. 9 38/96 .5 15/38. 1 141/358.1 11.8/9 .8/44 .7 87 Octane Non-Oxygenated o r 89 Octan e O xygenated IFS38 Stan da rd Hydraulic Disc Rear of Sea l Toolbox Footrest Standa rd O ption Opt ion Op tion Oil /Brake Ace Hi gh Beam Opti on Single Heat/Std 2 Up O ption Sid
Height (inJ cm. )

S ki Center Distance (in.fern.) T rac k Wi dth (in.lcm .) Track Length Ov erall (in.fern.) Fue l Capacity (U.S. gas .l lm p. gaL/liters)
47 .5/120.7 41 /104 .14

15/3 8.1
41/104.1
15/38 .1
121/307 .3 10.5/8.7/39 .7
87 Oc tane Non -O xygenated o r 89 Oc tan e
121/307 .3
11.8/9.8/44 .7 87 Octa ne Non- O xygen ated or 89 Octane O xyge nated IFS XTRAl 0 XTRA 10 Hydraulic Disc Rear of Sea t Toolb ox Under Hoo d Sta ndard Stand ard Op tion Opt ion Oi l/Brake Tem p Hig h Beam Op tio n Hi-Lo/Sld Sid Lenglh Option Option
Recommended Fuel
Oxygenated
IFS XT RAl 0 CRC XTRA 10 Ven ted Hydrau lic Di sc Rear Sea t
Front Sus pens ion Rea r Suspens ion Brake Type Sto rage
Speedomete r Tachometer Re vers e Elec tric Fuel Gaug e Accesso ry Lig hts
Standar d Stand ard O ptio n Optio n O il/Brake Ace High Beam O ptio n Single Hea t/Std Racing w/O pads Op tio n O ption
Electr ic Start Handwarm ersfT humbwarmer Seat Stora ge Rack Tow Hitch
9/97
1.130

1998 Model Indy Trail
098276 1 Engine Type Engine Model Number Displacement
Fan Twin EC50 PM0 43
Indy Trail Touring

098 236 2
Indy Trail RMK

098096 1 Fan Twin EC50PM 05 1 488
72x60
Indy Sup er Sp orl

098076 1
Fan Twin
EC50PM 043 488 72 x 60 2 Mikuni VM 34SS Slide Standard CO l 12V 200W 2P 114/289.6 46 .511 18/ 1 48/1 21.9 411104. 14 15/3 8.1 133 .5/339.1 11.8/9.8 /44.7 87 Oc tane Non-O xygenated o r 89 Octa ne Oxygena ted IFS XTR A-10 XT RA 10 Hyd raulic Disc Rear of Seat Tool box Under Hood Standard Standard Option Standard Oil/Brake High Bea m Standard Hi-La/Std Dlx 2 Up Touring Option
Optio n
Fan Twin
EC50PM061 488 72 x 60
(eel
488 72 x 60 2 Mikuni VM34SS Slide

Standard
Bore x Stroke (mm) Ca rburetlo n/Th rottle Body Oil Injected Ignit ion Alternator Output Length (in.lcm .) Width (in.lcm.) Height (in.!em.) Ski Cen ter Distance (in.tern.)
Track Width ([n./em.) Tra ck Length Overall (in.lcm .)
2Mikuni/A CCS VM34SS Slide

Standard
Standa rd COl 12V 200 W 108/274.3 46.5/118 .1 38.5/97 .8 41/ 104.14 15/38 .1 121/307.3 11 .8/9 .8/44 .7 67 Octane Non-Ox ygenated o r 89 Oc tane Oxygenated IFS XTR A-l0 XTR A 10 Hyd raulic Disc Rear of Sea l Toolbox Footres t Standard Standard
COl 12V 200W 2P 108/274 .3 46.51118.1 47.5/120 .7 41/104. 14 15/38 .1 121/307 .3 11.8/9.8 /44.7 87 Oc tane Non-Oxygenated o r 89 Octane Oxyge na ted IFS XTRA-l0 XTRA 10 Hydraulic Disc Rear 01Sea t Too lbox Und er Hood Standard Standard Op tion Op tion Oil/Bra ke High Beam O ption Hi-Lo /S td Standard Option Option
COl 12V 200W 2P 114/289.6 43 .5/110.5 46/ 116.8 38/96 .5 15/38.1 133.5/339.1 11.8/9.8 /44 .7 87 Octa ne Non-Oxygena ted or 89 Oc tane Oxyge na ted XTRA- l 0 IFS XTRA 10 Hyd raulic Disc Rear Seat/Toolbox
Fuel Capacity (U.S. gas.llmp. gal.lliters)
Recommended Fuel
Front Suspensio n Rear Suspensi on Brake Type Sto rage
Speedome ter Tachomete r Elect ric Fuel Gauge Rev erse Accessory Lights
Standard Standard Option Option Oil/Brake Ace High Beam Op tion Single HeaVStd Lon g Op tion Opt ion
Op tion Oil/Brake Ace Hig h Beam Option Single HeaVStd Standard
Electri c Start Handwarmers/Thumbwarrner Seat Storage Rack Tow Hitch
Op tion Op tion
1.13p
9/97
GENERAL INFORMATION 1998 Model Ident if icat ion
1998 Model
Indy 440 XCR

0981660
Indy 500
0982764 (0982764 A) (09 82764 B) LCTwln EC50P L1 71 488 72 x 60 2 Mik uni VM 38SS Slide Standard C Ol 12V 200W 2P 108/274 .3 46 .5/118 .1
Indy 500 RMK

098 2964
Indy Classic
0983865
Engine Type Engi ne Mod el Num be r Displacem ent (cc ) Bore x Stroke (mm) Carburetion/T hrottle Body Oil Injected Ignition Altema tor Output Leng th (in lem.)
LC Twin
SN4444LCOCSp 01 438 66 x 64 2 Mikuni VM3 4SS Slide Standard Digita l COl 12V 280W 109/276.86 46.5/118 . 1 44.0/111.76 4 1/104 .14 15/38 .1 12 1/307.3 10 .5/8 .7/39 .7 87 Octane Non-O xyg enated or 89 O ctane Oxy genated XC 10 CRC XT RA 10 Liqurd Cooled Hydraulic Disc Rear of Seat Toolbox Under Hood Standa rd Sta ndard Op tion Option Oil/Brake Temp High Bea m N/ A HiL o/Sl d Racing w/ pads
LCTwin
EC50PL1 61 488 72 x 60 2 Mikuni VM34SS / ACCS Stan dard C Ol 12V 200 W 2P 114/289.6 43 .5/ 110 .5/R MK 48/121.9 38 /96.5 15/3 8.1 133 .5/339.1 11.8/9.8/44.7
LC Twin EC50PL1 71
488 72 x 60

CO l 12V 200W 2P 108/1 21.9 48/12 1.9 49 .5/125 .7 42 .511 07 .9 15/3 8.1 121/307.3 11.8/9 .8/44 .7
Width (inJcm.)
Height (Inlem.) Ski Center Distance (in.lc m.) Track W idth (inJcm .) Track Length Overall (in.lem .) Fuel Capa city (U .S. gas ./l mp. gal Jliters)
4 1/104 .14
41/1 04 .14 15/38 . 1 121/30 7.3 11.8/9 .8/44 .7 87 Octane Non-Oxygenated or 89 Octan e Oxygenated IFS XT RA l 0 CR C XTRA 10 Hydraulic Disc Rear of Seat Toolbox Stan dard Standard Option Option Oil/B rake Temp High Beam Op tion Hi-Lo/Std Standard (Lon g Opt. A& B) Option Option
Recomm end ed Fuel
87 Octa ne
Non-Oxyg enated or 89 Octane O xygenated IFS 38 RM K XT RA 10 Hyd raulic Disc H O Pads Rear of Seat Toolbox Standard Standard Option Option Oil/B rake Tem p High Be am Option Hi-Lo/Std Long Opt ion Optio n
87 Octane Non-Oxyg enated o r 89 Octane Oxygenated

IFS XTRA12 XT RA 12 Hydra ulic Dis c Rea r of Se al Toolbox Standa rd Stan dard Stand ard Standard OiVBrak e Temp High Beam Standa rd Hi Lo/Std Long Op tion Opti on
Front Susp ension Rear Sus pens ion Brake Type Storage
Spee domete r Tachom eter Reverse Electric Fuel G au ge Acce ssory Ligh ts
Electric Start Handwarm ersfT humbwa rmer Seat Storage Rack Tow Hitch
opnon
Opti on
9/97
1.13q
1998 Model

09 833 65
Indy WideTrak LX
0982065 LC Twln EC50 PL201 488 72 x 60 2 Mikuni VM34SS Slide Stan dard C DI 12V 200W 128/325 .1 43 .51110 .5 49/1 24 .5 38/96.5 20/50.8 156/396.2 11.0/9.1/41.6
Indy XLT Touring

0983357 LC Tripl e EC58P L 130 59 7 65 x 60 3 Mikun i V M3 4SS Slide Sta nda rd C DI 12V 280W 115/292.1 48 /121 .9 51.5/130.8 42 .5/107 .9 15/38 .1 133.51339.1 11.8/9 .8/44 .7 87 Oc tane Non-Oxygenated or 89 Oc tane Oxygena ted IFS XT RA - 12 XTRA 12 Hydraulic DISC Rear of Seat Too lbox Under Hood Standard Standard Standard Sta ndard Oi l/Brake
Indy XLT LTD

0983756 LC Triple EC58PL130 597 65x60
Engine Typ e Engine Model Number Displacem ent (cc) Bore x Stroke (m m) CarburetionfThrottle Body O il Injected Ignition A lte rnator Output Lenglh (in./cm .)
LCTwin
EC50PL1 91 488 72 x 60 2 Mlku ni V M3 4SS Slide Standard C DI 12V 200W2P 115/292 .1 48 /121.9 51 .5/130.8 42 .5/10 7.9 15138.1 133 .5/339.1 11.8/9.8 /44.7 87 Oc tane Non-Oxygenated or 89 Oc tane O xyg enated IFS XT RA- 12 XT RA 12 Hydrau lic Disc Rear 01 Seal Toolbox
3 Mikuni VM 34 SS Slid e Standa rd

C DI 12V280W 1081 274 .3 48/121.9 49 .5/12 5.7 42 .5/107.9 15138.1 12 1/307.3
11.81 .8/44 .7 9
Wid th (in./cm.)
Height (in./cm.) Ski Center Dista nce (in.lcm .) Track Width (inJcm.) Tra ck Length O verall (inJcm) Fuel Capacity (U.S. gas ./lmp. gal.flilers) Recom mended Fuel
87 Octane
No n-Oxygenated or 89 Octane Oxy ge na ted IFS 38 WideTrak Single Slide Ra il M echani cal Under Sea t Standard Standard Standard N/A
87 Octane Nc n-O xyqen ated o r 89 Octane Oxygenated IFS XTRA- 12 XT RA12 Hydraulic Disc Rear SeaVToolbox Standard Standard Option Option O il/B rake Acc High Beam Opti on Hi -Lo/Sld Standa rd Leng th Option Op tion
Front Suspe nsion
Rear Suspension
Brake Type Storage Speedometer Tachometer Reverse Electric Fuel Ga uge Access ory Ughts
Standard
Standard Standard Standard OiL'Brake
OHfTemp
Rev High Beam Standard Sing le HeaVStd Wi deTrak 2 Up Standard Standard
Temp
High Beam Electric Start Handwa rrners/Thumbwarme r Seal Storage Rack Tow Hitch Standard Hi-Lo/S ld Deluxe 2 UplTo ur
Temp
High Beam Standard
Hi-La/Std
Deluxe 2 Up Touring Option Option
Option Op tion
1.1 3r
9/9 7
GENERAL INFORMATION 1998 Model Ident ifi cat ion

199B Model Indy XLT SP
0985776
Indy XLT Classic

0983857 LC Trip le EC56P1150 597 65 x60 3 Mikuni V M38 S S
Indy 600 XC
098 1758 LC Twin SN60-70LCDCSP-01 593 74 .5 x 68 2 Keihin 39mm D-S lide Standard Dig ital C Ol 12V 280W 109/276 .86 46.5 /11 8 .1 44/1 11.76 41/10 4 .14 15/38 .1 121 /307 .3 11.8/9.7 9/44 .66 87 O ctan e
Indy 600 RMK

098 095 8
Engine Type Engin e Mode l Number Displacement (cc)

Bore x Stroke (mm ) Carbu retionfT hrottJ Body e Oil Injec ted
LC Triple EC58P1140
59 7 65 x 60 3 Mikun i VM38SS
lC Twin
SN60-7 0LCDCSP-02 593 74 .5 x 68 2 Kei hin 39mm
b.ssoe
Standa rd COl 12V 280W 108/ 274 .3 46 .5/116_ 11 46.5/116 .11 4 1/ 104. 14 15/38 .1 12 1/307 .3
Standard
CDt 12V 280W 108/274 .3 46/121.92 48 .5/123.19 42.5 /1 07.9 15/36. 1
1211307 .3
Sta ndard D'g ilal COl 12V 280 W 116/294 .64 43 .5/110 .5 46 /116.84 38/96 .52 15138 .1 121/307.3 11.8/9 .79/4 4.66
Ign ition
Altern ator Output Length (in.le m.) Width (in.lcm.) Heighl (inlem.) Ski Cen ter Distan ce (in .lcm. ) Tra ck Widt h (in.lcm.) Track Length Ove rall (inlem.) Fue l Capacity (U.S. gas Jl mp. gal.lJil ers) Recomm ended Fuel
11.819 .8/44 .7
87 Octane Non-Oxygenated or 89 Octane Oxygenated IFS XTRA-lO CRC XTRA 10 Hydraulic Disc Rear of Seat Toolbo x Footrest Standar d Standard Optl on Opti on OU/B rake Temp /A ce High Beam Optio n Hi-LoI Std Agg ressive Mid Len gth Op tion
11.8/9.8/44.7
87 Octane
Non-Oxygenated or 89 Octane Oxygenated IFS XTRA-12 XT RA 12 Hydra ulic Disc Rea r ot Seat Too lbox Foo trest Standard Standard Standard Option Oil /Brake Temp /A ce High Beam Standard Hi-LoI Std Long Option Option
Ncn-Oxyq enatec
or 89 Octan e Oxygenated XC-l 0 CRC XTRA 10 Liquid COOled Hydrau lic Disc Rear of Seat Standa rd Standard Option N/A OillBrake Temp /A ce High Beam Option H i-Lo/Std Ag gres sive Mid Leng th Option Opti on
87 Octane Non- O xygenat ed or 89 Oc tane Oxy gen ated

38 RM K CRC XTRA1 0 LIquid Cooled Hydraulic DISC Rear of Seat Standard Standa rd
Front Suspe nsio n Rear Suspension Brake Type Storage Speedome ter Tach ometer Reverse Electric Fuel Gauge Accesso ry Ligh ls
Opnon
N/A Oil/Br ake Temp/ Ace High Beam Opti on Hi-LoISld Long Optio n Option
Elecl ric Start HandwarmersIThumbwarmer Seat Storage Rack Tow Hitch
Option
9/97
1_1 35

1998 Mo del Indy 600 XCR
0985677
Indy Ultra
09 86778 LC Tnple EC68PL050 679 66 .6 x 65 3 Miku ni VM38ALSiide Standard Digi tal CO l 12V280W 108 /274 .3 48 /121.9 48 .5/123 .2 42 .5/10 8 15/38 .1 12 1/30 7.3 11.8/9 .8/44 .7
Indy Ultra Tou ring

0985378 LC Triple EC68PL050 679 66 .6 x 65
Indy 700 XCR
0985678 (098 567 8A) LC Tripl e EC68PL06 0 679 66.6 x 65 3 Mikuni VM38AL Slide
Engine Type
Engin e Mode l Number
LC Triple EC59PL020 597 62.5 x 65 3 Mikun i VM38A L Slide Stan dard Digital C Ol 12V280W 109/27 6.8 46 .5/118 .11 44/111 .7 41/1 04.14 15/38 .1 121/307 .3 11.8/9.8 /44 .7 9 1 O ctane Min.
Displacement (eel
Bore x Stroke (mm ) Ca rburelio nfThroltle Body
3 Mikuni VM38AL Slide
Oil tnjeeled Ignition
Standa rd
Digital COl 12V 28 0W 115/292 .1
4811 2 1.9
Standard
Digita l COl 12V 280 W 109/27 6.8 46.5/11 8.11 44/1 11.7 4 1/104 .14
15138 .1
Alternator Output
Length (inl cm .) Width (in.lcm .)
Height (inJcm.) Ski Center Distance (in.lcm.) Tra ck Width (in .lcm .) Track Length Ove rall (in.lcm) Fuel Capacity (U. S. gas .ll mp . galJJiters)
51 .5/1 30.8 42.5 /1 08 15/38 .1

133.51339 .1
12 1/307.3 11.8/9.8/44 .7 91 Octane Min .
11.8/9.8/ 44.7 87 Octane Non-O xygenated or 89 Octane Oxygenated IFS XT RA 12 XTRA 12 Liquid Coo led Hydraulic Disc Rear of Seat Stan da rd Stand ard Standa rd Standa rd Oil /Brake Temp /A ce High Beam
Recommended Fuel
870clane Non-Oxygenated or 89 Oc tane

O xygenated IFS XTRA 12 XTRA 12 Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard Option Option Oil /Brake Temp /Ace Hiqh Beam
Front Suspension Rear Suspension Brake Typ e Storage Speedometer Tachometer Reverse Electri c Fuel Gauge Acc essory Light s
XTR A 10 CRC XT RA 10 Liqu id Coo led Hydraulic Disc Rear of Sea l Toolb ox Standard Standard Opti on Standard OiVBrake
XTR A 10 CRC XT RA 10 Liquid Cooled Hydraulic Dise Rear of Seat Too lbox Standard Standard
Opncn
Stand ard Oil/Br ake Temp /A ce High Beam
Tamp/Ace
High 8eam
Electric Start Handwa rmerslT hu mbwa rmer Seat Stc raqe Rack Tow Hitch
N/A HiL o/Std Aggre ssive Mid Length Op tion Option
Opt ion Hi- Lo/St d Stan dard Op tion Option
Sta ndard Hi-Lo/Std Delux e 2-up To urrng Stan dard
N/A
Hi-Lo/Std
AggreSSIVe Mid l en gth Opti on
Op non
Oouon
1.131
9197
GENERAL INFORMATION 1998 Model Ident if icat ion

1998 Model In dy 700 XC
098 1766
Indy 700 RMK

0980966
Indy Sto rm
0985782 LC Trip le EC 80PL052 79 4 72 x 65 3 Mikuni VM 38S S Slid e Standard Dig ita l CO l 12V 280W 109 /2 76 .9 46.5/ 118. I 44 /111.7 4 11104 .14 15/3 8. I 12 11 07 .3 3 11.8/ 9.8/44 .7 9 1 Octane M in ,
Engine Type Eng ine Model Number Displa cement (eel

Bore x Stroke (m m) Carburetion/Throttle Body Oil Injec ted Ig nition
lCTwin
SN7Q-70LCDCSP02 70 0 81 x 68 2 Ke ihin 39mm DSlide Standard Digital CO l 12V 280W 109/276.86
LC Twin
SN7070LCDCSp01 700 8 1 x 68 2 Keih in 39mm DSlide Standard Dig ita l C Ol 12V 280W 116/294.64 43 .5/110 .5 46/ 116.84 38 /96 .52 15/38 .1 121/307.3 11.8/9.79/44 .66 87 Octane Non-Oxygenated o r 89 Octane Oxygenated 38 RMK CRC XTRA10
Allernator Output
Leng th (inlcm. )
Width (in.lc m.)

Height (inlcm.) Sk i Cente r Distance (in.lcm .) Tra ck Width (in.lcm.) Tra ck Length Overall (in lcm.) Fuel Capacity (U.S. gas.llmp. gal./liters) Recomme nded Fuel
46.51118.1
44/111.76 41 /104 . 14 15/38.1 121/307 .3 11.8/9 .79/44.66
or 89 Octane
Oxygenated
Front Sus pens ion

Rear Suspension
XCl0 CRC XTRA 10 Liquid Cooled Hydrauli c Dis c Rear of Seat Standard Standard Option Opti on Oil/B rake Temp /A ce High Bea m Op tion HiLo/Std Ag gressive Mid Length O ption Option
XTRA 10 IF S XTRA 10 Liq uid Cooled Hydraulic Disc Rear of Seat Too lb ox Stan da rd Stan dard Optio n Stan da rd Oi VBrake Tem plAce Hig h 8 eam
Brake Type
Storage Speedometer Tachom eter Reverse Elec tric Fue l Ga uge Accessory Lights

Rear of Seat Standard Standard Opti on Op tio n O il/Br ak e Tem p/A ce High Bea m Option Hi-lo/Std Lon g Option Option
Electric Sta rt Handwarmersffhumbwarmer Sea t Storage Rack Tow Hitch
NlA
Hi- lo/Std Hi-La Aggressive Mid Length Option Op tion
9/97
1.13u
GENERAL INFORMATION
Paint Codes 1996 Polaris Snowmobile Paint Codes
Mo de l Indy Lite Indy Lite Deluxe Indy Lite GT 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 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 RMK 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 Storm SKS Indy Storm RMK Color Description Black Metallic Teal Metallic Dark Sapphire Meta llic Black Metallic Black Metallic Black Metallic Bright White Bright White Bright White Bright White Black Metallic Royal Plum Metallic Porsche Red Porsche Red Porsche Red Dark Cloisonne Dark Cloisonne Black Metall ic Black Metallic Black Metallic Teal Metallic Teal Metallic Black Sapphire Metallic Black Sapphire Metallic Black Sapph ire Metallic Black Sapphire Metallic Black Sapphire Metallic Black Metallic Black Metallic Black Metallic Black Metallic Eme rald Emerald Black Metallic Black Metall ic Black Metallic Pola ris
"P" No.
Pl 77 P168 P204 Pl 77 Pl77 Pl 77 P133 P133 P133 P133 Pl 77 P203 P136 P136 P136 P204 P204 PI 77 PI 77 PI 77 P168 P168 P173 P173 P173 P173 P173 PI77 PI77 PI 77 Pl 77 P210 P210 P177 PI77 PI 77
Po lar is Raw Materia l No. 852004 4 8520096 8520 154 8520044 8520044 8520044 8520 079 8520079 8520 079 8520079 85200 49 8520141 8520066 8520066 8520066 8520 154 8520 154 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" Num ber fro m Midwest Indu strial Coa tings (612-942-1840) (FA X 612-942-1838). Mix as d irect ed .
Polaris Industries inc .
1.14
9/97
GENERAL INFORMATION Paint Codes 1997 Polar is Snowmobile Paint Code s

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 U C Indy 500 EFI Indy XLT LT D Indy 500 SKS Indy 500 RMK Indy Classic Indy Classic Touring Indy Storm Indy Storm RMK Indy XLT Indy XLT SP Indy XLT SKS Indy XLT 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 ' Emeraid' 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 Metallic ' Deep Violet Metallic' Deep Violet Metall ic' Deep Violet 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 P1 73 P229 P133 P177 P230 P230 P230 P228 Raw Material No. 8520197 852 0154 8520199 8520225 8520163 8520201 8520225 8520201 852020 1 8520163 8520163 8520199 852020 1 8520199 8520199 8520141 85202 18 8520197 8520 154 8520 218 8520 197 85201 97 8520141 8520 141 8520 197 8520197 852019 3 8520228 8520193 85201 93 8520228 852020 1 8520 197 8520222 852022 2 852022 2 85202 18 Ditzler # 9000
4300
2185
-
2185 2185
4300 2185 4300 4300
9000
9000 9000
9000 9000 388 5
3885 3885
2185 9000
-
Blue Spruce ' P228 Indy 700 RMK 85202 18 Order Polaris " P" Number from MIdwest Industrial Coat ings (612-942-1840) (FAX 612-942-1 838). Mix as d irected.
, Receive clear topcoat (8520198) Receive clear topcoat with sparkle meta llic 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 Touring Indy Widetrak LX Indy XLT Classic Indy XLT LTD Indy XLT SP Indy XLT Touring Indy 600 XCR Indy 700 XC Indy 700 RMK 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 (Colo r Opt. 2) Metallic Topcoat Color Description Porsche Red Metall ic Teal Metallic Black Metallic Dark Cloisonne Emerald Bright White Metallic Dark Cloisonne Bright White Metallic Teal Metallic Teal Metallic Teal Metallic Bright White Metall ic 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 Dk Cloisonne/Blue Spruce Deep Violet Metallic Bright White Metallic Clear Topcoat with Sparkle Metallic Powde r Polaris "Po No. P245 P168 P177 P204 P210 P241 P204 P241 P168 P168 P168 P241 P243 P177 P203 P177 P203 P210 P228 P246 PH7 P228 P241 P241 P204 P230 P177 P230 P245 P24 1 P241 P1075 P230 P241 N/A Raw Material No. 8520066 8520199 8520 197 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 8520201 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 di rec ted . Receive clear topcoat (8520198) Receive clear topcoat with sparkle metallic powder (8520194)
1.14 b
9/97
GENERAL INFORMATION
Torque Specifications Standard Torque Specifications
T he foll owin g torq ue specifications are to be used as a gen eral guid elin e. There are exceptions in the steering , suspension. a nd engine a reas . Alway s consult the sta nda rd to rque cha rt and the specific man ual section for torq ue val ues of fasten ers. Use spe cial to rque value s w he n listed .
Bolt Size
Thread s/In (MMfThread) 24 32
0
Grade 2
Grade 5
Gra de 8
Torq ue in. Ibs. (kg/m) 27 (.31) 31 (.36) Torq ue ft . Ibs. (kg/m)' 1/4 20 5 (.7) . 1/4 28 6 (.8) . 5/16 18 11 (1.5) .. 5/16 24 12 (1.6) .. 3/8 16 20 (2.7) 3/8 24 23 (3.2) . 7/ 16 14 30 (4.0) . 7/ 16 20 35 (4.8) .. 1/2 13 50 (6.9) . 1/2 20 55 (7.6) . ' To convert It. Ibs. to kg/m multiply foot 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 (1 0.4) 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 speci al grade bolts and nut s required for spec ific applications . observe the fo llow ing torque values in the are as specifie d. Refer to speci fic manu al section for torq ue va lues of fa ste ners not listed he re. Bolt Size Area Where Used Torque Minimum-Maximum 28-30 ft. Ibs. (3.86-4.14 kg-m) 35-40 ft. Ibs. (4.83-5.52 kg-m) 40-50 ft. Ibs. (5.52-6.9 kg-m) 24-25 ft. Ibs. (3.3 1-3.45 kg-m) . . . 55-60 ft. Ibs. (7.59-8.28 kg-m) 28-30 ft. Ibs. (3.86-4. 14 kg-m) 28-30 ft. Ibs. (3.86-4. 14 kg-m) 28-30 ft. Ibs. (3.86-4. 14 kg-m) 28-30 ft. Ibs. (3.86-4.14 kg-m) 40-45 ft. Ibs. (5.52-6 .2 1 kg-m) 28-30 ft. Ibs. (3.86-4.14 kg-m) 15-17 ft. Ibs. (2.07-2.35 kg-m) . 8-10 ft. Ibs. (1.10-1.38 kg-m) . 8-10 ft. Ibs. (1.10-1.38 kg-m) 4-6 in. Ibs. (.05-.07 kg-m) 4-6 in. Ibs. (.05-.07 kg-m) 30-35 in. Ibs (.35-.40 kg-m) 25-28 ft. Ibs. (3.45-3.86 kg-m) 20-25 in. Ibs. (.23-.29 kg-m)
3/8
7/16 1/2
1/2 3/8 3/8
.. Outer Radius Rod End to Trailing Arm (Top & Bottom )

.. Inner Radius Rod End To Bulkhead (Top) .. Inner Radius Rod End To Bulkhead (Bottom) Radius Rod, Drag Link, or Tie Rod End Ja m Nuts Bellcrank (Center Steering Arm ) . . Drag Link to Steering Post Arm Drag Link to Bellcrank Tie Rod to Steering Arm Tie Rod to Steering Post Arm . .. Trailing Arm Rear Support .. IFS Shock (Top & Bottom) . . .. Steering Post to Bulkhead . . . . . . . . . Upper Steering Bracket to Hoop . . . . Handlebar Block . . . . . . . . . . . . . . . . . Side Panel to Nosepan Brace, Rubber Washer Side Panel to Nosepan. Well Nut Throttle Block Set Screw Ski Pivot Bushing Bolt Choke to Plastic Console
3/8 3/8
7/ 16
3/8
5/16 1/4 1/4 1/4 1/4 3/8
3/8
1.15
9/97
GENERAL INFORMATION
To r q ue Spec if icat io ns Spec ial Ap plicati on Torque Li st, Cont.
Bolt Size 1/4 . 5/16 .. 7/16 .. 7/16 7/16 .. 10-24 . . 1/4 ,.. 1/4 1/4 3/8
3/8
Area Where Used Coolant Tank to Hoop . . . Driven Clutch to Shaft .. Drive Clutch to Engine Engine Mount to Chassis . Engine Mount to Engine . . . . . . Regulator ,,.,.,. Side Panel to Nosepan Brace. Rubber Washer . Side Panel to Nosepan. Well Nut , . . , . . , , " ., ,. , Air Silencer ., Set Screw to Throttle Block , . , . . , . . , . . , Shock Rod Bolt . , , .. , .. ,." Rubber Motor Mount Nuts, Low Flex Rubber Motor Mount Nuts, High Flex " , ,. , Manifold Nuts .. ,. , .. , Ignition Switch to Plastic Console , Ignition Switch to Aluminum Console , Choke to Plastic Console ,.. , ,.. , Lock Collar Set Screws .. , . , . , . . , , . , . . , . . , . . ,
IQrque Minimum-Maximum 4-6 It. Ibs. (.55-.83 kg/m) 15-17 ft. Ibs. (2.07-2.35 kg/m) 45-50 ft. Ibs. (6.21-6.9 kg/m) 45-50 ft. Ibs. (6.21-6.9 kg/m) 44-48 ft. lbs . (6.07-6.62 kg/m) 38-43 in. Ibs. (.43-.49 kg/m) 4-6 in. Ibs. (.05-.07 kg/m) 4-6 in. Ibs. (.05-.07 kg/m) 4-6 in. lbs. (.05-.07 kg/m) 30-35 in. Ibs (.35-.40 kg/m) 10-12 ft. lbs. (1.38-1.66 kg/m) 15-18 ft. Ibs. (2.07-2.48 kg/m) 25-30 ft. Ibs. (3.45-4.14 kg/m) 13-17 tt. Ibs. (1 .79-2.35 kg/m) 20-25 in. lbs, (.23-.29 kg/m) 50-55 in. lbs. (.57-.63 kglm) 20-25 in. lbs. (.23-.29 kg/m) 70-80 in. lbs. (.8 -.92 kg/m)
Recommended Shop Sup plies/Accessories

Descrip tion Chaincase Lubricant - One Gallon Chaincase Lubricant - (Quart) Chai ncase Oil Pump Cable Lubricant , ,, ,.. , ,, , , ,, ,, ,, , , Part Number 2870464 287 1280 2870465 2870 510 2870505 2870 585 2870 584 2870 587 287060 1 , 2870632 2870 990 287079 1 , . . 287 1027 , 2870995 287 1423 287 1322 , . . 287 1323 2871 326 28706 52 " . . ," 287 1076 287 1326 287 1064 " , , 287 1477 2871 478 2871460 , .. , ", . , " .. , , , , ,.. , ,
Fuel System Deicer (Isopropyl) , .. , , Loctite Primer T - 6 Oz. Aerosol . . " Loctite RC 680 - 10cc Retaining Compou nd Loctite 5 15 Gasket Eliminator - 50cc Tube Loctite/Chisel - Gas ket Rem ove r 18 Oz Metal Polish - 8 Oz DOT 3 Brake Fluid . . , Fogging Oil . , Fox Shock Oil , , ' .. , ,.. ,
Corros ion Resistant Dielectric Grease . , . . ,., Premium All Season Grease (14 1/2 oz) Premium All Season Grease (3 oz) Premium 60/40 Anti-Freeze /Coolant Premium Carbon Clean Fuel System Additi ve Fuel Stabilize r (16 oz.) . , . , , . . , Polaris Battery Tender ., ." . . " ., Carbon Clean Fuel System Additive T-9 Metal Protectant " , Synthetic Chain case Lubricant Gallon Synthetic Cha incase Lubricant - 12 oz Starter Drive Gre ase
9/97
1.16
GENERAL INFORMATION Decimal Equivalent s

1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11 /16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/ 16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 3 1/32 63/64 1 0156 0312 0469 0625 0781 0938 1094 1250 1406 1563 1719 1875 203 1 2188 .2344 25 2656 2813 2969 3125 3281 3438 3594 375 3906 .4063 .4219 .4375 .4531 .4688 .4844 5 5156 5313 5469 5625 5781 5938 6094 625 6406 6563 6719 6875 7031 7188 7344 75 7656 7813 7969 8125 8281 8438 8594 875 8906 9063 9219 .. .. . .. .. .9375 9531 9688 9844 1.0 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" 18mm= .7087" 19 mm = .7480" 20 mm = .7874'" 21 mm = .8268" 22 mm = .8661'" 23 mm = .9055"
24 mm = .9449" 25 mm = .9843
1.1 7
11/95
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 (co) Imperial pints (Imp pt) Liters (I) Imperial quarts (Imp 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 C to of : 9 (O + 40) + 5 - 40 = of O to C: 5 (OF + 40) + 9 - 40 = C F x 12 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
Converts to
- rnm
= in. = cm =km = mile (mi.) = Gra ms (g) = 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 (US qt) =Liters (I) = US gallons (US gal) = Kilopascals (kPa) = Pounds - force per square inch (psi) = Kilograms - force per squa re 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 1/4-20 1/4-28 5/16-18 5/16 -24 3/8-16 3/8-24 7/16-14 7/16-20
Drill Size
3/64 53 53 51 50 5/64 45 43 42 38 37 36 33 29 29 24 21
Thread Size
1/2-13 1/2-20 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 2-4 1/2 2- 12 21 /4-41 /2 21 /2-4 2 3/4-4 3-4
Drill Size
27/64 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 43/6 4 1 25/32 1 59/64 2 1/32 2 1/4 2 1/2 2 3/4
17
4.6mm 7 3
F
I
0
Q U 25/64
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 lO x 1.25 l Ox 1.50 11 x 1.50 12 x 1.50 12 x 1.75 #39 3/32 #30 1/8 #19 #20 #9 16/64
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 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/ 16 11 /32 11/32 3/8 13/32 13/32
J
17/64 5/16 5/16 11 /32
R
3/8 13/32 13/32
Polaris Industries tnc .
1.1 9
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 ignition 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 commerciall y. Al ternator: 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. COl: 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 call. Cente r 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. Chai n 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 cylinder head and piston dome at T DC. 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 fueVair mixture. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Disp lace ment: The volume of the cylinder displaced by the piston as it travels from BDC to TDC. The formula is: Bore' x Stroke x 3.1416
4
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
GENERAL INFORMATION Glossary of Terms

Flat Head Bolt: To be used where finished surfaces require a flush fastening unit. Countersunk. Foo t 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 voitage 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 Call: A type of transformer which increases voitage 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. Kllogramlrneter: A force of one kilogram at the end of a lever one meter in length. applied in a rotationa l 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. Laby rinth 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 electromagneti c induction. Loose: When the rear of the vehicle slides outward in a tum . 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, ignition 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 fuella ir mixture; 2) improper spark plug heat range.
IF
1.21
9/97
GENERAL INFORMATION
Glossary of Terms
Pre-Ignition: A problem in combustion where the fuella ir 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 fuell air mixture; 5) Incorrect ignition timing . Prima ry 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 COl system the parts include the exciter coil, the trigger coil, the wires from stator plate to COl box and to the low resistance primary windings in the ignition coil. Primary Clutch: Drive clutch on engine. Primary Compressi on : Pressure built up in the crankcase of a two stroke engine, ps i.: 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 Colis : 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 which 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 piate mounted under the flywheel supporting the primary ignition com ponents and lighting coils. Stroke: The maximum movement of the piston from bottom dead center to top dead center. It is characterized by 180' 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 fuella ir 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 COl systems. Small coil mounted at the top of the stator plate next to the ignition generating coil. V Regulator: increases. Voltage regulator. 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 fuel to be pushed through jets, etc., and into the venturi to be mixed with air and form a combustible airlfu el 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
Polaris tnoustnes Inc.
GENERAL INFORMATION Service Tips
In order to perform service work efficiently and to prevent costly error s, the technician should read the text in this manua l, thoroughl y 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 insta lling. Protect hands
.&. Watch for sharp edges which can caus e personal injury, particularly in the area of the tunnel.
with gloves when work ing wit h sharp components . found. If it is necessary to tap the part into place , use a soft face hammer and tap lightly.
.&. If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be .&. 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 resu lt in injury or dea th 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.
The n, following the method and sequence indicated in this manual, tighten evenly to the specifie d torque value . When removing nuts, bolts or screws from a part with seve ral fasteners, loosen them all abo ut 1/4 turn before removing them .
.&. If the condition of any gasket or Q-Ring is in question, replace it with a new one.
around the gas ket are clean and smoo th 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.
.&. Because 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 othe r brands are substituted.
.&. Grease
sho uld be cleaned from parts and fresh grease appli ed befo re reasse mbly of compo nents. Deteriorating grease loses lubricity and may contain abrasive foreign matter.
.&. Whe never
removing or reinstalling batteries, care shou ld be taken to avoid the poss ibility of explos ion resulting in serious burns. Always disconnect the negat ive (black) cable first and reconnect it last. Battery electrolyte contains sulphuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing. A NTIDOTE: External - Flush with water. Internal - Drink large quantiti es 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 prom pt med ical attention.
1.23
9/97
GENERAL INFORMATION Warranty Policy

LIMITED WARR ANTY Polaris Industries Inc. 1225 Highway 169 North, Minneapolis, Minnesota 55441-507B, gives a ONE YEAR LIMITED WARRANTY on ali 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 Pola ris 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 verif ication 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 COVERAG E WI LL BE AL LOWED UNLESS YOUR SNOWMOBI LE 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. WAR RANTY COVERAGE AND EXCLU SIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The warranty excludes any failures that are not caused by a defect in material or workmanship. This 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 alte red 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 AR E THE ON LY REMED IES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIAB ILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAG ES OF ANY DESCR IPTION. WH ETH ER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTH ER CONTRACT, NEGLIGENCE , OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequentiai damages or implied warranties, so the above iimitations or exciusions may not apply to you if inconsistent with control ling state law. ALL iM PLIED WARRANTIES (INC LUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTAB ILITY AND FITN ESS FOR A PARTICULAR PURPOSE) ARE LIMIT ED IN DURAT ION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANT iES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warrant y lasts, so the above limitation may not apply to you if inconsistent with controlling state law. HOW TO OBTA IN WA RRAN TY SERVICE
-../
If your snowmobile requires warranty service. you must take it to a Polaris Servicing Dealer. When requesting warran ty service you must present your copy of the Warranty Registration form to the dealer. (TH E COST OF TRANSPO RTATION TO AN D FROM THE DEALER IS YOUR RESPONS IBILITY). Polaris suggests that you use your original selling dealer; howeve r, 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 taw, 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 Spec ial 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 add ress . 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 distribu tor should follow tool orde ring procedures established by thei r respec tive distribu tor parts departm ent.
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 (Canad ian Dealers) 1-800-413-4441
Phone Orders or Information (U.S.) 1-716-742-1790 (Canadian Dealers) 1-204-925-7125
1.25
9/97
MAINTENANCEfrUNE UP Maintenance Schedule

500 Mile (805 km) Initial Maintenance Inspection
Customer Name Machine Model Mach ine Serial _ Phone Miles _ _
1.
To rque cylinde r head (s) (cold) & cylinder ba se nuts On ly the following mode ls need to have their cylinde r heads periodically re-torqu ed:
_ ' 7a.Srakes-Hydraulic
A. Check brake fluid level. Should be

reservoir.
' /4 ~
from top on
EC34 2P M(E)02, EC443PM 01 & 02 (PRIO R TO 1996) EC50-PM(E) 03,04.05 &06. EC50PL(E) 17,18,19 & 20 EC65-P L(E)05 Check ignilio n liming
large style reservoir, 1/8" from top on older small style B. Check for prop er hose security and routing C. Check for system fluid leaks D_ Visually inspect pads for wear damage or looseness E. Check security and surface condition of brake disc. t 'zb.Brake-Me cherucat A. Lub ricate brake cable. NOTE : Must use Polaris Cable lubricant. B. Check brake pad an d brake disc condition and mount ing C. Adjust brake to proper specifications 18. Check auxiliary shut-oft switch 19. Perform throttle safet y swi tch tests _ 20. Check brake light tor prop er operation _ 2 1. Check taillights _ 22. Check headlamp securit y and high-low beam operation. _ 23. Liquid coo led model s:
obse rved BlOC

corrected BTDC
_ 3.
_ 4.
Check clutch offset (belt removed)

Check belt condition Check and adjust belt tension Inspec t rubber engin e mounts
_5.
_ 6.
_ 7.
Torque engine mounting plate to chassis fasteners Adjust engine torque stop (if equipped) Carburetor Inspection s A. B. Adjust choke plungers Adjust pilot air screw
_ 8.
_ 8.
C.
D. E. F. 10 . A. S. C. D. E.
Synchronize carburetor slide valves at idle

and off idle Adjusl engine idle RPM Adjust throttle lever free play Synchro nize oil pump lever Check and adjust tnrottte position sensor Check and adjust MR screw Check battery state of charge Adjust Idle RPM Check charging system Adjust throttle lever free play Synchronize oil pump lever
A. Check coolant level and spec ific gravity B. Check water pump dri ve belt condition & deflection
(where applicable) C . Check coolan t hose , routing and clamps D. Inspect heat excha ngers condition and fasteners
Electronic Fuel Injection System Inspections
E. Check cooling system for proper coolan t CI rculation.

_ 24. Lubricat e rear suspension pivot shafts. _ 25. Check all suspension mountin g fasteners. Recomm endat ions
F.
G.
11.
12. 13. 14. 15 _ 16.
Check ski toe alignment Torque and inspect all steering fasteners Torque suspension to tunnel moun ting bolts Check rear suspension fasteners lo r tightn ess Adjust track tension and align track Remove chaincas e cove r, flush chaincase, inspect and adjust chain, refilt with new cha incase oil.
Polaris Service Technician Authorized Dealer Dale _
_ _
Base Inspection Price Parts

Labor
_ _
_
2.1
9/97
MAINTENANCE/TUNE UP Maintenance Schedu le

1500 Mile (2400 km ) Maintenance Inspect ion
Customer Name Machine Model ,Machine Serial Phone Mlles
_1 gaoBrakes-Hydraulic
_ _
_7. _8. _ 9. _ 10. _1 1.
Torque cylinder neadts) & cylinder base nuts (cold) Only the following models need to have !heir cylinder heads & cylinder base nuts periodically r..torqued: EC34-2PM(E)02, EC44-3PMOl & 02 (PRIOR TO 1996) EC50-PM(E) 03,04,05&06, EC50-PL(E) 17,18,19 & 20 EC65-PL(E)05 Check corrpresson and recordreadings Check ignition timing observed BIDC correctedBTDC Inspect rec:ol starter rope Check drive to driven dutell offset (bell r"""veel) Removeclutches. disasserrtJIe & inspect all wear surfaces. Clean sheaves. repair dutch as necessary, reasserrere clutches and torque to specifications. Check belt condition Check and adjust belt deflection Inspect rubber engine mounts Torque engine mounting plate to chassis fasteners
Adjust eng ine torque stop (if equipped)
A. Check brake fluid level. Should be 1/4" from lop on large ~ reservoir, 118 from top on older small style reservoir. " B. Check for proper hose security and routing C. Check for system fluid leaks D. VISually inspect pads for wear damage or looseness E. Check security and surfacecordition of brake disc. F. Flush brake fluid and cI1ange every two years. _ 19b. Brake-Mechanical 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 _20. Ched<auxiliary shut-off swrtell & per10nn throttlesafety
switch tests .
_21. Inspect brake light, taillight. oil light and all electrical accessories
_ 22. Inspect Hilla beam operation and aim headlight

_23. Uquid cooled models: A. Check coolant level and specific gravity B. Check water pump drive belt condfion & deflection (where applicable) C. Check coolant hose. routing and clamps D. Inspect heat exchangers condition and fasteners E. Check oooling system for proper coolant circulation F. Replace recovery line filter: NOTE: Must use correct fitter G. Check coolant recovery line one way check valve (must hold pressure) H. Pressure test cooling system _24 . Fan Cooled: Inspect cooling fins and shrouds _25. Removechaincase cover, flush chaincase, inspectchain & sprockets and adjust chain. Inspectchaincase seals. _26. Check condition of drive shaft and jackshaft bearings. Lubricate greaseablebearingswith Premium All Season grease. _27. Inspect and a<!usl reverse cable (if applicable ) _28. Rerrove ski pivot bushings and Ilb<icate _ 29. Inspect ski wear bars , replace ~ worn to 112 original dameter _ 30. Ched< carroer alignment and lubricate spindles _31. Remove radiusrod end bushings. lubricate and reinstall , inspect all radius rOO ends. _32. Reinstall skis and inspect/adjust toe alignment _33. Check handlebarcentering and lubricate steering bell crank _34 . Torque tie rod end bolls and jam nuts _ 35. Inspect steedrq arms and torque bolls. Inspect handlebarboll
torque
_14 .
_15. 16.
_ 17. _ 18.
Carburetor Inspections A. Adjust choke plungers B. Adjust pilot air screw C. Synchronize carburetor slide valves at idle and off idle D. Adjust engine idle RPM E. Adjust throttle lever free play F. Synchronizeoil pump lever Electronic Fuel Injection System Inspections A. Synchronize throttle bodies B. Check and adjust throttle position sensor C. Check and adjust MR soe D. Rerrove battery, check fluid level and specdic gravity of each cell. Charge d necessary . E. Adjust idle RPM F. Check charging system G. Adjustthrottle lever free play H. Synctvonizeoii pu~ lever I. Replace secondary ete- @ 5,000 miles Remove chaincase cover, flush chaincase. inspect and adjust chain, refill with new dlaincase oil. Change primary fuel filler and oil filler Check fuel and oil line condition and routing Inspectfuel and oil tank vent lines/routing Inspectairbox fitlair filter Clean or replace . Change shock oil (Fox) annually before storage _
-,-Labor. _ _ _
Polaris ServiceTechnician: Authorized Dealer. Base Inspection Price: Date: Parts:
_36. Lubricate rear suspension pivot shafts (1000 mile Intervals) _37. Torque suspension mounting bolts and check all rear suspension fastenersand corroc oeots _38. Inspect rear suspension wheels. bearings and hi-fax _39. Inspect track for damage. Adjust tension and alignment For optimu m performa nce and reliability, repeat the above maIntenance and Inspections annually (preferably befor e off -season storage) or every 1500 miles, except where noted .
RECOMMENDATION: _
9/9 7
2.2
MAINTENANCEfTUNE UP Recom mended Maintenance Products

Recommen ded Maintenance Products
ENG INE OIL Part #
Description
RETAINING/SEALI NG PRODUCTS
Pa ckaging (size I quantity )
Quart Cans / 6
Part # 2870585
Description Primer N, Aerosol
Packaging (slze/quanuty)
2871721 Syntheti c 2-Cycle Premium Gold 2871722 Synthetic 2-Cycle Premi um Gold 2871723 Synth etic 2-Cycl e Premium Gold 2871098 Premium 2-Cycle Oil (TC-W3) 2871097 Premium 2-Cycle Oii (TC-W3) 2871240 Premium 2-Cyele Oil (TC-W3) 2871566 Premium 2-Cyele Oil (TC-W3) 2871385 Premium2-Cyele Oil(TC-W3) 2871096
Premium 2-Cycle Oil (TC-W3)
25 gr / 1
Gall on / 4
16 Gall on Drum
2870584 68 0 Reta ining Comp ound 2871949 T hreadlock 242 2871950 Threadlock 242 2871951 Threadlock 262 2871952 Th readl ock 262 2871953 Threadlo ck 271 2871954 T hreadlock 27 1 2871955 Instant Adhesive : Pris im 401 2871956 Pipe Sealant 565 2871957 Sili cone , Black ATV 2871958 Sili cone . Bla ck ATV
tocc /
50ee / 10
ecc / 12
SOce 1 10
Quart Cans / 12
Gallon / 6 2.5 Gallon / 2

16 Gallon Drum 30 Gall on Drum 55 Gall on Drum
sec / 12
Gee / 12
36ee / 6
3ec 130
2871281 Premium-4 Synthetic 4 C ycl e Oil (OW-40) 2871567 Premium-a Synthetic 4 Cyc le Oil (OW-40) MAINTENANCE PRODUCTS 2871326 Carb on Clean Plus 2871478 Pre mium Sy nthe tic Gearcase Lube 2871477 Premium Synthe tic Gear ca se Lube 2871280 C hain Case Lu bricant 2870464 Chain Case LUbrica nt 2871323 Premiu m Antifreeze 60 /40 Premix 2871534 Pre mium Antifreez e 60/40 Prem ix 2870995 Premium Gas Shoc k Oi l 2870990
Premium Brake Fluid DOT3
Quart Cans / 12
16 Gall on Drum
SOce / 6
3 oz tub e 1 12 11 oz Cartridge/ 12 3.35 oz 1 12 13 oz Cartridg e/1 2 SOcc 1 10
12 0z / 12 12 0z / 12
2871959
Ultra Blue RTV
2871960 Ultr a Blue RTV 2871961 51 8 Flange Sealant 2870587 5 18 G asket Eliminat or
Supercedes 5 15
Ga llon 1 4 Qua rt 1 12 Gall on 1 6 G allon 1 6 Quart / 12
CRANKCASE SEALANTS
50cc
2871557 3 Bond 1215
50z
Oua rt / 6
12 0z /12 12oz / 12
2870791 Prem ium Fogging Oil (spray) 2871518 Prem ium Fogging Oil (liquid) 2871312 Grease Gun Ki1 (All Seaso n) 2871322
Premium All Season Grease
2871517 Premi um Foggin g Oil (liquid with spo ut) Quart 1 12

Ga llon 16
3 0z /4 30z /2 4
2871423 Prem ium All Season Grease 2871460 Premium Starter Gr ease 2871592 Barr el Pump (for 16/30/55 gallon
drums )
14 0z /1 0
20z /12
Ea ch
2871285 Flex Spou t (fits gallon and 2.5 gallon lugs ) 2870505 Isopropyl 2870652 Fuel Stab ilzer 2871027 Corrosion Resistant DiElectric Gr ease 2871064 T-9 Metal Protectant 2870632 Metal Polish 2871076 Battery
Te n d er '~
25
10 0z / 24 16 0z /1 2
2 0z 8 0z
2.3
9197
MAINTENANCEfTUNE UP Lu bricati on
Lubricate the following fittings with Polaris Premium All Season grease annually or approxima tely 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 bracket bushings .
Ski Spindles and Bushings <l,ireasv
~ ,~
JJ
e
..
<,
~, Sld
~ ~
~, / - y
-~
./'
Trailing '97+
@j
Typical Spindle
l eading Type
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.
Pitman Arm
Polaris Premium All Season Grease 14 oz. PN 2871423 Grease Gun Kit PN 2871312 Jackshaft Bea ring 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 Gun Adapter: 2871174 Point Type Grease
Steering Post
II
Center Steering Arm (Bell Crank)
Bushings
Jackshaft Bearing Dr iveshaft Bear ing Greasing Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal. Drivesh aft Bearing Greasi ng - W ideTrak
WideTrak
9/97
2.4
MAINTENANCErrUNE UP
Water Pump Gear Case 1996 Ultra Models
The water pump gear case is a sealed unit on 1996 EC6BPL (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 inspecte d every 1000 miles on 1996 models, and changed annually (end of season before storage) .
Water Pump Oil Level Inspection (1996)

4. With the machine on a level suriace, check the fluid level in the sight glass. 5. If the oil level is below the top of the sight glass (see illustratio n at right). remove filler plug and add Polaris Premium 4 O W40 synthetic oil as required to bring the level back up to the top of the sight glass. CAUTION:
Failure to maintain the proper level could result in seve re 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 see n through the glass. Be sure that what you are see ing 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 chan ge lubricant, remove drain plug. 2. Allow oil to drain completely and reinstall 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 domesti c 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 variations 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 1/8 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 width is .345" (8.75mm) .
2. 5
9/9 7
MAINTENANCErrUNE UP
Lubrication Water Pump Belt Tension - FUji
1. 2. Loosen pump mounting bolts. Push on pump housing to apply tension to belt and hold in this position. Tighten pump mounting bolts.
3. Apply light pressure at center of belt span. Check total deflection of belt span and compare to specifications. Re-adjust if necessary.
"
Water Pump Belt Tension
1/8" - 3/16"
(3-4mm)
Th rottle 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.
J '.
Polans Industries Inc.
9/97
2.6
MAINTENANCErrUNE UP
Chain case Ch ain case O il Level (All Excep t W ide Tra k M odels)
Proper chalncase oil level is determined by checking the level on the dipstick with machine placed on a level surface. 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. Do not overfill.
Chaincase Lubricant PN 28 70337 - 'I Synthetic Chaincase Lubricant .PN 2870337 Refer to Page 9 .1-9.1b.for model type and capacity " 0 . ,.'
CAUTION: I
Polaris Synthetic Chaincase Lubricant is compatib le 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.
Drive Chain Ten sion (All Exce pt W ide Trak Mod els)
To obtain co rrect chain tension: 1. 2. 3. 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).
4. The chain is adjusted by loosening the adjusting bolt locknut (C) and turning adjusting bolt (D) until correct chain deflection is obtained. 5. 6. Lock the adjusting bolt locknut (C) while holding a wrench on the adjusting bolt (D) to prevent it from turning, Reinstall the chaincasa cover and drain plug. Add Polaris chaincase lubricant (PN 2870337) throug h the dipstick opening to the level described above.
NOTE: Clean the magnet ic 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. Observe jackshaft while rotating driven clutch to check for drive chain slack
4.
5. Tighten the Jam nut while holding the adjuster bolt. 6. The chain is now tensioned. Release the brake lock lever.
2.7
9/97
MAINTENANCEfTUNE UP
Chaincase C haincase O il 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. (600ee)
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. Loosen locknut and chain adjuster. Rotate driven clutch in the normal direction of rotation (top forward) to apply slight tension on drive chain.
3. Tighten adjuster bolt to 20 in. Ibs. <'23 Kg-m) 4. Back off adjuster bolt (counterclockwise)1 1/4 to 1 1/2 turns. 5. Hold adjuster bolt in position and tighten locknut. Driv e Chain Tension (1997 WideTrak Models) The 1997 model WideTrak Transmissions have self-adjusting chain tensioners and no adjustment is necessary. Drive Chain Tension (1998 WideTrak Models) Drive chain service is not required on 1998 model WideTrak Transmissions.
9/97
2.8
MAINTENANCEfTUNE UP Suspension Lubrication

Suspension Lubrication
"'--' 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 aillittings on Polaris snowmobiles. Order PN 2871312.
Polaris Premium Grease PN 2871423 Grease Gun Kit PN 2871312 '---' Refer to the following diagrams for suspension lubrication points . Sport Style and WideTrak Style
* LUBRICATION POINTS - Sport / WideTrak
Grease all fittings
Forward
*
*
* LUBRICATION POINTS - XTRA-Lile

Grease all fittings
*
2.9
9/97
MAINTENANCE/TUNE UP Suspension Lubrication Suspension Lubrication

XTRA 10 Style
Grease at fittings
* LUBRICATION POINTS
* *
*
Forward
* *
*
XTRA 12 Style
Grease at fittings
*
*
Forward
7<
* *
2.10
(Both sides)
11/95
MAINTENANCEfTUNE UP
Cooling Syste m
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 pressure 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 rating. Refer to the appropriate parts manual.
Coolant Level
Coolant level in the reservoir or surge tank must be maintained betwee n the minimum and maximum levels to prevent overheating and serious eng ine dama ge.
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 conta mination may result. Replace coolant every 2 years or if contaminated. Inspect coo lant filter annually/or contam ination and replace if necessary.
CooLA.NT
'OTTlE
Check Valves - tapered side points in flow direction
~~c"Le-C-k-va-I-~e- '~--------'
\ Flow 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: 1. Allow the system to cool completely. Fill the reservoir with coolant to the maximum indicated mark. 2. With pressure cap removed, add coolant and fill to the top of the filler neck. 3. 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. CA UTIO N: On models equipped with remote fille r 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 afte r bleeding. Lift Lock Lever To Bleed
fJlI
I
Remote Filler Neck Bieed at 600 RPM Filler Neck On Cylinde r Head Bleed at fast idle
~
~ p i
Caution:
Increase RPM slow ly when lever lock is up to avoid loss of coolant.
Remote Filler Neck Shown
Bleeding the Cooling syste m - 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. Allow the system to cool completely. Fill the surge tank with coolant to the maximum indicated mark . 2. 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 trapp ed air has been purged. Tighten the bleed screw. Recheck the surge tank coolant level and add coolant agai n if necessary. Fill Surge Tank Manifold Bleed Screw
" I
~~
''''-
.~
~~ f
I
t"
3.
4.
itl'
f'
9/97
2 .11
MAINTENANCEITUNE UP Track Maintenance/Alignment
WARNING
When performing the following checks and adjustments, stay clear of all moving parts to avoid seriouspersonal injury.
Track Maintenance
WARNING
Nevermake this maintenance checkwith the enginerunning as serious personal injury can result. Using a hoist, safely lift and supportthe rear of the snowmobile off the ground. Rotate the trackby handto checkfor anypossible damage. To inspect track rods, carefully examine the track along the entire lengthof each rod, bending the track and inspecting for breakage. Thethree mostcommon placeswhere breakage occursare shown in the illustration. If any rod damage is found, the track should be replaced.
2 1
1 2
WARNING
Broken track rods are a serioushazard, since they can cause a rotatingtrack to come offthe machine. Neveroperateor rotatea 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 runn ing evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. NOTE: If excessive hi-fax wear occursdue to poor snowconditions, 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. Inspecttrack alignment by lookingthrough the track windowto makesurethe railsare evenly spacedon eachside. Ifthe track runsto the left. loosen left locknutand tightenthe left adjusting bolt. If the track runs to the right, loosen right locknut and tighten the right adjusting bolt. 4. Afteradjustments arecomplete, be sureto tightenlocknuts and idler shaft bolts. Torque to specification.
Rail _ _~~rtr Looking through track window, make surethe 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 (Refer to Suspension Chapter for type) XTRA 12 121" XTRA 12 133" XTRA 10 121". 133".1 36" Standard 121" (Sport & Lite) Lite GT WideTrak GT I LX and Transport XTRA Lite Weight
Measurement Location Measurement
none
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
1-1 118" (2.54 - 2.86 em)
free hanging 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)
3/8 - 1/2" (1 - 1.3 em) 3/8 - 1/2" (1 - 1.3 em)
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 foliowing checks and adjust ments , stay ciea r of ali moving parts to avoid serious persona l injury.
Track Tenalon - Sport and XTRA Lite Style

1. Turn the mac hine off.
2.
Lift the rear of the mac hine and safe ly suppo rt it off the
ground. Place a 10 lb. (4.5 kg) downward pressure on the track at a point approximateiy 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. Track Sport & XTRA Li te Style Track Tension > 3/8 _ 112" slack (1- 1.3 em) ,il w/10 lb . (4.54 kg)~eight . 10 lb. Weight (4.5 kg)
3.
All Models Except Li te GT 4.
Indy Lite GT 5. 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: Measu re at the point where the weig ht 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. 7. 8. 9. Loosen rear idler shaft bolts (A) on both sides of the machine. Loosen track adj usting bolt iocknuts (B). Tighten or loosen the track adjusti ng bolts (D) even ly as necessary to obtain proper track tension . Tighten idler shaft bolts and adjuste r bolt locknuts .
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 10 page 2.12 for alignment procedure .
2. 13
9197
MAINTENANCEfTUNE UP Track Maintenance/Adjustment
WARNING
When performing the foilowing checks and adjustments, stay clear of all mov ing parts to avo id serious personal injury.
Track Tension - WideTrak LX & GT Style

Tens ion adjustments should be made only after the track is warmed up and limber. 1. Turn the machi ne off. ground .
2. Lift the rear of the machine and safely support it off the
3.
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 3/4 -1" (1.9-2.5 cm) slack between the inside of the track clip and the plastic hi-fax (C).
4.
C
10 lb. Weight
NOTE: Measu re at the point where the weight is hang ing .
(4.5 kg)
. .';'..:. '''. Wlde Trak LX & GT Style Track Tens ion 3/4 - 1" slack (1.9 - 2.5 em) w/10 lb. (4.54 kg) we ight
If the track need s adjus tment:

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
MAINTENANCErrUNE UP Track Maintenance/Adjustment
WARNING
When performing the followi ng checks and adjustme nts, stay clear of all moving parts to avoid serious personal injury. Track Tension - XTRA 10 Style
1. Tu rn the machine off.

2. 3. Lift the rear of the machin e and safely suppo rt it off the gro und. Place a 10 lb. (4.5 kg) downward pressure on the track at a point ap proximately 16" (40 .6 em) ahead of the center of the rear idler wheel (D). Check for 3/8 -1/2 " (1-1.3 em) slack between the inside of the track clip and the hi-fax (C) . NOT E: Measure at the point where the weight is hang ing .
4.
XTRA 10 121" & 133/136" Style Track Tensio n 3/8 -1/2" slack (1 -1 .3 em) w/10 lb. (4.54 kg) weight
Track
10 lb. Weight (4.5 kg)
If the track needs adjustment: 5. 6. 7. 8. Loosen rear idler sh aft bo lts (A) on both sides of the machine. Loosen track adjusting bolt locknu ts (S). Tighten or loosen the track adj usting bolts (D) evenly as necessary to obtain proper track tension . Tighten idler shaft bolts and adjuster bolt locknuts.
Always inspect track alignment after track tens ion 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 alignmen t procedure.
2. 15
9/97
MAINTENANCE/TUNE UP Track Maintenance/Adjustment
WARNING
When performing the following checks and adjustments. stay clear of all moving parts to avoid serious personal injury.
Track Tenslcn- XTRA 12 Style

1. Turn the machine off. 2. Uft the rear of the machine and safely support it off the ground . 3. 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.
Rail bumper
If the track needs adjustment:
4. Loosen rear idler shaft bolts on both sides of the machine. 5. Loosen track adjusting bolt locknuts.
6. Tighten or loosen the track adjusting bolts evenly as

necessary to obtain proper track tension . 7. Tighten idler shaft bolts and adjuster bolt locknuts . Always inspect track alignment after track tension adjustment.
Track
121"= 1/2-
Hi-fax
133 " = I-I l iS" measured 16"ahead of rear idler center
NOTE: Track alignment affects track tens ion. Misalignment will cause excess ive 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
MAINTENANCEfTUNE UP
Spark Plug s Spark Plu g Selection
Original equipment parts or their equivalent should always be used . However, the heat range of spa rk 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 excess ive 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 customer who normally operates the engine under medium or light duty to have spark plug failure . CAUTION:
A plug with a heat range which is too high will a/ways 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 preservative which has been added during 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 spa rk plug and its condition is gene rally indicative of 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 cor rect color.
Norm al
The insulator tip is gray, tan, or light brown . Th ere 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 injection 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 spark plug cleaner only. CAUTION:
A wire brush or coated abrasive should not be used .

3.
4.
Measure gap with a wire 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 ant i-seize compound.
5. Install spark plug and torque to speci fication.
Sp ark Plug To rqu e: 11 Ft. Lbs
2. 17
9/97
MAINTENANCE/TUNE UP Spark Plug Application Chart

1996 Models
Machine Model Indy Lite Models Indy Sport Mod els Indy Tr ai l Models Ind y 440 LC Indy 4 40 XCR Indy 440 XC R SP In d y 500/SKS/RMKlCIassic Ind y W ideTrak GT Indy W ideTrak LX In dy 500 EFI Ind y X LT Engine Model EC34-2PM02lE02 EC44-3PM01l02 EC50PM04/E04 EC45PL06 EC45PL07 EC45PL08 EC50PLE11/11114115 EC50PM03 EC50PLE, 2 EC50PL13 EC58PL03 EC58PL07 EC58PLE05 EC5802 EC59PLOI EC65PL05 EC68PLOI 1(04) EC80PL05 1 (04) Spark Pl ug PI Up' Gap MMI nches 0.7/.028 0.7/.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71 .020 0.7/.028 0.7/.028 0.7/.028 0.71.028 0.71.028 0.71.028 0.71.028 0.7/.028 0.71.028 0.71 .028 0.71.028
NGK
BRBES BRBES BRBES BR8ES BR9ES BR9ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR9ES BR9ES BR9ES BR9ES
Champion RN-3C RN-3C RN-3C RN3C RN2C RN-2C RN-3C RN-3C RN-3C RN-3C RN-3C RN-3C RN-3C RN-2C RN-2C RN-2C RN-2C RN-2C
I X LT SKS
Indy X LT RMK Indy X LT Tou ring Indy X C R 6 00 I X LT S P Indy 600 XCR SP Ind y RX L Indy Ultra SPISKSI (RMK) In d y Sto rm /SKSI (RM K)
1997 Models
Mach in e Model Ind y Lite Models Ind y SportlTranSporVSport Touring In dy XC F Ind y Tr a illTrai l Tou ring Ind y Tr ail RMK Ind y Super Sport In d y W ideTrak GT Ind y W ideTrak LX Indy 440 LC Ind y 440 X C Indy 440 XCR Ind y 500 RMK In d y 500/SKS Indy C lassic Ind y 500 EFI Ind y Classic Touring Indy X LT /S KS Indy XLT RMK Indy 600 XC Eng ine M o del EC34-2PM02 EC44-3PM02 EC44-3PM02 EC50PM04 EC50PM05 EC50PM06 ECSOPM 03 EC50PL20 EC45PL09 EC45PL08 SN44LCDCSP-Ol ECSOPL1 6 EC50PLE17 ECSOPL 11 EC50PL18 EC50PL19 EC58PL03 EC58PL07 ECS8PL08 Spark P lu g
NGK
BR8ES BR8ES BRBES BRBES BR8ES BR8ES BRBES 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 RN-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 MMiln ches 0.71.028 0.71.026 0.71 .02B 0.71.02B 0.71.028 0.71.028 0.71.02B 0.71.028 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 0.71.028 0.71.028
Bold indicates production spark plug.
9/97
2.17a
MAINTENANCE/TUNE UP Spark Plugs

1997 Mode ls (continued)
Mach ine Model Indy XLT Touringl XLT LTD Indy XLT SP 1 XLT LTD SP Indy 600 XCRIS E Indy RXL Indy UltraiSPlTouring Indy Ultra SPXJSPX SE Indy 700 XC Indy 700 SKS Indy 700 RMK Indy Storm/SE Indy Storm RMK Eng ine Model EC58PL09 EC58PL12 EC59PL01 EC65PL05 EC68PLOl EC68PL03 SN70LCDCSP-o l SN70LCDCSP-ol SN70LCDCSP-02 EC80PL05 EC80PL 04 Sp ark Plug BR8ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES BR9ES SR9ES RN-3C RN-2C RN-2C RN2C RN2C RN2C RN2C RN2C RN-2C RN2C RN2C
P I U~ Gap MMi nches
0.71.028 0.71.028 0.71.028 0.7/.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.02 8 0.7/.028
1998 Models
Mach ine Mod el Eng ine Model Spark Plug NGK Lite Models SporVTranSporVSport Touring/XCF Super Sport Trail/Trail 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 600 XCR 600 RMK UltraITouring 700 XC 700 XCR EC34-2PM02A EC44-3PM024 EC50PM061 EC50PM043 EC50PM051 SN44-44LCDCSP-01 EC45PL09 1 EC50PL16 1 EC50PL171 EC50PL171 EC50PL 191 EC50PL201 EC58PL 140 EC58PL 130 EC58PL 130 EC58PL150 SN6Q-70LCDCSP-o l EC59PL020 SN60-70LCDCS P-02 EC68P L050 SN70-70LCDCSP-02 EC68PL060 SN70-70LCD CSP-01 EC80PL052 BRBES BRBES BRBES BRBES BRBES 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 RN2C RN3C RN3C RN 3C RN3C RN3C RN3C RN3C RN3C RN-3C RN3C RN2C RN2C RN2C RN2C RN2C RN2C RN2C RN2C
PIU~ Gap MMI nches
0.7/.028 0.71.028 0.7/.028 0.71.028 0.71.028 0.71.028 0.71.028 0.7/.028 0.7/.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.028 0.71.0 28 0.71.028 0.71.028 0.71.028 0.71.028
0.7/.028
0.71.02 8 0.71.028 0.71.028
700 RMK
Storm Bold Indicates production spark plug.
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 satisfac tory 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. 2. 3. 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
Belt Installation
1. Drop the drive belt over the drive clutch and pull back the slack.
Install ation
2. Turn the driven clutch moveable sheave clockwise while at the same time pushing inward and forcing the belt down between the sheaves. 3. 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. 4. Close the clutch guard and reinstall the retaini ng knob or pin.
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 beit if worn past the service limit. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibratio n, or erratic operation. See Troubleshoot ing Chart at the back of this chapter for possible causes . NOT E: 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 specification s and measurement procedures .
-9/96
Center Distance
2.18
MAINTENANCE/TUNE UP Backrest Adjustment

Backrest Adjustmen t
The passenger backrest on the Classic Touring and XLT Touring Models is adjustab le. 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 Defiector
Backrest -------+~"....,Jf; Adjustment Lever
Grab Bar Adjustment Knob
2.19
91 96
MAINTENANCE/TUNE UP Headlight Adjustment - Standard Indy Models

Headlight Adjustment
Th e headlight can be adjusted for vertical aim using the following procedure: 1. Place snowmobile on a level surfac e with headlight appro ximately 25' (7.6m) from a wall . 2. 3. 4. Measure distance from floor to center of head light and make a mark on the wall. Start engine and turn head light switch to high beam. Observe headl ight aim. The most intense part of the headlight beam shou ld be aimed 2- (5.1 ern) below the mark placed on the wall in Step 2. NOT E: Rider weight must be included on the seal.
25' (7.62 m)
Lamp Center Height 2- (5.1
cm~_
--:.ri:rr-=
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.
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5. It necessary, the head light 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.
Remov ing the Bulb

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue , causing a hot spot which will sho rten the life of the lamp . 1. Push down on left side of spring until it releases from spring retainer. 2. 3. 4. Uft 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 carefu lly separate bulb from harness.
/ LJ "
\~ . ,',
(!. ~ . ! "
\
Halog en Bulb
Installin g the Bulb

1. 2. Hold bulb by metal base and insta ll into wire harness. Insert bulb into housing.
>r
W
Spring
Wire Harness
~/ ~
.a:rI
Bulb
Spring
3 . Carefull y flip spring back into hous ing placing it around wire harness. 4. 5. Push spring down until it is secured by spring retainer. Verify headl ight aim.
'"'~"=:i;~ I ~.: /
Wire Harness
9/96
2.20
Polaris Indust ries Inc.
MAINTENANCE/TUNE UP Headlight Adjustment - Evolved Style Models

Headlight Adjustment
The headlight can be adjusted for vertical aim using the following procedure: 1. 2. Place the snowmobile on a level surface with the headlight approximately 25' (7.6 rn) 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)
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 em) 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 adjustme nt 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,
~ bd u
Headlight Adjust ment Knob
--:;v-Spring
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. 2. 3.
Hold bulb by metal base only and install into wire harness. Insert bulb into housing. Push spring down until it is secured by spring retainer.
>r
Wire Harness
~/ """":;;J
a1 I
Bulb
4. Verify headlight aim.
Remov ing 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. Insert bulb assembly into housing. 3. Turn bulb assembly 1/4 turn to left to secure in housing. 4. Verify neadlight operation.
2.21
11/95
MAINTENANCE/TUNE UP
Headlight Adjustment Aggressive Style 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.
25 ' (7.62 m)
2. Measure distance from floor to center of headlight and make a mark

on the wall.
Lamp Center Height
3. Start engine and turn headlight switch to high beam. 4. 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.
2- (5.1 em)
5. If necessar y, 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. Push down on left side of spring until it releases from spring retainer. 2. Lift spring carefully around wire harness and flip to outside of housing. 3. With the wire harness attached to the bulb, withdraw bulb from
housing. 4. Grasp bulb by metal base and carefully separate bulb from harness.
Insert screwdriver into access
hole and turn serew to adj ust
Installing the Bulb

1. 2. 3. 4. 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.
Bulb
5. Verify headlight aim.
~ ~:Spring
:tr~
Taillight Bulb Replacement

1. Remove (5) Phillips screws from taillight lens. 2. Working from front to back, carefully pry lens away from seal and remove lens. 3. 4. Pull bulb straight out from socket and insert new bulb. Reinstall lens.
BUlbS,?
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#:1#:11$
11/95
2.22
MAINTENANCE/TUNE UP Handlebar Adju stment

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 ieft or right for access to back nuts.
3. Adjust handlebarto the desired height. Be sure that handlebars, brake lever and thrott ie lever operate smoothly and do not hit the gas tank, windsh ield or any other part of the machine when turned fuily to the left or right. 4. Torque the handlebar adjuster biock bolts to specificatio n. Maintain an equal gap on front and back of block. 5. Replace handlebar cover and foam.
Handleb ar Adjustment - Evolved and Aggressive Sty le Models

1. Remove two plastic fasteners holding console cover located below handlebar cover on hood side of steering post.
2. Using a 7/16" (11 rnrn) wrenc h, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or right for access to rear nuts. 3. 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 fuily to the left or right.
4. Torque the handlebar adjuste r block bolts to specification. Maintain an equal gap on front and back of block. 5. Replace console cover.
Bottom of Adjuster Block
Handlebar Adjustment - Indy Lite Style Models

,. 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, winds hield or any other part of the machine when turned fuily to the left or right. 3. Torque handlebar adjuster block to specificatio n. 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 loose ning of the handlebars , reSUlting in lOSS of control.
2.23
11 195
MAINTENANCEfTUNE UP
Brakes Replen ish ing 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 1/45/16" (.6-.8 cm) below the lip of the reservoir opening. 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 contam ination is suspecte d. Pola ris DOT 3 High Temp Brake Fluid PN 2870990
Master Cylinder Fluid Level 1/4 - 5/16" (.6 - .8 cm) below lip of reservoir opening
Brake Flu id Should Changed Every 2 Years or when fluid is dark or if contamination is suspected.
WARNING
Do not over fill 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 fiuid. 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. B leeding the Hydraulic Brake System Air in the hydrauiic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to remove air from Ihe system. 1. Remove brake fluid master cylinder reservoir cover and gasket. 2. Fill the master cylinder reservoir (B) and replace gasket and cover. Keep the fluid level 1/4-5/16" (.6-.8 cm) below lip of reservoir opening. 3. Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into a containe r.
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. 4. Squeeze brake lever a full stroke. Then unscrew bleede r 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 flows 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. Re-fill reservoir to proper level after bleeding operation. Do not overfill the master cylinder. 7. Replace gasket and cover. During the bleeding procedure make sure to keep the reservoir as level as possible to minimize the possibility 01 air entering the system .
~ Bleeder Tube
9/97
2 .24
MAINTENANCEfTUN E UP
Brakes/Exhau st System Brake Adjustme nt - Mechani cal 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 -Ca liper Adjustment

1. Bend locking tab (A) away from lock nut (B) and loosen lock nut. 2. "-" 3. 4. Push down on actuating lever (C) and insert a .015 " feeler gauge betwee n the brake disc and outer brake pad. Turn adjusting bolt (0) in until a slight pressure is felt against the feele r gauge. While holding adjusting bolt (0) , tighten locknut (B).
-.,----
--,
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 .0 15" clea rance. 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 deat h.
Brake Pad to Disc Clearance .015" (.38 mm)

m
.0 15" 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 Sys tem
"
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.
Pola ris Industries Inc.
2.25
9197
MAINTENANCE/TUNE UP
Brakes WT2 Brake Adjustment
1. Check to ensure floating parts move freely and that all other parts are mounted securely. Tighten hardware as required. Bracket Lock Nuts
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.
Move cable up or dow n 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 cab le 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 . 6. Slip long leg of lever spring off caliper and rotate to the side. 7. Rotate the lever one tooth in the direction opposite the actuatio n direction, and tighten bolt making sure spline teeth are properly engaged. 8. Bend up a tab aligning with one ofthe bolt head flats to prevent bolt rotation. 9. Return the spri ng to its original position on the caliper. Both lever and linkage must be free to return to original posit ion. 1D. Perform steps 3. and 4. to adjust lever freeplay. 11 . Verify proper brake operation. Disc sho uld rotate freely without drag. 12. 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
~ \
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.,'
Separator Plate
Tab Washer
"
9/96
2.25a
BRAKES/FINA L DRIVE
Reverse K it Maintena nce Adjustment Due to break-i n or replacement of components, the reverse shift mecha nism may require adjustmen t. Adjust with the shifter in the forward position. Standard Indy Style 1. Loosen jam nuts on lower end of cable . housing at the hand lebar bracket is 1/32" (.08 em). Do not adjust beyond this point. 3. Tighten jam nuts and re-check adjustment.
2. Adjust cable until endplay movement of cab le
Reverse Cable End Play 1/32" (.08 em)

1/32" Adjustment (.08 em)
Evolved and Aggressive Style 1. Lift shift leve r slowly while observing shift arm on trans mission.
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.
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 em) of freeplay before the cable starts to move the shift arm. Do not adjust beyond this point. Cha incase Cover
<
1-1 1/2" (2.5-3.8 em) free play
3. 4.
5. Tighten jam nuts and re-check adjustment.
Shift
~A~ (6[f.~p . ' Arm ~tp~.l

0
>
~ .~
Reve rse Shift Lever Freeplay 1 - 1 1/2" (2.5 - 3.8 em) measured at end of shift lever
9/97
2.25b
MAINTENANCEfTUNE UP
Off Season Storage Cleaning And Preservation Of Hood, Chassis And Trim
Prope r 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 ail corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grea se, oil, or paint). If the machine is equipped 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 fuil capacity. Remove and store the battery in a cooi dry place . The machine should be stored in a dry garage or shed out of the sunlight and cove red with a fabric snowmobile cove r. Do not use plastic to co ver the machine; moisture will be trapped inside caus ing rust and corro sion problems.
Controls And Linkage

Ail bushings, spindle shafts and tie rod ends should be coated with a light coat of oil or grease. Throttle controls and cables should be lubricated with Polaris Cable Lubricant. Force a small amount of lubricant down cables.
nn
Polaris Cable Lubricant PN 2870510
Electrical Co nnections
Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and reconnect. Replace worn or frayed electrica l wire and connecto rs.
Dielectric Grease 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 amount of lubrication, such as Polaris cable lubricant should be appl ied onto the roilers and weight pins. Ail lubrication applied as a rust preventative measure must be cleaned off before insta iling belt for service and operating machine.
Chaincase Lubricant
Change chaincas e lubricant as outlined in this section. Remove the outer cover and clean the chaincase thorough ly.
9/97
2.26
MAINTENANCErrUNE UP
Off Season Sto rage Lubrication
Refer to page 2.5-2.10 for complete lubrication information. To prevent corrosion which will 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 spindles. See 111. 1 and 2. Ski Spindle lOgs Grease
and B~S h
"""
III. 1
Jackshaft Bearing
~
~
( '
0
Grease
Polaris Premium All Season Grease PN 287142314112 oz.

III. 2
Driveshaft Bearing
_tJ
o
Located on left side 01 machine (clutch side)
Grease Gun Adapter: 287.1174 1m! Point Type
"
Use T-9 Metal Protectant on shock absorber shafts to help prevent corrosion.
I"' T9 Metal Protectant

PN 2871064
J~~
,:
Under normal conditions moderate track tension should 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 oft the ground to allow free hanging of track.
2 .27
9197
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 followi ng procedu re: 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 cranks haft bea rings before proceeding to next cylinder. Turn engine over seve ral times to insure coverage of piston rings, cylinder walls and crankshaft bearings. See photo at right.
Treat the fuel syste m with Polaris fuel system additive
If Polaris fuel system addit ive is not used , fuel tank, fuel lines , and car buretor should be complete ly drained of gasoli ne. To eliminate any fuel remaining in the carb uretor, run the engine until it stops.
Battery
Disconnec t and remove battery. Fill with distilled water. Clean terminals and cables. Apply dielectri c 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 cond itionerlstabilizer 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 mont hs , start and run engine for at least 15 minutes and re-fog wit h fuel stabilizer added to the fuel. Fill fuel tank and add the recommended amou nt of Polaris Fuel System Additive.
9197
2.28
ENGINE Variable Exhaust System Variable Exhaust System (V.E.S.)

'---' Some snowmobile s are equipped with the Polaris (pa tent pending) Variable Exhaust System (V.E.S.) Thi s unique exhau st valve management system changes the effective exhau st port height in the cylinder to provid e maximum horsepower at high RPM without sac rifici ng fuel economy and eng ine torqu e at low to midrange throttle settings.
r--- - - - - - - - - - - - -- - - - - - -----,
HIGH RPM POSlTJON -
LOW RPM posmoN7
I II
~---jt-- Piston
Bellows Hou sing Exhaust Valve

EXHAUST
PORT
CYUNOER
Fig . 1
In order to understand the operati on and function of the V.E.S. we mus t first consider the cha racteristics 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 whi ch the power occ urs. Exhaust systems are 'tuned' by design 10 match engine exhaust port configuration and desired power delivery characterist ics. Engines with relatively "high" exhaust ports (and exhaust pipe to match ) produce more horsepowe r at high RPM, but only at the expense of low to midrange fuel econo my and torque. On the other hand, "low" port engines provide good fuel econo my in the midrange and make their power at relatively lower RPM , but will not prod uce as much peak horsepower for a given displacement range. In gene ral, an engine designed for a racing or high pertormance snowmo bile will have a relatively high exha ust port compared to an engine of lhe same displace ment range designed for touring. Mhough the V.E.S. does not in rtsell increase horsepower. rt does allow an engine to be designed for maximum horsepower without the inherent disadvantages of a high exhaust port. The main compo nents of the V.E.S . are the exhaust valve . valve housing, bellows. piston, return spri ng, and cover. 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 1 the cylinder by a drilled passageway loca ted just above the exhaust 0 port. The upper chambe r is vented to atmospheric press ure. A valve retum spring is located in the upper chamber between the piston and cove r. At idle and low speeds, Ihe exhaust valve is held in Ihe "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 agains t spring pressure. The valve continues to move upwa rd lowa rd the "High Port" position as cylinder pressure, horsepower, and RPM increase.
'---'
2.28a
9/97
ENGINE Variab le Exhaust System
HOUSing ~,'
Housi ng BOltS .
/'
>
,~~"
O-ring~
Exhaust Valve
Gasket
?
/ /
.~ _cover
Cover Retum Spring
Retainer
l'~~~(j~
./ "
/
\
( \J ~'" ~
" '. /
\J, ~
~ <;
'~
Piston
C linder y
-, Fastener Strap Bellows 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 VES. 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 1721) only. The use of other lUbricants may cause improper function of the valve mechanism. and increase 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 cover retainer clip whil e holding the cove r 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 cou nte rcloc kwise direction while pulling outward on the spring. Do not distort the spring upon removal.
2. Slide Clip Down
CAUTION: Do not attempt to remove the plastic valve piston at this time. The bellows must first be removed from the piston or dam age may occur to the bellows or piston.
4. Remove two (Smm) hex screws from valve housing. 5. Lift entire valve asse mbly from cylinder along with gasket.
9/9 7
2.28b
ENGINE Variabl e 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. Remove
Lower Clamp 3. Hold exhaust valve securely and remove piston by turning the 10mm hex counte rclockwise . 4. Slide exhaust valve out of housing. 5. Remove a -ring from exhaust valve shaft. 6. Compress lower spring clamp and remove bellows and clamp. 7. Clean a-ring and bellows in warm water and mild dete rgent. Inspect bellows for holes, distortion or damage. Replace if necessary. Inspect a -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 free 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.
\J\
~1
\G:k!' .00
/ BeIlows
Piston (do not attempt to remove piston from exhaust valve until upper clamp and bellows are removed from piston.
: ~ :
HOUSin\ Gasket // -\- - 10mm Hex
a-ring~ / jJ
~H:"
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. (.28 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 108 in. Ibs. (1.24. kg-m). 7. Fit upper sealing edge of bellows into groove on piston. 8. Secu re the bellows by installing the fastener strap. NOTE: Move the valve up and down in the full travel range and check for smooth operation. If the 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
"'90 ';'~
I~ -"\
/' a-ring /
Housing Bolts: Appl Loctite - 242(blue) Torque: 108 in. Ibs. (1.24 kg-m)
2. Slide Clip Up
9/9 7
2.28 d
ENGINE Variab le Exhaust System
V.E.S . Troubles hoot ing

Sym ptom Engine will not reach designed operating RPM Poss ib le Cause Valve not opening or not ope ning 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. Poor acceleration; hesitation; High RPM perlormance 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 1. Remove carbon deposits, burrs etc. 2. Clean port 3. Inspect bellows , fastener straps , and gasket and repair as required 4. Inspect 5. Inspect Remedy
2.28e
9/97
MAINTENANCE/TUNE UP Routing Diagram - Speedometer Cable

1996 to Current Indy Lite Models
Route cab le down right side over post, under mounting plate, and out side of bulkhead.
2,29
9/96
MAINTENANCE/TUNE UP Routing Diagram - Speedometer Cable

1996 Indy 440 LC/Classic/Classic Touring/Trail/Trail Touring/500/500 SKS/500 RMKlXLT Touring Models 1997 Indy Trail/Trail Touring/500/500 SKS/500 RMKl440 LC/500 EFI/XLT LTD/XLT Touring/ Classic/Classic Touring Models
---.
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 Mode ls 1997 Indy XLT/XLT SKS/XLT RMKlU ltra SP Models
When pulling speedometer cable through clutch gua rd bracket be careful not to scrape cable housing .
Clutch guard
Speedometer cable
. . II
I
/ Route speedomet er 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 . ~
2.3 1
9196

1997 Indy 440 XC Mode ls
Clutch guard
Speedometer Cable
II
. '.,
/
( I 1(1
Cable tie wire harness only around hinge -brace
Both wire harness and speedom eter cable are cable lied to hood '-.",. hinge '-.",.
9/96
2.32
MAINTENANCE/TUNE UP Routing Diagram Wire Harness/Speedometer Cable

1997 Indy XLT SP Mode ls
Clutch guard
Speedometer Cable
)
1,
,, .
Wire
harnes~
Cable tie wire harness only around hinge brace---__
Both wire harness and speedometer cable are cable tied to hood hinge
2.33
9/96
MAINTENANCEITUNE UP
Routing Diagram - Wire Harness/Speedometer Cable
1996 Indy 440 LC/Classic/C lassic TouringIXLT Touring/500/500 SKS/500 RMKlTraillTrail Touring Models
1997 Indy TraillTraii Touring/500/500 SKS/500 RMKl440 LC/500 EFIIXLT Touring/classic/ Classic TouringlX LT LTD Models 1998 Trail /440 Indy /500 Indy /500 Classic / XLT Touring
Rosebud Clip 6 inches Cable Tie'-;,..
<p'ft-- - - - - - - - - - ---'-Hood
Wire Harness _
Nosepan Speedometer routed as shown with no other cable ties in th is area.
9/9 7
2 .34

1997 Indy Ultra Touring Models
2.35
9/9 6
MAINTENANCE/TUNE UP Routing Diagram - Wire Harness/Fuel Line

1996 Indy WideTrak LX/Sport/Sport Touring/TranSport/Super Sport/Trail/Trail Touring Mode ls
Brake line in front of steering post Fuel line behi nd steering post
To Fuel Pump
/
\
Recoil Mount
Roseb ud clipped to bulkhead
9/96
2.36

1996 Indy 440 LC/Classic/Classic Touring/500/500 SKS/500 RMK Model s
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 coil wire loop.
I
\
./
throu~ ~/
-,
2.37
9/96

1997 Indy TranSport/Super Sport/Sport/Sport Touring Models
Brake line in front of steering post Fuel line behind steering post
To Fuel Pump
/
/
/
/
\
Recoil Moun t
Rosebud clipped to bulkhead
9/96
2.38

1997 Indy Trail/Trail Touring Models
Fuel Line (Ove r Throttle Cable) Brake line (Over Steering Post)
Fuel line (Behind Steer ing Post)
Rosebud
2.39
9/96
MAINTENA NCE/TUN E UP Routing Diagram - Wire Harness/F uel Line

1997 Indy Trail/Trail Touring/500/500 SKS/500 RMKJ440 LC/Classic Touring Models
Brake line runs in front of handlebar block.
--.....
.....
Steering Post
Fuel line is routed behind steering post
/'
\
., 1
Coolant hose runs through ignition coil wire loop.
\ /
/
~ ~/
9/96
2.40
MAINTENANCE/TUNE UP Routing Diagram - Fuel Line

1996 to Current Indy Lite Models
Steering Post
To fuel tank Fuel Pump
Routed under carb and up to LH carb
Mounted on air box
\
ToRH carb To motor
Shut off valve mounted on oil tank
2.41
9/96

1996 Indy 600 XCR Models 1997 Indy 600 XC Models
{To Shut-Off Valve
--------:::::::::=======1
Oil Line
9196
2.42

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

1997 Indy Ultra/Ultra SP Models
Fuel Valve
-::::::=:=====:; To filter/la nk
Fuel Pump
PTO
Mag
I
Center
9/96
2.44
MAINTENANCE/TUNE UP Routing Diagram - Handlebar Harness

1996 Indy 440 LC/Classic/Classic Touring /XLT Touring/SOD/SOD SKS /SOO RMKlTaillTra il Touring Models 1997 Indy XLT LTD/Classic Touring/XLT Touring/Ultra Touring/440 LC Models
Handlebar harness should be routed down through handle bar block and connect with main harness.
A tie strap loosely holds the wire harness, throttle cable and brake line to the steering post. 4 wire connector plugs into throttle side.
2.45
9196
MAINTENANCE/TUNE UP Routing Dlaqrarn- Hand lebar Harness

1997 Indy Trail/Trail Touring/SOO/SOO SKS/SOO RMK Models
Reverse cable routing and cable tie.
Handlebar harness should be routed down between handlebar block and connect with main harness!
A lie strap loosely holds the wire harness , throttle cable and brake line to the steering post.
9/96
2.46
MAINTENANCE/TUNE UP Routing Diagram - Handlebar Harness

1997 Indy 500 EFI Models
Handlebar harness should be routed down between handlebar block and connect with main harness.
I
A cable tie loosely holds the wire harness. throttle cable and brake line to the steering post.
2.47
9196
MAINTENANCE/TUNE UP Routing Diagram - Oil Line

1996 440 XCR/XLT SKS/XLT RMK Models 1997 440 XC/XLTlXLT SKS/XLT RMKlXLT SP Models
Oil line route Air Box
o
Oil line route
Jackshaft
9/96
2.48
MAINTENANCE/TUNE UP Routing Diagram - Oil Line

1996 Indy WideTrak LXlWideTrak GT/Classic/Classic Touring /XLT Touring/SOO/SOO SKS/SOO
'--" RMKlTraiUTraii Touring/Sport/Sport Touring/Super SportlTranSport/Lite/Lite GT/Lite Deluxe/600 XCR/440 LC Models 1997 Lite/Lite Deluxe/Lite GT/Sport/Sport Touring/TranSport/Super Sport/440 LClTraillTraii TouringClassic Touring/SOO/SOO SKS/500 RMKl600 XC/XLT Tourlng/XLT LTD Models
Oil line route
Air Box
Oil line route
Jackshafl
Polaris Indu stries Inc .
2.49
9/96
MAINTENANCEfTUNE UP Routing Diagram - Miscellaneous
1996 Indy 440 LC/Classic TouringlXLT Touring /SOO/SOO SKS/SOO RMKlTraii/ Trai l Tour ing Models 1997 Indy 440 LClTraillTraii Touri ng/Classic/SO /SOO SKS/SOO RMKlClassic Touring/ O XLT TouringlX LT LT D/SOO EFI Models 1998 Trail / 440 Indy /SOO Indy /SOO Classic /SOO RMK / XLT LTD / XLT Touring Trai l Touring / XLT Classic
Harness secured around ignition switch
/"r "
~
~ ~
Recoil rope routes betwee n hoop and tank on X LT Classic and XLT
Oil tank vent line secured to steering' hoop at approximately this location. Do not pinch vent line!
Torque Regulator nuts 38 -43 in. Ibs.
9/97
2.5 0
MAINTENANCE/TUNE UP Routing Diagram - Oil Vent Line

1996 to Current Indy Class ic Models
Harness secured around ignition switch
Oil vent line cable tied to stee ring hoop at app rox. this location. Do NOT pinch vent line!
2.51
9/96
MAINTENANCEITUNE UP Routing Diagram - Vent Lines 1996 To Current Indy Lite Models
~-- P u s h
y
' - ' <:>
excess
:~,~,:~;:~~
Il------- To fuel tank
Torque 4-6
It. Ibs.
~~
J"---i I
9/97
2.52
MAINTENANCE/TUNE UP Routing Diagram - Vent Lines

1996 All Models Except Indy Lites
To Fuel Tank
Tinnerrnan' '' Clip (3 total)
\
Tlrmerman' v Clip
Steering Hoop
To Oil Tank Vent
Vent line routed around steering post and through vent line loop.
II
Tinnerman' v 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

Tinnerman Cl ip To Fuel Tank
Steering
Hoop
To Oi l Tank Vent
2.55
9196
MAINTENANCE/TUNE UP Routing Dlaqram- Vent Lines

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 Trail/Trail Touring/XLT SP Mode ls
To Fuel Tank
Tinnerman Clip (2)
1"
Steering Hoop
Tinnerman Clip (1 )
To Oil Tank Vent
-,
II
Steering Hoop
2.57
9/96
MA INTENANCEfTUNE UP Routing Diagram - Vent Lines

1997 Indy Sport/Sport Touri ngfTranSport/Super Sport/440 LC/500/500 SKS/500 RMKl500 EFI/ Classic/Classic Touri ngIXLT TouringIXLT LTD Mode ls 1998 Sport / Sport Tou ring / 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 .
(f
Cab le Tie
1
'\
/
9/9 7
2.57a
MAINTENANCEfTUNE UP Routing Diagram - Vent Lines

1998 Ultra/Ultra Touring/GOO XCR1700 XCR /Storm
Tinnerman Clip (3) To Fuel Tank
\ ~.~~
\\
Vent Spring Steering Hoop
/'
/
Cable Tie --Torque nut 4-6 ft. Ibs.
~ '.
8,
r-r: -;------,
--
--
1-
:
\
'\, '., ,; , J /I :\:I, ,--
Q .,p/
Torque nul 4-6 ft. Ibs.
_ _ ~1'J
2 .57b
9/97
MAINTENANCE/TUNE UP
Routing Diagram - Vent Lines 1997 Indy Ultra/Ultra SP Models
To Fuel Tank
Tinnerrnantv Clip
Steering Hoop
Steering post
Oil lank Airbox
9/96
2.58
MAINTENANCEfTUNE UP Routing Diagram - Vent Lines 1998 440 Indy /500 Classic / 500 RMK / Classic Touring / 500 Indy
To Fuel Tank
- : Tinnerman Clip (2)
Vent Line Routing
\
<:::::::.
~~~
To Oil Tank Vent

Steering Hoop / W-@Torque 4-6 It. Ibs .
Coolant Bottle & Hose

--
__... - :
10 ,
~1
Torque nut 4-6 ft. Ibs .
Oil Tank
2.58a
9/97
MAINTENANCEfTUNE UP Ro uting Diagram - Vent Lines

Tinnerman Clip To Fuel Tank
Steering Hoop
To Oil Tank Vent
Tinn erman Clip
9197
2.58b
MAINTENANCEfTUNE UP Routing Diagram - Vent Lines 1998 XLT LTD I XLT SP I XLT Touring I XLT Classic
To Fuel Tank
- : Tinnerman Clip (2)
c::::
~~~
To Oil Tank Vent Steering Hoop
Torque nut 4-6 ft. lbs.
Oil Tank
2.58c
9/97
MAINTENANCEITUNE UP Routing Diagram - Vent Lines 1998 700 RMK 1700 XC 16 00 XC 1600 RMK
Tinne rman Clip (3) To Fuel Tank
\
Vent Spring (2)
-.
Torque 45-50 in. lbs. Steeri ng Hoop
Cable Tie
9/97
2.58d
MAINTENANCE/TUNE UP Routing Diagram - Vent Lines 1998 WideTrak LX
Tinne rma n Clip (4) To F,el Tank
"<.\::c c'n::~iDl..
Vent Spring (3)
~ ~~~
To Oil Tank Vent
Ste"'09 Hoop
/ ---
Torque nut 48-72 in. Ibs. (.55-83 kg-m) Cable Tie
((
)
'\
/
2.58e
9/97
MAINTENANCE/TUNE UP Routing Dlaqrarn- Carburetor Vent Line

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

1996 Indy Trail/Trail Touring
-------
...........
Air Silencer
9/96
2.60
MAINTENANCE/TUNE UP Routing Diagram - Carburetor Vent Line

1996 Indy 500/500 SKS/500 RMKlClass ic/Classic Touring
-=---- ------- -o
Carb
-~
Carb
~ $
I
Air Silencer
Polaris Industries lnc .
2.61
9/96
MAINTENANCEfTUNE UP Routing Diagram Carburetor Vent Line

1997 Indy 440 LC Models
o
QO - --....
Air Intake Silencer
1998 Trail 1 Super Sport 1440 1 Class ic Touring 1 Trail Touring
Carburetor
i
Air Intake Silencer
9/9 7
2.62
MAINTENANCEfTUNE UP Routing Diagram Carburetor Vent Line

1997 Indy 500/500 SKS/500 RMKlClassic Touring Models
Air Silencer
1998 500 Indy I 500 Classic
db T
Air Box
2 .63
9/97
MAINTENANCE/TUNE UP Routing Diagram Carburetor Vent Line

1997 Indy Trailltrail Touring Models
-- ----------
c.,~ ~
Airbox
9196
2.64
MAINTENANCEfTUNE UP Routing Diagram - Carburetor Vent Line 1996Current ACCS Systems
Air Box
4 Way Manifold I Float Bowl Vent Control ACCS4-way Manifo ld mounted to air box 27S
\\
ACCS - - _Valve Vent line attachment to handlebars
9L \\
o
15S
,
3-way Manifold - _ attachment (1996 - _ ACCS Only) 4-way Manifold attachment ACCS Valve
Mag Carb
Vent line attachment to handleba rs 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 sepa ration of systems. See page 5.7a for line connections.
2.65
9/97
MAINTENANCEITUNE UP Routing Diagram Carbureto r Vent Line 1997 Current Indy Trail RMK and 500 RMK Models
Tinnerman Clips
Air Box
- --:...
/ ,=~=.Y
>'
I I
_......-::
./
if"
ACCS Valve
9/97
2.66
MAINTENANCE/TUNE UP Routing Diagram - Miscellaneous

1996 Indy RXL Models
Cable Tie Coolant Hose to Bracket
2.67
9/96

1996 Indy RXL Models 1997 Indy XLT TouringlUltra Touring Models
Small Tabs Up Position (4) Piaces
-:
--------:
1/1 6- Cleara nce - Bottom Tab to Tunnel (4) Places
//
/
;/
_.
9196
2.68

1996 Indy Lite GT Models
?r-_ ~ ~.~
9 ,
Recoil rope over top of wire harness and oi/ line
l ~
Wire harness and oil line cab le tied to bracket stand
Oi/Tank
Oil line toward - - - -f--r--tI outside
/%
Recoil Rope
Wire Harness
2.69
9/96

1996 Indy XLT Touring Models 1997 Indy Class Touring/XLT Touring/Ultra Touring Mod els
Slide hand le grip up to radius
<.; -'\
<,
Switch
!i
II
Connect wiring and tuck behind taillight hou sing so not visible from side
Cab le tie holds wire to tube
Wiring to be sepa rated at bottom one wire per slot
9196
2.70
ENGINES Engine Spec ifications 1996 Models

Machine Model Engine Model
EC342PM02 EC34-2PME02 EC44-3PM01 EC44-3PM02 EC50PM03 EC50PM0 4 EC50PME04 EC45PL06 EC45PL07 EC45PL08 EC50PL11 EC50PLE11 EC50PLE12 EC50PL13 EC50PL14 EC50PL15 EC58PL02 EC58PL03 EC58PLE05 EC58PL07 EC59PL01 EC65PL05 EC68PL01 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 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
Bore Inches
2.4528 2.4528 2_6661 2.6661 2.8346 2.8346 2.8346 2.666 1 2.6870 2.6870 2.8346 2.8346 2.8346 2.8346 2.8346 2.8346 2.5590 2.5590 2.5590 2.5590 2.46 1 2.6661 2.622 2.622 2.8346 2.8346
Stroke 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
Stro ke Inches
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 2.561 2.3622 2.5591 2.559 1 2.559 1 2.559 1
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 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 LitelG T
Indy Ute Deluxe

Indy SportlTra nSporti Sport Touring
Super Sport
Indy WideTrak GT
IndyTrail
Indy Trail Tourlng Indy 440 LC Indy 440 XCA Indy 440 XCA SP Indy 500 Carbl SKS Indy Classic Indy WideTrak LX Indy 500 EFIISKSI AMK Indy Classic Touring Indy 500 Carb AMK Indy 600 XCAlX LT SP Indy XLTISK S
Liq uid
liqui d liqui d
Liquid
liqui d
Liquid
liquid liquid
Liquid
Liqui d
Liquid Liquid Liquid Liquid

Liquid Liquid Liquid Liquid Liquid
IndyXLTTouring
Indy XLT AMK Indy 600 XCA SP Indy AXL Indy Ultra SP, SKS Indy Ultra AMK Indy Storm I AMK Indy StormiSKS
Non-oxygenated. MInimum octane when uSing oxygenated fuel IS89 and ra-jattinq IS required . See page 3.8 for fuel recommendation on 1996 mode ls.
. .
3.1
9/96
ENGINES Eng ine Specification s

1996 Models
Engine Model Cy l. Head CC 's Uninstalled Cyl. Head CC 's Installed 17 .3 23 .0 23.0 28 .6 24. 1 2 1.1 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 22.8 24.4
Piston
Rings
Piston/Cylinder Bore C learance +.05 mm - .00 mm .08-.14 (.003 1-.0055") .09-.14 (.0035-.0055") .09-.14 (.0035-.005 5") .10-.16 (.0039- .0063 ") .10-.16 (.0039-.0063") .09-.14 ( 0035. 005 5") .06 (.0023") .06 (.0023") .09-.125 (.0035 .004 9'1 .09 .125 (.0035-.0049") .06-.095 (.0023- .0037") .09-.125 (.0035 .0049") .06-.095 (.002 3 .0037") .09 .125 (.0035-.0049") .09-.125 (.0035-.0049") .09-.125 (.0035-.0049") .06-.0 95 (.0023-.0037") .12-.170 (.0047-.0066 ") .06-.09 5 (.0023-.0037") .06-.095 (.0023-.0037") .09-.125 (.0035-.0049'1 .09-.125 10035-.0049'1
Engine
Operating RPM 2 0 0 RP M 7000 7000 6800 6500 700 0 7750 82 50 825 0 7800 7800 7000 8000 780 0 7800 85 00 800 0 8500 8000 8200 8200 82 50 825 0
Recommended
Idle RPM
EC34-2PM02lE02 EC44 -3PMOl EC44 -3PM0 2 ECSOPM03 ECSOPM04/E04 EC4SPl06 EC4SP l 07 EC4 5Pl08 ECSOP111 ECSOPlE ll EC50P lE 12 ECSOP113 EC50P114 EC50P115 ECS8Pl02 EC58Pl03/E O S/07 ECS9P lOl EC6SPlOS EC68PlOl EC68 Pl 04 EC80P l 04 EC80Pl OS
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) 1.2 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 (2) 1.2mm (2) 1.2mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm (2) 1.2 mm
1600 1600 1600 1600 1600 1600 1800 220 0 1600 1900 1600 1600 1600 1600 2000 1700 200 0 2200 1800 1800 1600 1600
Piston Ring End Gap (Installed)

Piston ring end gap all engines (except EC80PL 04/05) .20 mm - .51 mm (.008" - .020") Piston ring end gap EC80PL04/05 eng ines .30 mm - .45 mm (.012" - .018")
9/97
3.2
ENG INES En gine Specifications 1997 Models

Machine Mode l Eng ine 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 70 1 701 794 794 794
Bore
MM
62.3 62.3 62.3 67.72 67.72 67. 72 72 72 72 72 67.72
67 .72
Bore Inch es
2.4528 2.4528 2.4528 2.6661 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
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 In ches
2.1889 2.1889 2.1889 2.3622 2.3622 2.3622 2.3622 2.3 622 2.3 622 2.3622 2.3622 2.3622 2.362 2 2.3622 2.3 622 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 2.559 1 2.5591 2.6772 2 .6772 2.55 91 2.559 1 2.55 9 1
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 3 3 3 3 3 3 2 2 3 3 3
Typ e of Coo li ng
Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan
Fuel Oct ane (Min)

87' 87' 87' 87' 87' 87' 87' 87' 87' 87' 87' 87 ' 87' 87' 87'
Indy Ute
EC342 PM02 EC342PM02 EC342PME02 EC443PM02 EC443PM02 EC443P M02 ECSOPM06 ECSOPM04 EC50P M05 EC50PME 04 EC443PM02 EC45PL09 EC45PL08 EC50PL17
EC50PL 17
Indy Lite GT Indy Lite Deluxe
Indy Sport
Indy TranSport
Sport Touring
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
li quid
Liquid
68 .19 72 72 72 72 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
Liquid
Liquid
EC50PL16 EC50P L18 EC50PLE17 EC50PL19 EC50PM03 EC50PLE20 EC58PL 03 EC58 PL03 EC58PL 07 EC58 PLE09 EC58 PL12 EC58 PLE09 EC58PL12 EC58PL08 EC59PLOI EC59PLOI EC65 PL05 EC68PL01 EC68PL01 EC68PL01 EC68PL03 EC68PL03 SN70LCDCSP 01 SN 70LCDCSP02 EC80PL05 EC80PL05 EC80P L04
Liquid
Liquid Liqui d
81'
BT
BT
87 ' 87' 87'
87 "
Indy ClassicTouring
Indy WideTrak GT Indy WideTrak LX
Liquid Fan Liquid Liquid Liquid Liquid Liquid Liquid Liquid

Liquid
Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT Touring Indy XLT SP Indy XLT LTD Indy XLT LTD SP Indy 600 XC Indy 600 XCR Indy 600 XCR (SE) Indy RXL Indy Ultra
Indy Ultra Touring
87'
87' 87' 87' 87' 87' 87' 91 91 87' 87' 87' 87' 91 91 87 ' 87' 91 91 91
Liquid Liquid
Liquid
Liquid Liquid
Indy Ultra SP
Indy Ultra SPX
Indy Ultra SPX SE Indy 700 SKS Indy 700 RMK

Indy Storm
Liquid
Liquid Liquid
Liquid
Indy Storm SE
Indy Storm RMK
Liquid
Non-oxygenated. Use minimum 89 octane when using oxygenated fuel. Polaris Industries Inc. 3 .3
9/97
ENGINES Engine Specifications

1997 Models
Engi ne Mode l Cyl. Head CC's Uni nsta lled Cyl . Head CC's Installed
17.3 23.0 28 .7 24 .1 19.0 21.I 22 _0 23.6 23 .6 23 .6 23 .6
19 .1
Pis ton /Cylind er Bore Clearance +_05 mm - .00 mm

.08- .14 (.0031-.0055") .09. 14 (.0035-.0055") .10-.16 (.0039-.0 063") .10-.16 (.0039-.0 063") .06-.095 (.0023-.0037") .09-.140 (.0035-.0055") .06-.095 (_0023-.00 37") .09-_ 125 (_0035 -.00 49") .09-.125 (.0035 -.00 49") .09-.125 (.0035-.0049") .09-.125 (.0035-.0049") .09-.125 (.0035-.0049") .09-.125 (.0035-.0049") .09-.125 (.0035-.0049" .09-.125 (.0035- .00 49") .09-.125 (_ 0035 -_0049") .07-.095 (_0028-.0037") .12-.170 (_0047 -.0066") .07-.095 (_0028-.0037") .06-.095 (.0023-.0037") .124 (.0048) .124 (.0048) .09-.125 (.0035-.0049") .09-.125 (.0035 -.00 49")
Piston Clearance Service Lim it

.2 (.0078 ) .2 (.0078) .2 (.0078) .2 (.0078) .15 (.00 59 ) .2 (.0078)
Engine Operating RPM 2 0 0 RPM

7000 6800 6600 7000 82 50 77 50 77 50 77 50 7750 7750 7750 82 50 825 0 8500 8250 8500 8500 8000 80 00 8600 8000 8000 84 00 84 00
Recommend ed Idle RPM
EC34 2PM02lE02 EC44-3PM 02 EC50 P M03 EC50PM041E04105 EC45P L08 EC45P L09 EC50PL16 EC50P L17 EC50PL18 EC50P L19 EC50P L20 EC58P L03 EC58PL07 EC58PL08 EC58PL091E09 EC58PL12 EC59P LOI EC65P L05 EC68PLOI EC68PL03 SN70LCDCS P-Ol SN7 0LCDCSP-02 EC80PL 04 EC80PL0 5
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
160 0 1600 1600 1600 1500 1600 1600 1600 1600 1600 160 0 1900 1900 1900 1900 1900 1500 2200 1500 2200 150 0 1500 1600 1600
.2 (.00 78)
.2 (.0078) .2 (.00 78) .2 (.0078) .2 (.0078) .2 (.007 8) .2 (.0078 ) .2 (.0078) .2 (.00 78) .2 (.00 78) .15 (.00 59 ) .2 (.00 78) .15 (.00 59) .15 (.0059) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078)
19.1 17.I
19 .1
17.1 18.0 20.4 20 .5 21.4 32 32 26.0 26.0
Piston Ring End Gap (Installed)

Piston ring end gap all engines (except EC80PL04/05) .20 mm - .51 mm (.008" - .020") Piston ring end gap EC80P L04105 engines .30 mm - .45 mm (.012" - .018")
9197
3.4
ENGINE Torque Specif ications

When tightening bolts . nuts. or screws . a torque pattern sho uld 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, torquing negligence is of the utmost importance. Torque is a force 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 force are the pound or ounce. and the length is the loot o r inch. In the Metric system. the unit of force is expressed in grams (gm) or kilograms (kg), and length as centimeters (em) 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 commo nly expressed in units of kg-m. Multiply foo t 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) 8 mm 17-20ft. lbs, (2.4-2.8 kgm) 10mm 24-26 It. Ibs. (3,3-3,6 kgm)
Cylinder Base Nu ts 24-28 ft. Ibs. (3.3-3 .9 kgm) 24-28 ft. lbs. (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)
Flywheel 60-65 ft. Ibs. (8.3-9.0 kgm ) 60-65 ft. lbs. (8.3-9.0 kgm)
20-2 4 tt.Ibs. (2.8 - 3.3 kgm) 18 - 22 ft. Ibs." (2.3 - 3.04 kgm)
30-34 fUbs (4,15-4,7 kgm) 30-34 fUbs (4.15-4.7 kgm)
20-24 fUbs . (2.8 - 3.3 kgm) 20-24 tt.tbs, 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 torq ue range .. Torque head bolts prior to torqu ing cylinde r base nuts. Apply Loctite ~ 242. All 6m m Crankcase Bolts . . . .. 108 in, Ibs. (1.24 kg-m) All 7/16-14 Engine Mount Strap Bolts . , . , . 44-48 It. Ibs. (6.0-6.63 kg-m)
3.5
9197
ENGINE Torque Patterns
o
o
CYLINDER HEAD - 5 STUD
o
8
CD
CYLINDER HEAD Domestic Twins 600/700
CYLINDER HEAD - 6 STUD
@@00800@@ @000
0 @@@
CYLINDER HEAD - EC58PL
@ @ @
000
80 0 000
CYLINDER HEAD - EC45/50PL
00
G(0
CYLINDER BASE - 600 1700 Twins Note: Torque Head Bolts Prior to torquing cylinder base.
@@
r: \.!Y
f.:\
00 CD 80
r>.
D
o
MAG SIDE
0 0
PTO SIDE
00
@0
@
0
PL TWIN BASE
Cylinder Head - SN44
o (00 0 @ o
@
CRANKCASE - TWIN CYLINDER (Except 600nOO Twins)
f11\ 00CD00~@@
00
@@000
0 @@@ @
CRANKCASE - 3 CYLINDER
0
G)
8 0 0 G
@
3.6
0
@
0
(2)
8 0
0
CD
@@
CD CD
@@
CRANKCASE - 600/700 TWINS
CRANKCASE - SN44-44LCDCSP-01 102
9197
ENG INES Piston/Cylinder Clearan ce Specifications Piston Measurement

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 the 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 chapte r for Target Clearance when re-boring cylinder, or Service Limit specifications (to determine if piston requires replacement. Specifications are listed by engine model number.
.>
---......
0
I 90
0
to pin I
---L
FUJI ENGINES - Measure 1/2" (12.7mm) up from bottom of skirt DOMESTIC ENGINE S - Measure 3/8" (10.0mm) up from bottom ot skirt Ni-Ca-Sil cylinde rs 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 Determin e Metric Displacement To Determine Compressio n Ratio
mm Bore
2 .::::
x itself, or A squared = x pi3.1416= x mm stroke = .;. 1000 = _

dis placemen t
of one cylinder in cc
Compression Ratio == Piston Displacement +

Installed Head Volume -eInstalled Head Volume = : 1 Ratio
3.7
9/97
ENGINES Fue l Recom mendatio n

Oxygenated Fuel
Due to increased emphasis on reducing auto emissions, some areas are required to use oxygenated fuels. Oxygenated fuels are those which include oxyge n in the molecule due to the addition of an ether or alcohol. Polaris engines are designed fo r use with a spec ific fuel octane number. If fuels with a lower octa ne number than that specified are used, the engine may be seve rely damaged . 1997 - current m odels are calibrated for a minimum 87 octane (no lead regular) or 89 octane (oxyge nated) tuel [(R+ M)/2]. Some high pertormance models require a minimum of 91 octane . No change is required to 1997 models provide d the minimum fuel octane requirement is met. Refer to the Specification Decal on the hood, Owner's Safetv 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 octa ne of 89 or higher (R+M)/2 method and jet carbs as outlined in step 2. 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 Specif ication Decal, Owner's Safety and Maintenance Manual, or Engine Chapter in this manual lor minimum octa ne recommendation. 2. When using 89 octane oxygenated fuel on 1996 models, insta ll main jets that are one size larger than that listed on the jetting chart for a given altitude and temperature. Fo r 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 It. and temperatures betwee n -20 and +10F ) is a 340. To use 89 octane oxygenatedfuel, install 350 main jets. 3. Tum the pilot air screws in (clockwise) 3/8 tum from the standard seltin g. Example: if the production air screw set1ing is 1 turn out, the selting for 89 octane oxygenated fuel would be 5/8 turn out. This adjustment may vary according to model and type at fuel. NOTE: The following 1996 Indy Classic charts are provided as an example only. 1996 Indy Classic
AMBIENT TEMPE RATURE
Below -20" F Below 29 "C
-20"
to .10"F
'340
300
2<0
. 10to +4O 'F

12" re +S C
-29 '10 12 ' C
Above +40 "F Aoove .. ~C
87 Octane (Non-Oxygenated)
Altitude Me1ers (Feel)
0-900 (Q-30001
901)-1800
360
320
300
320 260 2'0
(301)>6000)
"0
240 210
260 220
200
1800-2700 (6000-9000)
2700-3700
(9QO().12000j
230
= -Shaded zone should drop Jet Needle one position (raise EClip) Production Settinq
1996 Indy Classic
AMB IENT TEMPER ATURE
Below -20F Below 29"C
0-900 (0-3000 1 20 " 10 +10 'F 29 ' 10 12 "C
+10 "!o+40"F
Above +40 of
12" to .SC
Above ... C S
370 330
290
350 310 270 240
330 290 250 220
3'0 270
230
89 Octane (Oxygenated)
9O().1800
Allllude Meters (Feel )
(3000-6000) 1800.2700 16000-9000) 27003700 (9000- 12000)
250
2'0
= 9/96
Shaded zone should drop Jet Need le one position (raise E-Clip)
3 .8
ENGINES Fuel Recommen dation - EFI Oxygenated Fuel - 1996 EFI Models
The fuel used In the Polar is eng ine is as impo rtant to engi ne life and performance as the lub rica nt used.
CAUTION:
Polar is eng ines a re designed for use w ith a specific fuel octane number. If fue ls wi th a lower octane number than that specified are used , the engine ca n become severely damaged. Be ce rtain the fuel used in the Polaris engine meets or exceeds the req uired mi nim um 87 octane (no lead regular) or 89 octane (oxygenated) fue l [(R+ M)/2]. NOTE : See oxygenated fue l recomm en dation s below fo r 1996 EFI models. 1997 - current EFI models a re calibrated for 89 octane oxygenated fuel or 87 octa ne non -oxygenated fue l, and do not requ ire modifications below 5000 ft. '--' Refe rto the Specifica tion Deca l, Owner's Safety and Mainte nance Manua l. or Engine Specifications in this manu al fo r minimum oct ane recommen dation . Only winte r gaso line should be used in Polaris snow mobiles. The gasoline sold at the pumps and used in the summer is different tha n gasoline sold in the winter. "Summer" fuels used in snowmobiies can cause ha rd starting.
To use 89 octane oxygenated fuel on 1996 EFI models:
1. At altitudes be low 5000 ft., the co mpressio n ratio m ust be reduced by installing .020" head gasket shims
between the cylinder head gasket and cylin de r head . T he pa rt numbers are shown below. No cha nge is req uired if mac hine is ope rated at altit udes above 5000 feet (1500 meters) .
1996 EFI Cylinder Head Shims

Model
Sh im Part Number
1996 500 EFI/SK S/RMK 1996 RXL
(1) 52 114 16
(3) 52 114 14
Fuel System Deicers

If non -oxygen ated fuel is being used , Polaris recommen ds the reg ula r use of Isop ropyl base fue l system de icer (Polaris PN 2870505). Add 1 to 2 ounces per gallon (8-16 mi lliliters per lite r) of gaso line to p reven t engine damage result inq from fue l sys tem icing and lean mix tures. Never use deicers or add itives that contain methanol. Use only isop ropy l fuel sys te m deicers.
If usi ng oxygenated fuel containing etha no l, add itional alcohol deicers or wa te r absorbing add itives are not required an d should not be used. W hen ever servicing the ca rburetor or fuel sys tem , it is important to heed the warnings found on page 5 .1 .
3.9
9196
ENGINES Engine Removal

Engine Removal , Typical
1. Open hood and remove retention cable. Support hood securely.
2. Disconnect battery ground H from battery. Shut off fuel.
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 Repla cem ent

Disassembly
1. Remove recoil handle and allow rope to retract and spring to totally unwind. Remove retainin g 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 spring will remain in the housing.
\. .
.,
2.
3.
Assembly
1.
If the spring was removed, reinstall it by spiraling counterclockw ise towa rd the center.
2 . Lubricate cente r shaft and spring with grease.

Prem ium All Season Grease PN 287 1423 (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, Cant.
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.
Flang e Nut Torque5 ft. Ibs. (.69 kg-m)
Assembly, Ca nt.
9. Pull recoil rope to full extension and align notch on outside edge of reel with housing rope guide hole.
10. Using 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. Pull loop to outside of housing by pulling on rope handle. 13. Allow rope to fully retract and check for normal recoil and ratchet operation.
9/97
3.100
ENGINES Troubles hooting

PROB LEM Will not starV hard start ing PROBABLE CAUS E -Chec k ignition switch for run position. moisture contamination -Check auxi liary shut-oft switch ope ration -Low compression -Out of fueVfuel restriction -No spa rk -Spark plug(s) fouled -Disconnect engine connecto r to elim inate any sho rts that might be in the syste m -If starte r won't work (electric mode ls), chec k wires from starter solenoid and battery or check battery and battery cables
-O pen or broken reed valves
Low compresslon
-Sheared flywheel key -Broken piston skirt -Excessive piston ring end gap -Improper piston clearance -Head gasket faulty -Poor ring sealing, piston damage, cylinder scored -Spark plug touled -Secondary coil faulty or wires disconnec ted -Primary coil sho rted or open -Exciter coil faully -COl faulty -Trigger coil faull y -Ignition switch shorted, contaminated with moisture -Auxiliaryswitch shorted or contaminated with moisture
No spark
Engine idles but -Restricted fuel flow/air flow no accele ration -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 F,ump not operational -Impu se line restricted or plugged -Incorrect track tension -Incorrect main jet -Throttle slides not fully open -Drive chain too tight -Incorrect clutchin g, wo rn clutch components -Exhaust restriction -Excessive driveline friction (HiFax overheating)
-Incorrect air mixture setting Throttle stop sc rew incorrectly adjusted -Pilot jet restricted or plugged -Fuel pump lacks fuel to Impulse line -Air leak at earb adaptor -Incorrect carburetor synchronization -Low compression -Tight belt -Piston damage -Choke plungers not seating properly -Throlfle cable incorrectly adjusted
Engine runs but fails to idle
Engine runs, but ove rloads with fuel
-Chokes are not seating -Fuel pump diaphragm is ruptu red (can be caused by engine backfiring) -Carb uretor slides are not synch ronized -Too large main jet -Needle and seat not seating properly -Incorr ect float level -Poor reed valve condition -Restricted air intake or exhaust outlet
Carburetion and -If a lot of riding is on tra ils, and plugs foul and get black when doing so, verify all tune up adjustments : plug fouling carb sync, oil pump adjustment, pilot screw selli n~, spark plug type and gap, venting for carbs, proper jetting for allitude and temperature, belt tension, c utch operation. If tune up items are correct, check: float leve l, jet needle position, jet needle wear, inlet needle and seat wear, exhaust outlet clear, etc.
3,101
9/96
ENGINES Troubleshooting
PRO BLEM PROBABLE CAUSE
Engine runs but -Coolant level -Incorrect main jet overheats -Incorrect timing -Incorrect spark plug -Water pump belt loose or broke n -Cooling restriction -Air in cooling system (bleed properly) -Inadequate snow for cooling (ice and/or marginal conditions)
Battery will not charge (battery equipped models only )
connections -lnsu ident alternator output -Faulty diodes (rectifier ) -Sulfated battery -Battery electrolyte overiilled or low -Faulty cell in battery -Amp draw with key off -E xcessive load on alternator
-Engine not running -Check wiring harness connecto r - colo r matching -Check for bumed out bulbs -Check wiring for shorts or loose connections -Disconnect taillight wiring harness - if headlight works, short is in taillight wiring or taillight
-Fau'm
Lights don't
work
Unit fails to prope l ilself
-Check belt (center distance) -Check clutch -Check chain -Check drive sprockel assem bly -Track frozen or stuck -Check tune up items
-C heck ten sion
Track wea rs unevenly
-Check for rcroper alignment -Check for oose, bent, or broken suspension part s -Riding in marginal or no snow conditions -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 spin dle bushings -Check steering post bushings -Check carbide skags -Front limiter strap too short (if steering is heavy) -Torsion springs set too heavy
Chaincase gets hot
Unit hard to steer (heavy steering)
91 96
3.1 02
ENGINES Engine Remova l

Engine Remova l, Typical-Cant.
5. Free recoil rope from chassis.
6.
Loosen clamps at carb ureto r mou nting flange . Pull carbs from adaptors and secure out of the way. Note routing of all cab les and hoses fo r reassembly.
7.
Disconnect oil pump control cable .
8.
Disconnect and plug oil supply line. A spa re wate r trap plug can be used to plug the oil line from the oil reservoi r,
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, drain coolant into suitable container.
12. Disconnect coolant supply hoses. (liquid models)
9/96
3.12
ENGINES Engine Removal Engine Removal, Typical-Cant.

13. Disconnect electrical connectio ns from stator and starter motor (where applicable).
14. Remove 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 connected to engine, set engine on rubber mounts and loosely install mounting bolls and nuts.
3.
Install drive clutch and check clutch otfseUalignmenl. See page 6.44. Adjust torque stop (where applicable) to .100" (2.5mm).
4. Tighten engine mounting bolls to specification.
Engine Mounting Bolt TorqueFront - 28 Ft Ibs (6.67 kgm) Rear - 28 Ft Ibs (6.67 kgm)
9/96
3 .14
EN GINES Engine Installation 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 stead ily. 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 clamp s. Make sure hoses and cables are routed correctly.
8.
Install airbox.
3.1 5
9/96
ENGINES Engine Installation

Engine Installation , Typical-Cont.
9. Secure fuel pump and COl 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 Ins ta llation , Typical-Cont .
13. Install exhaust disassembly. system in reverse order of
14. Secure hood cable .
15. Remove any coolant bleed screws or radiator caps and fill coola nt syste m 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. (Bleed cooling system on liquid models .)
9/96
3.18
Polaris industries Inc.
ENGINES Fan Cooled Twin Cylinder

Engine Disassembly
The photo at right shows a complete twin cylinder engine.
1. Remove carburetors . 2. 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
9/96

Engine Disassembly, Cant.
5. Note position of shroud retainer mounts on cylinder 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
3.20
ENGINES Fan Cooled Twin Cylinder Engine Disassembly, Cont.

9. Using flywheel puller, remove flywheel.
Flywheel Pufler
PN 2871043
10. Mark stator plate and crankcase to reassembly. Remove stator plate.
ease
11 . Remove two bolts securing inner and upper shroud. Remove upper shroud.
12. Loosen and remove all bolts securing cylinder heads to cylinder. Remove heads.
3.21
9/96
ENGINES
Fan Cooled Twin Cylinde r

Engine Disassembly, Cont.
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

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

1. Clean all engine components thoroughly in a solvent tank. Remove all filings. excess sealer. and dust. Blow dry with compressed air.
2.
Apply 3-BondT" sealer to top half of crankcase and lubricate labyrinth seal and oil pump drive gear.
3Bond "" 1215 PN 2871557 120 Gram Tube
3.
Lightly grease seals and install on crankshaft on crankshaft with lip (spring) facing inward toward crankshaft. Place crankshaft in upper crankcase half. Make sure seal and PTO bearing retaine r fit properly into grooves.
4.
Install bottom crankcase half 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

6.
(~) on piston facing flywheel. Install C-clips securely in piston groove.
Lubricate rings and pistons with two stroke oil. Install rings with letter mark or beveled side facing upward. Install base gasket with adhesive strip facing up.
7.
9/96
3.24
ENGINES Fan Coo led Twi n Cy li nder

Eng ine Assemb ly, Co n t. 8. Lubricate cylinder with two stroke oil and install onto piston whi le compress ing 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 du ring assembly.
Piston Support Block PN 2870390
9.
Torque cy linder base bolts to specificatio n.
Cylinder Base Bolt Torque
24-28 Ft 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

spec ification. NOTE: Make sure th readed head nuts are in the prope r position for shroud mountin g. See "x" in photo at right.
Head Bolt Torque-
1918 Ft Ibs (2.3-2.65 kgm)
3 .25
9/96
ENGINES
Fan Cooled Twin Cylinder

Engine Assemb ly, Cont.
12. Install inner fan shroud. CAUTION:
Do not tighte n bolts until outer shroud is bolted in place. Outer shroud must dete rmine placeme nt of inner shroud, or damage may result.
13. Install stator plate aligning ignition timing mark as seen during disassemb ly. Tighten stator mounting bolts securely.
14 . Make sure key is on crankshaft and install flywheel aligning keyway. 15. Install flywhee l nut and torque to specification.
Flywheel Nut Torque-
60-65 Ft Ibs (8.3 -9.0 kgm)
9/96
3.26

Engine Assembly, Cant.
16. Install recoil starter hub and recoil housing. NOTE: Tighten two inner shroud bolts.
Recoil Hub Bo lt Torque:
8-10 It. Ibs. (1.11 - 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 Liqu id Twin Cylinder

Disassembly
The photo at right shows a complete liquid twin cylinder engine.
1.
Remove carburetors or throttle bodies.
2. 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
11111
PN 2871043
9/96
3.28
ENGINES
Liq uid Tw in Cylinder Disassembly, Cant.
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
9/96
ENGINES
Liquid Twin Cylinder Disassembly, Cont.
9. Remove head gasket. Note position of head gasket inlet and outlet hole sizes for reference during reassembly.
10. Remove cylinder.
11 . Remove C-clip retainer clips from piston as shown.
12. Using piston pin puller. remove piston pin from piston as shown.
Pis ton Pin Puller

PN 2870386
9196
3.30
ENGINES Liqu id Twin Cylinde r

Disa ssembly, 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 .3 1
9/96
ENGINES Liquid Twin Cylinder

Assemb ly 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 proper groove. 3. Apply 3-Bond T" sealant to crankcase halves. 3-Bond 1215 120 Gram Tube
T"
PN 2871557
4. Torque crankcase following torquing 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 Al
toward
6. Install C-c1ip using installation tool PN 2870773. 7. 8. Install base gasket. Lubricate rings and pistons with two stroke oil. Install rings with letter mark or beveled side facing upward. See page 3.87.
9/96
3.32
EN GINES 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 front-to-back rocking motion, being careful not to damage rings. Install cylinder base nuts and tighten to 24-28 ft. Ibs. (3.3-3.9 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 right.
3.33
9/96
ENGINES Liqu id Twin Cylinder Assembly, Cent.

14. Connect oil feed lines to cylinder. 15. Align stator as previously marked on stator plate and secure with screws.
16. Install flywheel and torque flywheel specifications .
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 I
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.
9196
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.
Polaris Ind ustries Inc.
3.35
9/96
ENGINES Three Cylinder Monob lock

Disassembly, Cont.
5. Remove water pump.
6. Remove flywheel retaining nut. Position flywheel 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
ENG INES Three Cy linder Monoblock Disassembly, Cont.

'--' 8. 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 a -rings in head cover. Also note the quantity and location of shim washers located beneath the a -rings.
3.37
9/96
ENGINES Three Cylinder Monob lock

Disassembly, Cont.
12. Remove cylinder heads. Mark PTO, Center. and Mag head to ensure correct reassembly. Shim
-Ring
13. Remove cylinder and base gasket. 14. Refert o cylinder inspection procedure on page 3.86 to inspect cylinder.
CAUT ION:
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

Disassembly, Cont.
16. Remove piston pins using piston pin puller and adaptor as shown. Refer to pages 3.79 through 3.90 for general inspection procedures.
Piston Pin Puller PN 2870386 Adapter PN 5130971
'"I
17. Remove all crankcase bolts.
18. Separate crankcase halves and remove crankshaft. 19. Follow procedure 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 ot upper and lower crankcase for damage.
9/96
3.40
ENGINES T hree Cylinder Mo nob lock

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 120 Gram Tube
T.
PN 2871557
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 PTO bearing. These models can be identified by the PTO oil check valve and wider housing. Make sure the crankshaft and crankcase male properly. 4. Install bottom crankcase half. Make sure anti-rotation pins are aligned properly and torque bolts to specification.
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-c1ips 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
9/9 6

Assembly, Cont.
8. Before installing cylinder, refer to honing procedure on pages 3.79-3.80 of this section. Inspect piston to cylinder clearance and piston ring installed gap as shown on page 3.87 . 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, moving 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
ENGINES Th ree Cyli nder Monobl ock Assembly, Ca nt.

12. Replace outer O-ring on cover.
13. Apply Loctite 515 to cover as show n. 14. Position shim and O-Ring as shown.
Cover
15. Install head cover. 16. Install and torque head cove r mounting bolts to specification.
Head Cove r Mounting Bo lt Torque 17-20 Ft Ibs (2.4-2.8 kgm)
17. Install stator in the previously marked position and tighte n screws 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 mountin g bolts.
"
Wate r Pump BeltTension
1/8" - 3/16"
(3-4m m)
3.43
9/96
ENGINES Three Cylind er Monob lock

Assembly, c ent.
20. Install oil pump and connect feed lines to rubber mount. If crankcase, oil pump, or drive compo nents 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 carburetors to rubber mounts.
9/96
3 .44
ENGINES
RXL
Disassemb ly
1. Remove water pump cover.
2. Markcylinders #1 mag side, #2 center, #3 PTO side. 3. Remove inlet water manifold.
4. Remove oil pump lines and secondary coils.

. ' -
5. Remove oil pump and drive gear. 6. Remove water pump.
1I '"" l '(?
" .
-.
;0 . . ";. ~~ ..t
I-
, (,
'.. "
1-."'."
.
. <
J .
, .
. ~l ~l.l:~ " ~
"fa ~~ ~~i Pli~t>!~~:'. . T~
oj . '.
'"
_1 ,r:TJ~lf~~~ji ~ . 4 '," I ' _. ~ - . ' '''

c ."
SECONDARY COILS .OIL PUMP AND LINES
' .
1.
":" 1Ii
- ~ .s. ~ . -ry~ ~ - , ~
"-::~ - 1\ t'
3.45
9/96
ENGINES
RXL
Disassembly, Ca nt.
7. Remove outlet manifold. 8. Remove heads either as a unit or individually.
9. Remove recoil starter cup and flywheel nut. 10. Using flywheel puller, remove flywheel.
Flywheel Puller PN 2871043
11. Mark stator plate and case.
Remove attaching
screws.
12. Mark cylinders' mag, center, PTO.
9/96
3.46
ENGINES
RXL
Disassembly, Con t.
13. Remove piston C-clips as shown.
14. Using piston pin puller, remove piston pin and mark pistons mag, center and PTO. Referto pages 3.863.87 for cylinder and piston inspection . Refer to pages 3.79 - 3.80 for cylinder honing information.
15. Remove seal plate 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. Remove old crankcase sealer from case halves. 2. Grease mag end seal lip, oil pump drive gear, and labyrinth seal area. 3. Make sure all bearing anti-rotation pins are aligned with reliefs in crankcase.
4. Apply 3Bondsealer to the bottom crankcase half. 3-Bond '" 1215 PN 2871557 120 Gram Tube
5. Torquecrankcase bolts as shown. Refer to torquing 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. Lubricate crankshaft bearings through access holes in the case. 9. 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 procedure 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. Carefully install the cylinder.
12. Install new head gasket with large diameter side of fire ring toward cylinder.
13. Install cylinder 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 1998 Engine Specifications

1998 Models
Machine Model Engine Model Cyl. Disp. CC's
339 432 432 432 432 432 438 488 488 488 488 488 488 488 488 488 597 597 597 59 7 593 593 598
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 74 .5 62.51 66 .6 66 .6 81 81 66.6 72
Bore Inches
2.4528 2.666 1 2 .666 1 2.666 1 2.66 6 1 2.666 1 2.598 4 2.83 46 2.83 46 2.8346 2.6661 2.83 46 2.8346 2.8346 2.8346 2.8346 2.5590 2.5590 2.5590 2 .5590 2.933 1 2 .933 1 2.46 10 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 2.36 22 2.36 22 2.3622 2.3622 2.3622 2.5 197 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 2.5 59 1 2.5591 2.5591 2.6772 2.6 772 2.5591 2.5591
No. 01 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 01 Cooling
Fan Fan Fa n Fa n Fa n
Liquid Liquid
Fuel Octane (Min)

87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87 ' 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 91 87" 87" 87" 87" 91 91
Indy Lite I 01, I Tr9 Indy Sport

Indy TranSport
EC34-2PM02A EC44-3P M024 EC44 3PM024 EC44- 3PM024 EC443PM024 EC45P l 091 SN44-44lCOCS P -01 EC50PM043 EC50PM043 EC50PM051 EC50PM061 EC50P l201 EC50P l 171 EC50P 1171 EC50P l1 61 EC50P 1191 EC58P l1 30 EC58P 1130 EC58P 11 40 EC58P 11 50 S N60-70LCOCS P -0 1 S N60-70l COCSP -02 EC59P L020 EC68P l 050 EC68Pl 050 SN70 70lCOCSP 02 S N7070lCOCS P -0 1 EC68 Pl060 EC8 0P l 052
Sport Touring
Indy XCF Indy 440 l C Indy 440 XCR

Indy Trail Indy Trail Touring
Fa n Fa n Fan Fan
Liquid Liquid Liquid
Indy Trail RMK

Super Sport Indy WideTrak LX
Indy 500
Indy Classic
Indy 500 RMK

Indy Classic Trg
Liquid
Liquid
Indy XLT lTD

Indy XLT Touring
Liquid Liquid Liquid

Indy XlT S P
Indy XLT Classic
Indy 600 XC Indy 600 RMK Indy 600 XCR

Indy Ultra Indy Ultra Touring
679
679 701 70 1 679 794
Liquid
Liquid
Indy 700 XC Indy 700 RMK Indy 700 XCR

Jndy Storm
Non-oxygenated. Use minimum 89 octane when uslnq oxygenated fuel.
3.4a
9/97
ENGINES Engine Specifications 1998 Models

En g ine Mo de l C y l. Head CC 's Un insta iled (Be n c h ) C y l. Head CC 's In s t a ile d P iston/Cyl ind er Bore C learance (Ta r g et) + .0 5 mm - .OO m m .08. 14 (.00 31 .0055-) .09-.14 (.0035-.0 055-) .09-.13 (.0035.0051") .09. 14 (.0035-.00 551 .10-.16 (.0039-.00631 .10-.16 (.0039-.0063") .10-.16 (.0039 .0063") .06-.095 (.0023 -.0037") .09-.125 (.0035-.004 9- ) .06-.095 (.0023-.0037") .06-.095 (.0023-.0037") .09. 125 (.0035-.004 9-) .09. 125 (.0035-.0 049") .09-.125 (.003 5-.0049") .07-.095 (.0028-.0037") .07-.105 (.0028-.004 1") .06-.095 (.0023-.0037") .11-. 15 (.0043-.0059- ) .11-.15 (.00 43-.00 59") 32 32 26 .0 .11-.135 (.00 43- .0053") .11-.135 (.00 43 .00 53") .09-.125 (.0035'.0049-)
Piston Clearance Service

Lim it mm (i n c h) .2 (.0078) .2 (.0078) .19 (.0075) .2 (.007 8) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.0078) .2 (.007 8) .2 (.0078) .2(.0078) .2(.0078) .2 (.0078) .2 (.0078) .15 (.0059) .15 (.0059) .15 (.0059) .2 (.00 78) .2 (.00 78) .2 (.0078) .2 (.00 78) .2 (.00 78)
Engin e Operating RPM 2 0 0 RPM 7000 6800 8250 77 50 7000 7000 7000 77 50 77 50 77 50 7750 8250 85 00 8500 85 00 80 00 8600 800 0 8000 80 00 8000 8400
Recomm end ed Id le RPM
EC34- 2P M02A EC44 3PM024 SN44-44 LCDCS POl EC45PL091 ECSOPM043 EC50PM051 EC50PM061 EC50P L161 EC50P L1 71 EC50PL1 91 EC50PL201 EC58PL1 30 EC58PL140 EC58 PL1 50 EC5 9PL020 EC68PL 050 EC68PL060 S N60-70 LCDCS P-Ol SN60 -70LCDCS P-0 1 SN70-70LCDCSP-Ol S N70-70 LCDCS P -02 EC80 PL052
21.1 28 .6 19.6 25.8 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 18.3 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
Pisto n Ring End Gap (Inst all ed)

P is to n ring end gap (all eng ines e xcep t E C 8 0 PL0 4 / 0 5 ) .2 0 m m - .51 mm (.008" - .0 2 0 ') P is to n ring e nd gap E C80PL e n gi nes .3 0 mm - .45 m m (.0 1 2 " - .0 1 8")
9/97
3.4b
Polaris Industries In c .
ENGINES
RXL
Assembly, Cont. 14. Install exhaust manifold gaskets and water manifold. Torque nuts to specification. Use caution when torquing nuts to avoid gasket damage.
Exhaust Manifold Nut 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 -
1/8 - 3/16"(.3 -.4 em)
9/96
3 .50
ENGINES
RXL
Assembly, Ca nt.
'--' 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 (6) 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
9/96
Water Pump Disassembl y/I nspection , 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 cove r 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. Install new mechanical seal using seal installation tool kit PN 5 131135 and parts hardware shown below.
I:::
Seal Install ation Tool PN 5131135
r--/.. PN 75 15554 -,
3/8 x 3 1/4" bolt
Install Bearing First

,..,.~;>,.,
'.~.
-,*~
~~~r Seal Installation
,JQI'~9@'
4 .JY
IQ~~)lJ,J: ~/8" nut

Q
/(
Tool PN 5 131135
PN 754/240 1
3/8" was'~h;;:e~ rs;--------=::::':'-u o PN 7555815 -'"-
9197
3.54
W ater Pump Di sas se mbly/ In s p ecti on Cont. 8. Install impe ller, apply Loctite 242 to bolt and torque to 72 in. Ibs. (.83 kg-m). Install impeller cover with new gasket and torque bolts to 72 in. Ibs. (.83 kg-m).
Water,Pump Gearcase Lubricant: (96 only) Approximately 50cc' Po laris All Season OW40 Synthetic PN 2871281 'Fill to top of sight glass with engine installed. Note: 97 models - do not add lubricant to th e waterpu mp gea rcase .
9.
10. Apply 3-Bond 1215 or Loctite 518 to sealing surfaces and install gearcase cover. Torque bolts to 72 in. lbs (.83 kg-m).
1996 Models Remove filler plug to add oil
1996 Models Oil level should be at top of sight glass
() ()
CJ
3 .55
9/96
Disassembly, Cont.
1. 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
ENGINES EC59PUEC68P L
Disassembly, Can t.
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 cylinder heads, cylinder base nuts, and cylinders . Mark cylinders mag, center, PTa for reference. Replace a-rings and base gaskets. Install new base gaskets with sealant toward the cylinder.
NOTE: Refer to pages 3.79-3.90 for general inspection procedures.
7. Identify pistons mag, center, and PTa . The arrow must point to Mag end of engine upon reassembly.
Cylinder Head Marking (EC68PL Engines) EC68PLOl EC68PL04
"C" Marked On Head "G " Marked On Head
8. Remove piston C-clips.
3 .57
9/96
ENGINES EC59PUEC68P L
Disassembly, Cont.
9. Remove pistons using piston pin puller.
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.
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.
9196
3 .58
Assembly 1. 2. Replace cranks haft end seals. Clean crankcase surfaces and apply a thin even layer of s- Bondt 1215 sea ler to both halves.
3-Bond
1215 120 Gram Tube
PN 2871557
3. "--'
Align crankshaft bearing anti-rotation pins with relief in botto m case half.
4. Torque crankcase bolts to speci fication following pattern on page 3.6.
Crankcase Mounting Bolt Torque:
smm - 18 ft. Ibs. (2.48 kgm) 10mm - 26 It. Ibs. (3.59 kgm)
5. 6. 7. 8. 9. Measure piston to cylinder clearance and piston ring installed gap before cylinder instal lation . Install pisto ns 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 3.87. Lubricate all top end compo nents with Polaris Prem ium 2 Cyc le Lubricant during assemb ly. Install cylinde r heads with new O-rings and arrows point ing to intake. Install wate r pump on crankcase .
Water Pump Bolt Torque: 8-10 ft.lbs. (1.11-1.38 kgm)
10. Alig n mark on stato r plate with crankcase projec tion . Apply t.octitet 242 to stato r plate screws and tighten securely. 11 . Apply Loctite' M242 to flywheel nut th reads. Torque nut to 60-65 It. Ibs. (8.30 - 8.99 kg-m). 12. Install recoil hub and torque bolts to 810 ft . lbs. (1.11 -1.38 kg -m) . 13. Install oil pump and torq ue screws to 4-6 ft . Ibs. (.55 - .83 kg-m). 14. Bleed oil pump and cooling system as outlined in Maintenance sect ion after engi ne installa tion. 15. Fill and bleed cooling system as outlined on page 3.91. 16. Inspect ignition timing.
3. 59
9/97
ENGINES 700 Case Reed

Disassembly
1.
Remove oil pump.
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 if width is less than .25" (6.35mm). Nom ina l new wid th is .345" (8.75mm). Refer to engine assembly for installation
Lips.
Replace if width is less than .25" (6.35mm)
9197
3.60
ENGINES
700 Case Reed Disassembly, Cant.
4. 5. Remove drive gears and belt. Remove flywheel nut using flywheel holder.
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

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 pump cover bolts.
9196
3.62

Disassembly, Cont.
13. Remove impeller retaining nut. washer, impelle r, and 1Ox14mm 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. tnstall seal guide over end of shaft and apply a light film of grease to seal guide. Caref ully install shaft and bearings in cover. Assembl e 10x1 4mm 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

Disassembly, Cont.
16. Remove reed cover, reed stuffers, 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 fo r illustration
18. Remove cylinder head. Note condition and placement of both cylinder head a-rings. Refer to pages 3.80-3.85 for general inspection procedures.
19. Loosen cylinder base nuts and remove cylinders.
9/96
3.64
ENGINES 70 0 Case Reed Disassembly, Cont.

20. Carefully remove 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
I ~l~
22. Remove water manifold by removing both retainer brackets.
23. Remove bottom crankcase bolts and separate crankcase halves.
3.65
9/97

Disassembly, Ce nt.
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

Assembl y
1. Clean all parts with solvent.
2. 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.
3-Bo nd 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
ENGINES
700 Case Reed Assembly, Cant.
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 mm (4.76-4.88") from crankshaft parting line.
6.
7.
Install crankcase halves together. Torque bottom crankcase bolt to specification in the proper sequence . Crankcase Mounting Bolt Torque: 8mm - 18 ft. Ibs. (2.48 kgm) 10mm - 26 fl. Ibs. (3.59 kgm)
8.
Install new O-rings on water manifold. O-rings and install manifold.
Grease
9. Install pistons and rings. Make sure C-elips are firmly seated in grooves. NOTE: Keystone ring bevel must be up. Marking near ring end gap faces upward. Straight Edge
~
Piston Ring Cutaway Keysto ne Piston Ring
9/96
3 .68
ENGINES 600 I 700 Case Reed

Assembly, Cent.
10. Lubricate pistons. rings, upper rod bearing. and cylinders with two stroke oil and install cylinde rs. 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 17 00 Cylinder Head
13 . Torque cylinder base nuts in proper sequence.
Cylinder Base Nut Torque 3034 Ft Ibs (4.15 - 4.70 kgm)
600 1 700 Cylinder Base
3.69
9197
ENGINES
700 Case Reed 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. lighten water pump to engine hose clamp and torque bolts to specification.
IgnitionlWater Pump Housing Torque

22 Ft. Ibs (3.04kgm)
17. Align timing marks and install stator.
9/96
3.70
ENGINES 700 Case Reed Assembly, Ca nt.

18. Apply Loctite ,. 262 evenly to flywheel taper. Install flywheel key and flywheel. Apply Loctite '" 242 to crankshaft threads. Torque nut to specification. Flywheel Nut Torque 60-65 fl. Ibs. (8.28-8.97 kg-m)
19. Install water pump belt and recoil hub.
Recoil Hub Bo lt 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 of hub and onto flywheel as shown
\
II
Water Pump Belt Width Service Limit 1/4" (6.35 mm) Min imum Wid th
Do not apply tape to face of hub.
21. Install recoil cover and oil pump. Make sure 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.
3.7 1
9/97
ENGINES 800 Case Reed Disassembly

1. Remove carburetors, 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.
Flywheel Holder" PN 8700229
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
800 Case Reed Disassembly, Cont.
4. Mark stator plate at case parting line and remove plate.
5.
Remove remainder of head nuts and cylinder base nuts.
6. Carefully remove cylinders . Measure piston to cylinder clearance and piston ring installed gap. Refer to pages 3.80-3.85 for general inspection procedures.
7.
Remove C-clip retainers.
8.
Use piston pin puller to remove piston pins.
3.73
9/96

Disassembly, Cant.
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
ENGINES
800 Case Reed Assembly
1. Grease oil pump drive gear and labyrinth seal area.
2. Grease end seals and oil pump drive gear.
3.
Position anti-rotatio n pins with relief in case.
4. Apply a lightfilm of 3 Bendt 1215 to crankcase and reassemble halves.

,;;'Ii
3.Bond
1215 120 Gram Tube
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 Mounting Bolt Torque : 8mm 18 fl. Ibs. (2.48 kgm) 1Omm 26 fl. Ibs. (3.59 kgm)
i'
6. Install piston pin bearings. 7. 8. Install piston with arrow

(~)
toward flywheel.
Install C-clip retainers using tool. NOTE: The C-clip opening should be in the up or down position.
i!1I
CClip Retainer Installation Tool

'i:.
PN 2870773
9.
Lightly oil rings and cylinder. NOTE : Keystone ring bevel must be up. Marking near ring end gap faces upward. Straight Edge
l?2...
----=::::
Piston Ring Cutaway Keystone Piston Ring
10. Carefully compress rings and install cylinder over piston. Torque cylinder base nuts to specification.
Cylinder Base Nut Torque: 28 fl. 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.
Tab Aligned With Notch In Head ~ And Over Left / "UP" T~ Exhaust Stud
C'?'o"it0
~~
Head Gasket Thickness .8mm
1'1-~~ ~<~ /
~ ~ W.%<.
~haust
Side
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 13 mm Mag
'"
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 jf damaged. Check each fiber reed for white stress marks or missing material. Replace if necessary.
Reed Pedal Clearance .0 15" (.38 mm) max.
Exaggerated for illustration
Reed Air Gap - Maximum .015" (.4 mm)
14. Install reed cages.
3.77
9/96

Assembly. ConI. 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.
See
19. Position stator plate at previously marked position and secure in place.
20. Torque flywheel nut to specification. Install new O-ring on water pump and grease lightly. Install pump, recoil cup, and beit.
Flywheel Nut Torque:
65 ft. Ibs. (8.97 kgm)
21. Adjust tension on water pump belt by loosening mounting bolts, applying tension, and re-tightening bolts. Install recoil housing and belt guard.
Water Pump Belt Deflection
1/83/16"(.3 .4 cm)
9/96
3.78
EN GINES 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 attem pt to reverse the reeds to reduce the air ga p. Alway s replace them if damaged. Check each fiber reed fo r whi te stress marks or missing material. Rep lace if necessary. Reed Pedal Clea rance .015" (.38 mm) max . Exagge rated for illust ration
V.E.S. Removal
2. 3. Pull back cover retainer clip while holding the cover in place . Remove cover and return sp ring . 2. Slide Clip Down
1. Hold Cover
4.
If the spring stays in the cover, hold the cover with spring facing toward you . Rotate spring in a counterclockwise direction wh ile pulling outward on the spring. Do not distort the spring upon remova l.
Retainer C~ Cover Rotate to remove
CAUTION: Do not attempt to remove the plastic va lve pisto n at this time. T he bellows must first be removed from the piston or damage may occ ur to the bellows or piston.
trorn OW"
~ '~ ~
~~
~~
f\
5. 6.
Remove two (5mm) hex screws from valve housi ng. Note location of "TOP" marks on housing and exha ust valve . Lift entire va lve assembly from cyli nder along with gasket. Align TOP ma rks
"
UP
NOTE: Refer to Maintenance Chapter page 2.28a - 2.28e for cleaning and inspection procedure.
<
3.78a
A~
a -ring
Housing Bolts : App l Loctite ~ 242(blue) Torque: 108 in. Ibs. (1.24 kg-m)
9197
ENGINES SN44 Case Reed

Disassembly, Cent.
7. Remove cylinde r head cover and inspect Q-rings (A. B) and sealing surfaces for damage.
8.
Remove cylinder head and inspect all Q-ring sealing surfaces and grooves for damage or debris. Use new Q-rings upon reassembly. Remove cylinder base nuts. Niote location of acorn nuts on exhaust side (where applicable). and connecting rods to prevent piston damage. Refer to pages 3.80-3.8 5 for general inspection procedures.
9.
10 . Carefully remove cylinders while supporting pistons
11. Remove outer piston pin Cvclips 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.
9/9 7
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 puller.
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
91 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 caref ul 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.
3. Lubricate and insta ll washer on pump shaft (water pump end). Install shaft with washe r through bushing and oil seal from the oil pump side of case. Be sure spring stays in position on seal lip. 4. 5. 6. Install remaining washer on shaft . Lubricate and install rear bushi ng with new D -ring until seated against shaft. Install oil pump, being carefu l to engage pump shaft in drive shaft.
Oil Pump Mounting Screw Torque: 60 in. Ibs. (.70 kq-m)
3 .78 e
9/97

Asse mbly, Cont.
7. Install mechanical seal guide (specia l tool) on end of pump shaft. Mechanical Seal Guide Too l: 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 10.3x1 4x1mm /
10 It.lbs.
~f1M kg ml
Mechanical Seal Washer .325x.75x.063"
9.
Lubricate all crankshaft bearings with Premium 2-Cycie 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 with grooves in case. 13. Apply a thin coating of 3-Bond 121 5 sealant to lower crankcase mating surface. 14. Install upper crankcase on lower cra nkcase. 15. Apply Loctite 242 to threads of bolts and install. Torque bolls 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
CV
G) G)
G)
9/9 7
@@ @@
CRANKCASE - SN44-44LCDCSP-01 /02
3.78f
ENGINES SN44 Case Reed Assembly, Cont.

"--' 16. Assemble engine mount straps to crankcase.
Eng ine 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 thoroug hly. 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 22-25 for other cylinder.
CAUTION: I
Straight Edge- l
'1e2;~"'i ............... i:~=======~

Piston Ring Cutaway Keystone Piston Ring
Do not twist or force cylinder during installation. 26. Install new cylinder head O-rings and install cylinder head. Make sure O-rings are properly seated in grooves. Apply a light film of grease to hold O-rings in place if necessary.
3 .789
9/97

27. Install new cylinder head cover O-rings and install cylinder head cover. Make sure O-rings are properly seated in grooves. Apply a iight l iim of grease to hoid O-rings in place il necessary. 28. Loctite 242 to threads 01 head bolts and install. NOTE: Torque cylinder head baits prior to torquing cyiinder base nuts.
29. Torque head bolts in proper sequence.
Head Bolt Torque : 2024 Ft Ibs (2.77 3.3 kgm)
!I
'l
G) G) @ 8
0
0
@
0 0
Cylinder Head
30. Torque cylinder base nuts in proper sequence.
Cylinder Base Nut Torque: 30 - 34 'Ft Ibs (4.15 - 4.70 kgm)

"
'I'
Cyl inder Base
31. install washers and water pump impeller as shown and torque nut to 10 It. Ibs. (1.38 kg-m).
Washer 10.3x14x1 mm /
Impeller Nut Torque: 10 Ft Ibs (1 .38 kgm)
(f-~f~
Mechanical Seal
.. m
10 ft.lbs. (1.38 kg-m)
Washer .325x.75x.063"
9/97
3.78h

Assembly, Cent.
32. Install water pump cover with new gasket.
Water Pump Cover Boll Torque: 9 FI Ibs (1.25 kgm)
33. Install new exhaust manifold gaskets and manifold.
Exhausl Manifold Bo ll Torque: 16 Fllbs (2.21 kgm)
34. Assemble V.E.S. valve as outlined Maintenance section page 2.28a-e.
in
35. Install reed valves, stutters. and carburetor adaptors. Place stato r 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 sealant. Install and tighten stator screws to specification. 37. Measure trigger (pulse) coil gap and compa re to specification. Slalor Screw Torque 60 in. Ibs . (.69 kg-m)
Trigger (Pulse) Coil Gap Min imum: Maximum: .020" (.5mm ) .040" (1.0mm )
3.78i
9/97

38. Apply Loctite" 262 evenly to the flywheel mounting taper on crankshaft. Install wood ruff 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 kq-rn) PN 8700229
41. Install recoil hub and recoil housing. Torque bolts to specification. Reco il Hub and Housing Bolt Torque: 108 in. Ibs. (1.25 kgm)
42. Install engine in chassis and align clutches. 43. Refer to Maintenance Chapter to fill and bleed cooling system and oil pump.
9/97
3.78j
ENGINES General Inspection Procedures Cylinder Honing

The cylinder bore must be de-g lazed whenever new piston rings are installed". A light honing with fine stones removes only a very small amount of material. A proper crosshatch pattem 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 ove rheating of the rings due to blow-by and reduced contact with the cylinder wall. Service life of the pistons and rings will 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 compan ies as Sunnen Products Company of St. Louis, Missouri; and Ammco Tools, Inc., of North Chicago, Illinois. Shown at right is the Ammco No. 3950 hone. Th is 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 excess ive, it will be necessary to oversize the cylinder using a new oversize piston and rings. Th is 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 specifications befo re honing. Complete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clea rance. See procedure on page 3.80.
--
- - 9/96
EXAMPLE OF CROSS HATCH PATTERN
3 .79
ENGINES General Inspection Procedures Honing Procedure

1. Wash cylinde r with 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 cylinde r walls (DO NOT OVERTIGHTEN). Cylinders may be wet or dry honed depending on the hone manufacturer's recommendat ions. 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 atthe 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 whenev er 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 wate r. 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.
9/96
3 .80
ENGINES General Inspection Procedu res Crankcase In s p ect ion 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 bearing 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 tight. Normal hand installation will be an indication of the recommended interference fit. If the bearing falls out of the case when the case is inverted, the case should be replaced.
Crankcase Bearing Interference Fit : C3 - .0006" (.015mm) - Crush C-4 - .001" (.025mm) - Crush Crankshaft Ma in Bearing Inspection 1. Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris Premium 2 engine oil. Carefully 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 with minimal side to side movement and no detectable up and down movement. Replace any loose or rough bearings.
3.81
9/96
ENGINES
General Inspecti on 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 (withi n .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 equipme nt and a sound knowledge of crankshaft repair and straightening is required to perform crankshaft work safely and correctly. Crankshaft repair should be performed 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. Run you r fingernail around the inside of the rod and check for rough spots, galling , or wear. 3. 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 . 4. With pin and bearing cente red in rod, twist ends back and forth in all directions 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 roughness is evide nt with a new pin and bearing, replace the connecting rod.
Piston Pin I Needle Bearing Inspection

1. Clean needle bearing in solvent and dry with compressed air. 2. 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.
3. Visually inspect piston pin for damage, discoloration , or wear. Run your fingernai l along the length of the pin and replace it if any rough spots, galling orwear is detected.
9/96
3.82
ENGINES
General Inspection Procedures Crankshaft St raightening
Lubricate the bearings and clamp the crankshaft securely in the holding fixture. On three cylinder crankshafts. straighten one of the ends (Magneto or PTO) and then straighten the center section. Place the center section in the holding fixture and then straighten the remaining end. If truing 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
Oli',
IHi
I
i'
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 like the one shown in the illustration at right, strike the shaft at point A with a brass hammer.
,,

HIGH .004 (.1mm) A . HIGH .004 (.1mm)
NOTE: The rod pin position in relation to the dial indicator position tells 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 CRANK SHAFT AT THESE TWO BEARINGS
HIGH .002 (.05mm) . HIGH .005 (.13mm)
6. If the crank rod pin location is 180 0 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+-.FA . HIGH .005 (.13mm) Al
3.83
9196
ENGINES General Inspection Procedures Crankshaft Indexing

Polaris crankshafts are pressed together or "indexed" so the connecting rod journal center lines are 180' (twins) or 120 0 (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 plug high tension leads; ground high tension leads to engine. Disconnect lanyard from engine stop switch before proceeding with the following steps. 1. Securely fasten 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. 2. Sharpen a coat hanger or section of welding rod and anchor it to a convenient spot. Point the sharpened end at the outer perimeter of the degree wheel.
Dial Indicator
.100 ATDC
3. Install a dial indicator into the magneto end cylinder spark plug hole (front) (#1). (The ignition timing is referenced by the magneto end.) 4. Rotate the engine to bring the piston to top dead center (TOG) on the cylinder with the indicator installed. 5. Locate TDC as accurately as possible by finding the center of the point 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). Degree Wheel
IMPORTANT: Do not allow the crankshaft to move from this position.
9/96
3 .84
ENGINES General Inspection Procedures Crankshaft Indexing (Continued)

6. Bend the pointer or move the degree whee l until the pointer aligns with the 180 or 120 mark on the deg ree wheel. With the pointer aligned, make sure the degree whee l and pointer are secured and will not move out of position. Re-check accu racy of this location by repeating steps 4. and 5. . The pointer should align with the 180 or 120' mark whe n the dial indicato r reads .100" (2.54mm) ATDC.
7.
IMPORTANT: Do not move the degree wheel or pointer afte r the initial setting on the mag end cy linder - simply read the wheel and dial indicator.
8.
Remove the dial indicator and install in cyl inder #2 or center cylinder. Repeat steps 4. and 5. Note the deg ree wheel indication when the dial indicato r reads .100" ATDC. It should be 180 or 120' ( 2) from cylinder #1. Repeat procedure on PTO cylinder (#3) where applicab le. Cylinder #3 shou ld also be 1200 ( 2') from cylinder # 1.
Symptom s of an out of index crankshaft can include: "- Difficulty calibrating carburetor (repetitive plug fouling on one cyli nder with no other cause); Unexplained piston failure on one cylinder (I.e. severe detonation, broken ring lands, piston holing); Excessive vib ration of engine, backfiring, etc.; Rough idle, poor top speed.
Polaris Industri es Inc.
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 cylinde r 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 dete rmine 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.
9/96
3.86
ENGINES General Inspection Procedures

Pis to n Inspect ionlMeasurement
1. Check piston for scoring or cracks in pisto n crown or pin area. Excessive carbon buildup below the ring lands is an indication of piston, ring or cylinder wea r. 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 measured at this point to provide accurate piston-to-cyllnder ciearance measurement.
3. Subtract this measurement from the minimum cylinder measurement recorded previously. If clearance exceeds the service limit, the cylinder should be re-bored and new pistons and rings installed. Refer to specifications on pages 3.3-3.4 for specifications.
Piston Ring Inst all ed Gap

1. Position ring 1/2 " (1.3 em) 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 cyiinder. NOTE: A difference in end gap indicates cylinde r taper. The cylinder shouid be measured for excessive taper and out of round. Replace rings if the instailed end gap exceeds the service limit. NOTE: Always check piston ring installed gap after reboring a cylinder or when installing new rings.
1l2'2;~41~~====_
~ Piston Ring Cutaway
Straight
Edg e ~
Keystone Piston Ring
3.87
9;96
ENGINES General Inspection Procedu res

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:
I
Pressed Apply pressure with Mity Vac' " to test. Check valve should pop off between 2 and 5 psi.
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 care 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. Inspect each banjo bolt to make sure it is not plugged or restricted. 3. Loosely thread only the banjo bolts back into the manifold or carburetors. 4. Place oil feed lines with their check valves away from the clutch area. Start the engine and let it idle at normal idle RPM. 5. Lift oil pump control lever up to its maximum flow position. Banjo Fitting
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. 7. "oil does not flow from one of the check valves, remove oil line from check valve and again idle engine. " oil then flows, the check valve is defective and must be replaced.
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
ENGINES General Inspection Procedures

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. Fill oil reservoir with Polaris injector oil. 2. Loosen brass hex head screw (A). After a short time 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: Measure distance from oil pump mounting surface to bushing. Call this measurement "A". NOTE: Make sure the bushing is fully seated in the crankcase . 1.
3 .89
9196
ENGINES General In s pecti on Procedures 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 measurement "S". Subtract measurement "S" from "A" to determi ne 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)
Opt ional Shims:
PN 3083671 = .006 "(.15mm) PN 3083672 = .012" (.3 m m) PN 3083673 = .024" (.6mm)
End Play
.008 - .016 " (.203 - .406 mm)
9/96
3.90
COO LING SYSTE M Cooling System " EC45/50PL With Positive Bleed Recovery System Fill ing 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 proced ure: 1. Elevate front end of machine approximately 10" (25
ern),
Lift Lock Lever To Bleed _ /

~
'--"
reservoir to indicated maximum level line. 3. Remove pressure cap and slowly pour coola nt into engine until the coo lant level is at the pressu re cap fitting neck . Install pres sure cap and lift lever. 4. Install the pressure cap with the lever lock up in its release posit ion 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 fiuid level. CAUTIO N: On models equ ipped 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 wh ich can lead to overheating and eng ine dam age. Reset idle to specs after bleeding. System is properly bled when no air bubbles are visible in overflow line when RPM is increased slightly.
2. Fill coolant expansion
Rem ote Filler Neck Bleed at 600 RPM Filler Neck On Cy linder Head Bleed at fast idle Cautio n : Increase RPM slowly when lever lock is up to avo id loss of coo lant.
I
.
~ .
t
Remote Filler Neck Shown
~
~..."' .
EC45/50PL ENGINES BRAKE COOLER

~~
II
NOT E: If system is diffic ult to bleed . inspect coola nt filter and check valve for restriction and proper installation .
-"-'" ~ OVE RFLOW BOTTLE FILTER GOLD BONNET / /CHECK VAlVE
~~~~~l'=~
"Cl~ Ii I l
j
RIGHT EXTRUSION CENTER EXTRUSION
~ r~
LEFT EXTRUSION )
b.
COOLANT FLOW SCH MATIC
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
l~~~=~:=~ ~
WATER IN
)!!
.L...,
BRAKE COOLER
COOLANT FLOW SCHEMATIC

SURGE TANK
r r:
FILLER NECK
I
'-- a
J lL
'-- C
LEFT EXTRUSI ON COOLER
RIGHT EXTRUSI ON COOLER
REAR TUNNE L COOLE R
9/97
3.92
COO LING SYSTEM Typical 440 Indy 1500 Indy 1500 Class ic 1500 RMK I Classic Touring I WideTrak LX
NOT E: 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 & Convolute d Tubing at Base of Chaincase Spring Only
"
,,
Convoluted Tubing Between Hose and Engine
3.93
9/9 7
COOLING SYSTEM EC58 Style With Center Coole r - XLT LTD I XLT Classic I XLT SP
NOTE: When leak testing cooling system, system pressure should not excee d 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 -----fHHt"-'j,
Hose, Center Cooler to Engine
9/97
3.94
COO LING SYST EM EC58 Style Without Center Cooler - XLT Touring
NOTE: When leak testing cooli ng system, system pressure should not exceed 2 Ibs. less than cap pressure. Refer to filling and bleeding procedure on page 3.91.
Black Clamp Convol uted to go against corner of chaincase Ho\ e, Engine OuVFiller / s
-: \
/
ve
/
/
"
.......
.. llll~
\
~
./
~-"' <,
<,
. 7 .
/'1
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/, Silver -: / Clamp /
\~
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~,
~ .::
~
/'
'"--- / 1 -:
/
1 /
/
/' 1
/'
<. //
~
- .1'-.....<,
/ /
Hose, Rear Cooler Inlet, 1"
1 <, ' 1 / /
_
/,/ _/
'. ~ .
k-,
II
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-yo
.
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~~ // ~.I -, ~<, /
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Spring, Hose Retainer
3.95
9197
COOLING SYSTEM EC59/68 Style Without Center Cooler - Ultra I Ultra Touring
NOTE: When leak testing cooling system, system pressure should not exceed 2 Ibs. less than cap pressu re. Refer to filling and bleeding procedure on page 3.91.
9/97
3.96
COO LING SYSTEM EC59/68 Style With Center Cooler -700 XCR I 600 XCR
NOTE: When leak testing cooling system , system pressure should not exceed 2 Ibs. less than cap pressure . Refer to filling and bleeding procedu re on page 3.91.
ffP e: . ..
Convoluted Tubing
Hose-Center CoolerlTop Surge
3.97
9/97
COOLING SYSTEM Domesti c Twin s 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
9/9 7
3.98
COOLING SYSTE M Domestic Twins With Center Coo lers - 600 RMK 1700 RMK
NOTE: When leak testing coo ling system, system pressure should not exceed 2 Ibs. less than cap pressure. Refer to filling and bleeding procedure on page 3.91 .
Hose, Brake Cooler/Rear
Hose, Coolant I Hose, Close Off, Cooler/Rear
1/
Hose, Center Cooler/ Mid Surge
3.99
9/9 7
COO LING SYSTEM Sto rm 0985782
NOTE: When leak testin g cooling system, system pressure should not exceed 2 Ibs. less than cap pressure . Refer to filling and bleeding procedure on page 3.91.
Hose, Autostal! Brake Cooler w/Spring Hose, Autostal! Engine
Hose, Surge Tank! Water Pump
Hose, Center CoolerlTop Surge
9/97
3.99a
Electronic Fuel Injecti on (EFI) Operat ion
WARNING
Gasoline is extremely flammable and expiosive under certain conditions.
A A A A "--' A
A
Always stop the engine and refuel outdoors or in a we ll ventilated area. Do not smoke or allow open fiames or sparks in or near the area where refueling is performed or where gasoline is stored or used. Do not overf ill the tank. Do not fiil 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. Gaso line powered engine exhaust fumes are poisonous and can cause loss of conscio usness and deat h in a short time . WARNING
Battery electrolyte is poisonous. It contains acid! Serious burns can resuit from contac t with the skin, eyes, or clothing. ANTIDOTE : EXTERNAL: Flush with water. INTE RNAL : 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 , flame, cigarettes , etc. away. Ventilate when charging or using in closed space. Always shield eyes when working near batteries. KEEP OUT OF REAC H OF CHILDRE N.
ROM Identif icatio n / Charge Co i l Tes t Specifications

Model
Sstem ype
ROM ID
ROM PN
Battery Charge Coil Test PO SItion/Resistance Bm
1996500 EFI/SKS/RMK 1996-1997 RXL 1997500 EFI
II
I
1996500 V1 1996650 V1 1997500 V1
4040061 4040065 4040073
Gr.JttoBmIW .2.2toto.4.4ohms GryIW ohms
GrNJO BmIW .2 to .4 ohms Bm to GryIW .2 to .4 ohm s G7vJO BmIW .2 to .4 ohms Bm to GrvIW .2 to .4 ohms
II
4.1
9/96
Electron ic Fuel Injecti on (EFI) Operation EFI Operation

Machines equipped with Polaris Electronic Fuel Injection (EFI) have many advantages over normal carbure tor equipped models. The most noticeable impro vements will be ease of throttle operati on, better cold weather starting and improved cold engine drive away. The EFI system also compensates for tem perature and altitude, and with minor adjustmen ts 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
System "
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 III
The following information is a more detailed explanati on of these three systems. It's very important during diag nosis 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 oil-season storage periods, high vibrations, and extreme temperature variations which are encountered in snowmobi le applications make periodic battery inspection and service essential. If the battery is partially shorted or in a low state of charge, or if connections oller 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 batte ry will be required to provide adequate cold cranking amperage.
EFI Accessory
Note
At no time should any accesso ries be added to the battery or battery side of the charging system . To do so may overload the system , discharge the battery and cause substandar d 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 syst em 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 functio n. The ECU conne cts itself to the battery via a self shut-off relay, whic h 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. '--' If the engine is stopped with the switches in the "Run" posit ion , the ECU will remain powered up until the batte ry is drained.
TYPE II (5005)
The Type II system is used on aliSOO 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 positio n of the switches in the event that the engine stops unexpectedly. This preserve s battery power. The key switch on these models only grounds the ignition in orde r to stop the engine . There is no battery power connected to the switch in these mode ls, unless electric start is used. This system uses an Alternator Controlled Switch (ACS). Mounte d on the battery box , it incorporates the voltage regulator/rectifier. The ACS senses the rotation of the cra nkshaft 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 automati cally.
[ "' CAUTION:
When servicing the fuel system on models with an ACS it is very important to first disconnect the battery. Turning the engine over wit hout disconnecting the battery could cause the fuel pump to run and create a dangerous fuel spill.
4.3
11/95
Electroni c Fuel Injection (EFI) Battery Maintenance Battery Mainten ance

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 lillie 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.
-.
1:~'CAUTlON:
_.~
It is extremely important that the battery condition and state-of-eharge be mainta ined at the highest level possible or serious performance and driveability problems will arise. Battery testing procedures are covered below. Off season storage for snowmobiles, espec ially EFI equipped machines, requires the battery to be removed. In the summer months higher temperatures and higher levels of humi dity, 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 batt ery of lesser quality when repl acement Is req uired. 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
i1' Polaris BatterY render

, PN 287 1076
Batt ery Servic e

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 voltag e 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 batte ry and on Type I units the monitor will incorrectly read voltage less than 10 VDC.
Specific Gravity . 1.270-1.300 Open Circu it Voltage 12.7-12.9 v DC
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? NoYes! Remove the battery. Service and test as outlined earlier in the engine electrical section. Before conti nuing, the batte ry must be In good serviceable condition and fully charged. IMPORTANT: Replace battery if questionable. Yes - See Block 2
2. Start engine and increase to at least 4000 RPM. Battery Check battery charging coil. Disconnect coil leads. 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 betwee n 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? NoYes - See Block 3 Yes! No! 3. Charging system is testing OK. Check for any~ o ssibl e 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 and/or flywhee l. Re-test system. See Block 1.
4.5
11/95
ELECTRONIC FUE L INJECTION (EFI) Power Up Testing

Refer to approp riate w iring diagram in Chapte r 10.
Type I (RXLs)
1. Check battery voltage. Must be 12.2 or higher. Use digital Charge , service, test andl or replace battery. volt meter. Does it read correctly? No---Yes! 2. Check EFI brown relay. YIBK wire should read 12.2 volts or more with switches turned on. Does it read correctly? No---Yes! 3. Check brown relay. Relar should connect R!Y from fuse link to RlBK (ECU) and RIB U (select monitor). Does it?
No~
Check circuit breaker, key switch, kill switch, connections and wires. Check relay ground black wire.
Replace relay and repeat tests.
Yes! 4. Check self shut-off relay and wires from relays to ECU. Are tests OK?
N o~
Replace wires and/or relays. '
Yesl 5. Replace ECU.
Type II (5005)
1. Check battery voltage using digital fluke meter. Mu.sl read 12.2 or higher. Is voltage within specification?
N a~
Charge, service, and test battery: or replace battery. Continue testing if needed. See battery service.
Yes! 2. Check voltage to ECU R/GN Pin #106. Should be 12.2 or higher. Is voltage within specification?
N a~
Check circuit from battery through circuit breaker and to ECU. Repair and/or 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! 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:
Yes! 3. Check voltage to ECU OIB K 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 coil and connecting wires. Replace coil and/or repair wires. Continue tests.
5. Check self-shut-off relay and circuit, OK? No---Yes! 6. Replace ECU and retest.
Repair relay circuit."
NOTE : Us e only res istor spark plug c aps on ign ition co il high ten sion leads. No n-re sistor ca ps m ay affect EC U
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 identif ied by the light green and brown wires in 2 prong white connectors. The fuse link is the circuit protectio n device in Type I electrical syste ms. If a system ove rload (such as a dead short) occurs , the fuse wire will ope n the circuit preventing further damage. If this link is open, find and correct the proble m and then repiace the fuse link. Never attempt to replace the fuse link with a conven tlonat fuse. Use oniy an OEM fuse link.
Inspection
Service of the fuse link is limited to verification of whe ther or not the wire is continuous. Remove fuse link from machine. Meas ure resistance on the light green wire and the brown wire. Replace the fuse link if resistance is greater than .5 Q . Type II systems (500s) use a self-setting circuit breaker, located near the battery.
Relay Coils
The system relay colis for Type I systems are mounted on the front side of the right footrest assembly. The relays for Type II systems are mounted on the ECU. Theirfunction is to contro l a major current carrying circuit with a smaller, low cur rent car rying control circuit. When the ECU or ignition switch closes the low current coil circuit within the relay, the magne tism in the coil closes the contact points , allowing current to pass through the relay and powe r up to the ECU, fuel pump , etc. Type I systems incor porate 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. Coli resistance shouid be between 65 and 70 ohms meas ured between the two pins marked "coil" on relay base . When relay is energized, volt drop across relay contacts should be less than.l vDC, meas ured in parallel with relay. On the bench, the relay can be checked by hooking the marked relay coil terminals to a 12v battery and checking resista nce 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 show n in the diagram at right. Measu ring volt drop across contacts .1vDC. Measure resistance of right side contact. This should be 100 ohms 10%. Right 100 ohms 10% Type II System
. I
BL U E BROW N
Bottom
4.7
9/96
Electronic Fuel Injection (EFI) Alternat or 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 batte ry charging ; 2) Connects the ECU with 12vDC battery voltage when an AC signal from the alternator indicates that the eng ine's cranksh aft is turning. NOTE: Even if the key switch and kill switch are in the "off' position , the ACS will power up the syst em if the crankshaft is turned. (See also page 4.6, Power up testing.)
IIp:l!llr\':''''----~~''!.!
Test Procedure
With ignition in the "on" or "run" position , crank engine over slowly. You will hear the fue l pump run for approximately five seconds. Th is tells you the ACS is working. If the fuel pump doesn't cycle when cranking , disconnec t ECU wire harness and reco nnect to reset ECU. Crank engine ag ain. If fuel pump won 't start work ing , unplug the harness at the ECU and check Orang e/Black wire PIN #11 on the ECU harness. Battery voltage should be presen t when cran king eng ine. NOTE: 500s have a five wire ACS LR36. The extra wire is for a center tap alternator. You can also use the select mon itor to determine if the ECU is getting power. If the se lect mon itor display lights up the ECU is getting power. Check the ACS wire at the ECU plug .
I;:\Pft.utlq~; i1~
Take care not to distort the pin with the tester lead. If no voltage is presen t, rese t ECU and check Orange/Black lead at ACS unit. If no voltage is present , check for alternator output or loose con nections. If alternator output is OK, replace ACS.
Cold Start ing

On Type I systems, during cold starting the ECU will seiect a special "start-up" mode. Thi s will occur any time the engine is being cold started , for example, any Type I syste m which has had the key off long enough for the self shut-off timer to powe r down the system wil l go to the start up mode. After turn ing on the ignition key to reset the system, the fuel pump will run from three to five seconds to pressu rize the fuel rail. When the ECU sees the first ignition pulse it provides a longer than normal "prime" pulse to the injectors to inject enough fue l into the eng ine for starting. On Type II systems, there is no ready light or ignition key reset. The pump mayor may not run forthe 3-5 second period depending on how long the engine has been off. In all systems, the "prime" pulse only occurs if the pump run s for the 3-5 second period . Once the engine is running the ECU provides a rich mi xture while the eng ine is wa rming up. It uses the eng ine when the eng ine is warm, and will beg in decreasing the fuel air ratio temperature sensorts) as an indicator accordi ngly. If the key is turned off, the ECU prov ides power to the self shut-off relay for a period of ten seconds to ten minutes , dep ending upon the system type, and will not repeat the fuel system pressurizing and prime pulse during that time . Once the self shut-off seque nce has expired, the eng ine will have had sufficient time to cool and th e ECU will aga in repeat the cold start sequence.
0:
In Type I systems only, during times of severely hard running or in very war m weather, if the eng ine cran kcase should approach a temperature which might resu it in engine damage the ECU will provide add itional fuel to the engine for coo ling . When the crankcase temperature senso r indicates a temperature of approximately 100 C (2 12F), the ECU will lengthen the pulse time and cause an over -rich condition which will cool the eng ine. As soon as the engine temperature returns to normal, the ECU will return to the orig inal map . In Type II systems , the engine is protec ted aga inst overheating by the eng ine coolant sen sor. If the engine coolant reach es 85 C (185F) the '1emp" light on the dash will begin to flash . If the eng ine 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 dam age. Fuel will continue to be added until the light stops blink ing. If the engin e should become flooded during starting, it can be cleaned out by holding the thrott le wide open While turni ng the engin e ove r. if the engi ne is not run ning , and the throttle is ope n 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 fuelsystem consists of all thepartsresponsible for storing,cleaning, delivering, pressurizing and injectingfuel 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 pickedupfromthe bottom ofthe fueltank by the fuel pick-up hoseand filter. It thentravelsthrough a hoseto the primary(75 micron) filter, located under the air box. Once leavingthe primary filter, it travelsto the electricfuel pump, located underthe mag end throttle body. The eiectric 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 wheneverthe 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!~55~
Pressure Regulator
/ Vent Line
Return Line
Fuel Rail Electric Fuel Pump Fuel Filter 10 micron
Fuel Tank
Throttle Bodies Fuel Filter 75 micron Weighted Pickup and Screen Screen on Inlet End Check Valve Outlet End
After leavingthe pump,the fuel goes through thesecondary 10 micron filter for furtherpurification. 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 greaterthan this is relieved or returned to the tank by a return line. The return line mustbe 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
Electroni c 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 weig hted pick up 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 HOS E
PR IM ARY FILTE R
The fuel tank, hoses, and filters req uire little maintenance or service. Periodically inspect tank and hose condition. Ensure tnatthe pickup is clean and properly positioned and vent tube is properly routed and not kinked or pinched. Replace any hose showing signs of deterio ration. 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 proble m does not rectify itself, proceed to fuel pump testing.
Wheneve r 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 , throug h 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 provide s cooling , corrosion protection and lubricatio n. Outlet Pump
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. howeve r, to betw een 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 betwee n these two valves. The fuel pump is a sealed unit. No internal repair of the pump components can be perfo rmed. Pump condition can be verified by an amp draw test, an output volu me 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 amme ter 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 defecti ve 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, discon nect fuel return hose and place it into a 200 milliliter graduated container. Activate ECU to cycle pump for approx imately five seco nds. The measured outpu t during this time period should not be less than 90 to 1DO milliliters.
NOTE: Battery voltage less than 12.6vDC or restrictions in the fuel lines or filters will cause output to be less than recom mended amount.
Fuel Pressure Test

Install EFI fuel System pressure tester in fuel line on PTa end of rail. NOTE: Use caut ion when removing hose. The rail may contain pressurized gas if engine has been recently run. Activate dea ler mode using select monitor service harness plug , by connecti ng 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 Re ulator
Fuel Filter 10 micron
"1" Fitting
I~
Pressu re Gauge
Connect Fuel Pressure Gauge Between Rail and 10 Micron Filter
Fuel pressure can also be checked with the gauge in place and with the engine running. Pressure should be checked at both idie and at operating RPM. A piugged filter or restricted fuel pickup hose may show good pressu re at idle but restrict flow at operating RPM.
4. 11
11/95
Electronic Fuel Injection (EFI) Fuel System Mainten ance 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 simpiy 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 fuei pressure within the rail by allowing pressure above the desired ievel 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
Electronic Fuel Injection (EFI) EFI Fuel System Maintenance and Testing
The regulator can also vary pressure consistent with engine load, atmospher ic 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 of the diaphragm , allowing the fuei 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 differentiai 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
"--"
4.1 3
11/95
Electronic Fuel Injection (EFI) EFI Fuel System Maintenance and Testing Injector
The injector is an ext remely 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
a-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. NoYes! Connect fuel pressure gauge and test as earlier outlined. Must read 35 to 37 psi. Pressure reading high_ Pressure reading low! Inspect pump pickup lines. filters and volume test pump. Is volume OK? NoYes! Replace pump. Check for pinched or kinked pressure regulator return line. Is line OK? NoYes! 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. Refer to 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. Wa it two minutes and remo ve cardboard. Some wett ing is OK, but a soaked cardboard ind icates a defective injector.
N
Some of the mechanical problems which will necessitate injector replacement are: internal and external leakage , part ial or total fuel blockage, open injector co il, and physical damage to the pintle and pintle case.
Throttle Body
The thrott le 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 butterfl y 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 bo re units . To synchronize the throttle assembly, synchronize the adjuster between each pair of throttle body units.
THROTTLE STOP REGULATOR
.........,
Throttl e 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 fuel/air 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 flash light into bore on eng ine 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 cab ie attaching po int on throttle shaft. Rechec k 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 De used on twin cyiinder engines.
4.15
11/95
Electronic Fuel Injection (EFI) System III - Electronics Operat ion

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 Cyiinder System Shown) Twins have 2 injectors
Injectcrs (Outputs)
TPS
ECU
Drop Resistor In From Battery Output
(Type II Systems Oniy)
The eiectronic control unit deiivers a iow voltage signai to each sensor. Depending on variat ions in air temperat ure, throttle position, etc., each sensor will vary the amoun t 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 seiect 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 miiiisecond s and referred to as pulse width.
Simulated prom map
Pulse Width (in miiiiseconds )

(Z)
Throttle Position RPM (X)

(Y)
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4.16
Electron ic Fuel Injection (EFI) System III - Electron ics Operat ion
Input from the other sensors either adds or subtracts a percentage from the pulse width to tailor the fuella ir ratio for the specific altitud e, 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 miliiseconds output by the ECU. Iii. 2 shows a situation where the air temperature is low, the machine is at low altitude with a cold 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
OFJ
Long Pulse Width (l.e, High RPM, Coid 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 revoiution.
aNn
OFF
IIi. 3
n
'------
Short Pulse Width (Le. Idling, Warm Temps., High Altitude, etc.)
4.17
11/95
Electronic Fuel Injection (EFI) System III - Electronic s Testing

Seiect Monitor
The select monitor is designed to provide easy, accurate diagnos tic 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.
PN 2870969
Remove protective plug from diagnost ic plug in machine harness next to ECU. Conne ct select monitor to instrument harness, to service harness , and to diagnost ic 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 powere d 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
11195
4.18
Electronic Fuel Injection (EFI) Sys tem III - Electronics Testing

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 for the 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 numbe r of special features. Some of these features are: adjustable low speed mixture control automatic cold engine start up enrichment engine over temperature protection 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 0 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 barometr ic sensor.
ECU Part Numbers

Type I w/o chip ,';~ Type I w/o chip Elect. Start Type II wlo Chip ....
d:n!,<
"' V tl ",, :~
en ,
Select Monitor Cartridge Select Monitor Cable
3084414 " 3084417
4.19
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Electronic Fuel Injection (EFI) System III - Electronics Testing

ROM Chip Removal and Install ation
The chip can be removed and repl aced with the appropriate chip puller and installation tool. You will need to suppl y a ROM rem oval tool and dielectric grease. Note the location of the indicator notch when repla cing the ch ip (see photo at right). The syste m will not function with the chip in backwards or with the chip pins not prope rly in their sockets. See the specifi cation section in this chapter for chip information .
NOTC H'-
FS M56 31
The compute r chip and the ECU are extremely sens itive to static electricity. The handling of either com ponent in a static electricity envi ronment will cause irreversible damage. Work on a meta l bench or other static dissipating surface. It is very Important that you ground yourself by touching the crystal inside the ECU befo re any interna l service work begi ns on the ECU asse mbly. See III. 1 and 2. If the ECU has not been removed from the machine, be sure to unp lug it before proceeding. 1. Disconne ct main harness con nector from ECU. Remove phill ips head cove r screws and cov er.
Connector
\0(
Wh ite line on board Be sure notch on RO M is positioned here
2.
Touch the crystal located inside the ECU box to ground yourself before proceeding. See
Illustrations 1 and 2.
~
The chip and the ECU are very sensitive to static electricity. Working inside the ECU without groundi ng yourself may cause irreversible damage to either or both components. III. 1
"L
t>:
RXL ECU Box
Crystal - touch before performing service to
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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. 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. 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 .
4.
@l
Crystal-...__IT touch before performing service to ground yourself
5. 6.
~
\
I"
-, 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.
Connector
500 ECU Box
III. 2
7. Align cover gasket , positioning cover rubber bumper above chip. Reinstall cover screws and reconnect wire harness. Install select monitor and check functions .
4.21
11/95

Troubleshooting EFI System
W hen key switch is turne d to the on position. vo ltage is supplied to ECU and the select mon itor. NOTE: Som e models will require the engine to be tu rned ove r. After the ECU is powe red up. it w ill run the fuel pump for five sec onds. rea d the senso rs and do a self diagnosis of the complete syste m. The ECU does not check the Air Temp eratu re Sensor (ATS) unti l the engine RPM is ab ove 1000 . Wit h a good und erstanding of how each compon ent functions, the tes t pro cedures given in thi s ma nual, and the use of the select mo nito r. you will be able to service and diagnose the Polaris fuel injection system . All information and specifi cation s are bas ed on the latest product information avail ab le.
Select Monitor Scrolling

With the ignition on and the monitor hooked up and turn ed on as de scribed ea rlier, the disp lay sh ould show the year and th e mode (FOO). By pressing the'" key, the display will pro ce ed to (F0 1). w hic h is the model. Press the ... again and the (F02) will appear, w hich is batt ery voltage. By press ing the '" or '" keys, you can either scroll forwa rd or backward through the modes. If you know the mode you want, simp ly press "F" follo wed by the two digit mode number, and enter. The mo nito r will display the mode number and the reqlstered information. Th e followi ng chart show s the modes, w hat th e read ings are for, and what an approx imate read ing should be. Mode Faa F01 F02 F03 F04 F05 F06 F07 Faa F09 F1 4 F21 F22 FAD FAI FA2 FBO FBl FCD Description Model Year Engine Code Battery Voltage Engine RPM Throttle ValveAngle (Whole Range) Intake Air Temp in C' Intake Air Temp in F' Crankcase Temp in C'
Crankcase Temp in FO Barometric Sensor
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
Throttle Valve Angle (Low End) MR (Idle Mixture) Position Water Temp Sensor in C' Ignition Key Diagnostic Dealer Mode Relay Check Existing Trouble Codes
0' to 35.9' small steps 2.5 or more than 4.0 for Alt. See page 4.27. Same as ATS or CTS Cold or 30' to 90' running KY + No. 3 LED (With key on) OM + NO.5 LED (with OM activated) FP,SD,SS + No. 1.2, and 3 LED when operating Faults presently existing
Faults that a re intermitte nt
! Memory Trouble COdes

I Memory Clear
1 Polaris Industries Inc.
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4.22

The ECU determines the amount of fuel to be injected by accurately calculating the eng ine's need for fuel de livery. To do this , the ECU memory ch ip reads the three dimensional map discussed on page 4.16. Various sensors such as air temperature sensor, coo lant temperature sensor, barome tric 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 volt age on the select monitor if the actual voltage is below approximately 10vDC. If you suspect a low battery, use a Fluke meter to directly meas ure 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 rece ives an engine RPM signal from the COl box. This signa l 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 grou nd, the ECU will not function properly. Whenever COl or intermittent runn ing problems are occu rring , the switches shoul d be suspected. These switches will also fail more often when hum idity is high. To troubl esh oot the switche s, disconnect or iso late them from the circuit.
~RPM
OUTPUT

Mode F03 Description Engine RPM Normal Read ing Cranking 300-500
Polaris inau stnes Inc.
4.23
11/95

Throttle Posit ion Senso r (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 proportionatel y to the butterfly angle. The ECU passes a specific current throug h 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 delive ry 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 approx imately 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 consi stent prog ressive increa se 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 cons istently, progressively increas e with throttle opening to more tha n 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 throttl e stop screw until the butterflies are !Q1afu' closed. Connect the select monitor to the system diagnostic plug. Turn on the ignition switch and the monitor onloff switch. Scroll the monitor to mode F04 or F1 4 and verify the sensor positioning. NOTE: F1 4 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 Descript ion
Throttle Valve Ang le-Range Throttle Valve Angle Low End Not Used on All Systems
Norma l Reading
F04 F14
0 to 77' Large Steps

See TPS Adjustment
0' to 35 Sma ll Ste ps

Depend ing on Position
-"
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4.24
Electronic Fuel Inj ection (EFI) System III - Electronics Testing

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 the rmal 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, depe nding on its temperature, a certa in amount will pass through to ground. By measuring how much passes through, the ECU can calculate air inlet temperature and vary fuella ir ratio accordingly. The intake air temperature sensor can be tested in a manner similar to the crankcase temperature sensor. Determ ine 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 temp erature 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 tem perature on the select monit or. Radical differences between room temperature and the indicated reading indicate a problem with the senso r, wiring, battery, or ECU. Verify and repair any problem before attempting to operate the machine.
Select Monito r Readings

Mode F05 FDa Desc ription Intake Air Temp C Intake Air Temp e F Nor mal Readi ng Room Temp"Engine Cold" RoomTemp "Engine Coid"
Crank case Temperatu re 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 It (500) systems do not use a crankcase temperature sensor.

Mode FO ? FDa Desc ript io n Crankcase Temp C Crankcase Ternp " F Norm al Reading Room Temp"Engine Cold" Room Temp "Engine Cold"
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11195
Electronic Fuel Injection (EFI) System III - Electronics

Barometric Pressure Sensor (BPS)
The barometric pressure sensor is located inside the ECU. Its function is to read atmospheric pressure. This information is then used by the ECU to determine fuel/air 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 barometr ic 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.
C HIP

Mode Description
Barometric Senso r
Normal Reading
Barometric Pressure in Millimeters of
FOg
Mercury
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4.26
Po/ans industnes Inc.
Electron ic Fuel Injecti o n (EFI) System III Electro nics MR Adjustments

On Type I (RXL) systems, the fuellai r ratio at engin e RPMs below 3500 can be adjusted slightly richer or leaner tha n the standard progra m mixture by adjusting the MR control. Th is adjustment is made to improve idle quality and drive away. It affects the same carb area as an air screw. To adjust the MR cont rol, remove the rubber plug. Install the select monitor, power up the system and press F-2 1. A correct reading on the mo nitor is between 2 and 3, with 2.5 being the most des irable. (The production setting is 2 .5) . Turning the MR screw clockwise will increase the observed number and richen the mixture. Turning the screw coun terclockwise will lower the number and lean the mixture. The leanest setting is 0 and the richest will ap proach 5. NOTE: At high altitudes, a higher number will result in earlie r drive-away after startup. Adjusting the MR con trol screw on Type II (500) systems will only affect cold starts and cold drive-away. (It is designed to assist the driver when using poor or summe r grade fuels.) If a lean condition is suspected, change the number to a higher val ue. If a rich condition is sus pected, change to a lowe r number. Approximately two minutes after starting, this adju stme nt has little effect; afte r 10 minutes it has no effect.
'-""

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

The following table s list MR screw settings for various temperatures and altitudes . Whe never pe rformi ng MR adjust ments, take th e operator 's riding location and weather cond itions into account before making an adju stment. Numbers anywhere with in the rang es listed should provide acce ptable operation.
Type I Systems - RXL Production Settings 2.5

Ambient Temperature Below +20 'F (-6'C)
I +20 '
to +50 'F (_6' to 10 'C)
I Above +50 'F (10 'C)

3.5-4.5 3.5-4.5 4.5 4.5
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
3.0-3.5 3.5-4.0 4.0-4.5 4.0-4.5
Polaris Ind ustries Inc .
4.27
11195
Electronic Fuel Injection (EFI) EFI Electronics

Type II System Type II EFI systems incorporate an engine coolant temperature sensor. This sensor is positioned in the engine water jacket where it is abie to receive and relay reliabie engine top end temperature to the ECU. This sensor also controls the temperature light and "fail safe" mode. The "TEMP" light will come on and begin to blink slowlywhen 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 designedto protect the engine in an overheatcondition. The increased fuel will continue until the enginecoolant reaches a safe temperature and the light goes out. Correcting this problem may be as simple as driving the machine slowerand/or driving in a snow condition which allowsmore snow to be thrown onto the heat exchangers. If this condition continues, check the cooling system, coolant level, water pump belt tension, etc. To checksensorfunction, connect a selectmonitor and advanceto modeF22. Withenginecold, observe reading. It should be nearthe readings of the ATS and CTS in degreescentigrade. Start engineand observetemperature increase as enginewarmsup. If readingsvarygreatlyor fluctuate from other sensor readings, checkharnessand connectors for condition and repair as necessary. If no other problems can be found, and incorrect readings continue, replace sensor. Select Monitor Readings Mode
F22
Description Water Temp C'
Normal Reading Cold Engine Room Temp
To bench test a temperatu re sensor, measure resistance between sensor wire terminal and sensor shell; then compare reading to the graph shown below. An easier and moreaccurate method is to use the select monitorto 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 repairany problem before attempting to operate machine. The sensor's resistance CUNe is shown at right. Resistance of the sensor is high when it is cold, and lowers as its temperature increases. This creates low current flowthrough the sensor at low temperatures and high current flow as the temperature increases. NOTE: The formula for converting F to ' C is (. F = c C x 1.8 + 32) Resistance (kQ)
80 40 20
10
6 4
2 ---- --
2.5kQ /20' C
0.6
0.4
0.2 - 20
20
40
60
80
100
120
Temp (OC)
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4.28
Electroni c Fuel Injecti on (EFI) EFI Electroni cs
Fuel lnlectors
Variation in the amou nt of fuei delivered per stroke to suit varyi ng load and speed conditio ns can be obtained by cont roiling the disc harge duration of the injector. The injector is a solenoid-act uated constant stroke plunger consisting of a soleno id, plunger, needle valve and housing. The ECU wiil determ ine the duration time the injector is energ ized to deliver fuel. The resistance betwee n the two pins on the injector (isolated) should be 2 to 2.5 ohms . There should be no continuity to ground.
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 Description Normal Reading
FBO-21 FBO-22 FBO-23
Type One System RXL Type Two System 500 EFI Type One System Type Two System TypeOne System
Mag Side Injector Center of PTO Injector on Twin Cylinders PTO Injector
Dropping Resistor
The dropping resistor is mounted on the engi ne side of the battery box . The three cylinder system consists of four individual resistors wired in parailel wit h 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 resisto rs, through an injector and into the ECU. A failure of any injector or resistor wiil cause one cylinder to quit operating. The ECU wiil then flash the trouble code for that injector.
..
"---'
NOTE: The ECU can oniy determine electrical failure. If an injector failure code is flashing, the problem could be anyw here 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 betwee n 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 readi ngs are outside of the spec. Clean the terminals if they become corroded. The injecto r's operati ng power com es through these resistors. Any suspected injector electr ical problem must first be traced through the dropping resistor. Polaris Industries Inc.
4.29
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Electronic Fuel Injection (EFI) EFf Electronics

ECU Diagnostics
If any ofthe mainsensors should malfunctionwhilethe machine is beingdriven, the ECUwill sensea problem and proceed to an over-rich''fail safe"mode. An open or shortedcircuit in any ofthesensor circuitswill showthe 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. Oncethe sensor problemis determined and corrected, the ECU will return to the original map. If any ofthe injectors or sensors should malfunction during operation, the ECUwill record this information andstart flashing a LightEmitting Diode (LED)code informing the mechaniclownerwhich componentfailed. The LEDis 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 flashthe code. If the problem occurred but the machine is now operating properly(intermittent), it will be stored in the memory and can be drawn out of the ECU by connecti ng 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 longpulsesare the first digit in thecode andthe short pulsesare the seconddigit. Compare the codeto thetroublecodechart on page4.31to determine the problem. Rememberthat the problemcan existin the sensor, the power feed to the sensor, the sensor ground, connectors, or the part of the injector or sensorcircuit inside the ECU.

Mode FBais for existing problem diagnosis. Press buttons F, B, a andenter. Ifthere is an existing problem, a code number andthe abbreviation ofthe problem component willappear. See the chart on page4.31 for an explanation ofthe code numbers. The LED will also display this code. For example, if the LEDdisplays one long andtwo short pulses, this is a code 12. Mode FB1 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 wasat fault. This helpsfind intermittent problems such as a wiring open or short. Pressthe F, B, 1and 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. 1. Select the mode for the component which indicated a failure. 2. Press F, C, 0, and enter on the monitor. 3. The display will ask "Memory clear? a-yes and 1-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'.
CHIP
11/95
4.30
ELECTRON IC FUEL INJECTION (EFI) EFI Fail Codes

Mod e 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 One Two Abb. THV T Case Component Throttle Position Sensor Crankcase Temperature Sensor Intake Air Temperature Sensor Barometric Pressure Sensor Water Temperature Sensor Barometric Pressure Sensor Mag Side Injector Center I ~ ector or PTa on wins PTa Injector Low Battery Voltage Low Charging System Output COl Output
- -
11 12 13 14 14 15 21 22 23 31 32 33
X X X X
- -----
X X X X
T Air ALT
--- -- ---- -
TW
ALT Inj 1 Inj 2 Inj 3
X X X
X X
----
-- --
--- ----
X X X
VB VB COl
---
-- -
4.31
9/97
Electronic Fuel Injection (EFI) EFI Electronics

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 FAD, the display shou ld show KY. Whenever the ignition switch and the handlebarkill switch are in the run position, the number 3 LED should also light. Cycle the switches a few times and makesurethe LEDgoesoffwhenthe switches areturnedoffandcomeson whenthe switches are returnedto 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 monitordisplayshouldread DM (Dealer Mode),andthe number 5 LED should be iit. During dealermodeoperation, the fuelpumpwillcycleon and offin onesecond intervalsandanystoredproblem 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 appearon the display. Whenthe EFI system Is in the normal run mode, the number1 LEDwill be lit whenthe fuel pump is required to run. This will be for five seconds when the key is initially turned on, and wheneverthe ECU senses engine ignition pulses. The number3 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, andthe selectmonitorreturns to mode FA2, the number3 LEDwill not be lit. The number2 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 selectmonitor on mode FAD, the monitorshould show an ST and DM on the left, and a KY on the right of the display. The number 1 and 5 LEDs will iight whenthe key is rotated to the start/reset position. The number6 LEDwill lightwhen the gray and blackdealermodewires areconnected together onthe service harness. The fuel pumprelay will only cycleon andoff for three one second runseach time the systemis reset while in dealer mode. Due to the different operational method used In the Type Two system, there is not an FA1 or FA2.
11/95
4.32
E .2(1l ti ...
C
. - (1l
96 RXL
ST.IITOR RES IST"NCES 288 OH.l S 6I...K /FH~F6>j 20 OHUS A - !iAN 96 0H.ws .~W/R 0HIJ5 V-BAN '4-. 8 OHMS GAY -GRO W ' 3 - 5 OHMS
HANQ WARloER RES IST ANCES
QlCl
-0
LL'i:
C'-
-01
g:
.Z-."
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EX,o. MPL : E!L.U ,fR : BL1JE 'II I TH FlED TR....CER
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POLAR IS TO FU JI HARNESS I NTERCONNECTION VIE W FR OM THE 6ACK OF
THE
POL~R IS
PLUG
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W
BLU/W 6LU/GRN GRN/R 6 LK OR/6LK Y/6LU Y/ GRN GRN/Y 6LK/Y
SEE POLAR IS WI R ING HARNESS

POLAR I S HARNESS FUJI HA RN ES S
SEE POLAR IS WIRI NG HARNESS

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-- ------------ --------------- ---- - -------- ------- -------------------------- --- - -- - -- - - - -e-FUEL PUMP

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EX AMPLE :
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Mo~i+OR
POLARIS ELECTRONIC FUEL I N ~ E C T I ON CONTROL UNIT
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 fill the lank 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 lime.
Jet Part Numbers

The following chart lists all Mikuni main and pilot jets and the part number of each that are presently available.
Mikuni
PILOT .JET NO PART NO
Mikuni
PILOT JET NO PART NO.
Keihin
PILOT J ET PART NO
Keihin
PILOT JET PART NO
25 . .. . .. .. 30 35 40 45
3130064 3'30065 3130066 3'30067 3'30068
50 55 60 65
3 '30069 3 '30070 3 ' 3007 ' 3130072
35 38 40 42 45 48
30502' 9-35 30502' 9-38 30502 ' 9-40 3050219-42 30502'9-45 30502 '9-48
50 52 55 58 60 62 65
30502' 9-50 30502 ' 9-52 30502' 9-55 30502'9-58 30502' 9-60 30502'9-62 30502 ' 9-65
Mikuni
HEX HEAP MAIN JET NO PART NO
Mlkuni
HEX HEAP MAIN JET NO PART NO
Keihin
Long Hex Head (Amal Type) MAIN JET NO PART NO
80 85 90 95 100 105 ,'0 ', 5 ' 20 125 130 ' 35 ' 40 145 '50 ' 55 160 165 170 175 180 185 190 195 200 210 .. .. . 220 230 240
3130099 3 130'00 3 '30'0' 3 130'02 3' 30103 3 '30'04 3' 30105 3130106 3130 '07 3 '30108 3 '30109 31301'0 3130111 3130112 3130113 3130114 3130115 3 130116 3130 11 7 3130118 3 130119 3 130120 313012' 3'30'22 3 '30123 .. 3' 30' 24 .. 3'30125 3'30126 3'30 127
250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 4 '0 420 430 440 450 460 470 490 500 530 . . 560 .. 590 .. 620..
3 130' 28 3130 129 3130 '30 3130131 3130132 3130133 3 130134 3130135 3130 '36 3130137 3'30138 3 '30139 3 '30290 3'30140 3130480 313014 ' 3130599 3130'42 3130'43 313014 4 3130,45 3130 '46 3130 '47 3130148 3' 30 '49 . .. 3130'50 .. . 3 130 ' 51 . .. 3130'52 . .. 3'30153
140 142 '45 '48 '50 152 155 '58 ' 60 '62 165 '68 '70 172 176 178 180 182 185 188 190 192 195 198 200 205 2'0 2'5 220
3050235-'40 3050235-' 42 3050235- '45 3050235 ' 48 3050235-' 50 3050235-' 52 3050235-'55 3050235-'58 3050235-'60 3050235-162 3050235-'65 3050235-'68 3050235-'70 3050235-'72 3050235' 76 3050235-'78 3050235-180 3050235-182 30502 35-185 3050235-188 3050235-190 3050235-192 3050235-195 3050235-198 305023 5-200 3050235-205 3050235-21 0 3050235-2 ' 5 3050235-220
5. 1
9197
Jet Part Numbers Jet Needle Part Numbers (Mikuni)
JET NEEDLE NO 5DP7 5DT49 . . . . . . . . . 5DP10 . .. 5DP10 5DT2 .. . . .... .. 5078 ..... . .. . . 5F81 ... .. ... .. . 50 78 6CEY6 6CGY3 . . . . . . . .. 6CGY6 6DH3 PART NO 3 130155 3130 154 3130333 3 130310 31304 73 3 130667 3130528 3130667 3130476 3130484 3130652 3130 470 JET NEED LE NO 6DH4 6DH5 6DH7 6DH8 6DH29 6DP1 6DP17 .. 6EJ26 6EJ3 6F4 6F9 PART NO. 3 130402 313039 1 3 130329 3 1306 45 3 130462 3 130156 31303 74 3 130423 3 130680 3130319 31 30378
Jet Needle Part Numbers (Keih in)

JET NEEDLE NO R-1368G .. R- 1370G " R-1371G R-1372J . . . . . . . .. PART NO 3050244 3050220 3050256 3050247 JET NEEDL E NO. R-1369G . . . . . . . . . . . . . R-1370J .... . R- 1371J .. . ... .... . PART NO 3050245 3050221 3050246
Needle Jet Part Numbers (Mikuni)

NEEDLE J ET NO P-4 (159) . P-2 (166) .. p.a (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) . P2 (255) . P-2 (259) . P-O (247) . P-2 (247) . P-4 (247) .. PART NO. 3130162 3130460 3130348 3130499 3130160 3130421 3130376 3130166 3130409 3130358 3 130469 3130453 3130035 3 130579 3 130608 3130 161 3130671 3130672 3 130641 NEEDLE JET NO PART NO P-6 (247) .. . .. .. .. .. 3130655 P8 (247) .. .. .. . .. 3130382 QO (247) .. .. .. .. 31304 14 Q-2 (247) 3130165 Q -4 (247) .. 3130603 Q-8 (247) 3 130485 R-O (247) 3 130477 P-O (286) 3130607 P-2 (286) , 3130608 0 -4 (286) 3 130635 0 -6 (480) 3130429 0 -8 (480) 31306 83 P-2 (480) 3 130675 P-4 (480) 3 130639 Q 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 .
PART NO . 3050234-802 3050234-C02 3050234-002 3050234-J0 2 3050234E02 3050 234-K02 . .. 3050 234-F02 3050234-L02 3050234-G02 3050234-H02
6.5
7.0 . 7.5 80 9.0
9/97
5.1 a
FUEL SYSTEM/CARBURETION 1996 Condensed Data

Mac hine Model Eng ine M odel
Cy l.
Oisp .
CCs Indy Ute/GTIDeluxe Indy Sport/Sport Touring! TranSport Indy Super Sport Indy 440 LC Indy 440 XCR Indy 440 XCR SP Indy TraiVT ouring Indy Classic Indy Classic Touring
Indy WideTrak GT Indy W ideTrak LX
Carburetor Model, M ount Type & No.
Std . Main Jet

& Type
Std .
Pilo t
Jet
145 Hex
180 Hex 180 Hex
Air Scre w Ad just (counterclockwis e fr om light seat )
Fuel Oc tane Reqrn t.
EC34-2PM (E)02 EC443PM0 1 EC443PM02 EC45PL06 EC45PL07 EC45PL08 EC50PM(E)04 EC50PLE ll EC50PL14 EC50PM03 EC50PL12 EC50PL11 EC50PL15 EC58PL03 EC58PLE05 EC58PL07 EC58PL02 EC59PL01 EC68PL01 EC68PL04 EC80PL04 EC80PL05
339 432 432 432 439 439 488 488 488 488 488 488 488 597 597 597 597 598 679 679 794 794
VM30SS (2) Zinc VM34SS (2)

Z inc
35 35 35 40 50 50 35 40 40 30 35 40 45 35 35 35 35 40 50 50 45 45
1 112 Turn
1 1/4 Turn
1 1/4 Turn 1 1/2 Turn
87" 87" 87" 87" 91 91 67" 87" 87" 87" 87" 87" 87" 87" 87" 87" 91 91 87" 87" 9' 91
VM34SS (2) Zinc VM34SS (2) Zinc VM34SS (2) Aluminum VM34SS (2) Aluminum VM34SS (2) Zinc VM38SS (2) Aluminum VM34SS (2)
Zinc
260 Hex 260 Hex 260 Hex 220 Hex

340 Hex
240 Hex 200 Hex
1 Turn
1 Turn
1 Turn
1 Tum
314 Turn
1 Turn
3/4 Turn

Z inc
190 Hex
Indy 500/SKS Indy 500 RMK Indy XLT/SKS Indy XLT Touring Indy XLT RMK w/ACCS Indy XLT SP/600 XCR Indy 600 XCR SP Indy Ultra SP/SKS Indy Ultra RMK Indy Storm RMK Indy Slorm/SKS
VM38SS (2) Aluminum VM38SS (2) Aluminum VM34SS (3)

Zinc
340 Hex
240 Hex
1 Turn 1 Turn 1 Turn

1 Tum
210 Hex
250 Hex
190 Hex

Zinc
N/A
(see page 5.32)
VM38AL (3) Aluminum VM38SS (3) Aluminum VM38AL (3) Aluminum VM38AL (31 Aluminum VM38 (3) Aluminum VM38 (3) Aluminum
260 Hex
400 Hex 340 Hex 280 Hex
1 Turn
1 1/2 Turn 1 Turn
, Turn
1 Turn
1 Turn
PTO Cl' Mag 330330350 PTO Ctr Mag 400 400 420
Non-Oxygenated. When using oxygenated fuel increase octane minimum to 89.
9/97
5.2

Engine Model EC342PM02 EC443PMOl EC44-3PM02 EC45PL02 EC45PL07 EC45PL08 EC50PLE11 EC50PL14 EC50PME04 EC50PM03 EC50PL12 EC50PL11 EC50PL15 EC58PL03 EC58PLEOS ECSBPL07 ECSBPL02 ECS9PLOl EC68PLOl EC68PL04 EC80PL04 EC80PLOS Jet Needl e No. " E" Clip Positio n 5DP72 6DH7-3 6FJ6-3 6DH73 6DH32 6DH3-3 6F9-3 6EJ26-2 6DH73 6DH7-3 6EJ26-2 6F9-3 6F9-2 6DP17-3 6DP17-3 6DP17-3 6DH7-3 6CEY6-3 6DH8-2 6DH8-2 6CGY6-3 6CGY6-3 Needle Je t No. 0-6(169) P-4 (166) P-8 (166) P2 (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.S 1.S 1.5 1.5 1.5 1.5
Valve
Cutaway
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
Fuel/O il Mixture
2.5AL 2.5CH 2.0 2.0 2.0 2.0

.'
Variable Ratio Auto Injection Variable Ratio AutoInjection 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 VariableRatio 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
D-4 (286) D-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) 0-6 (480) 0.2 (247) R-Q (247) P-4 (247) P-4 (247) P-6 (247) 0.0 (247)
2.5 3.0CH 3.0 3.0CH 3.0CH 2.5 CH 2.0 2.0 2.5 2.0 2.5CH 2.5 2.0 1.5 3.0 3.0
Auto Injection
Variable Fatio
Auto Inj..;!ion
Variable Ratio Auto Injection Variable Ratio Auto Injection
5.3
11195
FUEL SYSTEM/CARBURETION Exploded View - VM30SS
Ref. Oty.
1, 2. 3. 4. 5. 6. 7. 8. 9, 10. 11, 12. 13. 14. 15. 16. 17.
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
Ref. Qty.
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
Description
Clamp, Hose Clamp, Hose Plug, Trap Line, Fuel Nipple D-Ring Main Jet Washer Asm ., Carburetor (Incl.
1 Asm.. Mixing Chamber Top 1 1 1 1 1 1 1 1 1 1 1
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
1
1
1 1
4 Asm.. Screw and Washer
9/97
5.4
Ref. Qty
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Description
Ref. QIy
Description
1 Asm., Mixing Chamber Top (I ncl. Gasket ) 1 Spring . Throttle 1 Plate, Thrott le 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.. Carb uretor (Incl. 1.-17.23.-31.) 1 Screw, Air 1 Spring, (Air Adjuster) 1 Spring, Th rottle Adjuster 1 Screw. Throttle Stop
17. 1 Pilot Jet 18. 1 Plate 19. 1 Ring 1 Main Jet 20. 21. 1 Gasket. Float Chamber 22. 2 Asm. Float 23. 4 Asm. Screw and Washer 24. 1 Clamp. Hose 1 Clamp, Hose 25. 26. 1 Plug, Trap 27. AR Tube, Sedi ment 28. 1 Nipple 29 . 1 O-Ring 30. 1 Arm. Fioat 31. 1 Pin, Float 32. 1 Asm ., Fuel Inlet Needle Valve 33 . 1 Packing, Needle Valve
Polaris lnaustries Inc.
5.5
9197

1. =--1
3.
4.
- -"1
5. --11
i=== I
-
34 .
33.
- 32 .
6 .-....
7. _
8. ~", /"
l( 1::h
/
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v-
-y
15 .
11. /I~ O . 12 . ~ '. 13. -:- I~" '~. 14 .
~~?~r- 25.. 24
23
/ /'- ~.L~ 26.
3 1. _j~ 30 . "',.?' <, _ _ 29 . . 'r:~.l\li,L....l.. 2 to; ' ~ .;;~. I zt . .~ 28 .
-@ '-,J
15.
, ~ '1 A ~ 13. , ~'. l-. ~ V---- 14. ~

<,
/
14 7
Ref. Qly
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
16 . --~
l....----- 22 .
19. 18.
Descripllon
~
-
;~.'
Descripllon
Plug, Trap Clamp, Hose Line, Fuel Clamp, Hose Asm., Screw and Washer Gas ket, Float Chamber Main Jet (#340) Ring Plate Pilot Jet (#40) Th rottle Stop Screw Spring
Air Sc rew
Ref. Qly
1 Asm.. Mixing Chamber, Top (Incl. Gaske t) 1 Spring 1 Plate 1 E Rin9 1 Jet Needle (6F93) 1 Throttle Valve (2.5) 1 Needle Jet (P- 8) (247) 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
18. 2 19. 2 20. AR 21. 2 4 22. 23. 1 24 . 1 25 . 1 26. 1 27. 1 28. 1 29. 1 1 30 . 3 1. 1 1 32. 33. 1 1 34.
Spring Asm., Plunger Plunger Spring Plunger Cap
9/9 7
5 .6
FUEL SYSTEM/CARBURETION Exploded View - 1996-Current VM34SS with ACCS

1996-Current ACCS Systems
Air Box
4 Way Manifold / Float Bowl Vent Control ACCS 4-way Manifold mounted to air box 27S
ACCS _Valve Vent line attachment to handlebars
9L
15S
s- way Manifold , attachme nt (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 Man ifold / Pilot Ai r Control (1996 ACCS Only)
NOTE: There is only one ACCS valve. The illustration above has been divided to show the separati on ot systems.
Do not change calibration setting or ser ious engine damage may result.
----n,,--I--iI
5 .7
9/97
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 Needie - 5DP7-2 Needle Jet - Q-6 (169)
AMBIENT TEMPERATURE
Below 20' F Below 29' C -20' 10 _IO'F 29'10 . 12 'C "45
. 10' \0 +40'F
Arlove +4Q" F AboveS 'C
, 12" to . SC
0 '00 (0 3000) l3OOD-SJOO)

l El(ll).21OO (6OOG-90001
270(}37oo
155 140 '30 '2 0
135 . 25
130
120
...... 1 Ft)
All .
9OD-''''''
.35 120 11 0
...
11 0
(!lOOD-'2OOO)
' 05."
.00
[=:J . Shaded l 0'l8 shou ld c1ropJel Needle 01'1 8 position traee E<l tpl
ProductionSen,ng
Indy Lite GT EC34-2PM02 Carburetor Type - VM30SS Pilot Jet - 35 Main Jet - 145 Cut Away - 2.5 AL Air Screw - 1.5 Turn Jet Needle - 5DP7-2 Needle Jet - 0 -6 (169)
AMBIENT TEMPERATURE
Below-20 'F BeIow-29"C
-2'Q "Io .. IO"F
-29" 1O 12'C
. 100Io . "O F . 12' 10.S ' C
Ar:!ov6 __O' F
Above S' C
D-9OO
(G-3000)
155 140 ' 30 ' 20
" 45 135 120
135 ' 25
115 : ;;;.-;
~
130 ' 20 J
9Ol).1800
An. ......
1 Ft)
(3000-60001
1800-27OQ
{600G- 000 9 1
'"110 ;.~8t'1
.....
(!lOOD-12OOO)
27003100
11'ci\'It:
.05 - , 1 ': ~:~::N: ,1.o0
[=:J ~ Shaded zone should drop Jel Needle one posilion (raise E-cllp)
- ProdlJCllon Sening
Indy Lite Deluxe EC34-2PME02 Carburetor Type - VM30SS Main Jet - ' 45 Piiot Jet - 35 Cut Away - 2.5 AL Air Screw - 1.5 Turn Jet Needle - 5DP7-2 Needle Jet - 0-6 (1 69)
AMBIENT TEMPERATURE
Below 20' r
BelOw29' C
20' 1 .10 ' F 0 29 lO12 C
. , O' 10.40F .12' 1 0.S' C
AboY . 40' F a
Above S' C
(0-3000)
900-1800 (3000-6000) 1800-2 700 (6000-9000) 2 700-3700
(9000- 12OOO)
0'00
155 '40 125 110
145 135 t 20
135 125
130
AI L
....t.
I"%l:'i:;;;'Ni
I,
1Ft)
ii!i;~,
' 05
41!;,o """
I ,.
110
"
":' ;;:;!(" 100
[=:J -Shaded l one should drop Jet Needle one po$J1ion (raise Ecllp)
Indy Sport EC44-3PM01 Carburetor Type - VM34SS Main Jet - 180 Pilot Jet - 35 Cut Away - 2.5 CH Air Screw - 1.25 Turn Needie Jet - P-4 (166) Jet Needle - 6DH7-3
AMBIENT TEMPERATURE
Below-20 "F
BelowX1"C
D-9OO
(03000)
20 to . IO"F 2910 12"C
. 10"IO . 40"F . 12" 10 . SC
Abov6 .~F Above SoC
tOO
t eo
165
170
150 ' 45 ' 30 ........
AIt. ......
(Fl)
9OD-'''''' (3OOD-llOOO,
1800-2100 (llOOD-9OOO) 2700-3100
H .,
150 145
'55 140
130-
' SO
. 40
(!lOOD-'2OOO)
1 +
' 20
[=:J -Shaded zone should drq:t Jet Needle (ll'le position (nllSe E< lip)
11/95
5.8

Indy Sport Touring EC44-3PM01 Carburetor Type - VM34SS Main Jet - 180 Pilot Jet - 35 Cut Away 2.5 Air Screw - 1.25 Turn Jet Needle - 60H?-3 Needle Jet - P-4 (166)
AMBIENT TEMPERATURE
8eklw-20 ' f Belo.... 29 C 20" 1 ~ 10 ' F 0 -29"1 -12' C 0 . \ O to , -lO'F 12' 10.SC AtIO\IQ . <ilO'F Above S'C
0 '00
(Q-30001
9 00-1800 (300G-6000)
190 160
180 165
170
160
All.
Met.
(FI)
1600.2700
(6000-9000 )
2700.3700
(9000-12000)
' 50 ' 45
L;:- d d/I . sneoec zone should drop Jet Needle one coeltlon (raise E-cJip) ,:
Indy TranSport EC44-3PM01 Carburetor Type - VM34SS Main Jet - 180 Pilot Jet - 35 Cut Away - 2.5 Air Screw - 1.25 Turn Jet Needle - 60 H?-3 Needle Jet - P-4 (166)
AMB IENT TEMP ERATURE

Balow -20~ F Below -29' C -20" to . 10' F -29' 1012 C .1 O' ID. 406 F -12' 1 , 6' C 0 Above . 40F AbovaS 'C
Co-3000j
901)-1800 (3QO(} 6000l
160(}-2700 (6OO().9000j
0 '00
190 175 160 150
"60
170
'50
All.
165
Met.
(f l)
27()(}.3700
(9COO-12000)
!:tH 1. Shaded acne should drop Jet Needle one position (raise E-cllp) v::
- Production Setting
Indy Sup er 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-B (166)
AMBIENT TEMP ERATUR E

BeloW -20' F Below 29 "C
(0-3000) 900.1800 (300 0-6000)
20 " lc +l0 F -29"10-12' C
. 10"lo+ 40'F -12" to +5"C
Abr)v s +40' F Above S"C
0 '00
190 180
160
All.
Mol.
(Ft)
1800-:2700 (600D- 000) 9 2701>-3700

(~1 2000)
1-/dn<3_ :t : Shaded. zone should drop Jet Needle one position (raise E-cllp) ;
Indy Trail EC50PM04 Carburetor Type - VM34SS Main Jet - 220 Pilot Jet - 35 Cut Away - 3.0 Air Screw - 1.5 Turn Jet Needle - 60 H?-3 Needle Jet - P-B (166)
AMBI ENTTEMP ERATUR E
Bolow-20' F aecw-za-c
j G- 000j 3
900.1800 (3001>-6000) 1800-2700 (6000-90 00)
-20' !O +10" F -29'\O-12'C
, 10'to+40"F 12 ' to . 5 C
Abov9+4 0"F Above S'C
0 ' 00
230
220 200
210
200
Alt.
2' 0 195 160
Met.
(Ft)
2700-3700
(9(XX)-12000)
L : n : ~ ;{ An _ Shaded zone shoulCl drop Jet Needle one posillon (raise E-clip)
Indy Trail Touring EC50PME04 Carburetor Type - VM34SS Main Jet - 220 Pilot Jet - 35 Cut Away - 3.0 Air Screw - 1.5 Turn Jet Needle - 60H?-3 Needle Jet - P-8 (166)
AMBI ENT TEM PERATURE
Balow20 "F BelOw29 C
j 0-3000) 900-1800 (300G-60llO) 1600-2700 \5000-9000) 2700-3700 (9OCO-12000)
-20 'lQ +10"F 29 "to -12' C
,10'I O,40"F -12"IQ. 6"C
Above , 40'F AbOv 6' C e
0'00
260 230 210 190
2'0 220
220
210
.~ I t
Mol.
IFl)
1 (:;: ;:;,;:" Shaded lone should drep Jet Needle one position (raise E-clip) :;,;, ; ,1_
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)
AMBIENT TEMPERATURE
Below 20 "F
BeIaw-29 ' C
0-900
-20 ", . l OF
~10 12 C
. IO"to . " O "F 12 " 10 -s-c
Above . 40'F
Above S" C
(l>3OOOl
900- 1800
(3000-6OOO)
1 ~2 100
280 250
23<l
" 0
260
,4()
"0
23<l
'J()
"".
(Ft)
All
220
200
'.
(flOClO.90001
:i!1OO-3700
220
200
"0
(lOX>' 2000l
190
,eo
C3 Indy Class ic 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)
Shaded zone should drop Jet Needle one pos ition (raise E-dlp)
AMBIENT TEMPERATURE
Below 2Q <F
BeCw 29 "C
(0-3000)
901).1800
20" 10. 10"F 29' 10 .re-c
. 1010. 40"F -1210 . S C
Atxwe . 4Q 'F AooYe S"C
oe'"
360
'340
320
3<lO
260
Alt. Mel.
(3OQG-&)OO1
320
280
3<lO
,eo
N
'.
IF')
1800-2700
(6001).9000)
260
i.
,4()
220 5'
2700-3700
(lOX>'2OOOl
"0
Ii
ll30
,'0
ii
200
C3 -Shaded zone should drop Je! Needle one poslbon [raise E-Cl1p)
- Prod uctIOn Settin g
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)
AMBIENTTEMPERATURE
Below 2Q'F
20" to . , O "F
-29"10 ' 2C
"240
Below 29'C
+IO"lo."O"F -12 " to .S"C
Above +40"F
Above S'C
..900
(o-3OO0)
250
,J()
'J()
"0
""..
(Ft)
All
900-1600 (3Q00.6000 ] 1800-2700
220
200
~",.
21 0
: iliil
.66
1 6000-9000)
2700-3700
210
,go
q Ii. '80'W
(lOX>'2OOOl
iss
'00
111l ''''F
C3 . Shaded zone ShOUld drop Jet Needle one posrllon (raise E-e:lipl
o
PrnductiOn Setti ng
Ind y 500 EC50PL1 1 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)
AMB)ENT TEMPERATURE
flaQw -2Q' F
Below -29' C
-20' kl .\OF 2~ 1O 12 C
. 10"1O.4 0'F 012' 10 -s-c
A.boYe .4(I "F
Above !JC
0<00
(1).3000)
360
320
340
320
3<lO
900-'800
All Mel. (FIJ
1 3Oll<><OOO)
3<lO
280
.eo
220
1800-2700
(8000- 9000)
280
,4()
260
230
'40
210
210Cl-3700
;C
(lOX>12000l
200
C3 . Shaded zone should drop Jet Needle one pOSition (raise E<llp)
o
Production S&ning
11/95
5.10
FUEL SYSTEM /CARBURETION 1996 Jetting Compensation Charts

Indy 500 SKS
EC50PL11 Carburetor Type - VM38SS Pilot Jet - 40 Main Jet - 340 Cut Away - 2.5 CH Air Screw - 1 Turn Needle Jet - P-8 (247) Jet Needle - 6F9-3
Below-20"F Below ~ C (0-3000) 9()(>.1800
1 3000-6000)
1800-2700
AMBIENT TEMPERA TURE

-20' lo -t-10' F -29"le-12' C .10"to.40'F -12" to .S C AOOV9 . 40F Above SoC
"'00
360 320 260 240
' 340
32<l
300
AIL
Met.
(Ft)
300
(6000-9000)
270Q-3700
(9(XXl-1 2000)
nill dUt:'I . Shooedzone should dropJet Needleone position (raiseE-dlp) L

~ Production setting
Indy 500 RMK

EC50PL15 Carburetor Type - VM38SS Pilot Jet - 45 Main Jet - 240 Air Screw - 1 Turn Cut Away - 2.0 Jet Needle - 6F9-2 Needle Jet - P-4 (247)
Below-20"F SelO'N 2\J'C
AMBI ENT TEMPER ATURE

-20'lo. 10'F -29' 10 f2 C .10" O+40'F 12' to . 5C Above+40 'F Above SoC
(0-3000)
900-1800
"900
340
All. Met.
(Ft)
(300Q.6000j 1801)-2700 (50 00-9000)

2700-3700
260
"240
220 200
(9000-12000)
210
I,',.',;:":, -----.~l ;:":' ~"~K-'
- Shadedzone should raise Jet Needleone pO$itiOfl (lower E< flpto 1t3 )
! : i :;; : : : -' ~ - I _ Shaded zona should raise Jet Needle two positions l10wer E-<:lIp to #4)
, . Production Setting
Indy WldeT GT rak

EC50PM03 Carburetor Type - VM34SS Pilot Jet - 30 Main Jet - 200 Cut Away - 3.0 CH Air Screw - 1 Turn Jet Needie - 6DH7-3 Needle Jet - P-6 (166)
Below 20F Below -29' C
(Q..3000l 900-1600 (3000-60001 11300-2700 {600Q..90001 2700-3700 {9<XX)-12000)
AMBIENT TEMPERATURE
20' 10. IO F _29 6 to _126 C +10"lo . 40 ' F -126 to +SoC Abo>ill .40"F Above f1 ' C
"'00
210 195 160 160
200
165
190 176
160
All.
Met.
(FI)
1- ':i<:;, ~ A :< :'1

Indy WideTrak LX
EC50PL12 Carburetor Type - VM34SS Pilot Jet - 35 Main Jet - 190 Cut Away - 3.0 Air Screw - 3/4 turn Needle Jet - P-6 (166) Jet Needie - 6EJ26-2
_Shadedzone should dropJet Needle one positon (mise E-<:liPJ i

AMBIENT TEMPERATU RE
BeIoW -20"F Below -29"C
C0-3000l 900-1800 (3000-60001 1800-2700 (600Q..9000l 2700-3700 {9(XXl-120001
-20' lo +10'F -29'1o-12' C

' 190
+10"to+40' F _12 10 +5"C
ADove+40 "F Above S"C
"'00
200
165 170 150
160 165
170
All.
175
Mot .
{Fl}
h::-:<f M _Shaded zone shoulddrop Jet Needleone position (raise E-<:llp) : J

, - Production Setting
5. 11
11/95
FUEL SYSTEM/CARBURETION 1996 Jetting Compensation Charts

Indy 440 XCR EC45PL07 Carburetor Type - VM34SS Main Jet - 260 Piiot Jet - 50 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 6DH3-3 Needle Jet - 0-4 (286)
AMB IENT TEMPERATURE
BeIow-2 0"F
-20~ 10 ..10
-t o-e ... 40'F

-12' 10.S"C
Ab<l\I e +40' F
8elow 29 C
-29' 10-12'C
Above S' C
o-soc
(0-3000)
270 260
230
MO
250
230
900.1eoo
All. {3ooo-6000)
240
Met.
e Ft)
11100-2700
(6000(9000)
2700-3700
(!lOO).l2000)
210
f1$)h :n! _Shaded zone should Clrop Jet Needle one position (raise E-<:Iip)
- Produc tion Setti ng
Indy 440 XCR SP EC45PLO B Carburetor Type - VM34 Main Jet - 260 Cut Away - 2.0 Jet Needle - 6DH3-3
AMBIENT TEMPERATUR E
B6low-20'F Below -es-c 20 lo.10'F 29 '10 12"C . IOto . 40"F -12" to -s-c Above . 40 'F
aecves-c
230
Pilot Jet - 50 Air Screw - 1 Turn Needle Jet - 0 -4 (286)
<>900
(o-30aOI
9(1)-1800
260 '"0 230

200
MO
250
All.
(300o-6000j
180(}.2 700
250
Met.
(Fl)
(6000-9000) 2 700-3700
(9000-12OOJ)
P h t:'.
-I . Shaded zone shook! drop Jet Needle one coencn (raise E-clip) AMBIENTTEMP ERATUR E
8e low-20"F Below _ 29C {Q-3000} 2 0' to . t o"F -29"\0 -12"C . 10"to .40F -12" \0 -s-c Above ..40' F Above SoC
Indy 600 XCR EC5BPL02 Carburetor Type - VM3BAL Slide Main Jet - 260 Pilot Jet - 35 Cut Away - 2.5 Air Screw - 1.0 Turn Jet Needle - 6DH7-3 Needle Jet - 0 -2 (247)
eeoc
270 250
220
260 240 220 200
240 220
230 210
aco-ieoo
All. (300o-60oo)
Mel.
(Ft)
1800-2700
(800 0-9000 )
270Q-3 100
(9(j()(}l2000j
200
l :> "::;1 Shaded zone should drop Jet Needle one pcstno n (ra rse E-elip) ,.//{
Indy 600 XCR SP EC59PL01 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)
AM BIENT TEMPERATUR E
aecw-ao-s
Below-29C
-au-to ... 10' F

-2910 12C
. 10' to . 40F 12" 10. s oC
Abo'I'e.4 0"F Above SoC
e- oc e
(0-3000j 900- 1800 All.
420 390 350 310
400
370
350
(3ooo-BOOOI
1800-2100 (8000-9000) 2700-3700 (9OC()-12C'OOj
370
Mel.
{Fl )
~
Indy XLT EC58PL03 Carburetor Type - VM34SS Main Jet - 210 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.0 Turn Jet Needle - 6DP17-3 Needle Jet - 0 -2
- Shaded l one should drop Jet Needle one position (raise E-cllp)
AMBIEN T TEMPERATURE
BeKlw -20 F Below-29 ' C (0-3000) 900-1800 {300o-6000j 1600-2700 (6000-00001 2700-3700 {9a12OOO}
0-'00
-20" to . 10"F -29lo1 2'C
.1 0"10. 40"F - 12" to -s-c
Allovll . 40F Move SoC
220 200 175

180
210 190 170 '50
200
180
185 185
All. Met.
(FI)
!)--:t):tnd . Shaded zone snono drop Jet Needle one cosmon (relse E-elip) x
11/95
5.12
Indy XLT SKS EC58PL03 Carburetor Type - VM34SS Main Jet - 210 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.0 Turn Jet Needle - 6DP17-3 Needle Jet - 0 -2 (166)
Below -20 "F
Below29"C
_ 20 to ...10'F 29"lo -12"C
...1010 + ~ O F
-12" 10 -s-c
Above . 40F
AboveS 'C
o-aoo
((1.-3000)
220 200
210
190
200
185 185
900- 1800
All. Mat.
(3000-6000)
(FI)
1800-2 700
(800 009000)
27~3700
''''
175 160
170 150
{OOOO-l2000l
l , h: l ;~~,~ x::1
Shadedzone should dropJet Needle ana position (raise E-dlp)
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 - NIA (ACCS) Cut Away - 2.0 Needle Jet - 0 -6 (480) Jet Needle - 6DP17-3

Below20 F
Below -29"C -20' \0 +I O 'F -29"10-12"C
...t o-te +40 "F

-12"\0 . SoC
AboVe .40"F Above SoC
Mw,
J ot
Production Setting
230
210
'190
" 0
Indy XLT SP EC58PL02 Carburetor Type - VM38AL Main Jet - 260 Pilot Jet - 35 Cut Away - 2.5 Air Screw - 1.0 Turn Jet Needle - 6DH7-3 Needle Jet - 0-2 (247)
AMBIENTTEMPERATURE
Below20 ' F BeJow-29"C -20' to +10"F -29 "lo -12"C
+10"'0 . 40 F
12 to . 5 C
Above . 40"F AlloYe S"C
o-sco
((1.-3000)
270 250 220 200
260 240 220 200
240
230
All. Mel. (FI)
900-18 00 {30Q1). 6000J

16()(}2700
(6000-9000)
2700-3700
(9CXX>-12000j
I+rn:F@rj _Shadedzone shoukl drop Jet Needle one position (raise E-chPI
Indy XLT Touring EC58PLE05 Carburetor Type - VM34SS Main Jet - 250 Pilot Jet - 35 Cut Away - 2.5 Air Screw - 1.0 Turn Jet Needle - 6DP17-3 Needle Jet - 0-2 (166)
AMBIENT T EMPERATURE
Selow -20' F Below -29C -20" 10.IOF -29' \0 -12' C . 10to . 40"F -12' to .. SC Above . 40"F Above S' C
c-soc
(().3000)
270 240
'' '0 230 210 190
240 220
230 210
A n.
Mot.
(Ft)
I-".=+-.:....:....--+----.:::..:.---+- - +_ lBQO.27oo
(6000-9000l
2700-3700
[9<XXJ-12000)
900- 1600 (300Q-6000)
220 200
IC: ~: : : -: : : : : : : :, ~] _Shaded zone should dropJet Needle one position (rais9 E-clip)
- Productiort Setting
5.13
11195
FUEL SYSTEM/CA RBURETION 1996 Jetting Compensation Charts

Indy Ultra RMK EC68PL04 Carburetor Type - VM38 Main Jet - 280 Cut Away - 1.5 Jet Needle - 6DH8-2
AMBIENT TEMPERATURE
Below20"F 20' 1 +10'F 0 .. ' 0' 1 +40' F 0 Above ..40"F
aeow -zs-c
-2'9"lQ -12' C
.12 " 10' S C
AbQve S' C
Pilot Jet - 50 Air Screw - 1.0 Turn Needle Jet - P-4 (247)
0-900 (0-30001
All.
Mel.
(Ft)
9(. 1800
(3000-6000)
1600-2700 (6000-9000)
2700-3700
(9OOJ-12000 j
290 270
sec
260
270 250
260 240
I ':,:,:;:~i'i'i :\ : ]
_Shaded Z0I19 change cylinder head

Shaded zone prcc uctlon setl lnQ
c=:=J Indy Ultra SKS EC68PL01 Carburetor Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
No Jet Needle Changes are g ecommetoec
AMB IENT T EMPERATURE

6e low 20 F Below -29' C -20' to +10'F -29' to -12' C +10 to . ",O'F 12 ' to +S' C
Above ..40 'F
Abovo S' C
0-'00
(0-3000) 900-1800
(300o-6000j
tSl)D-2 700
(6OQ().9000)
350 320
290
340 310 280 260
320 300 270 260
300 280 260 240
All
Mel. (Ft)
2700-3700 (OCOO-l2000)
270
Indy Ultra SP EC68PL01 Carburetor Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
AMBIENT TEMP ERATURE

Below '2 0"F Below -29' C -20' to +10"F
+10" 0 +4l)4F
-29'\O -12' C
-12' to +S'C
A1XW8.4 0 'F AbOVoS' C
0-'00
(C).30 0 0)
350 320 290 270
340 310 280 260
320 300 270 260
300 280 260 240
900-1800
All
Mel. (Ft)
(3000(6000)
1800-2700 {60000 9000l

27()(}37QO
(8000-12000)
Indy Sto rm EC80PL05 Carburetor Type - VM38SS Main Jet - 400-400-420 Pilot Jet - 45 Cut Away - 3.0 Air Screw - 1.0 Turn Jet Needle - 6CGY6-3 Needle Jet - 0 -0 (247)
A MB IENT TEM PERATURE

Below -2Q' F Below 29 C
0-900 (GaOOOj 20' 1 0
+10"F
. 10 ,o ...40'F -12" 10.S C
Aboye ..40F
AlXNe S' C
-29 "to 12 C
420 420 440 390 390 410

360 360 360
400 400 420 370 370 390
380 380 400
360 360 380
All
Met.
(FI)
901).1800 (3000-6000)
1800-2 700
(600l).9000)
2700-3700
(llOOO-12000,
320
320 340
l.:d:%wul Shaded zone Should drop Jet Needl e one position (raIse E-elip)
c:::::J .Producncn Setling

?TO
emeneet - Mag blggast. PTO..cenler-Maq lett to right
11/95
5.14
FUEL SYSTEM/CARBURETION 1996 Jetting Compen sation Charts
Indy Storm SKS
BeloW -20+F
EC80PL05 Carburetor Type - VM38SS Main Jet - 400-400-420 Pilot Jet - 45 Cut Away - 3.0 Air Screw - 1.0 Turn Needle Jet - 0-0 (247) Jet Needle - 6CGY6-3
-20" \0
Below 29"C
~900
.' O "F
-291 _12 C 0
.10"10.40 "F -12' 1 .S C 0
ecove . 40 +F
AOOVQSoC
(0-3000)
420 ' 20 " 0 390 390 410 380

380
400 400
420
380 380 400
380 380 380
All. Met.
911800
(300D6000j
(Ftl
1800-2700 (6QOO.9000j
390
2700-3700
{9(XXJ..12OOO)
320 320 340
h'h ~ifu eH . sneeee Z0I'I8 should drop Jet Needle one posulon (raiss E"Clip)
c:::J -Prooucuon
Indy Storm RMK
Setting
PTO smallest - Mag biggast, PTO-Center-Mag left
to right
AMBIENT TEMPERATURE
EC80PL04 Carburetor Type - VM38SS Main Jet - 330-330-350 Pilot Jet - 50 Air Screw - 1.0 Turn Cut Away - 3.0 Needle Jet - P-B (247) Jet Needle - 6CGYB-3
o-soo
(0-30001
M e1.
(Ft)
.,.
900-1800 (3000-6000)
aEl.OW 6000 FT (1800 M) INSTAll DOUBL HEAD GASKET E 1800-2700
(6000-9000)
330 330 3SO 300 300 310
310 310 330 280 280 300
2700-3700
(9OQ[)-12000)
p 'MrfMU .Shaded zone should raise Jet Needleoneposition (Iower E-clip 10 #4)
c:::J -
Production Setting
c==::J -ShBdad zone should dropJet Needle one pOSition(raise E-elip)

PTO smallest - Magbig gest. PTD-Center-Mag leftto nght
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
Balow -20 'F -20' to . 1Q' F +10'\13 . 40" F
Abo~ e
. 4Q' F
Below 29' C
~900
29'10 12 C
12" to . S"C
Above S"C
10-3000)
900-1800 (30QI}-60001
160 145 130 "5
'50
140
135
Alt.
Mel.
(Ft)
1800-2700
(600D-9000)
2700-3700
(9000-1 2()((1)
I ~: ~ g ;:':> d
Indy Lite GT 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)
_Shaded
zone Slloold drop J et Needle one positiOI1 (raise E-cIiPJ

8elow -20' F Belew -29 " C
~900
-20' !o +10' F -:<'9'10 '12"C
. 10' to +40' F 12' to . 5" C
Above . 40" F Above 5" C
((}'3000)
160
150
140
135
All.
901l-t800 (3QOO.6000J 1800-2 700

(600Q.9000j
Mel.
IF !)
'"
130 " 5
2700-370 0
(9000- 12000)
I"f~ ~ ,:;:,;" , ~ t:1 _Shaded zone shOUld drop Jet Needle one pcetuon (raise E-clip )
Indy Lite Delu xe 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
Blllow -20' F Below -29"C
~BOO
-20' tc .. 10'F -29'10 -12"C
..10010 ...l0 'F"
12" to
. ~C
AboVe ..40<F" Above S"C
to-3000}
160 '45 '3D 115
1SO
140
'35
Al l. Met.
j F1}
90().1SOO (3000-6000)
180().2700 (6000-9000) 270().3700 (9OOO- 12000)
l,; yH'n'HI _Sha ded zone should d rop Jet Nee<J'le one pennon (raise E~IIP)
Indy Sport 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)
AMBIENT TEMPERATURE
Below -20 ' F Below -29'C
~900
-20" 10 .T O"F
-ss- -12"C
165 170
. 10' [0 ..40'F"
-12" to . SC
AbOve <.\O' F Above S C
{().3000j 90D-1 800 (3000-6000)
195 185
"5
All. Met. (Ft)
180l}2700 (600().9000) 270l}3700 (9OQ().1200Cf)
I:F~ ; ~ < )JF--;;j _Shaded zone shou ld drop Jet Needle one pc suion (raise E-chp)
Indy Sport Touring EC44-3PM02 Carburetor Type - VM34SS Main Jet - 185 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.0 Turn Jet Needle - 6FJ6-3 Needle Jet - P-B (166)
AMBIENT TEMPERATURE
~iow-20 " F"
20" to .I O"F"
Below-29'C
0-900
29'10 ' 12' C
.1 0' 1 .,:O 0 "F -12" to _S' C
Above +40"F Above 5 C
i().3OO01
900-1800
(3 00 ()' 60 DO )
195 185
16'
175
All.
M~ .
(Ft)
1800-2700 (600 0-9000) 2700-3700 (900C 2000) H
~
9/96
- Shad ed zone Should drop Jet Needle one position (raise E-clipl
5.15a

Indy TranSport EC44-3PM02 Carburetor Type - VM34SS Main Jet - 185 Pilot Jet - 35 Air Screw - 1.0 Turn Cut Away - 2.0 Jet Needle - 6FJ6-3 Needle Jet - P-8 (166)
AMBIENT TEMPERATURE
Below-as- c
aecw-ao-s
-20'!o +10' F 29 'I\l12'C
0-900
(0-3000)
900-1800 (3000-6000)
160 0-2 700
' 95
185
185
"5
All.
Mel.
(Ft)
(6000-90 00)
2711G-3700
(9OO:).12OOOJ
~
Indy Super Spo rt
- Shadedzone should drop Jet Needle oneposition (raise E< lipJ
AMBIENT TEMPERATURE
Balow 2D~F Below -29"C
0-90 0 (0-3000)
EC50PM06 Carburetor Type - VM34SS Main Jet - 250 Pilot Jet - 45 Air Screw - 1 Turn Cut Away - 2.0 Jet Needle - 6DH7-3 Needle Jet - 0 -8 (480)
-20 ' 1 ..10"F 0 '29 10- 12C
..10 '10 .. 4D"F 12' to ..s-e
soove ..40f
Abova S'C
"3
250 220
250
240
'30
911800
All. Met.
(300Q.6000j
lFI>
1800-2700 1 OG-9000j 6C
2700-3700 {!IOO[). l2QOO,
,>0
- snacec zonesnould drop Jet Needleone posmcn trarse E-chp}
Indy Trail EC50PM04 Carburetor Type - VM34SS Main Jet - 230 Piiot Jet - 35 Cut Away - 3.0 Air Screw - 1.5 Turn Needle Jet - P-8 (166) Jet Needle - 6DH7-3
AMBIENT TEM PERATURE

Balow -20' F -20 ' to . , Q' F
aeic.... -29"C
0-900 (0-3000 1
-29 ' (0 , '2 'C
.. l O ~ IO +4D"F .12 ' to . 5 C
Above ..40 F Above S C
240 220 200 190
230 210
220
210
All.
Mel. IFl)
90Q-1600 (3000-60 00)

1600-2700 (600 0,90 00 ) 2 70 0-3700
(9000-' 2000)
~
Indy Trail Touring EC50PM04
Shaded lone snono drop Jet Needle one position (raise E-<:llp)
AMBIENT TEMPERATURE
Be!CIw- 20"F Below-29' C
0-900 {D3000l
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)
20'!O ..10' F 29"to-12' C
. 10' to ..40"F
AOOvtl ..40 ' F
-tz-tc ..S'C
220
xtcve s -c
2'0 220 200

190
230 "0
All. Mel.
900-1600 130 00-6000)

1800-2700 (5000-9000) 2700- 3700 {llOOO-:2000 }
W!}
p ,j # :):;MI _Shaded zone should drop Jet 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)
AM BIENT TEMPERATURE
Beiow-20"F BeIQw -29 'C -20" 10..10"F -29' 10-12'C +10'lo ..40"F - \2 ' to ..S-C
Above . 40 F Abo vo S' C
0 900
(().3000) 90(}16oo (3000- 60 00)
3'0 3' 0
#3
"
290 .3 290 290 .2 290
270
#3
250 250 250
270 270
"
All.
Me t.
iFt'
11.'100-2700 t600().9000j 270Q-3700 (900(} 12000)
310
"
"
310
"
".
"
ea
ea
ez
270
.,
250
Production Sel'llng
"
9196
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
Below -20 "F Below 29v C 0-900 (0.3000 ) -20 ' to .. IO' F -29' 1 -12"C 0 ..10"1 +40"F 0 -12" to .. s-c Above +40 "F Above SC
290 260 240 220
270
250
240
900-1800
All.
Mel.
(3000-6000)
IFI)
1800-:1700
(6000-9000)
27Q o.37Q O
(9COO- l 2000)
1:::< ;:;: .1 . Shaded zo ne shoo ld drop Jet Needle c ne positi on (raise E-c hp) ;:'2;:
Ind y 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)
AMBIENT TEMPER ATURE
aec.... -20 F 8elow 29 -C
0-'00 10.3000)
20' to +l O"F
.1 0 "1 ...40"F 0
29 'IO 12"C
"350
-12' to . S C
Above . 4C F Aoovo S"C
370 330 290 2'"
330
"0
"",.
All.
(Ft)
90G-1800 (300G-6000j
1801}2100 (6000-eeOO)
'"
270 2' 0
270Q..31Q O
1 9C1()O.12000 )
I,.,<t:+:!,'l Sh aded zone should drop Jet Needle one pOSItion rrarse E-c1ipJ :
Proc ucucn Settlng
Indy Class ic Touring EC50PL19 Carburetor Type - VM34SS Main Jet - 250 Pilot Jet - 40 Cut Away - 3.0 CH Air Screw - 1.0 Turn Jet Needle - 6EJ26-3 Needle Jet - P-2 (480)
AMBiENT TEMPERATURE
Bolow -20'F Below -29' C
0-900 (0--3000) 900-1600 {300Q6000)
1801).2700 1600G-9000) 2100-3100 (OOOO-t 2000 )
-20 ' [0 ~1 0' F -29"10-12 "C
~ 10' IO
_"O' F -12" [0 .5"C
Abo~o
..40' 1' Above 5"C
'60
240 220 200
-aso
230
"0
230
Alt Me\.
tFt)
I : +: ~: ~: ~? : : I _Shaded zone should mop Jet Needle on e posi tio n (raise E-<:hp)
, - Prcoucton Settlng
Indy 500 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)
Below-20 ' F Below -2S"C
0-900
to-3OO 0) -20 " lO. 10 "1' -29 ' 1 -12 'C 0 ..10 "[0 . 40 -1' -12' [O _S"C
Above . 40 "1'
Above
5 ~C
370 330 290 250
' 350
3 10
330
290
310
All. Mel.
tFl)
900-1600 [3001).60 00)

lBOG-2100 10000-9000) 2100-3100 (5000-12000)
If "'0
270 240
III .JilII.! I i1i~! II"
1,,\: ::,,::,'"'11 _snecec zone shoul d drop

, - Production Semng
_I ""m:. ~
Jet Need le one posi tion (raise E-cl ip)
9196
5.15c

Indy XCF EC44-3PM02 Carburetor Type - VM34SS Pilot Jet - 35 Main Jet - 185 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 6FJ6-3 Needle Jet - P-8 (166)
AMBIENT TEMPERATURE
BeJo -20"F w Balow-zs-c 0.900 1O-300Q}
900-1800 (3DOQ.60001
-20'IO .lO' F -29"10-12"C
...10lo +4Q'F -12' to +5"C
Aoove ..40'JF Aoo e S'C ....
lOS
185
All. Met.
{Ft }
185
1800-2700
(6000- 90001
2700-3700
(9OOl).120001
I;-':H'i'H \ !
Indy 500 SKS EC50PL1 7 Carburetor Type - VM38SS Pilot Jet - 40 Main Jet - 350 Cut Away 2.5CH Air Screw - 1.0 Turn Jet Needle 6F9-3 Needle Jet - P-8 (247)
.. Shaded zone should drop Jel Ne edle one position (rajse E-c lip)
AMBIENT TE MPERATURE
Balow -20 "F aecw.. 29 'C
Q.900 (Q. 0QO) 3
9O(}. 18oo
2Q" to . l0 ' F -29 ' 10- 12"C
. , O'! O.40 F -12" 1 . S"C 0
Aoove +40'F
ecve s-c
3 10
370 330 290 250
'350
330
All.
Mel.
(Ft)
(3000-60 001
310
270
180/).2700
(60 01).9 0 00 )
2700-37 00
(9000-12000)
240
H:: v/:::::: . Sl'1aded acne sho uld d rop Jet Needle one POSIIJO!'I (rai se E-ctipJ d
... Production Setting
'--'"
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)
AMB iENT TEMPERATURE Sa lem 20"F

8e low 2Q-C jD-3 0001
900-1800
.. 0 " to. 10' F 2 -aa-e -12 ' C
. 10' lo . 40' F , 12 ' to .S'C
AbOVe +40"F Aoove S'C
~'OO
290
Al t,
(3ooD-80 00j 160D- 700 2 {600o-00oo1 2700-J700 19OOl).12000t
"" 290
290 290
270 .4 270
250 250 '3 '250 250 '3
.,
"
240 .3 240 '3 240

'3
Met. (Ft)
..
#4
'4
270 '3 270 '3
ea
I': ':! :! !:i!i~~ , iii

:i4)
I J~?' ~ >, I . Shaded zc ne shou ld raise Jet Nl!edle one oosmc n (lov.er E-<;l lip to It.'))
c=J -sne e ec zona should raise J et Needle two pos.uons uowe r E--dip 10
, - Production Setting
Indy WideTrak GT EC50PM03 Carburetor Type - VM34SS Main Jet 200 Pilot Jet- 30 Cut Away 3.0 CH Air Screw - 1 Turn Jet Needle 6DH7-3 Needle Jet- P-6 (166)
AMBI ENT T EMPERATUR E

BelOw , 20' F Blllow-29' C
0-900
-20' to .10' F -29' tO- 12' C
.10' 10.40' F -12' 10 ' S'C
eco ve .40' F AbQIIll S' C
(o-J OD O) S00-18OO (JOOD-60001 1600-2700

\6000- 9000)
210
' 200
190
160
Alt.
Met. (Ft}
19'
160 160
16'
27003 700
(9000-1:<'000)
I ~ P ?/ ('~" I . Shaded zone should drop Jet N eedle one POSition (raise E-clip)
, - Produc tion Setting
5.15d
9/96

Indy WideTrak LX EC50PL20 Carburetor Type - VM34SS Main Jet - 195 Pilot Jet - 35 Cut Away - 3.0 Air Screw - 1/2 turn Jet Needle - 6EJ26-2 Needle Jet - P-6 (166)
AMBIENT TEMPERATURE
sec..... -20 'F
20~ IO
Below 29"C
0900 (G-300D)
. 10 F -29 ' [012'C
.lC" lo ...40F
Atlovtl .40"F
-12" 1 ..S C 0
Above S' C
2("
190 175
155
'195
,8()
,'"
000-1500
All. Mel. (AI
(300 0-60 00)
l BOG- 700 2
(6000-9000)
2700-3700 (9000-t2OOO)
I S~ j F----::_1 Shaded z one sncuo drop Jet Needle one POSllion {raise E~lipJ
- Production Sell ing
Indy 440 XC EC45PL08 Carburetor Type - VM34SS Main Jet - 240 Pilot Jet - 50 Cut Away - 1.5 Air Screw - .75 Turn Jet Needie - 6DH3-3 Needie Jet - 0 -4 (286)
AMBIENTTEMPERATURE
8e low-20"1= 20" lo.l0"F . 10"10 ..40 ' F AOOVe +40 'F
aeo..... 29'C
-29'm -l2" C
-12+ to ..S' C
Al':l<we 6"C
0-900
(0-3000)
250 230 2' 0
240 220
230
220
Alt.
Mel.
900-1800 (300D-6OO0)
(Ftl
1/3 00-2700
(l3oo D-9 0 00)
2701)-3700 (9COO- 120oo) ,---;;;;;;]
' 95
one POSITio n (raise E-c llp J
L-...Jiij - s naoer zone should d rop Jet Needla
Indy 600 XCR EC59PL01 Carburetor Type - VM38SS Main Jet - P-360/C-380IM-380 Pilot Jet - 40 Cut Away - 2.0 Air Screw - .5 Turn Jet Needle - 6CEY6-4 Needle Jet - P-6 (247)
AMBIENTTEMPERATURE
Se lOw-20' F
Below-29' C
" 900 (0-3000 )
-20' to ...l O'F -29'10 -12 C
t e -te .40' F -12 ' to s oC
Aeeve .40' F
s cove S'C
All. Mel.
400
90"1800 (3000-6000) laOO-2700 (6000-9000)
300
iFt)
3'"
2700-3700 (9000-12000)
1- << _ > : 1 Shaded zone should drop Jet Needle one posrnon (raise E-ellpl
0
Indy 600 XCR SE EC59PLOl Carburetor Type - VM3BSS Main Jet - P-360/C-3BO /M-3BO Pilot Jet - 40 Cut Away - 2.0 Air Screw - .5 Turn Jet Needle - 6CEY6-4 Needle Jet - P-6 (247)
Below -20' F Bolow -29'C

Q.900
AMBIENT TEMPERATURE -20 ' to . 10' F . 10"1 .40F 0 eeove +40' F

-29"10 12 ' C
12' 1 .. SC 0 Above S C
(0-3000)
All. Mel.
WI)
400 90(}laOO
(300(}.6000) 180(}o27QO
380
360
.-/
3 60
350
/6000,900 0)
2700-37 00 (9OQO. 12000)
c:::::::JjjJ . Shaded zone should c-eo Jet Neec'e one position (ra-se E-cllpJ
9/96
5.15e

Indy 600 XC EC58PL08 Carburetor Type - VM38SS Main Jet - 270 Pilot Jet - 35 Cut Away - 2.0CH Air screw - .75 Turn Jet Needle - 6DH7-3 Needle Jet - 0 2 (247)
AMBIENT TEMP ERATURE
BeloW
-~ 'F
Beltr '29 'C N

0-900
20' 10. IQ' F 19 '10 -ra -c
.10',0 .;O"F -12' 10..S C
At!a-'1I .40' F Above S'C
(o-JOOOJ
000-'800
An
Mol (Ft)
290
V1l
250 240
220
2'0 230 210 190
13000-60001
1800-2700 lSO(lO.9000l
2700-3 700 (00'.12000)
260 240 220
250 23O 210
200
c:::==J .
Indy XLT EC58PL03 Carburetor Type - VM34SS Main Jet - 220 Pilot Jet - 35 Cut Away - 2.0 Air screw - 1.0 Turn Jet Needle - 6DP 17-3 Needle Jet - 0-2 (166)
Shade d zon e shou ld drop Jet Need le one pcsmon (raise Ec llp)
AMBIENT TEMPERATURE
Below '20 ' F Below '29 'C -20 ' 1 .. IO' F 0
.. 10 1 . <10 "': 0
Above .Kr F
29' !o- IZoC
, 12' 10 .S C
o\lO>Ie S' C !
0->00 10-3000 )
2:lO 210
220
200
210 190 17' 170
200
900-1800
All.
(3000-60001
1&:10-2 700
(6000-9CIOO )
180 170 170
Mol {Fl)
19'
180
185 170
1700-3100
(9'.lXI-I20001
c:::==J .
Indy XLT SKS 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)
Shad ed ZOl'1 e should drop Jet Need !" one po,.llon lraiM! E c: g ) h
AMBIENT TEMPERATURE
Betow 2Q' F Bt!/ow 29 'C
0900
((l.3000)
20 to . 10' F
29 ' 11l12 C
,, ' O'\0 .40' F
AOoYe..oI 'F O
12" to .S C
Above S'C
23O 210 195 180
220
210 190 17' 170
200 180 170 170
All.
900.\ 600 (30006000) 1800-2700

i6(jlJQ. 9000~
200 18' 170
Mat.
(Fl)
2700-3700
!9'Xo-l2O:O'l
c:::==J _
IndyXLT RMK EC58PL07 Carburetor Type - VM34SS (ACCS) Main Jet - 240 Pilot Jet - 50 Cut Away - 2.0 Air Screw - .75 Jet Needle - 6EJ3-2 Needle Jet - P-2 (480)
Sh ad ed zOI'l shotJld drop Jel Nee dle one pc)S e 'hon (ra,se E-clip )
AMBIENT TEMPER ATUR E
moc ates E -chp Loca llOl'l lrom lop 01 Jel
eece-ss -c
0-900
Balow -20' F
-20' khl O' F 29" ",l]'C
::~: l~
..
z:
Nee-ojle
AboVe
.40' ~
A.oo. e S'C
,o-JOOOJ
900-'800
All.
(3OOQ.6000)
280 280 '2 260 '2 280 '2
.,
260
ea
260 260
.2
Mel (FI)
11'.00-2700
[t;()OO.9000)
"
2'0 '2 2<0 .2

' 240
2:lO '2 230
ea
230 230
ecoo 12(00)
P rcoc cnco Setting
2700-3700
260
ea
'2 2' 0 .2
"
"
5.151
9/9 7

Indy XLT SP EC5BPL12 Carburetor Type - VM3BALSS Main Jet - 270 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1.5 Turn Jet Needle - 6DH7-3 Needle Jet - 0 -2 (247)
AMBIENT TEMPERATURE
eecw -ao -r
BelO 29 ' C w
-20' to .. t o' F
29' 10 '1 2~C
...10 ' 10 ..40' F -12 ' 1 +5' C 0
Above . 40' F
acove 5' C
0900
(o-3000j
290 270 240 220
270 250 230 210
250
240 230 I t' 2 ' 01l2
All.
900-1eOO (3000-6000 1 160Q.2 700 (60DO-9000) 2700-3700 19CXlO-12000)
240 220
Mel.
(Ft)
~ - Shaded zone should drop Jet Neadle one position traise E-chp} ~
~
..10"10+': 0' F -12 ' 1 0.S C
Indy XLT Touring EC5B PL09 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) Inlet Needle Seat - 1.5
AMBIEN T TEMPERATURE
Below -20' F
aecw 29 ' C 0.900

t().3000j
-20' to ,,"1 D F -as- e -12'C
Above +40'F
Above5'C
280 250 230

21D
240
230
900-1800 All. Mel. (Fl)

(300 Q-6000 j
1110O-2700 \6000-9000 j
2700-3700 (9l)JO>120(0)
I n ' w ~ D}l
Indy XLT LTD EC5BPL09 Carburetor Type - VM34CS Main Jet - 260 Pilot Jet - 35 Cut Away - 2.5 Air Screw - 1.0 Turn Jet Needle - 6DP173 Needle Jet - 0 -2 (1 66) Inlet Needle Seat - 1.5
_Sha ded ZOIle sh ould d rop Jet Needle on e po sition (raise E-clip )
AMB IENT TEMP ERATURE
Balow -20 ' F
Below -29 'C
Q.W)
Production Sellin g
20'
to . 10 ' F
.1 o-re .40' F
1 2 ' 10 . S C
Above . 40 ' F
-29 "10 .1 2'C
eecves-c
230
(0-3000)
9~1800
260 250 230 210
2 60 '
240
~
All.
Mia!.
(3000-6000, 1B00-2700 (lOC o-9000) 2 700-3700 (9000-1200))
2.0
{F!}
ItI'" ",p g! iIi;~B!r9 W i < soiiJ Ii Sc.;gj;"liii il ii \~;; iiE 1 i,> 3<lii'O
i)>56
~
Indy XLT LTD SP EC58PL1 2 Carburetor Type - VM38ALSS Main Jet - 310 Pilot Jet - 35 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 6DH73 Needle Jet - 0 -2 (247)
Shadedlone should drop Jet Needle one POSition rree e E-clipl
Production setting
AMBIENT TEMPERATURE
Below -20 'F Below -2gC -20 ' 1 +10 ' F 0 -29 '10 -12 ' C .10"0 +40'F -12' 1 . 5"C 0 Above .40 F s bcve s -c
...00 {a-3C oo)

900-1800
A lt. Mgl. (F I) (3001).6000)
330 310 260 260
310 290 270 2.0
290 270 250
270 260
180 0-2 700 (6000-9000) 2700-3700

(90'12000)
Iii .; (Riilili
L>: ~ ,u:,: :,:) ::,' :1
Shaded l one shO\Jld drop Jet Needle one posilion (raise E-clip)
9/97
5.15g
FUEL SYST EM/CARBURETION 1997 Jetting Compensation Charts

Indy Ultra EC68PL01 Carbure tor Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
AMBIENTTEMPERATURE
Below 20"F
20 to
-ro-s
..10"10 +40' F
ADl)vEl+40 ' F
6eiOw-29 'C
-29' 10- 12'C
-12' to ..S'C
aocve S' C
300 260 260 240
Pilot Jet - 40 Air Screw - 1.0 Turn Needie Jet - P-4 (247)
0900
{(}.JOOO)
350 320 290 270
340 310 260 260
320 300 270 250
All.
Met.
900-1600 (3000-60001
lftl
1600-2700 (6000-9000) 21Q(}.3700

(9000- 12 000)
Indy Ultra SP EC68PL01 Carbureto r Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
AMBIENT TEMPERATURE
Below -20 'F Beklw -29 'C
-20" 1 +10'F 0 -29"1 -12"C 0
+,O'1 . 40' F 0
, 12' to .. S"C
AOOWI ..<l Q <F
AooyeS' C
0-900
to-JOOO )
350
320
340 310 260 260
320 300 270

.<:50
300 260 260 240
soc-taco
All. Mel . (FI)
(SOO(l- SOOO)
1600-2700 (6000-9000)
270().37QO (9QOO.12000)
290 270
Indy Ultra Tou ri ng EC68PL01 Carburetor Type - VM38 Main Jet - 340 Cut Away - 2.0 Jet Needle - 6DH8-2
AM BIENT TEMPERATURE
aeew-ao-r
Below-29'C
20lo . tO "F
-29 ' 1 -12"C 0
"l O' to ..40 ' F . 12' to _S'C
Abo ye . 40'1'"
AboveS"C
(}.900 CD-30M)
900-1800 {300Q-SOOOJ
350 320 290 270
340 3' 0 2BO 260
320 300 270 250
300
All.
Mel.
(Ft)
280 260 240
160(}.2700
(6000-90001
2701)-3700 (9OOO-1201X1)
Indy Ultra SPX EC68PL03 Carburetor Type - VM38 Main Jet - 380 Cut Away - 3.0 Jet Needie - 6CEY6-4
AMBIENTTEM PERATURE
Below 20"F Bebw 29 "C
Pilot Jet - 50 Air Screw - 1.0 Needle Jet - 0-2 (247)
0-900 (1)..3OQOj
9{)1)..18oo (3000-6000) 1800-2700 (6000-9000) 2700-3700 {9000-12000)
400 370 .4 340 .3 310

#3
-20 ' to +10"F -29"10-12'C
380 350 320 '3 290
.
"
+10"10+<lO ' F - 12" to . S' C
AboV +40"F e Above SoC
360 330 300

#2
340 310
#2
"
"
"
#l
AIL
Mol (Ft)
280
#2
ea
270
..,
250
. Produ ction setting
Indy Ultra SPX SE EC68PL03 Carburetor Type - VM38 Main Jet - 380 Cut Away - 3.0 Jet Needle - 6C EY6-4
AMBIENT TEMPERATURE
Below -20"F BeloW 29"C
Pilot Jet - 50 Air Screw - 1.0 Needle Jet - 0 -2 (247)
0-900 {0-30001 900-1800 13000-600 0) 1600-2700 i8G00-9000) 2700-3700

(9OClO-12000)
400 370 .4 340

#3
.
#3
-20' to . 10"F -29"10- 12'C
,,'O'Io.40'F
-12 ~
"360
10..S'C
Above..40"F Abo SC ve
360
#3 330 #3
300
340
#3
All.
Mel.
350 '3 320 290 '2
310 260
..,
#l
1 Ft)
3' 0
"
.2 270 .2
ea
250
Production S elling
5.15h
9/96
FUEL SYSTEM/CAR BURETION

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 Needle Jet - Fixed Jet Needle - R1 370G-3
AMB IENT T EMPERATURE
Below-20 'F
Below 29 ' C
-20 ' to +10"F 2'9'10 . 12C
..l O to .40"F -12' 10 .S C
Above ..40'F AboveS ' C
0-"" ,D-30001
9QO. I8 oo
100
".
,65
175
165 ,
178 168 158

' 8
172 162 ' 5'
All MeL (Fl)
(300IH OOO)
1800-2700
{6OOQ-9000)
168 158
2700-37 00
(9000-'2000)
155
15<)
'45
c::::::::J -Above 6000ft use IN R I370J.3. 5.0 CA, 55 pset, ana 1121um 31fscrev. c==J -lower Je1 1 u e se E<l IP) and Ins tall RMK com pon en ts
N&ildle po$lllOn
liSled above ProduetJon 5etllng
Indy 700 RMK SN70LCDCSP-D2 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 - R1 370J-3
BelOW '20 'F
0-000
(Q.-3000)
... ..
Below 2t! 'C
-20 '10 .. IO' F -29'10 " 2"C
. 1 0 to ~O F
Above .40 "F
' 12' 10..SoC
Above S'C
;" 190
ii
185
17'
" 8
900- 1800
All.
(3000-6000)
1600-2700 (600Q.-90001
2700- 3700 (9000- 12000)
178
Mel. (Fll
172 ,I
I.'
155
'.8
158
165
" 58
150 '4 ' c==J -Lower Jet Needle 1 POSition va lse E-cllp} c==J .Below 6OO0tt use IN R1370G3. 6.5 CA, 40 pilot, B.rld , turn air screw , PrOduction Setling
/5,
Indy 700 XC SN70LCDCSP-Ol Carburetor Type - Keihin PWK 39 Main Jet - 185 Long Hex Pilot Jet - 40 Cut Away - 6.5 Air Screw - 1 Turn Jet Needle - R1 370G-4 Needle Jet -Fixed
# Indicates E-elip Localion 'fl)rn top 01Jet Needle
Below 20 "F Below 29' C
0-900
10-30001
900-1800
190
.,
...
"20'\0 .' O 'F 29 "101 2 'C
. '0'\0 , 40' F
"2' 10 ,S'C
,65
175
#4
178
Above .4()' F AOO v&S' C
178
.4
172
All. Met .
(Ft)
13000-6000) 1800-2 700 ISllOO- 9COC) 2 700-3 100
'.8 .,
158
'.5 .J 155
168 'J 158 'J ,5<)
"" '.2 .J
'55
.,
(9000-12000)
, ProdlJetl()fl 5et1ing
'"
ea
""
'" ""
Indy Storm ECBOPL05 Carburetor Type - VM38SS Main Jet - 410-400-420 Pilot Jet - 50 Cut Away - 3.0 Air Screw - 1.0 Turn Jet Needle - 6CGY6-3 Needle Jet - 0-0 (247)
AMB IENT TEM PERATU RE

IndICates E-d .p Localion from top 01Jel Needle
Below -2C' F Below29" C
20 '1O IO F 29 "1012'C
'410'400"420
J6OO5(YJ70
,10"o , 40 ' F "12' 10, S' C
Above .w F AlXllI& ,s' C

37006013&1
ea
All.
Mol.
(Ft)
(0-3000 )
0-""
4301420 ,440
'J
3801370090
000- '800
(3000- 6000)
1800-2700
1600Q-9000 }
J4OI330135O
2901280I3OO
., .,
.J
'"
3901380I400 'J
ea
.J
32lVJl0030
340133013S0 'J 3OCV29OI31 0

250124D1260
3201310030 .2
29012801300
240f23G'250
.J
27006<>"280
2700-3700 (900)-12000)
, ProdUClIO!'l
'"
""
settmg
""
.2
ea
M ag b199 8St, PTO-C enl er-Mag lell to ngll \
9/97
5.15i
Indy Sto rm SE ECBOPL05 Carburetor Type - VM38SS Main Jet - 410-400-420 Pilot Jet - 50 Cut Away - 3.0 Air Screw - 1.0 Turn Jet Needle - 6CGY6-3 Needle Jet - 0 -0 (247)
AMBIENT TEMPEAATIJRE
Below -20'F Belo"'-29 'C 43G'.:201440
20' \0 . 10F ' 29' 10-12 'C . 10 'O.40 F . 12" 105C
AbOVe .ofQF
Abo-.e 5 'C
#3
<>-900
(().3 000j
ea ea
'410:400'420
300," 501370 3
32Q'310030
27CY'~
All.
Mel. (Fl)
900- 1800 (300 0-6000)

1800-2700 (600().90 00j 270t).3700
380137013 90 340/3301350
29a12BOi300
t900CH20001
., .,
., ., " ea
39013B0i4OQ 340''330050
., .,
"
a
'7006Of3llQ
.,
ea
3201 1'330 '310 29012801300

24012301250
300129013 10
25012 401260
"
.2
Indy Sto rm RMK EC80Pl04 Carburetor Type - VM38SS Main Jet- 300-290-310 Pilot Jet - 55 Cut Away - 2.5 Air Screw - 1.0 Turn Jet Needle - 6CGY6-3 Needle Jet - P-6 (247)
AMBIENT TEMPERATURE
BeloW2QF
.,
Me l.
(Fl)
Below 29 C
e-eoc
{G-3000j
430/4 20i44 0
900-\ 600
3BOJ'37ot'J90
.
'
'20' 10 " O' F -29"10-12' C 410/400/4 20
36llf.l5OI370
3201310"'330
.
"
'".
{300D6000J
1800-2700
(6OO().90001
" ,,= "" 2901280I300
. '=01350
" -3OOI29Oi3.
0 .'
, 10 IO.40' F 12' to . S C
At::eYe . 40 "F
Aoove S' C
39013601400
3701360080 32013101330
29O'2BOOOO
2400'23Q1250
2 700-3700
(9(.00-120001
-prod UC1lOll Se lting
.
It
" 27Qf260!280
., .,
"
"
.,
25012401260
.,
Mag biggest, PTO-Csnler-Mag leM. 10 ngnt
"-",
Indy 440 XCR SNMLCDCSP-D1 Carburetor Type - VM34SS Main Jet - 360 Pilot Jet - 40 Cut Away - 2.0 Air Screw - 1/2 Turn Jet Needle - 6DH7-4 Needle Jet - P-4 (286 or 159)
AMBIENT TEMPERAT URE

Indicates E-etip locallCfltrom toP 01Jet Needle -20"\0 . IO' F
-29'\Q ' \ 2'C
Below -20 'F 66bvr -29'C
- tc-re . 40"F
-' 2' to
.~' C
At/lWe . 40 F AbOYe ~" C
o-soo
((}'3000)
3BO
-360
All. Me..
(Ft)
900- 1800 (3000-6000) 1800-2"0 0 (5000-9000) 2100.31 00
" "0
"'0
.,
.'
" '"
320 290
26ll
., ''"
'00
270
19QX)-'2OOlI
, ProdI..ct>on Se tting
.,
" .,
" ., ''" "
., ., ""
250 220
320
270
.,
.J
5.15j
91 97
FUEL SYSTEM/CARBU RETION 1998 Jetting Compensation Charts

Lite Lite Deluxe Lite Touring
EC34-2PM 02 VM30SS
(1)-30001 AMBIENT TEMPERATURE
II Indicates
e-cac Location from top of Jet Needle 20 to

+10'F
-29' 1 0
AIL Mel{FtJ
Below
-es-c
160
-20' F
-tu 'tc <t-40'F -12' tc ...S C
Above +.:lO'F Aoeve 5' C
-12-C
"150
Main Jet - 150 Pilot Jet - 35 Cut Away - 2.5 AL Air Screw - ' .5 Turn Jet Needle - 5DP7-2 Needle Jet - 0 -6 (169)
900-1800
[300Q.5ODO) lflOQ.2700
1"
1 6000-90001
:270(}3700
130 115
., ., .,
,,, .,
125 .2 11 5
ea
1'0 130
.,
135
ea
ea
125 1'5 105
., .,
"
120 110
#l
.,
j9C()C)-l2000J
.,
.,
Sport Sport Touring TranSport

XCF
AMBIENT TEMPERATURE
:I
Indicates E-clr location from top 01Jet Needle p Below

~20'
Alt. Met(Ft)
to
+\ O"to
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)
Below -29' C
0-900
(0-300 0)
-20"f
+10'F -29 ' \0 -12'C ' 185
+40 'F . 12 ' 10+S'C
Aboye +40 ' F .A.bolJe S'C
195
ea
115
165 150 135
900-1800
(3000-600 0)
160(} 2700 (6000-90001
185
'"
170 155
165 150
" "
160 145 135
.,
"
.,
"
.,
ea
2700-3700 \9000-12000)
'" .,
ea
.,
145 .2
ea
125
Super ;:rcort EC50P 061 VM34SS Main Jet - 250 Pilot Jet - 45 Cut Away - 2.0 Air Screw - 1 Turn Jet Needle - 8DH7-3 Needle Jet - 0 -8 (480)
1/ Indicates E-cIip tccauon from lOpOf Jel Needle
AMBIENT TEMPERATURE
Below
-20' F
AIL
Mel.(Ft)
-20 ' to
+10 ' F -29' 1 0 - 12 C '250
...10 ' 10 +40 'F

- 1 2 to +5 ~C
Above
+40"F
Below
-29 'C 0-900 (0-3000)
Abo'Je5' C
260
900-1800 (3000-6000) 18002700 j6001).9OO01 2700-3700 (9000.1 2000)
"
250 .3 220
#3
240
.3
230
#3
#3
230
#3
220 '3 210
210 ,2 200 200 .2
210
#3
"
200
.,
210
#3
200 .2
.,
Trail Trail Touring

Alt.
AMBIENT TEMPERATURE
# Indicates E-ellp Location from lop of Jet Needle
EC50PM043 VM34SS Main Jet - 230 Pilot Jet - 40 Cut Away - 3.0 Air Screw - 1.0 Turn Jet Needle - 6DH7-3 Needle Jet - P--8 (166)
Met(Ft)
Below
-20"F
-2 0 ~
Below
-29'C
0900 (0-3000)
to +10 "F -29 ' 1 0 -12 ' C 230
+10 "10 +40" F -12" !0.,.S"C
Above
+40 F
Above SoC
240
#3
220 200 185 180
#3
900-1800 (300Cl-6OO 0)
1800-2700 10000- 90001 2103-3100
(900).12000)
220
#3
210
#3 19'
#3
200
ea
.,
'" "
210 '3 190 .2 180
sa
190
#3
lEO
.,
.,
160
.,
9197
5.15k
FUEL SYSTEM /CARBURETION 1998 Jetting Compensation Charts

Trail RM K EC50PM051 VM34 (ACCS) Ma in Je t - 270 Pilot Jet - 45 CuI AlVay 2.0 Air Screw - 1 Turn Jet Needle - 6EJ3-3 Needle Jet - 0 -6 (480)
AMBIENT TEMPERATURE
l ndlcal e s E-d iP locatIOn !com lop 01 Jet Needle
All.
MeL (Ft)
......
-20 ' F
20 '10
. , O'F
+10 ' 10
Be~W -29 'C
-29 '10-1 2 ' C
+40 'F
_ .
'F
-12' 10 ...5 C
AtlOYe S'C
0900
(G-JOOO)
31.
ea
290
ea
270 270
270
900 1800
13000-60(0)
310 "0
.,
290 290 290-
1800-2 700 (6000-90001 2700-3700

(900( ). 12000)
., 310 .,
., ., .,
., .,
ea
250 250 250 250
.,
"
".
.,
270
ea
440 L C EC45PL09 1 VM34SS Main Jet - 270 Pilot Jet - 40 Cut Away - 2.0 Air Screw - .75 Turn Jet Need le - 6DH7-2 Needle Jet- P-2 (480)
AMB IENT TEMP ER ATU RE ~ Indicate l Ecllp Loca tion Irom lop oj Je t N&edJe
Alt. Met .{Ft)
Belew
-20 ' F
20' 1 0
+, O'F
-29 '10
+10 ' 10
Below 29'C
0900 (0 3000)
.40 'F -12 "10 +S' C
_.
+40 'F
AboveS 'C
12'e
' 270
290 '2 260 '2 2' .
.2
250 .2 240
(3000600O,
1800-2 700
sco-reco
250 230 '2 210
(6000-9OOJI
2700-3700
~ ' 2OOJ,
"
ea
240 '2 230
220 200
22.
'2
"
.,
"
arc
' 90
.,
., .,
"
1998 440 XCR SN44-44LCDCSP-01 VM34S S

MainJ et36 0 Hex Pilot Jet - 45 Cut Away - 2.0 Air Screw - 1.5 Turns
AMB IEN T TEMPERATUR E w Indi ca tes E cl lp l ocation from l op 01Jet
N eE'dl ~
All.
Me l.{Fl )
Be lOW
20" F
Be low 29C
-20 10 +10" F 29' {0

.1 2 C
1"1 0 ' 1 0 +40 ' F . 12 10 +5 ' C
Aoove
t4 0 'F
Abo ve
s-o
0900
!().3000j
" 0
ea
' 50
3'0
Jet Needle - 6DH7-3 Needle Jet- P-4 (286)
(3000-60001 1800-2700
(&000- 9000)
""'900
3'0
" 320
ea
320 280 250

220
300
" '00
27.
2 700- 3700 (9)>J- 12OC())
., .,
" 290 " 250 "
270 "0
., .,
.,
., ., .,
.,
500 500 Clas sic EC50P L l71 VM38SS Main Jet - 350 Pilot Jet - 45 Cut Away - 2.5 Air Sc rew - .75 Turn Jet Needle - 6F9-3 Needle Jet - P-6 (480)
AMBIEN T TEMPERATUR E " In(hcales E chp Loca l lOOfr om l op 01 Jet Needle
Alt. Met.(Ft )
..,.
37.
330 290 250
-20 'F Below 29 ' C
20 ' 10 .1 0' F
29 ' 10
.1 0 ' 0
....40 F 12 ' l O . S' C
Above . 4Q' F Above 5 ' C
.1 2 "C
0000 CQ-JOOOJ
900-1800
(3000- 6000)
1800-2700
(6000-9000)
2700-3100
f9i)))-12COO1
., ., ., .,
" 3>0
sa
27.
' 50
' 30
ea
3>0 270
290 25. 220 '2
"
ea
"
sa
23.
2>0 .2
" 0 '2
"
"
500 RMK EC50 PL161 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)
/I 1l'lQ ICaI&S E cl tp
t cca u cniron 10;:> al Jet

20' to .1 0 F
N eedle
Alt. MeT IA)
Be low
-20 'F
Below
29' lo- 12' C
10 '10 +4Q- F - 12 ' 10 . S C
....sOF Af.>o.IeS C
.""'
29 'C
0 000 'C>- 3OOO1
290
27. 270 270 270
900-1800
(3O<JO.lIOOl
ll!OO-2700
(60Q0.9000)
" 290 " 290

290-
.,
260
.,
" "
" 26. .,
' 260 260
"0
.,
". "
".
" 0
2700-3700 (OCOO 12cnD)
.,
"
"
"
"
5.1 51
"
Polaris industries inc.
9/97

Classic Touring EC50PL191 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)
AMB IENT TEMPERATURE Indicates E-ellp l oca tion 'rom top 01 J et Nee dle All. Met.{ FI)
Below
20 F Below -29 ' C
20'to
+10' F 29 " 0 12' C
10' 10
.,.40'F -12' to ..S C
... Q' F 4 AboveS 'C
Ab"" e
t().3000)
o.soc
'60 240 220
&00-1800
(3001>60OO1
.,
"
'60 .,
"0
210 190
240
220 195
(6Ol 90001
2100-3700
19('l 12OOj)
1800-2700
ea
200
.,
" ., .,
" ea
ea
'2
'30
210 '2 16'
.,
.,
.2
180
tzs
WideTrak LX EC50PL20 1 VM34SS Main Jet - 195 Pilot Jet - 35 Cut Away 3.0 Air Screw - 1/2 turn Jet Needle - 6EJ26 -2 Needle Jet - P-6 (166)
AMBIENT TEMPERATURE
teoceies E-clip locallOl\ IT om lop 01Jet Needl e
Alt. Met. (Ft )
Balow -lO ' F

Belo w
20 1~
' O' F
-29 to 12C ' 195
.10 "0 .,. 0 ' F 4 - 12 " IO +S ' C
Al,. . . ... 0 F 4
Above SoC 175
-29'C
0900(0-30001
900-18 00
{JOOl). 6QOO/
210 190
175
1801).2700 (6000- 9000 1 2700.3700

(90)>12000)
..,
.2
.,
.,
"
18. .2 170 '2 1;;
180
.,
"
'2 170 145
16.
1>0
.,
"
"
'"
Below Belo w
140
ras
" "
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 TEM PERATU RE # IndicatE'S E-cl iP t c csuc o t-orn lO of Jet Needle P Al l. Mel.( Fl )
-ao- re
""0' F
+10 "10
20 ' F
-29' C
0900({}JOOOl 250
-aa-e
-12' C
'2 40
+40 ' F - 12' to . S' C
Above +40F Above 5 ~C
&00- 1800
13000- 6000 1
(6000-9000) 2 700-3700
1500-2700
(9(X0 12COO)
" 230 " 210 " '90 "
220 210 '2 ' 90
210
19;
" 220
.,
" "
"
"
200 180
'2 180
" ,,. "
ea
165
-a
XLT SP EC58PL140 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 rocce tes E -chp Locahon lrom top 01J el Needle All. Met .(Fl ) Be low
Below
20 " 0
+10 ' 1 0
20' F
.10F
29'10 -12 'C
. 40 'F 12 10 -+-S C
""""e . 4O'F
Above S'C
-29 'C
1~3OOOI
~900
3>0 '20
.,
-a
-aoc
310
300
900-1800
< 3001>60OO1
1800-2700 16O()O.90001
2700-3700
Itl(');;O. 2OC 1 ()j
290 270
" "
" 300 " 27"

ea
2>0
" 280
ea
2>0 230
270
"
ea
.,
240
220
.,
.,
., .,
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 TEM PERA TURE

0/ IndiCates E-clip
locatiOn lrom lop 01Je t Need le

-20 " \0 +10 ' F
10 "0 ... 0 "F 4
AM.
Me1.(Ft)
Below 20 "F
Below
""""e ..s O F
Aoove S"C
-29C
{()-30001
900-1800
~900
29 1 0 12 C
-12' to +S'C
360
IJOOO.sooo:1
1!lQ().2100
(600<HiOO /J) 27DD-3700 !9(()(} t2lXlOJ
" aac " '00

280
"'0 3' 0 250 '3
.,
3'0 '90 260
., .,
.,
., "
"
3'0 25O
250
.,
"
"
'50
.,
" 240
5.15m
230
.,
9/97

600 XCR EC59PL020 VM38SS MainJet- PtoiCenlMag
AMBIENT TEMPERATURE
AIL
(PTOICENTERiMAG)
h''ldlC3tes E-cltp Lccencn !rom lop 01 Jel Need le
Mel.tf ll
Be!Ow"-20"F Selow 2Q'C 3601400/400
. ,OF -29'lO-12'C
' 3 13(1381)'38 0
-20 ' II)
+10 "10
.4 0'F 12 IO ' S'C
AOOVe ..sO F Al)ove 5'C
360/3801380
Pilot Jet - 40 Cut Away - 2.0 Air Screw - .5 Turn Jet Needle - 6CEY6-4 Needle Jet - P-B (247)
<>-900
(1}-3000)
900-1 800
3401'300r 360
31Ql33G'330
200000'300
13000-60001
1800-2 700
(fiOOO. 90001
.. ..
"
34il'36Q1360
3201340134 0 290131 013'0

2tl/Y2801280 240..26G'260 '
33G/35013&J
"
" 31Ql 3Q1330 3

2801300I300
.,
"" " .,,,.,,. ea

271l'29Cl'29O
__"'''101
2700-3700
25CY.!7lW210
"
Below '20" F Below
"
-20' to ..10' F
-29 " 10
.,
.,
"
.,
" ea
600 XC SN6D-70 1CDCSP-Ol Keih in - PWK 39 Main Jet-185 Long Hex Pilot Jet - 45 Cut Away - 6.5 Air Screw - 1 Turn Jet Needle- R1368G-3 Needle Jet - 2.9mm Fixed
AMBIENT TEMPERATURE " reccetes E-e~p Location fromlop of Jet Needle Art. Me l lFt)
..10" 10
..40'F
-12' to +S' C
29C
188
Abov' ..40 "F Above S'C

172
-12"C
0-900
(MooO)
900- 1800
(3000-6000 )
#3
'85 #3
175 #3
178
178 168 158

#3
'" 168
160
'50
#3
162 '55 '4.5
1800-2700
tOOOCl-9000,
2700-3700
(9OC'iO.l2000J
"
"
165 '3 156
.,
" ., .,
., .,
#3
600 RMK SN60-70LCDCSP-02 Type -Keihin PW K 39 Main Jet - 160 Pilot Jet - 45 Cut Away - 6.0 Air Screw - .5 Jet Need le R1368G-2 Need le Jet - 2.9mm
F!;led
AMBIENT TEMPERATURE II Indicates E-d ip location from lop 01J el Need le AI< Met(Ft)
Below 20 F
-29"C
(0-3000)
Below
-20' to +10 'F -29 to 12' C
+1010 +40'F 12IO ... C S
Abo<" +40F Above S" C
<>-900
,l"J
9O().1800 13OOll-6OOO,
1800-2700
t6000-90001
21QlH1QO (9C(l(I.12OlX1j
F ltJ;0 ./T/ ,..e . I/)'f~ fZ 112;;;; / / (./ l~ / "". '/. 168 178 175 '62 ., ., ., ., 168 165 ' 60 155 .., ., ., .,
158
.,
155
.,
160
14.5
"
.,
Shaded zone Tum Air SCr w 1 11Um e 0
Ultra Ultra Touring EC68PL050 VM38 Main Jet - 340 Pilot Jet - 40 Cut Away - 2.0 Air Screw - 1.0 Turn Jet Need le - 6DH8-2 Needle Jet - P-4 (247)
AMBIENT TEMPERATURE " Indicates E< lip Location from lop 01Jet Needle AIL Met (Ft)
Below
-20' F 29<C
Below
,r..3000)
9QG.1 800
~00ll-60001
<>-900
350
320
., ., .,
-20"0 + 10'F -29 ' 10 -12' C
.1 0 +40'F -12 '10 +S' C

Qlo
accve
+40 ~F
Above S' C 300
"0
310
.,
320
300
.,
ea
.,
1800-2700 16OOll-9IlOO1 27(.3700 (9CXX}12COO1
290
270
.,
280 260
.,
., 270 .,
280 '2 260
.,
.,
250
.,
240 112
5.15n
9/97
FUEL SYSTEM/CARBURETION 1998 Jetting Comp ensation Charts

700 XC SN70-70LCDCSP-02 Keihin PWK 39
MainJet-185 Long Hex Pilot Jet - 38 Cut Away - 6.0 Arr Screw - 1 Turn Jet Needle - R1368G-3 Needle Jet- 2.9mm Fixed
AMB IEN T TEMPERATURE # Indica tes E-eIIP tocanon from top of Jet Needle AI<
MOI.(Ft)
Below
-2 0 ~F
Below -29' C
0.900 t().300D) 900-\800
(300D-600 0}
-20' to ...10"F
-29 ' \0 -12"C
+10 10
Above
...40 F -12' to ... ' C S
t40F
Above S'C
190 178
1!3
'"
' 185 1!3
'"
1!3
172
#3
175
1!3
168
#3
162
#3
1e00-270 0 \6000-9000) 270 0-3700

(9(X)O.1200J)
170
1!3
165
1!3
158
#2
155
#2
145
158
ea
155
#2
150
#2
ea
700 XCR EC68PL060 VM38 Main Jet - 380 Pilot Jet - 50 Cut Away - 3.0 Air Screw - 1.0 Tu rn Jet Needle - 6CEY6-4 Needle Jet - 0 -2 (247)
AMBIENT TEMPERATURE (1 Indicates E-cllp Lccanon from lop 01 Jet Needle

AI< Met.IF t)
Below
-2Q'F
20" 1O +10 " F
Below -29 ' C

0-900 1003000) 90 0-16 00 (3000-6000)
_29v lo 12'C
'380
350 '3 320 '3 290 #2
' DO
370 340 310
16QO.2700 (6000-13000)
2 700-3700
.
'" '"
#4
..
..'0"10 t 40 ' F -12' e -s-c 360 330 300 270
Above +4Q'F soove S' C
340 310 #2 280 250
!9OO'J- 12000l
. .
'" "
.
"
"
700 RMK SN70-70LCDCSP-01 Keihin PWK 39

MainJet-158 Long Hex Pilot Jet - 42 Cut Away - 5.5 Air Screw - 1 Tum Jet Needle - R1371G-3 Needle Jet- 2.9mmFixed
AMBIENT TEMPERATURE It lndlceres E-elip Location from top of Jet Needle
Alt.
Met.(Ft)
Below
-2 0~ F
Below -29"C
0-900 (0.3000) 9000-1800 (3000-6000)
1BOO-2 700
-2Qc 1 0 .. 10 ~F 29 ' 10-12C
. 10 clo +40F - 12' lO.S ~ C
Above +Jo cF Abo.... e SoC
;"'",:"" 4i3,J / " / ,- :,' /
l5/'/ S " '~/ :/;U ,// //.;17 / ,1'",-#3 . / ,:3

178
~~
;%:: 112;:; / '" /

162 152
#2
sa
175 162 155
(6000-9000)
168 158
2700-3700 (900CH2COOI
"
'"
r;;-77l
" " "
155
158
148
#2
" "
"
145
#2
LL.:...:J . Shaded acn e shou ld turn

Storm EC80PL052 VM38
PTO - CEN MAG
Ajr Sc rew 1 1/4 turn . 0
AMBIENT TEMPERATURE (PTOICENTERiMAGj I: rnoeetes E-<:llp Localion /rom l op 01 Jel Needle All. MeI.(FI ) Below -20<F Below _20G to +lO 'F -29 10
-12~C
-ae-c ea
+101 0 ..4Q cF -12 1 ..SC 0 390138 01400 340/3301350
Above .40'F Above S'C 370/360/380 32013101330 #2
MainJ et-4 10-400-420 Pilot Jet - 50 Cut Away - 3. 0 CH Air Screw - 1.0 Turn Jet Needle - 6CGY6-3 Needle Jet - 0 -0 (247)
0.. 00 9 (1). 0001 3 901).1800

(3000-6000)
430/42014 40 380/3701 390 340/3301350
410/400'420 360050070
32(lIJl003Q
1601).2700 [6001).9000) 270Q-3700 /9000-12CXX)j
#3
"
." "
"
.3
30012901310 #2 25012401260
"
29012ao /300
270126lY2'8O
Main jets uereo lento right - PTO-eenw Mag
"
"2 .
2901280/300 #2
24012301250
#2
#2
9/9 7
5.150
FUEL SYSTEM /CARBURETION Gasoline Volatility

Whenever servicing the carburetor or fuel system, it is important to heed the following warnings.
A 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 youspill gasoline on your skin or clothing, immediatelywash it off with soap and water and changeclothing. Neverstart the engine or let it run in an enclosed area. Gasolinepoweredengine exhaustfumes 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, vaporlock, flooding, or icingof fuel lines, fuel pumps, or carburetors. One of the sometimes misunderstoodproperties 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 closedcontainer and applying a specified amount of heat to the containerfor a certain amount of time. Thispressure will vary fromabout7.0 PSI duringthe summerto approximately 13.5PSI duringthe colder months. Service stations selling a largevolumeof fuel will normally havethe correct blendto workwell 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 warmupproperly Ifsummerblendfuel,whichhasa low ReidVapor number, is beingused,lillle or no vaporization . will occur. Droplets will form causing flooding and very hard starting. If winter blend fuel is being used duringthe summer months, it may cause vapor lock (boiling fuel) insidethe fuel lines, fuel pump, or carburetor. This will causewarm engine driveabilityproblems and hard startingwhen warm. Somestatesare limitingthe ReidVapor numberto 9.0 PSI year around to helpmeet evaporative emissions standards. Warm Weather Maximum Reid Vapor Class A
B
Low Vaporization Rate Ambient Air Temp. Range Low 60 F 50 F 40 F 30 F 20 F High 110 F + 110 F 97 F 85 F 69 F High Vaporization Rate Pressure 7.0 PSI 9.0 PSI 10.5 PSI 12.0 PSI 13.5 PSI
C D
E
Cold Weather
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 creati ng a pressure difference between the venturi and the float bowl. The greater the pressu re diffe rence. 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 pressu res (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 carbure tor 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 differe nce 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 --~"""cr='=IIr(""n1 One Way Check Valve
--~j
~~~-l-- Atmospheric
Fuel Through Valve Some Models Have Interco nnecting Lines Between each Carb
Drain Hose---II
6Ii~:ction
Pressure
-V
_
r- -
Tee Fittings Are Orientated Vertically
I
' '-- -
I i
- 1
'e
- ---- Air Box
Baffle Tube
Some models have atrbox venting
5. 17
11/95
Fuel Delivery System - Typical

The fuel system contains manycomponents whichdirectlyaffect fuel mixtureand driveability. When performing diagnosis or carburetor maintenance, the entire fueldeliverysystem 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 replacedevery other season or moreoften if they become brittle or swollen. Fittings should be inspected at that time for cracks or leaks. Test run and checkthe fuel system for leaks any time parts are replaced. Verify that all lines are routed correctly away from any moving parts. Vent Lines Carb Mounts
Cylinder Base Gasket
Weighted Pickup and Line
Crank Seal
8~
Crank Check / Seal Valves Impulse Fitting at Crankcase
Fuel Hosa- Indy Storm/SKS/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
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 en(;;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 emuls ion 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.
11-
r -- - - - - - --"""- - - - - - - - - - - --,I ~
II
Cable Adjuster
ii
I,
I I I I
I I I I
Cable Adjuster Lock Nut Plunger Spring
II I
!l)I ,
II
L..
PI C unger ap
Starter Plunger Inlet Starter ir
II I, 1I 4 trtr-"-'
II II
Id II
Throllie Valve
I <--.ll;::;}.---/..
9~~~~;j...:Emu lsion Tube

Inlet Bleed Air
Starter
Starter Jet
5. 19
11/95
FUEL SYSTEM/CARBURETION Pilot System (0-3/8 Throttle)

Thepilot system's mainfunctionis to meterfuel at idle andlow speeddriving. Thoughits main functionis 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 mixtureis regulated to somedegreeby adjusting the air screw. Whenthe air screw is closed, the fuel 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. -..,/
I '
"
Throttle Valve
'1
11/95
5.20
FUEL SYSTEM/CARBURETION Slide Cutaw ay (1/8-3/8 Throttle)

Throttle valve cutaway effect is most noticeable at 1/4 throttle open ing. The amount of cutaway is pre-determined for a given engine to maintai n a 14:1 airlfuel ratio at part throttle . A steep angle would indicate a fairly lean mixture beca use there is less resistance to air flow. A flat angle would provide a much riche r mixture beca use 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 bott om of the valve (e.g. 2.5) indicating the size of the cutaway. The higher the number, the steepe r the angle.
Cuta wa y An gl e
~~~;~~:n
Throttle Valve Jet Needle By-pas s Pilot Outlet
Air Jet
..
')
Pilot Jet
- - - - "/L.'" " ,II
1tI-p'9!tI-~:"-'_ Need le Jet

Main Jet
3.0
1.5
Leaner
Richer
5.2 1
11/95
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 accomp lished by changing the location of the "E" clip on the need le. 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 indicat ing sizes and tapers of each.
Clip Position Throttie Valve Jet Needle Air Jet By-pass Pilot Outlet
. . 'j
II I
i~
.. -
'I'
Pilot Jet Needle Jet
,,
Main Jet
11/95
5.22
FUEL SYSTEM/CARBURETION Main System (3/4 to Full Throttl e)

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 needlejet system. During low speed driving, there is very little clearance between the jet needleand 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,thetaperedjet needleis raisedfartheroutofthe needlejet, allowing greaterfuel flow. Underfull throttle opening, the cross sectioned area of clearance between the jet needle and the needlejet becomesgreater than the cross sectioned area of the main jet. Thus the main jet is now controlling the amount of fuel flow.
II
Throttle Valve Jet Needle By-pass Pilot Oullet
Air Jet
.... ..
')
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 mixtureto the engine. A properratio meansan ideal airlfuel mixturewhich can burnwithoutleavingan excess of fuel or air. Whetherthe proper mixture ratio is maintained or not is the key to efficient engineoperation. 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. Inorder to meetthe requirements for the proper mixture ratio under these varying conditions, a low speed fuel system, or pilot system, anda main fuel system areprovidedin Mikuni VM type carburetors. The Mikunicarburetor hasvarying operationsdepending 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
~b'F~~~~:j~lffY-.. - Float Arm

Float
IF;f:JTn;~i==ltH1f-
Needle Valve
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 floatand the fuel pressure of the fuel pumpbalance, the needlevalve sticksfast 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 of fuel in the fuel mixture. Too high a level allows more fuel than necessary to leave the nozzle, enriching the mixture. Too Iow a 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 passesthrough 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 projectsinto 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 pilotjet 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 venturitype carburetor. In this type of carburetor, the needle jet and jet needle serve to control a proper airl fuel mixture ratio at the medium throttle valve opening (between 114 and 3/4 opening). Having the proper needlejet 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 airlfuel mixtureratio 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 "E" ring.
15
50
75
100 %
Throttle ValveOpening
5.25
11/95
FUEL SYSTEM/CA RBURETION Compon ent Functions

Jet Needle
The jet needle has five adjustment groovescut into the upper portion, and is tapered from approximately the middle of the needleto the lowerend. The top is fixed to the center of the throttlevalve by the needleclip, and the tapered end extends into the needle jet. Fuel flows through the space between the needle jet and jet needle. This spacedoes 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 needleclip is changed from the standard position to a lower groove, the needletaper starts coming out of the jet sooner, resulting in a richer mixture. Moving the clip higher producesa leanermixture. If the taper is worndue to vibration, fuel flow may be significantly affected.
P .~
-
~1 2p
Leaner
3 Groove 5
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 needlejet brings in air measured by the air jet. This air initiatesthe mixingand atomizing processinside 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 V5. Fuel Flow
In a full throttlecondition the cross sectioned area between the jet needle and the needle jet is larger than the cross sectioned area of the mainjet. The mainjet therefore has greatercontrol over fuel flow.
J\
Large Clearance
Closed Throttle
One-half Throttle
Full
Throttle
11195
5.26
FUEL SYSTEM/CARBURETION Component Functions

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 contro l is performed chiefly by the cutaway . By cont rolling 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 cutaway. The higher the number, the leaner the gasoline/air mixture.
I
~--*+
Cutaway
Mikuni Main Jet

When the throttle openi ng becomes greater and the area betwee n the needle jet and jet needle increases, fuel flow is metered by the main jet. The number on the jet indicates the amount of fuei CCs which will pass through it in one minute under controlled conditio ns. Larger numbers give a greater fiow, resulting in a richer mixture. Main jets are screwed directly into the needle jet base.
Round
Hex
Keihin Main Jet

The number on the Keihin (Round) main jet corre sponds to the diamete r 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 effecti ve 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 1/4 throttie opening. Throttle valves are numbered 1.0, 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 consistentiy increases to full throttle opening .
z en w
o
~
II:
EFFECT
Cl
en
II:
I
I I I
I
o w c
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 essentiall y the amount of oxygen available for combustion. In iow elevations and cold tempe ratures , the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. Carburetors on mast Polaris models are calibrated for an altitude of 0-3000 It (0-900 meters) and ambient temperatures between -20' to + 1A' F (-29' to -12' C). All carburetors must be re-calibrated if operated outside the production temperature andlo r 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 se rious engine damage. Jet the carburetors carefu lly for elevation and temperature according to t he jetting charts In this manual , t he specification decal on the hood, or t he Jetting charts In the Owner's Safety and Maintenance Manual for each particular model. See additional Info rmati o n regarding the use of oxygenated fuels on fo llowing page. NOTE: It is the dealer's responsib ility to ensure that the correct jets are installed in the machine for a geographical area. Be very careful when jett ing down in warm weather. As the weather turns colder it will be necessary to re-je1 upward to prevent engine damage. When seiecting the proper main jet always use the lowe st 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 emiss ions , some areas of the U.S. are required to use oxygenated fuels. Oxygena ted fuels are those which include oxygen in the molecule due to the addition of an ether or
alcohol,
Oxygenated fuel contain ing 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 metha nol is not recommended.
On carbureted models
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 Specificat ion Decal or Owner's Safely and Maintenance Manyal for octane recommendation. 2. Whe n 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 +1OF ) 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: if the production air screw setting is 1 turn out, the setting for 87 octane oxygenated fuel would be 5/8 turn out.
NOTE: The follow ing Indy Class ic charts are provided as an example only. Indy Class ic
1.
AMBIENT TEMPERA TURE

Bek)w
20~F
~lO .. t o"F
+10 "0 +40 'F
Below -29"C
.29\0 -12 "C '340
.12 0 10 +S'C
Above +40 of Above +S"C
89 Octane Oxygenated
A"""""
Met""
(Feel)
0-900
(Ch3 000)
3eo 320
320
300
260 220 200
900-1800
(3()l)Q-6()()Q)
,aoo-VOO
(600o-90001
27ClO-3700
('9~120001
300 ,eo
Z1<l
,eo
2010
240
2' 0
[:=J Shaded zone should drop Jet Needle one position (raise E-elip)
Production Selting
Indy Class ic
Below -rooF Below29 C
-20 to .. 10F .29 10 12 C
.10lo +40 F
12 " 10..S"C
Above .4() F
Above ..S'C
87 Octane Oxygenated
Attilutl e
370 330
290
350
330
290
310 270 230 210
(0-3000)
000-'800
(3OOG-<OOO1 1800-2700 (600o-900O)
27Q0.3700
310 270 240
M81"" (Feel )
250 220 ..
250
(9000-' 20(0)
[:=J - Shaded zone should crop Jet Needle one position (raise E-Clip)
11/95
5.30
FUEL SYSTEM/CARBURETION 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 instaliing .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 mixtu res. 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
FU EL SYSTEM/CARBURETION ACCS System 1996 To Current Altitude Compensating Carburetor System (ACCS)
The Altitude Compensating Carb uretor System (ACCS) is des igned to auto maticaily compensate for changes in altitude . This allows the snowmobile to operate in changing elevations without having to cha nge jets , altho ugh extreme tempe ratures may requi re re-jetti ng for optimum performance. Refer to the jetting compensation chart on page 5.15f. 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 vacuum line is con nected 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 Beilows compress Fuel flow increases Vacuum from Venturi To Float Bowls
n7~,,~~: - II
I
~~
t
This
end fixed
Low Altitu de / High Atmosp heric 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 thro ugh the ACCS valve (see III. 2). This preven ts atmospheric pressure from reaching the float bowl , allow ing the vacuum line to reduce the pressu re 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 Vacuum from Venturi
To Float Bowls
~~
~~-;;'Og,,
1 \
High Altitude / Low Atmosp heric Pressure
This end fixed
1996 to Curre nt ACCS System
III. 2
9/96
5.32
FUEL SYSTEM/CARBURETION ACCS System

Altitude Compensating Carburetor System (Cont.)
NOTE: The 1997 to current ACCS models are equ ipped with air screws to adjust the low spee d (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 ins ide the valve . At low altitude, the spring pushes the plunger into a close d pos ition (see III. 3). Vacuum ACCS Valve Operation
Float Bowl
way man i f~d
Pi lot air~_ ~ S L-
9 tI'--------'==---"
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 air flow in the secondary slow air system and making the fuel mixture leanerto compensate for the thin ner air at high altitudes. ACCS Valve Operation
Vacuum
Float Bowl
Pilot air jet to 3 way man ifold
~:
I -===--.-j -
ItI
1996 ACCS Only III. 4
Hig h Altitude / At mospheric Pressure
5.33
9/96
FUEL SYSTEM/CARBURETION ACCS System
ACCS System
Air Box
ACCS 4-way Manifold mounted to air box
4 Way Manifold / Float Bo wl Ven t Contro l
ACCS ya lve Vent line attachment to handlebars
,
3-way Manifold attachment (1996' , ACCS Only) 4-way Man ifold attachment I .;'-; c,""--,c aIc-ve I r A c'""" s V;-; Center Carb Mag Carb
PTO
Carb
3 Way Manifold /
Pilot Air Contro l (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 systems. See page 5.7a for line connections.
9/96
5.34
FUEL SYSTEM/CARBURETION Mikuni Carburetor Service

Carbu retor Remova l, 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.
[::'jCAUTION:~
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
--".
I~
'I~
, /
Retainer Plate Jet Needle
----.- /"
,
~Q)
Slide Valve
4. Remove choke plunger. Check condition 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 Mikuni Carburetor Service

Carburetor Disassembly and Inspection Cont.
6. Remove water trap assemb ly from float bowl and inspect O-ring . hose and clamp condition . Refer to exploded view corresponding with carburetor being serviced.
qfl
H ose
Trap Nut
Clamp Drain Plug
;/
~
7.
Inspect choke fuel supply passage in bowl for obstruction.
8.
Use an automatic cente r punch to remove float arm pin. Remove inlet needle and seat assembly.
9.
Inspect needle for wear and replace sealing washers upon reassembly.
CAUTION:' I
Do not bend float arm during disassemb ly. Do not use excessive force to remove float arm pin. The float pin tower castings are very easily damaged and are not repairable.
Q :o=illll>
9/96
5.36
Mikuni Carburetor Service Carburetor Disassembly and Inspection Cant.
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 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 cleane r. Dry all 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/CARBUR ETION Mikuni Carburetor Adjustme nts

Float Level Adjustment
1. Remove float bowl. 2. 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. 3. To adjust float arm, bend tang contacting inlet needle.
CAUTION :
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.
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
Polaris Industrie s Inc.
FUEL SYSTEM/C ARBURETION

Keihin Carburetor Se rvi ce Carburetor Removal, Disassembly, and Inspection
1. Remove carburetor from engine. 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 throl1le cable . Disconnect cable holder and remove jet needle. Note "E" clip position and inspect needle taper for wear. An indication of wear would be an hourglass shape or polished spots somewhe re along the taper.
4.
Remove choke plunger. Check condition 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. Plunger Seat
5 .38a
9196
FUEL SYSTEM/CARBURETION Keihin Carb uretor Service

Disassem bly Cont.
6. Remove water trap assembl y from float bowl and inspect a-ring , hose and clamp condition. Refer to exploded view corresponding with carburetor being serviced.
fVJ--- Trap Nut

I
Hose ~
n
I
Clamp Drain Plug
t/
~
7.
Inspect choke fuel supply passage as shown for obstruction.
8.
Remove float arm pin. Remove inlet needle. NOTE: Seat assembiy is not replaceabie. DO NOT remove.
9.
Inspect needle for wear.
CAUTJO/ll:
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 .
9/9 6
5.38b
FUEL SYSTEM/CARB URETION

Keihin Carburetor Service Carburetor Disassembly Cont.
10. Remove main jet.
11. Remove pilot jet.
Wear eye protection when using compres sed 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
FUEL SYSTEM/CARBURETION Keihin Carburetor Service

Carburetor Assembly
1. Install pilot jet and main jet.
2.
Install inlet needle and float assembl y.
Adjust float with tange only
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.
4. To adjust float level. bend tang contacting inlet needle. See photo above.
Do not bend float arm. Adjustment should be made with tang contacting inlet needle.
9/96
5.38d
FUEL SYSTEM/CARBURETION Keih in Carburetor Service

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. 8. 9. Install idle screw and air adjusting screw. Install jet needle clip onto needle jet.
10. Install jet needle into throttle 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 T hrottle Gap Un der Cutaway
Air Screw CCW From Sea t 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 '.0 1.0 ACCS 1.5 1.0 1.0 1.0 1.0
Idle RPM
Lite , Lite GT, LiteDeluxe Sport, Transport. Sport Touring

Super Sport 440 440 XCR 440 XCR SP WideTrak GT
EC34-2PM02 EC44-3PMOl EC44-3PM02 EC45PL02l06 EC45PL07 EC45PL08 EC50PM03 EC50PM04 /E04 EC50PL11 EC50PLE11 EC50PL12 EC50PL14 EC50PL15 EC58PL02 EC58PL03 EC58PLE05 EC5BPL07 EC59PLOl EC68PLOl EC68PL04 ECBOPL04 ECBOPL05
.240"' 6. 1mm .236"'6.0mm

.200'"/5.1mm
1600
1BOO
1600 1600
.2 10"/5.3mm .210"/5.3mm .210"' 5.3mm .240"'6. 1mm

.240"/6.1mm
lBOO
2000 1600 1600 '600 1900 1600 '600 1600 2000 1700 1700 '700 2000 1500 1800 1600 1600
Trail, Trail Touring

500,500 SKS
.2 1(),,/5.3mm .21()"/5.3m m
.240" /6 .1mm
Classic WideTrak LX Classic Touring

500 RMK XLT SP, 600 XCR XLT, XLT SKS
.240"/6. 1mm .2 10"'5.3mm .221"/5.6mm .193"'4.9mm .230'5.Bmm . l 93"/4 .9mm .l B7"/4.Bmm . l B7"/4.8mm .250'6.4mm .2 1B"/5.5mm .21B"'5 .5mm
XLTTouring
XLT RMK 600XCR SP Ultra SP, Ultra SKS Ultra RMK Storm RMK
Storm, Storm SKS
9/97
5.381
FUEL SYSTEM/CARBURETION Thr ottle Gap Specifications

1997 Throttle Gap Chart
1997 Model Engine Mod el
Throttle Gap- Under
Cutaway
(Un der fron t of slide on Kelhln)
Idle Sync . Gap (Under Cutaway)
Ai r 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
Idle RPM
Spec ial Too! Required
DrillSize (lnches/mm)
.240"-8 (6.10mm) .200"-8 (5.10mm) .190"- 12(4.80mm) .210"-8(5.30mm) .190"- 12(4.80mm) .240"-8 (6.lOmm) .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(6.10m m) .193"-11(4.90mm) .193"- 11(4.90mm) .190"-12( 4.80mm) .228"- 1(5.80mm) .187"-3/ 16(4.75mm) .187" -3/16(4.75mm) .187"-3/16(4.75mm) .248"-1 /4(6.30mm) .0469"-3/64(1.19mm)" .0937"-3/32 (2.38mm)" .248"-1/4(6.30mm) .248"- 1/4(6.30mm)
Drill Size (lnches/mm)

Lite, Lite GT, Lite Deluxe
Sport. Sport Trng. Transpo rt. XCF 440 XC 440 440 XCR WideTrak GT EC34-2PM02 EC44-3PM02 EC45PL08 EC45PL0 9 SN44LCDCSP-Ol EC50PM03 EC50PM04 EC50PM0 5 EC50PM06 EC50PL17 EC50PL16 EC50PL19 EC50PL20 EC58P L03 EC58PL07 EC58PL08 EC58P L09 EC58PL 12 EC59P LOl EC68P LOl EC68PL03 SN70LCDCSP-{)1 SN70LCDCSP-{)2 EC80PL0 4 EC80PL04 .219"- 7/32 (5.55m m) .180"-15(4.57mm) .172"- 11/64(4.37mm) .190"-12(4.80mm) .172"- 11/64(4.37m m) .2 19"-7/32(5.55mm) .2 19"-7/32(5. 55mm) .2 19"-7/32(5.55mm) .180"- 15(4.57mm) .190"- 12(4.80mm) .210"-4 (5.3mm) .219"-7/32 (5.55mm) .219"-7/32(5.55mm) .172"-11/64 (4.37mm) .172"- 11/64(4.37mm) .172"-11/64(4.37mm) .210 ' -4(5 .3mm) .166"-19 (4.22mm ) .166"-19(4.22mm) .166"-19(4.22mm) .228"- 1(5.79mm) .031"-1/32(0.79mm)" .078"-5/64(1.98mm)" .228"-1(5.79mm) .228"-1(5.79 mm) 1600 1600 1600 1600 1800 1600 1600 1600 1600 1600 1600 1600 1600 1700 1700 1700 1600 1600 1600 1800 1800 1500 1500 160 0 1600 PN2871810 PN2871811
Trail, Trail Touring

Trail RMK Super Sport 500. 500 Classic. 500 SKS 500 RMK
Classic Touring
WideTrak LX
XLT, 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
Storm, Storm SE
" Requires Special 1 wilh two drill gauges spaced 8mm apart. Measured on forward edge (engine Side) of slide. 001
5.39
9197
FUEL SYSTEM/CARBURETION Throttle Gap Specifications 1998 Models

1998 Model
Engine Mo del Throttle Gap-Un der Cu taw ay {Front of slide on Keihin) Idle Syn c. Gap Und er Cutaway (Fron t of slide o n Keihin )
Air
Screw (Turns
out)
Id le RPM
Tool
LiteDeluxe
Lite I Lile Touring
SpM I Sport Tour Transport XCF 440 XCR 440 Indy
Trai l
EC342PM02A EC443PM024
.219" 7132 (5.55mm)

. 180" 015 (4.57mm)
.240" #73 (6. 1mm) (15164=.2344") .200"(5. 1mm ) (07 or 1316 ) 4" .217"(5.5m m) (7132") .208'(5 .3mm) (07 or 13164") .240 073 (6. 1mm ) (15164) .240" - 073 (6.1mm) (15164) .200" (5. 1mm) (#7 or 13164") .240" - #73 (6. 1mm) (15/64) .208"-(5.3mm) (#7 or 131 ) 64"
1.5 1.0
1600 1600
SN44 44LCDCSpOl EC45PL091 ECSOPM043 EC50 PM051 EC50PM061 EC50PL1 71 (EC 50P L 191 ) EC50PL1 61 ECSOPL 140 (P L 150) EC50PL 201 EC58PL130 SNSo-70LCDCSPOl
.200" 13164 (5.1mm)

. 189" 012 (4.80mm) .219" 7132 (5.55mm ) .219" 7132 (5.55mm) . 180" "5 (4.57mm) .219" -7132 (5.55 mm) .189" - #12 (4.80 mm) .166" #19 (4.22mm) .2 19" 7132 (S.SSmm) .213 1# 3 S.5mm=0.216S" .7mm (.028') Tool PN: 2872093 1.98mm (.078") Tool PN: 287 1811 . 166" #19 (4.22mm) . 166" " #19 (4.22mm) .228" " 1 (S.79mm) .70mm (.028 ") Tool PN: 2872093 1.3mm (.05 1") Tool PN: 2872092 .228" " 1 (5 .79mm)
1.25 .75 1.0 1.0 1.0 .75 1.25 1.5 0 .5 1.0 1.0
1600 1600 1600 1600 1600 1600 1600 1600 1600 1600 1500
Trail Touring
Trail RMK
Super Sport
500; 500 ClaSSIC (Ctassic Touring)
500 RMK XLT SP (XLT Classic)
.18T 3116- (4.8mm)

.240" #73 (6. 1mm) (15164) .234" A (S.94mm) (7132") 1.Smm (.059") Tool PN: 2872093 2.38mm (.09 4") Tool PN: 287 18 11
Widetrak LX
XLT LTD
XLT Tour
600 XC
0.5 1500
SOO RMK
SNSo-70LCDCSP02
.5 1.0 1.0 1.0 1600 1800 1800 1500
600 XCR
Ultra
ECS9PL020 EC68 PLO SO EC68 PL060 SN7o-70LCDCSP-Q 1
.18T - 3116 (4.8mm) " .18T 3116 (4.8mm) "

.248" 0 (6. 3mm) (114") 1.5mm (.05 9") Tool PN: 2872093 1.60mm (.063") Tool PN: 2872092 .248" 0 (6.3mm) (11 4')
Ultra Touring
700 XCR 700 RMK
1.0 1500
700 XC
SN70 -70LCDCS P-Q2
1.0 1600
Storm
EC80PL052
Requires Special tool with two drill gauge s spaced 8mm apart. Measured on forw ard edge (engine side) of slide.
9197
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 reinstailed.
2. 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. 3. Referr ing to charts on pages 5.39-5.39a, select the correct diameter throttle gap drlll gauge for the engi ne. Place driil gauge beneath slide valve cutaway as shown in iU ustration 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 ail cyli nders. Hold throttle cable junction block in same location as noted in step #1. This is vel}' important , since synchro nization changes if throttle cable or junctio n block are improperly positioned. With driil gauge instailed under throttle slide as shown , turn cable adjuster out (up) until the gauge starts to move. NOTE: The drill gauge must be centered in the carburetor bore. Turn cable adjuster clockwise (down) 1/3 turn. Repeat for ail cylinders. The throttle slides must raise from the idle position In unison. Check by visually observ inq a drill gauge in all carburetors , noting and compar ing while lightly depressing the throttle lever. Check throttle lever freeplay. If adjustment is required, the throttle cable adjusters must be turned equally to maintain synchronization. Tighten jam nut while holding cable adjusters. Check oil pump adjustment. Reinstall ai r box and correctly position throttle cable and junction block . Start engine and adjust idle stop screws evenly until prope r idle RPM is achieved. (See chart above.) Re-check throttle lever freeplay and reset by turning cable adjusters evenly. Tighten cable adjuster jam nuts.
4. 5.
o
See cha rt for size
I~ t==::::-..J T'........~'--., '-----",
6.
7.
8. 9.
10.
Throttle Free Play (Std.) 0.010 - 0.030 " (.2S-.76mm) EZ Throttle 0.050 - 0.060 " (1.2S-1.S0mm)
11 . 12.
5.39b
9/97
Adjustments Throttle Synchronization Procedure-1997 to Current Mikuni and Keih in (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 reinstalied. Drill gauges with Bmm ap
Throttle Cable Synchronization (Throttle Gap) Referring to chart on page 5.39a-b, select correct diameter Throttle Gap synchron ization drill gauge for your engine . NOTE: Keihin carburetors, require a special tool with two drill gauges separated by an Bm m gap. See chart on page 5.39a and Illustrations at right. 3. Back out idle screws about three turns. 2.
l-c::z::;t;::L----=,.......,..,,--,---------=;~=
8mm
Tool Body
T
KEIHIN Carburetor Synchronizatio n Tool KEIH IN Insert too l under slide; push in until tool body stops against carb body
4. Slightly lift throttle slides with throttle lever and insert drill gauge under throttle slide. Allow throttle slides to return. 5. Loose n lock nut and turn throttle cab le adjuste r (on top of carburetor) in (clockwise) or out (counterclockwise) as required until a slight drag can be felt on the gauge . 6. Securely tighten throttle cable synchronization lock nut. 7. Repeat steps 3 through 5 on remaining carburetor. Idle Gap Synchronization 8. 9. Referring to chart on page 5.39a, select correct diameter Idle Gap drill gauge for the engine. Slightly lift throttle slides with throttle lever and insert idle gap drill gauge under throttle slide. Allow throttle slides to return. Turn idle adjustment screw in as required until only a slight drag can be felt on the gauge. Repeat steps 8 through 10 for remaining cylinders. Verify proper throttle lever free play and adjust if necessary, by loosening cable adjuster locknuts and turning adjusters out equally until throttle lever freeplay is correct.
Forward
KEIHIN
~orward
10. 11 . 12.
Tool must extend to front edge of slide
Th rottle Free Play (Std.) 0.010 - 0.030" (.25-.76mm) EZ Throttle 0.050 0.060'~
MIKUNI
(1.25-1.50mm)
iI.
9/97
5.3 9c

Machine Mo del Engine Model
Cy l. Olsp. 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)Z1OC (ACCS) VM34SS (2)Zinc VM34SS (2)Zinc VM34SS (2)Zinc VM34SS (3)Zlnc VM34SS (3)Zinc (ACCS ) VM34CS (3)Zlno VM38AL (3) AL VM38AL (3) AL VM38SS (3)Zino VM38SS (3) AL VM38AL (3) AL VM38AL (3) AL PWK 39-Ke ihin PWK 39-Ke ihin VM38SS (3) AL VM38SS (3) AL
Std. Main Jet & Type
Std . Pliol 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
Ai r Screw Ad Just
Fuel
O cta ne
(counterclockwise from light

seat)
1 1/2 Turn
Reqmt.
Indy liteJGTlDeluxe Indy Sport/Sport Touring! TranSport Indy XCF Indy Super Sport
EC34-2PM(E)02 EC44-3PM02 EC44-3PM02 EC50PM06 EC50PM (E)04 EC50PM05 EC45PL09 EC45P L08 EC50PL17 EC50PL16 EC50PL19 EC50PM03 EC50PL20 EC58PL03 EC58PL07 EC58PL(E)09 EC56P L12 EC58PL12 EC58 PL08 EC59 PLOI EC68PLOI EC68PL03 SN70 LSDCSP -Ol SN70LCDCSP-02 EC80PL04 EC80PL05
150 Hex 185 Hex

185 Hex 250 He x
87" 87" 87" 87" 87"

87" 87" 87"
1 Turn 1 Turn 1 Turn

1 1/2 Tum
Indy TraiVTouring
IndyTrail RMK
Indy 440 LC Indy 440 XC Indy 500l SKSICIassic Indy 500 RMK
230 Hex 270 Hex 270 Hex 240 Hex 350 Hex 250 Hex 250 Hex 200 Hex
195 He x 220 Hex
1 Turn
31 Tum 4 31 Tum 4
1 Tum
87" 87" 87"

87" 87" 87" 87"
31 Tum 4

Indy WideTrak GT
Indy WideTrak LX
1 Tum
1 Tum 1/2 Tum
Indy XLTISKS Indy XLT RMK Indy XLT Touring/LTD Indy XLT SP Indy XLT LTD SP Indy 600 XC Indy 600 XCRiSE Indy UltraiSPfTouring Indy Ultra SPXlSE Indy 700 SKS Indy 700 RMK Indy Storm RMK Indy SlormiSE
1 Turn
240 Hex 260 Hex 270 Hex

31 0 Hex
3/4 Turn
1 Turn
1.5Tum
87"
87" 87" 87" 91 87" 91 87" 87" 91 91
1 Turn
3/4 Tum
1/2 Turn
270 Hex PTa Ctr Mag 360 380 380Hex 340 He x 380 Hex 185 Long Hex
1 Turn 1 Turn
1 Turn
1/2 Tum
158 Long Hex

PTa Ctr Mag 300290310 PTa Ctr Mag 410400420
1 Tum 1 Tum
Non-Oxygenated . When using oxygenated fuel increase octane minimum to 89.
91 96
5.3a
FUEL SYSTEM/CARBU RETION 1997 Condensed Data

Engine Model EC34-2PM02 EC44-3PM02 EC45PL09 EC45P L08 EC50PM0 3 EC50PM04 EC50PM0 5 EC50PM06 EC50PL16 EC50Pl17 EC50Pl19 EC50PL20 EC58PL03 EC58PL07 EC58PL08 EC58PL09 EC58P L12 EC59P L01 EC68PL01 EC68PL03 SN70LCDCSP-01 SN70LCDCSP-02 EC80P L04 EC80PL05 Jet Need le No. "E" Clip Position 5DP7-2 6FJ6-3 6DH7-2 6DH3-3 6DH7-3 6DH7-3 6DH7-2 6DH7 -3 6EJ26-3 6F93 6EJ26-3 6EJ26-2 6DP17-3 6EJ3 -2 6DH7-3 6DP 17-3 8DH7 -3 6C EY6-4 8DH8-2 6CEY6-4 R1370G 3 R1370J-3 6CGY6-3 6CGY6 -3 Need le 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 (480) 0-2 (247) 0-2 (186) 0-2 (247) P-6 (247) P-4 (247) 0 -2 (247) Th rottle
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)
5.3b
9/96
FUE L SYSTEM/CARBUR ETION 1998 Condensed Data Machine Model Engine Model
Cyl.
Oisp. CCs
Carburetor Model. Mount Type & No.
Std . Main Je t & Type
Std.
Pi-
Air
Scr ew (Turns
lot Jet
150 H e x
Fuel Octan e Reqmt.
J et
Needl e
Out)
EClip
Needle Jet #
Throt.
Valve
Cutaway
Indy Ut e! Ute Deluxe!
EC34-2PM02A
339
VM30SS (2)Z;nc
35
1 1/2
87"
5DP7 #2 6FJ6 #3 6DH7 #3 6DH7 #3 6EJ3 #3 6DH7 #2 6DH7 #3 6F9 #3 6FJ43 #2 6EJ26 #3 6EJ26 #2 6DP17 #3 6DH7 #3 6DH7 #3 6CEY6 #4
R13680
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
Ute Touring
Indy Sport! Span Touring! rraosccn. XCF tndy Super span
Indy TrailfTouring Indy Tra il RMK
EC44-3PM024
432
VM34SS (2)Z;nc
185 H e x
35
87"
2.0
EC50P M061 EC50PM 043 EC50PM051 EC45PL091 SN44-44LCDCSP01 EC50PL171 EC50PL1 61 EC50PL191 EC50PL201 EC58P L130 EC58PL1 40 EC58PL1 50 EC59PL020 SN60-70LCDCSP -01 SN60-70LCDCSP -02 EC68PL050 SN70-70LCDCSP -02 EC68PL060 SN70-70 LCDCSP -01 EC80PL052
488 488 488 432 438 488 488 488 488 597 597 597 598 593 600 679 701 679 701 794
VM34SS (2)Z;nc VM34SS (2)Z;nc VM34 (2)Z;nc (ACCS) VM34SS (2)Zlnc VM34SS VM38SS (2) AL VM34SS (2)Z;nc (ACCS ) VM34SS (2)Z;nc VM34SS (2)Zinc VM34SS (3)Zlnc VM38SS (3)AL VM38SS (3)AL VM38SS (3) AL Keihin PWK 39 (2) AL Keihin PWK 39 (2) AL VM38 (3) AL Kethin 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 35 40 45 45 40 38 50 42 50
1 1
1 31 4 1 1/2 31 4 1 1/4 3/4 1/2 1 1.5 1.5 1/2 1 1/2 1 1 1 1 1
87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 87" 91 87" 87" 87" 87" 91 87" 91
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
23 0 Hex
270 Hex
Indy 440 LC Indy 440 XCR Indy 500/ 500 Classic Indy 500 RMK
270 Hex
360 Hex
350 Hex
260 Hex
250 H e x
Indy Classic Tmg

Indy Wid eTrak LX
195 Hex
2 40 H ex
Indy XLT LTD/ XLT Touring Indy XLT SP 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 Indy Storm
330 Hex
340 H ex
PTO Ctr Mag
360 380 3M Hex
185 Hex
160 Hex 340 Hex
.,
.,
RI3680
FIXED P-4 (247) FIXED 2.0 6.0
6DH8 #2
Al36eG
185 380 158

PTOClr Ma g
41() 400 420
'3
6CEY6 #4
1=113110
0-2
(247)
3.0 5.5
'3
eCGY6
FIXED 0 -0 (247) 3.0CH
'3
Non-Oxygenated. When using oxygenated fuel increase octane minimum to 89.
9/97
5.3c
FUEL SYSTEM/CARBURETION Exploded View - Keihin
GaSket~~
Spring
~ . ~/ LOCkNut I ~
~
i
~ /
/ Spring Seat Retainer "E" Clip
Adjuster
~ !:E!.
Jet Needle
Enricher (Choke)
V 1" ~
~
d~~/
SIJde
p ,""",,----
:"
Float
.. e
Idle Adjustment Screw
~~ Fuel Inlet Needle

e
~ '"
Main Jet
""
G-Ring
5.3d
9/9 7
FUEL SYSTEM/CARBURETION Adjustments - Choke Choke Adjustments

With the dash mounted choke contro l toggle flipped to the full off position, the choke plunge r must be seated on the fuel passage way in the carbu retor. 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 functio n.
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 assemb ly. Installation instructions are included with the kit.
Full On
Choke LeverKits -
"
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 adjust ing nut (8) clockwise on carburetor(s) until 1/4- (.6 em) or more choke toggle
free play is evident. 4. Turn cable sleeve adjust ing nut counterclockwise on one carburet or until toggle has zero free play, then rotate it clockwise until1 /B--1/4- (.3-.6 em) toggle free play is evident. 5. Tighten adjustrnent locknut (A).
6. Repeat steps 4 and 5 for remaining carbu retor(s).
1/8-1 14" (.3-.6 em) ---Freep lay
r:
l/
f.
111 95
5.40
FUEL SYSTEM/ CARBURETION Adjustme nts

The amoun t 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 tempe rature and humidity in this case are considered constan t). The amount of air in question decreases in proportio n to a rise in elevation as show n 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
80
500
1000 1500 Altitude (rn)
2000
Chart B shows the relationship between a rise in temperatu re and the amount of air drawn into the cylinders. In this case, the atmospheric pressu re (elevation) and the humidity are considered unchanged and the amount of air going into the cylinders at 32 F (0 Cl is taken as 100.
Chart B 100
r-'
90
80
----------I ,
,
20 30 68 86 Temperature
o
32
10 50
40 (OC) 104 (oF)
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 01fuel no
Mainfue sys l tem

Pilot fuel syslem
Throttle valve ODenlng (%l .....
CHART C
5.41
11/95
FUEL SYSTEM /CARBURETION Fuel Pump - Operation

The fuel pumps on all Polaris engines are basically the same. The difference s 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 pressu re 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, caus ing 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, caus ing the fuel pump diaphragm to move in the opposite direction and reversing the pressu re 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 standa rd level , the needle valve will close, preventing more fuel from entering the carburetor, even though the fuel pump continues to try to provide the carb uretor with fuel.
o
Maintenance
The impulse operated diaphragm fuel pump does not require any specific scheduled maintenan ce. However, the following procedures should be observed. Ope ratio n : The pump may be checked for operation by removing the fuel supply line from the carburetor and placing it into a conta iner. With the engine idling at appro ximately 2000 RPM, a steady flow of fuel should be visible.
Cle aning: The pump and impulse line must be disassembled and cleaned of foreign material in the event of piston or other interna l engine part failures which produce fragmen ts.
In specti on : 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 , repiace all diaphragms, check valves , and gaskets.
11/95
5.42
FUEL SYSTEM /CARBURETION Exploded View Fuel Pump
Taio 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)
----i~--2
.t2). ..
5
6--~~~
Y---2
5.43
11/95
FUEL SYSTEM/CARBURETION Exploded View - Twin Cylinder (Typical) Fuel Pump
3 _- 1
2 ----1.t!5.
!
s --!
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 extreme ly flammab le and explosive under certain condifions. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where L.l). gasoline is stored.
l' l'
L.l).
A A
l'
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 swallow gasoline , see your doctor immediately. Ifyou 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. --..-"
L.l).
1. Turn fuel vaive off. 2. 3. 4. 5. Remove air silencer. Position a shop cloth or container below drain plug and water trap plug. Remove drain plug and sealing O-Ring, or slide clamp upward and remove water trap plug. Drain waterlfuel. Clean trap with electrical contact cleaner and dry with compre ssed air. Float Bowl
6. Lightly grease O-ring and install water trap assembly into bottom of float bowl, or reinstall trap plug in hose and position. Tighten securely. 7. Turn fuel on, start engine and check for possible fuel leaks. 8. Reinstall air box.
DrainPIUg~
- - O-Ring
Clamp
t--Hose
The water traps should be periodically inspected and drained . Draining frequency will depend upon fuel supply, riding conditions, and fuel handling precautions.
~ater Trap
Plug
11/95
5.46
Polaris Inaustries Inc .
Troub leshooting
Fuel system diagnosis shou ld follow a specific path, first examini ng 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 mechan ical 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 condit ion as a guide for further determination of whether the mixture is too rich or too lean. Use the thrott le lever to determine at what degree of throttle valve opening the problem exists. CONDITION Mixture Too Rich SYMPTOMS -Black spark plug tip; plug fouling -Hea vy exhaust smoke -Engine runs worse after warm up -Engine "loads up" -Spa rk plug electrodes white -Fluctuation in engine speed -Power loss -Engine over heats -Cylinder scoring I Holing pistons -Backfiring - detonation -Throttle diagnostic openi ng check points -Incorrect ignition timing -lrnproper track tension (too tight) -Incorrect carburetor jetting - Fuel leaks (lines. fittings. fuel pump) -N eedle and seat leaks -Plugged exhaust -Carburetor vent line problems -Clutching incorrect for conditions I worn belt
Mixture Too Lean
Poor Fuel Mileage
Troubl.:shooting Tips, 01/4 Throttle :

Pilot air screw misadjusted Pilot jet of wrong size. loose , or obstruc ted 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
,
5.47
9/96
Troublesh ooting Troubleshooting 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, 3/83/4 Throttle :

Main jet incorrect size or clogged (lean) Needle jet damaged or loose Needle jet/jet need le worn (rich) Incorrect throttle synchroni zation
,
Troubleshooting Tips, Full Throttle:

Main jet size (rich or lean) Fuel filter blocked (lean) Fuel vent lines or che ck valves plugged Exhaust system plugged Air box restricted Fuel pump we ak Exhaust leaking into engine compartment (rich) Water in float bowl (lean) Incorrect throttle synchroni zation
9/96
5,48
CLUTCHES Service Tools
.A
WARNING
All drive clutch maintenance, disassembly and assembly must be pertormed only by an authorized Polaris dealer who has attended current model Dealer Service Seminars, has received a certificate of completion, and displays the Polaris Servici ng Dealer decal.
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 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 Clutc hes T-Handle Drive Clutch Puller (Large Shaft ID) Drive Clutch Puller 14mm (Small Shaft ID) 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/P90j , . ". . P-85 Drive Clutch Compression Tool .. , . , . , . , , . . . . . . . . .. Driven Clutch Puller (P-90) " , " .. , ,. , Torque Wrench, 250 ft. lb " , . . ... . .. . . . Torque Wrench, 0600 in. lb , .. , . , . , , . . .. .. . .. Clutch Compression Tool , ,..,,,.,.,................. Part Number 28709 14 2870426 2870506 287 1757 2870336 2870389 2870338 2870341 2871358 5130518 2870576 28709 85 2871025 2870984 287 1056 Commercially Availab le Commercially Available 8700220
6.1
9/97
CLUTCHE S Clutch Torque Values

Bolt Size Area Where Used 7/16" 1/4" 1-1/4" 1-1/4" Drive Clutch Retaining Bait Drive Clutch Cover Baits Drive Ciutch Spider Drive Clutch Spider Ja m Nut . .. Torque Minimum-Maximum . 40-45 ft. Ibs. (5.52-6.21 kgm) . 50 It. Ibs. (6.9 kgm) . 90 in. Ibs. (1.03 kgm) . 30 in. Ibs. (.34 kgm) 200 It. Ibs. (29.60 kgm) 235 It. Ibs. (32.43 kgm)
14mm . .. Drive Clutch Retaining Bolt #10-24" . Drive Clutch Weight Pin
5/16" . . .. Driven Clutch Retaining Bolt
. . 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 Spe cificati ons 1996 Clutch Spec ifications 0-3000 Feet (0-900 Meters)
Machine Model
Engine Model
Operating
RPM 200
Production Clutch Part No.
Spnng Color. Wire Dia. Silveri
Shih WI. I.D./Gram
Bore Taper Dia.
Indy Lite/GT
Indy Lite Deluxe
EC34 2PM02
700 0
1321601 13216 02 13215 94
10
1.160
Clutch Center Distance +.100" -.000 11.030"
Driven Helix Angle & Location
Chaincase Gearing
Indy Sport
Indy Sport Touring Indy TranSport
Indy Super Sport
EC44 -3 P MOI
68 00
Gold .216 Brown .200 Red !

White
36 .5' B-2
36.5 0
16:39
10
1.160
12.00
B-2 10Al
Bushed
16:35 16:39 15:39 17:3 5
EC50PM06
7000
1321619
1.160
12.00"
36.5" B-2 36 ' #2 36 ' #2 36 " #2 36 ' #2 34' #2 34 ' #2 R-8 #2 36 ' #2 36' #2 36 ' #2 34' #2 36' #2 36 ' #2 34' #2 34 " #2 34 " #2 3 4' #2 R-l #2 36' #2 3 6' #2 36' #2 R-3 #2 R-3 #2
Indy Trail
EC50 P M04
7000
13216S9
Indy Trait Touring
EC50PME 04
700 0
1321660
ECSOPM03 ECSOPlE12 EC4SPl06 EC4SPl07 EC4SPl08 EC50Pl II ECSOPL11 ECSOPlEl 1 ECSOPl 14 ECSOPl13 EC50 Pl 13 EC58Pl03 EC58P l 07 EC58PlE05 ECS8Pl02 EC59PlOl EC65Pl05 EC68PlOl EC68Pl04 EC8 0P l05 EC80Pl04
6600 700 0 8000 82S0 82S0 77S0 77S0 77S0 77S0 800 0 80 00 800 0 800 0 825 0 8500 8500 8000 820 0 8200 825 0 8250
1321661 1321644 1321S 80 132 1648 1321643 132 1663 132 165S 132'666 1321 606 1321663 132 '655 132 1665 1321656 132 1664 1321678 132 1650 1321650 13216 82 13216 78 1321651 1321 658
Indy 44 0 l C Indy 440 XCR Indy 440 XCR SP Indy SOO Indy 500 SKS Indy SOO RMK'
Indy Classic Indy Classic Touring
Indy SOO EFI Indy 500 EFI SKS Indy 500 EFI RMK' Indy XlTlXlT SKS Indy XlT RMKIndy XLT Touring
Indy XlT SP/ 600 XCR Indy 600 XCR SP Indy RXl Indy Ultra SP /SKS Indy Ullra RMK" Indy S torm! (Indy S torm S KS) Indy S torm RMK
~
.192 Red ! White . 192 Red ! White .192 Brown .200 Brown .200 Gold .207 Blue .207 Blue .207 Gold .207 Gold .207 Gold .207 Gold .20 7 Gold .20 7 Gold .207 Gold .20 7 Gold .20 7 Gold .207 Blue .207 Blue .207 Blue .20 7 Silver! Gold Silver! Gold Blue .207 Blue .207
10Al
Bushed
1.190
12.00"
2 1:39
10Al
Bushed
1.190
12 .00"
20 :39
10
Bushed
1.190 1.190 1.190 1.190 1.190 1.190 1.190 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" 12.00" 12 .00" 12.00" 12.00" 12.00" 12.00" 12.00" 12.00" 12 .00" 12.00" 12.00" 12 .00" 12 .00" 12.00" 12.00" 12 .50" 12.50"
19:4I 19:41 21:39 2 1:39 21:39 2 1:39 20 :39 20:39 21:39 20:39 21:39 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
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
10-60
Bushed
' 0-60
Bushed
NOTE: RMK prccu ction setup IS 6 000-9000 feet. Refer to page 6.4 for 19 9 6 RMK production setup.
6.3
9197
CLUTCHES High Elevation Specifications
1996 HIGH ELEVATION RECOMMENDATIONS

3000 Ft. to 6000 Ft.
Machine Model Indy li te! GT/Deluxe Indy Sport
Indy Sport
6000 Ft. to 9000 Ft.

Chain-
9000 Ft. to 12000 Ft.

ChamChain-
Shift Weight
Clutch Spring
Gold
Driven Helix 36 .5" #S 2 36 .5" ' S2

36.5
case
Gearing
Shill Weight 10M White 10 Bushed 10M

Bushed
Clutch Spring
Gold
Gold
Driven Helix
case
Gearing
16:39
16 :35
Shift Weight 10M While or

10M Red 10 or 10M Blue 10 or 10M Blue 10 or 10M Blue
Clutch Spring Blue Gold

Blue
Driven Helix
36.5"
R8 -2
case Gearing
16:39
16:35
10MB 10 10 10 10 Bushed
l OAl Bushed
16:39
16:35
36 .5' #S 2
36.5<1
Red/White
Redl\\'hile
#8-2
Gold 36.5<;
Gold
36.5 #8 2
36.5 #8 2
16:39 15:39
17:35
16 :39 15:39 17:35

2 1:39 20 :39 19:41 19:4 1
Touring Indy TranSport

Indy Super Sport Indy Trail l Touring Indy WideTrak GT Indy wideTrak LX Indy 440 LC Indy440 XCA Indy 440 XCASP Indy 500 RedJWhile RediWhite Gold RedNlJhite RedJ\oVhite RecLWhile Blue Blue Blue Gold Gold Blue Gold Gold Gold Gold Gold Gold Gold Blue Gold Gold Blue Blue Blue
#8 2
#82
Gold Gold Gold Red/White Red/Vvhi1e RedtWhile
Blue Gold
Blue Gold RedlW hite Gold Gold RedlWhile AedNIJh1te RedtWhite Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue
16:39 15:39 17:35

2 1:39 20:39 19:41 19:41 21:39
36. 5 #8-2
36 .5~
10 10Al Bushed 10 Bushed 10M Bushed 10MB Bushed 10MA Bushed 10MW Bushed
10MW Bushed
36.5"
"8- 2
36S #S2 36' '2 36' '2 36 ' #2 34' .2
36.5" #8 -2
36 .5
.S2 36' #2 36 ' #2 36" '2 21 :39 20:39 19:41

19:41 2 1:39 21:39 2 1:39 2 1:39
10MB Bushed 10 Bushed
10MS Bushed 10MS Bushed

10MW Bushed
10 Bushed 10 Bushed
l QMW Bushed 10MW Bushed 10MB Bushed
'S2 36' '2 36' '2 36' #2
34'
#2 34' .2 AB 36 ' '2 36' '2 34' '2 36' '2 36' .2 36" '2 36" .2 36" '2
Blue Slue Blue

Blue Blue Blue Blue
21:39 2 1:39
21:39 2 1:39
10MA Bushed
lQMR Bushed
34'
'2
34'
'2 A8 36' '2 36 ' .2
34"
34'
#2 A-8 36 ' #2 36' '2 34 " '2 36 ' '2 36" .2 36" '2 36' '2 36' '2 34' '2
21 :39
2 1:39 2 1:39 20:39
10MA Bushed
10MR Bushed 10MA Bushed 10MR Bushed
10 MB Bushed
10MB bushed
10 MW Bushed 10 MW Bushed 10MW Bushed

10MW Bushed 10MW bushed
Indy 500 S KS Indy Ctessic Tourin g

Indy Classic Indy 500 AMK Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI AMK Indy XlT
In d~ X LT
20 :39 20 :39 21 :39 20 :39 2 1:39 20 :39 20:39

2 1;39
20 :39 20:39 21:39 20 :39 21 :39 20 :39 20 :39

21:39
10MS Bushed 10MS Bushed 10 MS Bushed

10MB Bushed 10MB Bushed 10MB Bushed
20:39 21:39 20 :39

2 1:39
#2 36' #2 36" '2 36" '2 36' .2 36' #2 34 ' '2 34 ' #2
10MA Bushed
10MA Bushed
Slue Slue
Blue Blue Blue Blue Blue
10MW bushed 10 MW bushed 10 MW Bushed 10MW Bushed 10 MW Bushed 10MA Bushed

10MW Bushed
10MA Bushed
lOMR Bushed
20:39 20:39
2 1:39
10MA Bushed 10MA Bushed

10MA Bushed 10MA Bushed lOMR Bushed
10 MB Bushed 10MB Bushed

10MW Bushed 10MB Bushed
34'
'2 34' '2 34' '2 34 '
20 :39 2 1:39 20 :39

18:39
20 :39 20 :39 20:39

18:39
S lue
Blue Blue
34'
'2
20 :39 2 1:39 20:39 18:39

21:39
SK
Indy XlT SP Indy Xl T Tounng

Indy XL T AMK Indy 600 XCA
Ind~ 600 XC S P
34'
'2
34'
.2 34' .2 34" '2 34' #2 A l #2 34-> #2 36" #3
Slue
Blue Blue Blue Blue
34'
#2 34 ' .2 34 ' '2 Al .2
34 e #2 36" #3
10MB Bushed 10MW Bushed 10 Bushed 10 Bushed
#2 34'
'2 34 ' '2 A l #2 36 ' '2
lOMW Bushed 10MA Bushed 10 M Bushed 10MS Bushed
10MA Bushed l QMA Bushed

10M B or 10M W
Slue
Blue Blue Blue
21:39 21:35 20 :35
21:39 21:35 20:3 5
2 1:35
20:35
Indy AXl
10MW Bushed
9/9 7
6.4

1996 HIGH ELEVATION RECOMMEND ATIONS (Cont.)
3000 Ft, to 6000 Ft.
Machine
Model
6000 FI. to 9000 Ft. 9000 Ft. 10 12000 FI.
ChainShift
Weight
Chain Shift Weight Clutch

Sp ring
ChainShih Weight Clu(Ch Spring

Driven Helix
Clutch Spring Blue
Driven
H elix
case
Gea ring
Driv en Helix
case
Gea ring
case
Gea ring
Indy Ultr a SP Indy Ultra RMK

Indy Ultra
10M Bushed 10M Bushed 10M

Bushed
Blue Blue
Blue
36 ' #2 36 #2 36 '2 R-3 '2 R3 '2 R-3 .2
2 1:35 20:35 20:35 23:37

20:35
10MB Bushed 10MB

Bushed
10M B
Blue Blue Slue
36 #2 R-9 #2 36 #2 R-3 #2 R-3 #2 R-3 .2
21:35 20:39 20:35

2 1-37" or
lOMW
Bushed
Blue
Blue
10 MW
Bushed
36 ' '2 R-9 #2 36 ' '2 R3 '2 R-3 '2 R3 .2
2 1:35
20:39 20:35
2 1-37" or
10MW
Bushed
10AL
Blue
Blue
SKS Indy Storm

Indy Storm
1058 Bushed
10 -58 Bushed
Bushed 10 56 Bushed
Blue
Bushed
10 AL Bushed
Blue
Blue
S KS
Indy Storm
10-58
Bushed
10 56
Bushed
Blue
Blue
20:35 20:35 20:39
Blue Blue
20:35 20:35 20:39
20:3 5
RMK
10-56 Bushed
l QAL Bushed
Cannot be used with reverse kit
6 .5
9/97
CLUTCHES Specificatio ns 1997 Clutch Specif ications 0-3000 Feet (0-900 Meters)
Machine Model
Engagement RPM 3oo
Operating RPM 200
Production Drive ClutchPart No.

132 1601 132 1602 132 1667 132 1594 1321659 132 1659 1321660 1321 683 132 1698 132 1661 1321 692 132 1662 1321686 1321704 132 1663
Spring Color, Wire Dia.
Shih WI. I.D .lGram
Driven Spring Color
Clut ch
Center Distance
+ .100'"
Driven Helix Angle &
Cnaincase Gearing
Location
36.5' 8 -2 36.5 ' 8 -2 36.5'" 8-2 36' #2 36 ' #2 36 ' #2 16:39 17:35 16:39 15:39 2 1:39 21:39 20:39 19:40 20:39 19:41 19:41 21:39 21:39 22:41 2 1:39 20:39 21:39 20:39 21:39 19:39 21:39 20:40 20:39 2 1:39 18:40 21:39 2 1:39 21:35 20:35 21:35 21:35 20:35 21:35 20:35 21:39 23:37 (20:39)
- .000 Indy Ute /GT Indy U te Deluxe Indy Sport 4100 4000 3500 4000 3600 3600 4000 3800 3800 3800 4900 4900 4000 7000 7000 7000 7000 7000 7000 7000 6500 7000 7750 8250 8250 7800 7800 8000 7800 7800 7800 8000
Silver/Gold .218
RedlWhite .192 Brown .200
10 10Al Bushed 10 Bushed 10Al Bushed 10Al Bushed 10Al Bushed 10 Bushed 10 Bushed 10 Bushed 10 M8
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"
Sport Touring Indy TranSport

Indy Sup er 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'
RedfvVhite _ 192
RedIWh ite .192
Re dM'hit9 .192
RedlWhite
.192 Brown .200
34 '
#2 36 ' #2 36 ' #2 34 ' #2 R-8 #2 R-8 #2 36 ' #2 36 ' #2 36 ' #2
Brown
.200 Gold .207 Dark Blue .2 18 Almond l Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Gold .207 Blue _ 207 Gold .207 Dark Blue 2 18 Almond square
Bushed
10 Bushed S-53R Bushed 10M Bushed 10M
Bushed
Silver Silver
Red
3800 4000 4000 4200
13216 55 1321690 1321691 1321665 1321689 1321571 132 1678 132 1656 132 1665 1321 693 132 1708 132 1650 1321682 132 1682 1321 688 132 1708 132 1695 1321696 132 1651 (132 1658)
Red Red Red Red
12.00" 12.00" 12_00" 12.00'
Indy Classic Indy ClassicTouring

Indy XlTlXlT lTD Indy XLT Touring Indy XlT SKS Indy XLTSP Indy Xl T RMK
o
10 M Bushed 10 M8 Bushed 10M Bushed 10 M8 Bushed 10 M Bushed 10M Bushed 10 M Bushed 10-54 10 Al Bushed 10-54 Bushed 10-54 Bushed 10-60 10-60 Bushed 10-58 Bushed
34 '
#2 34 ' #2
4200 4000 4400 4200 4800 4000 4500
8300 8000 8300 8300 8500 8000 8200
Red Red Red Red Gold Red Red
12.0012.00" 12.00" 12.00' 12.00" 12.00' 12.00"
34 '
#2
34 '
#2 34 ' #2 34' #2 R l #2 36 ' #2 36' #2 R-8 >2 36' >2 R-l1 #2 R-4 #2
Indy Xl T l TD SP Indy 600 XC Indy 600 XCR Indy 600 XCR SE Indy RXl
Indy Ultra Indy Ultra SP Indy Ultra Touring

Indy Ultra SPX Indy Ultra SPX SE Indy 700 SKS Indy 700 RMK Indy Storm Storm SE (RMK)
Blue .207 Dark Blue .2 18 Almond square Dark Blue _ 18 2 Dark Blue .218 Almond square
4800 4200 4200 4800 IS
8600 8000 8000 8400
Gold
12.00' 12_ 50' 12.50' 12.50"
Silver Silver
Gold
NOTE : RMK production setup
6000-9000 feet.
9197
6.6
Polaris Industries lnc.
3000 Ft.
Machine
Model Ind y Lile l GT/Del uxe Indy Sport
Indy Sport Touring Shift We ight Clutch Spring
to 6000 Ft.
D rive n He lix
1997 HIGH ELEVAT ION RECOM MENDAT IONS 6000 Ft. to 9000 Ft.
ChainGearing
16:39 17:35 16:39 15:39 21:39 21:39 20:39
19:40
Chai nShift Weight
9000 Ft.
to 12000 Ft.
C hain-
case
10M
Blu e
Go ld
RedlW hite Bro wn
36 .5" #B2
36 . 5 ~
10M
Wh ite
Clutch
Spring
Go ld
Driven He lix
case
Gearing
Shift
We ight
Clutch Sp ring Bl ue Go ld
Driven Helix
case
Gearing
36 .5" #B2 36.5" #B2

36.5'"
16 :39 16:35 16 :39 15 :39 20 :39 2 1:39 20 :39

19:40 16:35
10M W hile or 10 M Red

10M Blue or 10 Bushed 10M Blue Bushed 10M Blue Bushed
36.5" #B2 36 .5" #82
16:39 16:35 16 :3 9 15:39 20:3 9

2 1:39
10
Bushed
#8 2 36 .5" #82 36. 5 #B2 36" #2 36" .2 36" .2 34' '2 36 .2 36' '2 34' .2 RB .2 36' #2 36' #2 36" .2 34' #2 36" .2 34' .2 34' #2 34' .2 34" #2 34" #2
34'''
10AL Bus hed
Go ld
Gold Go ld
Red,White
Rec1l\'Vhite
Go ld Go ld Go ld RedNVhile
10 M
Bushed
10M
Bushed
#8 2 36.5" #B2 36 " #2 36 " '2 36 " '2 34" '2 36 ' .2 36 " #2 34" '2 RB #2 36 ' '2 36 ' #2 36 ' '2 34' .2 36" #2 34' .2 34' #2 34' #2 34" #2 34" #2 34' #2 R' #2
34" #2
365 0
#B-2
Indy TranSpo rt
Ind y Super Sporl
10 M
Bushe d
Brown
RedlWhite
Bushed
10
Bushed
10M
36.5" #B2 36" #2 36 " '2 36" .3 34" #2 36 ' #2 36" '2 34' '2 RB #2 36 " '2 36' #2 36 " .2 34" #2 36' '2 34' '2
34"
10Al
Bushe d 10Al Bushed
10MB
Bushed
Indy Traill Touring
RedflNhile Red/W hile RedANhile RedIWhile RedlW hite Blue Dark Blue Gold
10
Bushed 10M B Bushed
RediW hite RedJWhite Gold RedM'hite RedM'hite Blue Dark Blue Blue Blue Dark Blue Blue Blue Blue Blue Blue Blue Blue Dark Blue Almond Blue
10MB
Bushed
Redl'Nhite RedM'hile Gold RedM'hite Aedl.. .Vhile Blue Dark Blue Blue Blue Dark Blue Blue Blue Blue Blue Blue Blue Dark Blue Dark Blue Almond Blue
20:3 9
19:40
R K XCF
I n~ T ra il
10
Bushed
10 MW
Bushed
10M
Bushe d
20:39 19:41
19:4 1
10 M
Bushed
10MB
Bushed 10MB Bushed 10MW Bushed
16:35
19:4 1 19:4 1
Indy WideTrak GT Indt. wideTra LX Indy 440
10
Bushed
10M
Bushed 10MB Bushed
19:4 1 19 :4 1
2 1:39
10
Bushed tOMW Bushed
21:39
21:39
10MR
Bushed
10MR
Bushed 10MW Bushe d 10MR Bushed
2 1:39 20:3 9 21:39 20:39 20 :39

19:39
LC
Indy 440
10M
Bushed
10 MB
Bushed
20:39
21:39
XC
Indy 5001 Classic Indy 500
10MB
Bushed
21:39 20:39 20:39 19:39

21:39
10MW
Bushed
10MB
bushed
Go ld
Gold Blue Gold Go ld Gold Gold
10MW
Bushed 10MW bushed
20 :39 20 :39
19:39 21:39 21:39
10MR
Bushed
SKS
Indy 500
10MB
Bushed
10MR
Bushed 10MR Bushed 10MR Bushed
RMK
Ind~Classic auring
10MB
Bushed
10MW
Bushed 10MW bushed
Indy 500
10MB
Bushe d
EF I
lndf' XLTI
2 1:39
21:39
10 MB
Bushed
21:39 20 :39 21:39 20:40

18:40
10MW
Bushed
10MR
Bushed
XL LTD
Indy XlT
20:39 20:39 21:39 19:39

l B:40
20 :39 20 :39
2 1:39
10MB
Bushed
10MW
Bushed
S KS
Indy XLT
10MR
Bushed 10MR Bushed 10MR Bushed
#2 34' #2 34" #2 34' #2 34 ' .2 R l '2

34" #2 36" #3
10MW
Bush ed
10MR
Bushed
SP Indy XLT
Touring Indy XLT
10 MB
Bushed
Go ld
Go ld Dark Blue Almond Blue
10MW
Bushed
19 :39
18:40
10MB
Bushed
10MW
Bushed
10MR
Bushed
RMK
Indy 600
'OMB
Bushe d
2 1:39
2 1:35
10 MW
Bushed
21:39 20:39 20 :35
10MR
Bushed 10MB or
XC
Indy 600
#2 R l #2 36' '2
2 1:39 20 :39 20 :35
10
Bushed
10M
Bushed
XCR Indy RXL
10MW 10MW
Bushed
10
Bushed
20:35
10MB
Bushed
36" #3
6.7
9/97

1997 HIGH ELEVATION RECOMMENDATIONS
3000 ft. to 6000 FI. 6000 Ft. to 9000 Ft.
C ha in9000 F t. to 12 000 Flo
Machine Model
Indy U ltra! U ltra S P
Shift Weight
Clutch Spring
Driven Helix
case
Gea ring
Shift Weight
Clutch
Spring
Dark Blue
Driven Helix
Chaincase
G e arin g
ChainShift
Weight
Clutch
Sp ring Dark Blue
Driven Helix
case
Gearing
20 :35 20 :35
10
Bushe d
Dark Blue
SPX
Indy Ultra
10
Bushed
Almond
Dark Blue
Dark Blue Dark Blue
Indy Ullra Tounng 700SKS

Indy 700
10
Bu she d
10-58
10-58
RMK
Indy Storm 10-56 Bushed
10-58 Bushed
Almond
36 ' '2 R8 '2 36' .2 R l1 '2 R-l1 .2 R4 '2 R36 .2
2 1:35 21:35
20:35 20:35
10M
Bushed
10M
Bushed
Almond
Dark Blue Dark Blue
Dark Blue Almond
10M
Bushed
10 58 Bushed 10-58 Bushed
36" '3 R-8 '2 36< '3 R-l1 .2

R t l
20:35
10MB
Bushed
20 :35
21 :39
10MB
Bus he d
Almond
10 MB
Bushed
Dark Blue
Dark Blue or Almond D ark Blue
36' '3 R8 '2 36 '3

Rl1
21:39 20:35
20 :39
20:35 20:39
21 :3 7
to-ss
1056 10- 54
Bushed
.2 R-l1 '2 R-4 '2 R36 .2
20:39
23:37
20:39
10 56
Bushed 105 6 Bushed
'2 R4 '2 R-36 '2
or Almond
Almond or 20:35 20:39
21:37
or
Indy Storm
Almond
Almond
1054
Bushed
Almond
20 :35 20 :39
RMK
Cann ot be used with reverse kit
9197
6.8
CLUTCHES Drive Clutch Weight Identification - Actual Size
U Gram Weight: 34 1 PN 5630 107
y
Gram Weight: 35 1 PN 5630139
W Gram Weight: 37.5 1 PN 5630109
G - (8 Modif ied) Gram Weight: 41.5 1 PN 5630063
B
8
A
A
AlP 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
o
o
03
03 Gram Weight: 32.5 1 PN 5630227
6 .9
9/9 7
04
04 Gram Weight: 57.5 1 PN 5630229 M1 (Modified) Gram Weight: 46.0 1 PN 56303 01
N1 (Modified) Gram Weight: 51.5 1 PN 56303 02
K1 Gram Weight: 39 1 PN 5630144
P1
J1
05 Gram Weight: 53.5 1 PN 5630234
06 Gram Weight: 50 1 PN 56302 43
07
07 Gram 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 Gram Weight: 55.5 1 Gram Weight: 55.0 1 PN 5630286 PN 5630274
10M Gram Weight: 49.5 1 PN 563027 3
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-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 9/96
6.11
10 66
10 64
10-AL Bushed Gram Weight: 53 1 PN 1321531
10-66 Bushed Gram Weight: 66 PN 1321584
10-62 Bushe d Gram Weight: 62 PN 1321586
10A Bushed Gram Weigh t: 55 PN 1321589
10-56 Bushed Gram Weigh t: 561 PN 1321684
s
538
10-54 Bushed Gram Weight: 541 PN 1321685 9/97 853 B Gram Weight:49 1 PN 1321730
s
53R
853 R Gram Weight:5 1 1 PN 1321731
S
55R
855 R Gra m Weighl:53 1 PN 1221759

Pola ris Industries Inc .
6.12
CLUTCHES Drive Clutch Spring Rates

The following chart will aid in the setup and balance of engine RPM power curve s for special converter tuning requirements such as high operating altitude. heavy loads. mountainous terrain, etc.
Dri ve Clutch Spring Compressi on Rate Chart
Drive Clutch Spring Compression Rate Chart

340 320 300
I
I
280
-' I.. I" I

-'-
P 90TRAVEL P-B5TRAVEL
260 240 -
I
I
+-
-+1
Y
/
/
+--s/
1 -+- - - - -+-- - - --lL-
220 200
-I
1
1
. ,
~
~
180- -
K
~
o
U.
/'
160 V ' 140 120

10 0
' /
. .)/f.(~
, ', /
~.j ' " ;-....:~~:~g~o / / ' Y! ( <' II , ' .> ...; / I / 1/'.';:: ( ~ /T'~: " ' r//~4 __ ~~~~~65 y ~/ / ,..' I I L ,~--~ I . }(. y / I I - -- ;~~~~68 1':'% y--<--L ~ - _. I r;~J;1~63
I /
I
/ 17~ /
i.
j, ~. /. //1 .'/
~y ~ I . : ://~(
jJ' ," 1.//d-r

.I
I I I
I
7 "1,
- - ... -
Y~'
y
,{L :I /
I I " ,/ ( ~ ,
' I If , " I /'y'. _ . -
~ I tm __:~~;I~~~e'GOld
Il
- - ~~~~~6
Dark Blue
" ~- 704 1286
:~I::~I:Ol d
70 4 1645
Almond/Go ld
- - 7b~~~62
Red
7041083
-- -:~l~148
v/ ~(Li
- -,-'I' r ----~~~~~61 ,
+.y - - . . Pink
/
Red/White
704 1150
A!'
<'
704 1102
/ -(-/
//
1 //
y'
1 /-( " ~l l'

.
('/ /
/II/
I
-J ~- -
80 -
v: / 1 ,//1
?
I . :
/ -I' /
//
/ 1 /
,/( ,
~/
'7
-'~ /
I/-- - -~ -I ~
'
:.. - - - - / , - I . / " " , 'I
. ----~
,,~
"
-~ I
~ I I
-_
White
704 1132
./ /
- " _ .>
.
1
--- r;b~~021
Black 704 1022 Blue/Green 70 41157 ATV only
60 - /
40 -~. /
20 - /
/ .>:
,~
-l-
V ,, ......-j'
I"
/ ' 1'
2.25
2. 00
1.75
,-
-.
-
1.25 1.19
I I
COMPRESSED SPRING LENGTH (INCHE S)

6 .13
9/9 7
CLUTCHES Drive Clutch Spring Data

PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH +/- .125"
7041021 7041022 7041063 7041062 7041065 704 1060 7041080 7041083 70411 02 7041061 70411 32 7041168 7041148 7041150 7041286 7041080 7041526 7041566 704 1645
Clear Black Purple Silver Pink Orange Blue/Gold Red Yellow Brown White Green Gold RedlWh ite Silver/Gold Blue Dark Blue Almond Almond/Gold
.157" .140" .168" .208" .177" .196" .207" .192" .192" .200" .177" .177" .207" .192" .218" .207" .218" .207" (Square) .207"
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"
CAUTION :
Never shim a drive clutch spring to increase its compression rate. This may result in complete stacking of the coils and subsequent clutch cover failure. 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 easiiy serviced parts is the drive clutch spring. Due to the severe stress the spring is subject to during operation, it should always be inspec ted and checked for tolerance limits during any clutch operation diagnosis or repair. With the spring resting on a flat suriace , measure free length from outer coil surfaces as shown. Refer to Ihe chart above for specific free length measurements and tolerances. In addition to proper free length. the spring coils should be parallel to one another whe n placed on a flat surface. Distortion of the spring indicates stress fatigue. Replacement is required.
9/97
6.14
CLU TCH ES Driven Clutch Spring Rates Driven Clutch Spring Data
Part Number Description Red Gold Silver Blue Silver I Blue
70411 98 7041501 7041499 7041296 7041646
Refe r to page 6.37 f or driven clutch helix in formation
Driven Spring Charts

.!--Blue Silver or Silver/Blue Gold
o -;--
- - - - - -- - - - --1
Degree of Rotation
80 70
~ ~
f-- - - Silver/Blue
Biue
,.-/'
60 50
~
~ ~
/~
~/
~ 40 c
:0
V~
/ .
,. "
~
"0
30
0 -' 20
'"
-- -r.:./
,."
'
#, # ...-_..~/
.....;,'-
...............
..-
-,. ,.
.' '
..-
...... "-
-- -~
. . . . ~~ Gold
>
Silver
Red
10 0
2.5"
Compression Distance (In)
1.375"
6. 15
9/97
CLUTCHES P-85 Drive Clutch Exploded View Typical

2.
Do not lubr icate drive clutch components
5.
12 .
Ii
~.
15.
16.
1.
Ref. Qty Description

1. 2. 3. 4. 5. 6. 7.
1 Asm. Drive Clutch Basic 62

6 6 1 1 1 3 1 6 6 (Less 6,14) Bolt Washer, Spring Lock Cover. Bearing Ring, Retaining, Cover Spring , Clutch Pin, Roller Kit - Shim, Drive Clutch Button, Guide Washe r, Multilube Asm., Roller & Bushing Nut, Jam Space r, .050mm Spacer, .032mm Spacer, .020mm Asm., WeighVBushing Pin, Weight. Hardened Nut, FLEXLOC Bearing, Sleeve Insert, Moveable Kit- clutch rebuild, inc1.7-11 , 15
B. 9.
10.
11. 3 1 12. 13. AR AR AR 14. 3 15. 3 16. 3 1 17. l B. 1
9/96
6.16
CLUTCHES P-85 Driven Clutch Exploded View - Typica l
Do not lubricate driven clutch components except inside of helix hub to reduce fretting and corrosion .
16
1.
~----------
~--------~)

1. 2. 3. 4. 5. 6. 7. 8.
14 1 1 2 1 1 1 1 NR 3 1 3 1 3 1
Sc rew Plate, Driven
Ring, Retaining Washer Ramp. Driven Key, Square Spring, Driven Clutch Bushing, Driven Large DU Washer Pin, Adjustment, Driven Cam, Adjustment, Driven Screw Cap, Driven Button Asm., Driven Clutch - Adjustable (IncI.1 .-13.)
' 9. 10. 11. 12. 13. 14. 15. 16.
AR 7556804 Washer .030" AR 7555898 Washer .020"
6.17
9/96
CLUTCHES pogO Drive Clutch Exploded View - Typical
Do not lubricate drive clutch components
3.
g \\/o.
~~
13. 11.
~J
14.
1.

1. 2. 3. 4. 5. 6. 7. 1 Asm., Drive Clutch Basic 42 (Incl. 2"4.,7.-12.,14.,15.) 6 Bolt 6 Washe r, Spring Lock 1 Cover, Bearing 1 Ring, Retaining, Cover 1 Spring, Clutch 3 Pin, Roller 6 Button, Guide 6 Washer, Muitiiube Asm., Roller and Bushing Spacer, .050mm Spacer, .032mm Spacer, .020mm Bearing, Moveable 11 2" Weight , Shift Pin, Weight. Hardened Nut, FLEXLOC Gea r, Ring Screw
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.
~"
"
3.
Do not lubricate drive n clutch co mponents except inside of helix hub to reduce fretting and corrosion.
6.
7.
A - Snap Ring Retainer (Used on some mode ls) e .g. Lite GT, Sport Touring, TranSport. Can be retro-fit to all P90 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.
1 3 3 1 1 Asm., Driven Clutch Bolt, Tap Button, Ramp Ring, Retaining, Extension Ramp, Statio nary, Cast
5. 6. 7.
1 Spring, Clutch
Bearing, Moveable, 1/1 Bearing, Moveab le, 1/2 " Washer Washer
1 B . 1 9. AR 10. AR
6.19
9/96
CLUTCHES
Oper ation
The Polaris drive system is a cen trifugally actua ted variable speed belt drive unit. The drive clutc h, driven clutch, and belt make up the torque converter system, Each clutch comes from the factory with the proper internal compone nts installed for its specific engine model. Therefore, modificat ions or variat ions of components at random are never recommende d. Proper converte r setup and adjustments of existing components must be the primary objective in conve rter opera tion diagnosis.
<:
CAUTI ON:.
All conve rter maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the prope r procedu res as outlined in this manual. Because of the critica l 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 spec ial tools and service procedures. Any unauthorized modifications to clutches, such as adding or removing weights, will void the wa rranty.
Relationship Between Drive Clutch Weights And Spring In Maintaining Operating RPM
The drive clutch is an RPM and torque sensing unit designed to transferthe maximum amount of horsepowe r from the engine to the grou nd. This is acco mplished by we ights and a spring inside the unit which react to the centrifugal force from the engine RPM. The spring and weig hts work in combination. In a properly set up clutch, the maximu m desired operating RPM will be reached immediately afte r clutc h engage ment, under full throttle cond itions . To gain optimum powe r 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 clutch sheave and increase vehicle speed.
9000 8000
---------::==-=__== _ :-:=/
, ,,
7000- - - -
, ENGINjOPERATING RANGE 250 RPM
ii:
~
6000
7
3000 - - - - - - -- -- - -
If the weig hts are too light, or the spring rate too high, the maximum RPM will be too great and the drive belt will 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 - - - - - - - --
---
8 0 0 0 - - - -- - - -- - - ______ ENGINE OPERATING RANGE 250 RPM 7000 - - - - -- - - - - - -
:;
a. 6000
./
a: 5000 ," 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 engi ne damage .
9 0 0 0 - - --
- --
8000 - - - - - --
- - --
7000 - - - - - - - - -- - ::.;2~==_:-:.-:...:==_-::.-:...:== NGINE OPERATING RANGE 250 RPM E 6000 5000.,.,:.---- - - - - - -- --
--
ENGAGEMENT~-----------3000-- - - - - -- - --
If the weights and spring are matched properly. the engine RPM will increase quickly to the desired range and remain there on both upshift and backs hift.
6.21
9/96
CLUTCHES Driven Clutch Operation

The driven clutch operates in conjunction with the drive clutch. Its functio n is to maintain drive belt tension preventi ng slippage. and sense variations in load requi rements necessary to maintain optimum engi ne torque output and load requirements from the trac k. Output torque is transmitted through the chaincase jackshaft and chaincase to the front drive shaft and track. When the load on the driven clutc h is increase d and beco mes greate r than the torque delive red from the engine. the driven clutch becomes do minan t and overri des the drive clutch. The drive n clutch downs hifts into a ratio which will match the increased load. Because the driven clutch can sense and shift into the prope r ratio, engine RPM will remain within the spec ified range.
Driven Clutch Adjustments

The driven clutc h has a prov ision for vary ing the torque requirement to change its ratio. It can be readjusted by relocating 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-ba r with a hammer until clutch is removed .
Strap Wrench PN 287033 Clutch Puller PN 2870506- 3/4-16 ID Clutch Clutch Puller PN 287175714mm ID 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 287 1757.
2. Slight galling or scoring of bore taper can usually be corrected using a tapered reamer. Place reamer in a vise and lubricate with cutting oil. Clean clutch taper by manua lly 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 variation for individual engines. For easy identificat ion, refer to the three numbers behind date code on clutch cove r 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 Inspecti on 1. Install drive clutch in clutch compression tool (8700220). Mark both moveable and fixed sheave. cover. and spider with a permanent marker. CAUTION :
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.
";Dr lve Clutch PN 8700220

~;~wH,;:tjJi~, ' "
Com
resslonTool
'""'f
Dr ive Clutch' PN 287~358 ,t
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) Tool

PN 2870338
4.
Install spider removal tool and remove spider in a counterclockwise direction (standard thread).
Spi der Removal Tool

PN 2870341
'C
t.
.~'h
9/97
6.24

Disassembly, Cen t. 5. Measure the total thickness of the spacer washers installed beneath spider and re.QQ[Q. CAUTION:
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 finge r 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 smooth ly (flat spots) or if bushing is loose.
Polaris Ind ustries Inc .
6.25
9197
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
C LU TCH ES Drive C lut ch Roller Installati on, Cont.

3. Place roller on pin as it protrudes from first land. 4. 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 lower half of the towers as shown. Measure tower h at bottom . ravel
Use Dial Caliper
10. Install spider buttons using a soft face hamme r.
11. Record width of spider buttons on each leg.
12. Add shims beneath trailing side spider button to obtain specified button-to-tower clea rance when assembled.
Button to Tower Clearance P-B5t P-90
=.002" (.05 mm)
9/97
6.28
CLUTCHES
Drive Clutch Drive Clutch Assembly
1. Place the co rrect number of spacer wa shers beneath the spider.
2.
Assemble clutch making sure "X" marks on movable sheave and spider are aligned to achieve proper balance.
NOTE : If belt to shea ve clearance is being changed by add ing or removing washe rs from under the spider. and the sheaves were marked before disassemb ly, follow index ing procedure on page 6.32.
3.
Torque spider to specif ication.
Spider Torque - P6S and P90 200 ft. Ibs. (27.6 kgm) Spider Removal Tool PN 2670341
"-.....,.
4 . Torque jam nut to specification (P-85 Clutches). Install weigh ts with weight pin nut on traili ng side . Use new nuts to ensure proper retention. Torqu e nut to 30 in. Ibs.
Jam Nut Torque - P6S models only 235 ft. Ibs. (32 .43 kgm) Jam Nut Tool PN 2670336 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 cover to 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 cut1ing 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 wnh lacquer thinner or isopropyl alcohol.
9/96
6.30

Installation, ConI. 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 ciutch to specificatio n after first period of operation (such as a test ride).
6.31
9/96
CLUTCHES Drive Clutch Spider Indexing

NOTE: Spider indexing affects clutch balance and belt to sheave clea rance. 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. Disassemble drive clutch as described on page 6.24. Take care to note the amount and thickness of the shim washers under the spider.
2.
3.
Add or remove spider washe rs as required to achieve 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:
Wash ers: 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 cha nged, the sheave marks made before disassembly no longe r 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 spider 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 reindex spider clockw ise 1/3 turn Two .050" or .064" washers removed re-index clockwise 2/3 turn
NOTE: Align ment 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 adjust ment bolt holes. Use a suitable space r on the end of the jackshaft.
pogO Driven Clutch Puller

PN 2871056
3. Inspect jackshaft keyway (splines / 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.
CAUTIO N: Wear eye protection during disassembly and assembly of driven clutch .
2. Hold fixed sheave and tum movable sheave 1/4 turn. Hold movable in place tap helix down with a sof1 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 Torx' " screws. P-85 buttons can be removed by applying heat to the button housing or drill button with an 1/8" drill bit. The ramp buttons should be replaced when worn. See Maintenance section for inspection intervals.
9/97
6.34

Disassembly, Cant.
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 an'i 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 locating hole in the movable sheave and 4 holes in the helix. P-90 driven clutches have 2 spring locating 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 shifting and RPMs. lighter spring tension will raise engine RPMs during clutch upshift and allow quicke r downshift when pulling or negotiating a hill. The lighter tension positions will tend to have a slower downshif1 and a harder upshift. pogO Examole: Spring! Position Moveable Helix Sheave B -1 B - 2 A - 1 B - 3
A 2
Spring Tension
A-3 Soft P-90 production settings are usually B2 P-85 production settings are usually #2
T
6.36
4. Align inner keyway (P-85) 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 Angles 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'
Descriptio n 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 513075 1 5130895 5130717 5130723 5130724 5130725 5130726 5130898 5131287 5131288 513 1289 5131290 513129 1 5131292 5131293 5131294 5131295 5131296 5131297 5131623 5131298 51310 13 5130383 5131161 5131162 513 1163 5131164 Degrees 34 34 36 36 38 40 42 44 40-36 40-32 42-32 45-32 5032 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 P85 P85 P85 P85 P85 P85 P85 P85 P85 P85 P-85 P90 P90 P90 P90 P90 The helix spring should always be adjusted within its limits before a helix cha nge is performed . The normal rate of cha nge 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). NOTE : Increasing spring tension increases engine RPM. RPM changes may not be evident if other drive or driven clutch components are substandard.
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 belts, 2 (two) additio nal (for a total of three) .030" 1.8 mm washers (PN 7556804) should be installed under the snap ring to prevent the belt from touch ing 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
9197

Assembly, Cant.
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
CLUTCHES Dr iven Clutch

Installation
1. Install proper number of spacer washers on jackshaft between clutch and jackshaft 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 movernent is detected, disassemble to deterrnine 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 krn) 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 offset between the drive and driven clutch. 2. Lightly grease jackshaft keyway or spline. With square key in place (P-B5s) slide clutch onto jackshaft.
3. Install spacer, bolt and washer to hold driven clutch in place.
Driven Clutch Retaining Bolt Torque15 ft. Ibs. (2.0B kg-m)
4. P-B5 and p o gOdriven clutches should float from side to side (.040-.0BO" (1-2 mm)). Without a slight free float, jackshaft bearings could be side loaded, causing premature bearing failure. NOTE: Some models with pogO 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 rnm) Torque bolt to specification.
Driven Clutch Torque/Float P-B5/ P-90 - .040-.0BO" (1-2 mm) pogO with reta iner .000-.010" (.000-.254 mm)
6.39
9197
CLUTCHES
Drive Belt Drive Belt
Part No. Be lt Wid th ' (Proj ected) Side Angle Overall' Center to Cente r' +.100" Outer Circum ference ' Notes
-.000"
3211042 3211045 3211057 3211058 32 11059 3211061 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" (36.52m m) 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" 43.313" 45.125" 47.188" 48.375" 47.250" Common production belt for P-85 systems Close tolerance version of 3211042 Obsolete - origi nal Stonm Belt Indy Lite belt (P-90) Longer Indy Sport Belt (P-90) CVT version of 3211045 CVT Dou ble Cog Storm belt
3211070 3211073
28 28
12.00" 12.50"
3211074
28
12.00"
3211075
28
12.00"
Double cog - CVT - thicker than 3211070. Production on higher horsepower snowmobiles. 47.250" Double cog-Good for short runs on higher horsepower engines (Drag Racers) - Good for lower horsepower trail riding 47.250"' Comm on produc tion belt for late mode l P-85 syste ms 48.375"' Double ceq-Good for short runs on higher horsepower eng ines (Drag Racers) - Good for lowe r horsep ower trail riding 47.625" Double cog-Good for short runs on higher horsepower engines (Drag Racers) - Good for lower horsepower trail riding 47.625" Double cog - CVT
' Belt dimens ions given are nominal dimensions. There is a varia nce tor 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 efficiency from the converter, drive belt tension (deflection), clutch offset, and alignment must be adjusted properly. General Belt Selection Guidel ines NOTE: Refer to appropriate parts manual for proper belt. Production belt is recomme nded unless tuning for a specific applicat ion. 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 9197 More aggressive at low speeds Reduced heat and drive clutch sheave wea r Used for short, higher horsepowe r runs (Drag Racing) Good trail belt for lower horsepower engines.
6.4 0
CLUTCHES Drive Belt

Drive Belt Inspect ion
1. Measure 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 bell. Place another straight edge on top of belt. Measure the distance where the side straight edges intersect the top, as shown in the illustration at right.
~ rOjected B el~ Width
o o
\
Solution
2.
Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Replace if necessary.
3. 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.
Belt Wear I Burn Diagnosis
Belt Wear I Burn Diagnosis

Possible Cause Of Wear Or Burning
Driving at or about engagement RP M lo r extended pencds in all types of conditions Cold weather startups Drive at hig her RPM if pos sible . Gea r the machine do wn. Make sure belt def lection is at 1.25" 1 achieve optim um starting ratio 0 Be pa tient. Wa nn up engine at least 5 minutes or until it readily respo nd s 10 throttle input. For the quickest most efficient driveaway in extreme cold weather, lake drive belt off machine and bring it in to a warm environment. Break skis and track loose from the snow. Eng age throttle aggressively for short du rations for initial cold dr iveaway Wh en poss ible , do not go in deep snow when towing another rnachine . Use fast. effective throttle to engage the clutch . Not all rnachi nes are intended for pUlling heavy loads o r othe r macfunes . Lower the gear ratio. Remove winda ge plates from driven clutch . If possible . move to be tter snow conditio ns and redu ce RPM . Avoid riding in very hig h ambie nt temp eratures . Break loose snow and ice unde r tunne l. Allow longer than no rmal warmup. Allow belt to warm sufficie ntly and increase grip ability on clut ch sheaves. Use fast. effective throttle when engaging clutch . Mainta in good stale of tune includ ing th rottle and choke syncnronizati on . Che ck for fouled spark. plug {s). Chec k lor foreign mat erial in ca rbs . Make sure no water or ice in fuel tank, lines. o r carburelars . Use cautio n when loading machin e. Ca rbide skags may gouge Into trailer and prevent drive train from spinning freely. Use eno ugh speed to drive completely onto trailer . If ma chine canno t be driven completely onto trail er, it ma y need 1 be pulled or pushed to avoid 0 belt wear I burning Che ck for co rrect clutch components. Use fast, effect ive thro ttle to engage the clutch
Towing another machine at or abou t engagement RPM
Spinning track while vehicle is stuck (high RPM , low vehic le speed, high ambient temp. Examp le: 8000 RPM, 1O mph vehicle speed, 60 mph indicated on spe edometer. Ice and snow piled up between track and tunnel ove rnigh t or after stopping for a long period of time (enough 10 re-freeze the snow). Poor running engin e (Bog, Miss . Backfi re. etc .)
Loa ding machine on traile r
Clut ch ma lfun ction Slow , easy belt engagement - easing on the throttle
6.41
9/97
CLUTCHES Drive Belt

Belt Deflection
Too much bell 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 eno ugh belt deflection (bell too tight) - If the drive belt is too short or the center distance too long, the ratio will again be incorre ct. In addition, the machine may creep when the engine idles, causing damage to the internal face of the drive belt.
9/96
6.42
CLUTCHES Dri ve Belt

Meas uring Belt Deflec ti on
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 em)
Ad justing Belt Deflection (P-90)

1. Belt deflection on P-90 clutches is controlled by adding or removing shim washers from between the driven clutch sheaves. To change belt deflection, disassemble clutch as outlined on page 6.34. 2. 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 3. Reassemble clutch as outlined on page 6.36.
Adju sting Belt Deflection (P-85)

Belt deflection can be adjusted without removing the clutch from the jackshaft. 1. Pull belt into driven clutch to slightly open sheaves. 2. Loosen three bolts on adjustmen1 cam. Used to adjust belt tension. One must always be installed.
3. Turn cam counterclockwise to reduce distance between sheaves. Do not rotate past # 1 position.
iji
Optional Thin Adjustment Washer (P-85)

.048" - PN 7555899
4. Torque boits to specification. 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 adjus tment pins.
6.43
9/96
CLUTCHES
Drive Bel t
Clutch Offset Ins pect ion
NOTE: Proper offset aligns the fixed sheaves of both clutc h assemblies. This allows the clutches to be aligned througho ut the shift range. 1. 2. Remove drive belt. Belt deflection adjustments affect offset. Set belt deflection first. Offset - Non-Electric Start Models
c. _ _ A
-.--:
:.: ;.::
No gap at point "A"
21/32" Offset All models with P90 drive n clutc h
Install proper alignment tool, depending on type of clutch, as shown in III. 1. 3. Rear of driven clutch moveable sheave should just contact tool when clutch is pushed inward on jackshaft. Clu tch Al ignment (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)
., .-
".
5/8" Offset All models with P85 driven clutch
.~
<:
..'
NOTE: Up to .060" (1.5mm) air gap allowed at point "B-. B Up to .125" is acceptable on new machines.
'"
:~
... .: ..
'. '
Clu tch Offset Adjustment

Determine direction driven clutch needs to be adjusted . (Refer to Clutch Offset Inspection procedure above). 2. Remove driven clutch retaining bolt, and remove driven clutch. 3. Add or take out washers on jackshaft between the drive n clutch and jacksha ft 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 retainer (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 offset and alignment. Driven Clu tch Boll Torque 12 fl. Ibs. (1.66 kgm) 1.
III. 1
Offset Alignment Tool
Offset Electric Sta rt Models NOTE: Up to .060" (1.5mm) air gap allowed at point "B". (.125" on new machines)
Straight Edge
B
P90 Electric Start 1.28" P85 Electric Start 1.00"
III. 2
9197
6.44
CLUTCHE S Drive Belt

Clutch Alignment Inspection
'-NOTE: Drive clutches are purposely misaligned slightly forwa rd to compensate for the engine shifting on it's mounts. Under load. the engine will pull back slightly so both clutches are in alignment.
1. After clutch offset has been verified, inspect alignment. 2. Install proper alignment tool, depend ing on type of clutch, as shown in III. 1 page 6.44. 3. There should be a .060" - .090" (1.5 - 2.25 mm) gap between front of driven clutch and tool, with the tool just touching at the rear. Up to .125" (3.1 mm) gap is acceptable in the front on new machines .
Clutch Alignm ent 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 alignme nt. 5. Verify proper torque stop adjustment.
Torque Stop Adjustment

NOTE: There are two types of torque stops currently used. Refer to the illustrations below for adjustment of each type.
1. After aligning clutches, adjust torque stop by looseni ng 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 engine mount to .010" - .030" (.25 - .75 mm) .005" (.13 mm)
/~' ~I
I,; ;-. . -,
"". " . /
"
Engine Mount
'fr-~ .' . ~' " . .

"-...--
.( { }
<',;~ /'~ 'fik
! "-- .j /),<. '3

' . /'
. :-.
~_
~/;/
/J
<;
,? "-2. / .',o' ..
<,
Torque Sto p \
._ ......
'.
r .
h
LOCk ~'>
~
c'
,;'
Lock Nut
N ut ~
-~.
Adjust gap between stop and engine crankcase to .100" (2.5"mm) .010" (.25 mm)
6.45
9/97
CLUTCHES
Drive Belt Belt to Sheave Clea rance Inspect io n
NOTE : The distance between the belt and the moveable sheave on the drive clutch is very important. This distance controls the start ing ratio (lowest starting ratio is most preferable) and the pos ition of the clutc h weight to engine RPM. The distance betwee n the belt and move able 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 cieara nce with a new beit.
2. Instali feeler gage between other sheave and belt.

',I
Belt to Sheave Clearance .020" .015"(.5 mm.4mm)
Belt to Sheave Clearance Adjustment

Belt to sheave clea rance can be adjusted in two ways. 1. Try severa l new belts to achieve proper clea rance. 2. Can add or remove shims from under the spider to increase or decrease belt to sheave clea rance. See Spider indexing on page 6.32 . NOTE: Spider index ing affects clutch balance and belt to sheave cleara nce. Read proced ures carefuliy befo re proceeding. NOTE: Belts with vario us widths wili also affect belt deflection since theywili 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 287 1025
Item 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 1 Qty. 1 Part Description P-85 Drive Clutch Moveable Bushing Removal and Installation Tool P-90 Drive Clutch and Driven Clutch 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 Number Two Puller Adapter 5020628 5020629 5020630 502063 1 5130862 5222768 5020632 50 10279 5020633 9912260 Part No. 5020627
11 1 Instruction 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 Remova l

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: GarmaxStyle (Installed Dimension) 1'1 Nominal Bearing Bore: 1.125" (28.57mm),L Service Limit: 1.140" (28.95mm)
I
Cover Bushing Inspection: Teflon/Bronze Style Service Limit: Replace cover bushing if more bronze than Tetlo n' is visible. NominalBearing Bore: 1.125" (28.57mm) Service Limit: 1.132" (28.75mm) , (Measure When Bushing is Installed) .
6 .47
9/97
CLUTCHES Clutch Bushings P-85 P-85 Drive Clutch Cover Bushing Removal Cont.
3. O n models equipped with snap ring, remove round wire snap ring from inside of clutch cover using a sma ll sc ribe or pick and set aside. Insta ll main adapte r (Item 8) on pul ler.
3) into cover bushing.
4.
5. From outside of cl utch cover, insert rem oval too l (Item

6 . Wi th inside of cove r towa rd vise, slide cover onto puller. 7.
Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed .
8.
Turn clutch cove r counte rclockwise on p uller rod until bus hing is removed. Rem ove nut from puller rod and set aside.
9.
10. Remove bush ing and bushing removal too l from puller. Discard bushi ng.
P-85 Drive Clutch Cover Bushing Installation

1. On Garrnax' sty le bushi ngs (PN 35 76516) apply Loctite 680 retaining compo und (PN 2870584) to the oute r surface of the bushi ng. Retaining compound is not requ ired on bronze / Tetlon t type bushings (PN 3576510) . Do not lubricate bushings, or prema ture wear will result. W orking from inside of cover, insert bushing and bushing installation tool into center of clutch cove r. With main adapter on pul ler, inse rt cover onto pulle r rod, placing o utside of cover toward vise . Install nut on rod and hand li ghten. Turn pu ller ba rrel to apply more tension if needed.
2. 3. 4.
5. Turn clutch cove r co unterclockwise on puller rod until bushi ng is seated. 6. 7. Remove nut from puller rod and take installati on too l and clutch cover off rod. Sq ueez ing ends of snap ring. gently fit ring into clutch co ve r.
9/9 7
6.48
CLUTCHES Clutch Bushings P-85

P-85 Drive Clutch Movable Sheave Bushing Removal
1. Inspect bushing and replace if excessively worn.
2. Install handle end of piston pin puller (PN 2870386) securely into bench vise and lightly grease puller threads.
3.
4.
Remove nut from puller rod and set aside. Install main adapter (Item 8) onto puller. See III. 1.
5. Working from inside of moveable sheave, insert removal tool (Item 1) into center of sheave. With towers pointing away from vise, slide sheave onto 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. Main Adaptor
7. Turn sheave counterclockwise on puller rod untit it comes free. 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.
III. 1
6.49
9/96
CLUTCH ES
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 tighte n. Turn barrel to apply additional tension if needed.
4.
5. Turn sheave counterc lockwise until bushing is seated. 6. 7. 8. 9. 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.
10. With towers pointing towa rd vise. instal l sheave onto puller rod. 11. Install nut on puller rod and hand tighten. Turn barrel to apply additiona l tension if needed . 12. Turn sheave countercloc kwise until ring is seated . 13. Remove nut from puller rod and set aside . 14. Remove sheave from puller. 15. Remove installation tool. Do no t lubr icate bushings, or premature wear w ill resul t.
9/96
6 .50
CLUTCHES
Clutch Bu shings P-S5 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.
Moveable Sheave Bushing
Insp~6iio~:
Note position of split
Replace the cover bushing if more brass than Teflon'" is vis ible on the bushing.
1.
Inspect bushing and replace if excessively worn. Insert bushing removal tool (Item 6) into sheave, cente ring 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 cente r 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.
7. Turn sheave counterclockwise until bushing is removed and sheave comes free. 8. 9. Remove nut from puller and set aside. Remove tool and bushing from puller. bushing. Discard
III. 3
Bridge
10. Remove bridge and adapter from puller.
6.51
9/96
CLUTCHES Clutch Bush ings P-85 P-85 Driven Clutch Movable Sheave Large Bushing Installation
NOTE: The P-85 driven moveable has a split bushi ng. The bushing is held in place after installation by screws .
11. Insert bushing (PN 3569803) into clutch and tap lightly with a soft face ham mer.
III. 4 12. Install adapter numbe r two (Item 10) onto puller. See III. 5. 13. Slide clutch sheave onto pulle r wit h back side away from vise . 14. Turn puller barrel until rod extends past back side of sheave . 15. Insert large installation tool for DU bush ing (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 counte rclockwise until bushing is seated . 18. Remove nut from puller rod and set aside. 19. Remove insta llatio n tool and slide clutc h sheave from puller. III. 5 Adapter Number Two
NOTE: The screws hold the bushing in place .
'---------------'
9/96
6.52
CLUTCHES Clutch Bushi ng P-90 Polaris Ki t PN 2871 226 Item 2 3 5 8 9 10
Q1Y,.
1
1 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 Adapter Adapter Reducer Number Two Puller Adapter
Part No. 5020628 5020629 5020631 5020632 5010279 5020633
pogO Drive Clutch M o v eab le Sheave - Bushing Removal
Moveable Sheave Bushing Inspection: Replace t he cover bushing if more brass than Teflon'" is visible on the bus hing. 1. Install handle end of piston pin puller securely into bench vise and lightly grease puller threads. 2. Remove nut from puller rod and set aside.
3.
Install main adapter (Item 8) onto puller.
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. 5. Install nut removed in step 2 onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Nut is left hand thread.
6.53
9/96
CLUTCHES Clutch Bushing P90

6. Turn sheave and puller barrel togethe r counterclockwise on puller rod until bushing is removed . 7. Remove nut from puller rod and set aside.
8. Pull bush ing removal tool and adapter from puller rod. Remove bushing from tool and discard.
Drive Clutch Moveable Sheave - Bush ing 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 il 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.
9196
6.54
CLUTCHES Clutch Bushing pogO

P-90 Drive Clutch Cove r - Bush ing 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. 3. With inside of cover toward vise, slide cover onto puller. 4. Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed.
5. Turn clutch cover counterclockwise on puller rod until bushing is removed . 6. Remove nut from puller rod and set aside. 7. Remove bushing and bushing removal tool from puller. Discard bushing.
6.55
9/96
CLUTCHES Clutch Bushing P-90

pogO Drive Clutch Cover - Bushing Installation
8. On Garmax' style bushings (PN 35765 16) apply Loctite 680 retaining compound (PN 2870584) to the outer surface of the bushing. Retaining compo und is not required on bronze I Teflontype bushings (PN 35765 10). Do not lubricate bushings, or prematu re wear will result. Working from inside of cove r, 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 counterclockwise on puller rod until bushing is seated. 12. Remove nut from puller rod and take installation tool and clutch cover off rod.
9197
6.56

P-90 Driven Clutch Moveable Sheave Bushing Remova l 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 appea r.
CAUTION:
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

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 furthe r 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.
9196
6.58
pogO Driven Clutch Moveable Sheave - Bushing Installation

'--24. Working from the top, insert adapter number ten onto puller. See illustration at right.
Adapte r 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

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 procedu re for other rnoveable bushing.
9196
6.60
CLUTCHES Troubl eshooting

SYMPTOMS PROBABLE CAUS E REMEDY
Harsh drive clutch engagement
-Drive belt worn too narrow -Excessive belt to sheave clearance with new belt (high performance version without detent shift weight)
-Replace -Perfonm 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 circum ference 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 , jackshaft 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 tightltoo loose -Drive belt surface 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 -Jackshaft bearing seizure -Replace -Reduce gear ratio (chaincase mode ls) -Rep lace -Subtract driven clutch washers
6.61
9/96
CLUTCHES Clutch Syste m Troubleshooting

SYMPTOMS Engine RPM below specified ope rating range, although engine is prope rly tuned PROBABLE CAUSE 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 REM EDY
a) Replace with recommended spring b) Instal correct shift weight krt 1 l 0 match engine application c) Replace spring; refer to prope r installation location d) Install new belt and/or adjust bert tension e) Install correct parts and/or adjust to match engine application andrna chine use
Erratic engine operating RPM during acceleration or load variations
Drive clutch binding or driven clutch malfunction Converter sheaves greasy; belt slippage
- Dlsassernble drive clutch: inspect shift weights for wear and free operation Clean clutches; instalf new belt -c rean and polish stationary shaft hub; reassemble clutch without spring to determine problem area
-Replace rampbuttons
-msoect moveable sheave tor 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)lmprope r driven clutch setup
a) Install proper spring b) Install proper stitt weights c) Disassemble and clean clutch, inspecting shift weights and buttons. Reassemble without the spri g to n determine probable cause. oj-Dtsassembre. clean and inspect driven clutch, noting worn sheave bushing and ramp buttons and helix spring location e) Clean clutches; install new belt f) InstaU correct parts and/or adjust I 0 match engine application and rna chine use a) Repla with reeomnended spri g ce n b) Install correct shift weightkit to match engine application c) Replace spring; refer 1 proper 0 installation location d) Install new beltand'or adju belt st tension e) Clean clutches; install new belt I) Install correct parts and/or adjust to match engine application and ma chine use
Burnt Belts I Premature Wear Also see Belt Wear I 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
9197
6.62
CLUTCHES Belt Wear I Burn Diagnosis

Be ll Wear I Bu rn Diagnosis Possible Cause Of Wear Or Burn ing Driving at or about engagement RPM for extended periods in all types of conditions Cold weather startups So lution 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 engi ne 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 agg ressively for sho rt durations for initial cold drive away 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 norma l warmup. Ailow belt to warm sufficientiy and increase grip ability on clutch sheaves. Use fast, effective thrott le 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 caut ion when loading machine. Carbid e skags may gouge into trailer and prevent drive train from spinning 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 I burning. Check for correct clutch components. Use fast, effective throttle to engage the clutch.
Towing another machine at or about engag ement RPM
Spinn ing 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 tunn el overnight or after stopping for a long period of time (enough to re-freeze the snow). Poor running engine (Bog, Miss, Backfire, etc.)
Loading mach ine on trailer
Clutch malfun ction Slow, easy belt engagement - easing on the throttle
6.63
9/97
CLUTCHES 1998 Clutch Specifications
1998/ 0-3000 Feet (0-900 Meters)

Machine
Model
Engagement Operating
Se rvice
RP M 300
RPM 200
Drive
Clutch Part No. 132 1596 1321596 1321596 132 1739 132 172 1 1321762 1321735 132 1738 132173 5 1321735 132173 6 132 1737 13217 3 6 132 1737 13217 38 1321733 13217 33 1321734 132 1734 13216 94 13 217 32 132171 3 132 1733 1321734 1321694 1321732 132171 3 1321740
Drive Clutch Spring Color, Wire Dia. Silver/Gold
Sh ih WI. I.DJGram
Driven
Clutch
Cen te r
Spring Color
Distance
+.100
Driven Helix Angle & Location

36 .5 ~
Chaincase
Gearing / Cha in
Pitch
Lite Lite Detuxerrrng
4100 4000 3500 3800 4000 5000 3600 3600 3600 3600 4000 3800 4000 3800 4200 4200 4200 3800 4200 4800 4200 450 0 4200 4000 4200 4500
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
10 10Al. 10 10 MB Bush ed 10 Bushed S53R Bushed 10Al. Bushed 10 Bushed 10Al

Bushed
Silver
- .000 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" 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
.2 18
RedlWhite
Sport
Sport Touring TranSport
Red Re d Red
Silver
440 XCF 440 XCR

Trail
.192 Brown .200 Gold .207

R edlWhit e
_192 Almond! Gold RedfWhite .192

RedlWhile
IBlue Silver
I Blue
Red
Silver
Trail Touring
Trail RMK~ See Note Below Super Sport
500
500 Classic
500 RMK"
See Note Below
Classic Touring WideTrak LX
XlTS P XlT LTD

XLT Classic XLT Touring
600 XC 600 XCR 600 RMK'

See Note Below Ultra Ultra Touring
.192 RedNv'hite .192 RedIWhite _192 Gold .207 Gold _ 207 Gold .207 Brown .200 Dark Blue .218 Silver/Gold .218 Dark Blue .218 Silver/Gold .218 Dark Blue .2 18 Almond (square) Dark Blue .2 18 Dark Blue .218
Dark Blue
Red
Silver
A l 36 .5" B-2 36 .5" B-2 34 ' #3 34 ' #2 R8 #2 36 ' #2 36 ' #2 34 ' #2 36 ' #2
36 ' 1#2 34 ':/#2
10Al.
Bushed
10M
Bushed
Gold Red
Silver Silver Silver
10M
Bushed
10 MB Bushed 10 Bushed 10 MB Bushed 10 M Bushed 10 M

Bushed
Red Red
Silver
Silve r
10 MB
Bushed
10-58
Bushed
10-54
Bushed
Gold
SilverI Blue
10-58
Bushed
10-54
Bushed
Red
Silver
34 ' #2 34 ' #2 36 ' 02 R32 #2 34 ' #2 34 ' 02 34 ' #2 R32 #2 Rl #2 R-8 #2 36 0 #2 36' Mod #2 R8 #2 R-l1 #2 R-4 #2
16:39 64P 17:35 62 P 17:41 / 66 15:39 / 64 22 :41 68 P 19:39 66P 22:4 1 70 P 22 :4 1 68 P 20:40 66 P 18:41 66 P 22:41 68P 22:41 68P 17:41 66 P 19:40 66P 19:41 66 P 22:41 68P 22:41 68P 22:41 68 P 20:40 66P 22:40 70 P 23:40 68 P 19:40 68 P
23:40/68P 22 :40/6 8P
700 XC 700 XCR 700 RMK' See Note Below Storm
10-60
Bushed
.218 Almond (sq ua re) Dark Blue .218 Almond (square)
10-54
Bushed
Gold
Silver/ Blue
10-60
Bushed
10-58
Bushed
Gold
24:40 70 P 24 :40 68 P 21:41 70 P 25:40 70 P
* NOTE: RMK production setup is 6000 -9000
ft. Refer to Page 6.8b for produ ction RMK Specs
6.8a
9/97
CLUTCHES 1998 High Elevation Clutch Specif ications
1998 HIGH ELEVATIO N RECOMMENDATIONS
3000 Ft. to 6000 Ft.

Machine Mod el
ChainShift We ight
6000 Ft. to 9000 Ft.

Chain-
9000 Ft. to 12000 Ft.

Shift W eight 10M Wh ile or
Clutch Spri ng
Gold
RedJWhite
Driven Helix
case
Gearing
Shitt
Weight
Clutch Sp ring
Driv8n Helix
case
Gearing
Clutch Spring
Blu e Go ld
Driven Helix
Chaincase
Gearing
' 6:39 16:35 ' 6:39 '5:39 21 :41
22:41
Ute! Deluxe
10M
Blue
36,50
16:39
17:35
'OM
White
Gold Gold
Gold
1T 00!'ng
Sport Sport Tour-
#A'
36 .5" #B-2 36 .5 .6-2
36.5 0
10
Bush ed
10AL
Bushed
ing
Tran Sport Supe r
Bushed
'OM
Brown Brow n
AedJ White
16:39 '5:39
22 :41
10M
Bushed
36.5' #A ' 36 .5" 'B-2 36 .5" #9-2 36.5'

#8-2
16:39 16:35
10 M Red
10M Blue o r 10 Bus hed 10M Bl ue
RedlWhile
Gold
36.5 #A ' 36 .5" #B-2
16:39 15:39 21:41

22;41
Gold
Gold
Bushed
10M Blue
36 .5'
#8 -2
10 M
Bush ed
.B-2 36" '2 36' '2 36' '2
10M BUShed ' OMB

Bu shed
Gold
RedJWhite RedlWhite RedlWhite Redr'INhite
Bushed
10MB
Bu sh ed Bushed
36.5" #B-2 36" '2 36" '2 36' .2 34' '3 34' '2 36' '2 34 ' #3 R-32 .2 36 ' .2
Sp<>rt
Trail TrailTou ring Tr ail RMK
Bush ed
' OM 10
RedIWhite Redl'Nhite RedlWhite RedlW hite Re d!V'Jh ile Go ld Almo nd! Go ld Go ld Gold Gold Blue
22:4 1 20 :40
18:41
' OMB
Bushed
Bushed
10M
Bushed Bushed
10MB
Bush ed
'A
34'
'2 34' '2 36' '2 34' '3 R-B #2 36' #2 34' '2
10MB
Bushed
XCF
WideTrak LX
10M
Bus hed Bushed
19:39
19:4 1 22 :4 1 22: 4 1 22: 4 1 22 :41 17:41
10 M
Bushe d
Gold
RediWhite Gold Alm ond ! Go ld Dark Blue Da rk Blue Dark Blu e Blue Dark Blue Dark Blue Dark Blue Blue Alm ond! Gol d Armond Dar k Blue Dark Slue Dark Blue Alm ondGo ld Almo nd Dar k Blue A lmond
36" '2 36' '2 36" '2 34' '2 34' .2 36 ' .2 34' #3 R-B #2 36' '2 34' .2 34 ' '2 34' '2 R-32 '2
Aed!White
Red/White RediWhde RedNJhite
' OMW 10MB
20:40
20 :40
18:4 1 19 :41 19:4 1 22:4 1
Bushed
l B:41
19:41 19:4 1 22:4 1 2 1:4 1 22:41 22:41 17:41
10MW Bus hed
' OMB
Bushed 10MW Bush ed
Gold
RediWhite Gold Almond!
'A
10MB
Bus hed
440 LC 440 XCR

500
500 Classic
IOMW
Bus hed
10MW
Bu sh ed
' OM R
Bushed
S 53
Blue
10M
Bu sh ed
' OMB
Bus hed
2 1:4 1
22: 4 1
Gold
Dark Blue Dark Blu e Dark Blue Blue Dark Blu e Dark Blue Dark, Blue Blue A lm on d! Gold Alm ond Dark, Blue
10MB
Bushed
10 MW
Bus hed
10MR
Bu shed 10M A Bushed
10 MB
Bushed
IOMW
Bus hed 10M W Bushed
34'
'2 34' #2 34 ' '2 R-32 .2 34 ' '2 R-32 '2
22:4 1
17:4 1 19 :40 21 :41 2 1:4 1 21 :41 19:40 2 1:4 1 21 :4 1 19:40
500 RMK
Cla ssic Touring
10MB
Bushed
34'
'2 34' #2 R-32 .2
10MR
Bushed
10MB
Bu shed
19:40
22:4 1 22 :41 22 :41
10 MW
BUshed
19:40
2 1:4 1 21:41 21 :41
10MR
Bu shed lOMR Bu shed
XL TSP XLT LTD

XLT Classic XLT Touring
10MB
Bushed 10MB Bushed
Dark Blue
Sil ver Gold Da rk Blue Silve rG old Alm ond l Go ld Alm ond Dark Blue Dark Brue Dark Blue A lmondG old Alm ond Da rk Bl ue Alm ond
' OM R
Bushed
34'
.2 34' .2
10MW
Bushed
34"
.2
R-32
' OMR
Bu shed 10M R Bu shed
10MB
Bu shed
' OMR
BUshed
10MB
Bushed
34'
.2 R-3 .2 R-l '2 R-B 36" '2
20:40 22 :40 23 :40

19:40
10MW
Bushed
600 XC 600 XCR 600 RMK

U ltra Ultra Tour-
10-56 10
Bu sh ed
10-54 ' OM
Bushed Bushed
'2 34 ' .2 R-3 #2 R-I .2 R-B
19:40
2 1:4 1 2 1:41
10MR
Bu shed
34'
'2 R-3 #2 R-l '2 R-8 36 ' .3 36' '3
R-1 1
10AL
10MB or
10MW ' 9:40

22 :4 1
21 :40 10 Bu shed
ro-se
Bu shed Bushed
' a-54 10M
'A
23 :40
22 :40
36"
'3 36' #3
R- l1
Bu shed
Bu shed
' OMB
Dar k Blue
Da rk Blue Almond-
22 :4 '
21 :40 23 :40 23 :40 2 1:4 t 2 1:4 1
10
Bus hed
36"
'2
R-l 1
' OM
Bu shed
' OMB
Bu shed
'09
700 XC 700 XCR 700 RMK
Sto rm
10-56 10
Bus he d
24:40 24:40
21 :4 1
.2 R-B '2
R-11
' a -56
Bu shed
23:40 23 :40
2 1:4 1 2 1:4 1
l a -54
10M B Bus hed 10-56 BUShed
.2 R-B .2
Gold
A lm ond Da rk Blu e Alm ond
10M
Bu shed
10-5B
Bush ed
to-ss
Bu sh ed 10-56 Bu sh ed
a-n
R-4 '2
'2 R-B '2 R-11 R-4 '2
io-ss
Bush ed
R-4 '2
25 :40
ro-sa
Bu sh ed
9/9 7
6 _8 b
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 steering rod end orientation pages in this chapter for diagrams depicting location. orientation. and torque valu es of fasteners. Always use genuine Polar is parts and fasteners. Bolt Size 3/8 7/16 1/2 1/2 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) 24-25 ft. Ibs. (3.31-3.45 kg-m) Radius Rod, Drag Link, or lie Rod End Jam Nuts Bellcrank (Center Steering Arm) (Non-C RC) 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) lie Rod to Steering Arm 28-30 ft. Ibs. (3.86-4.14 kg-m) lie Rod to Bellcrank 28-30 ft. lbs. (3.86-4.14 kg-m) Trailing Arm Rear Support 40-45 ft. Ibs. (5.52-6.21 kg-m) 28-30 ft. Ibs. (3.86-4.14 kg-m) IFS Shock (Top & Bottom) 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. lbs. (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 kg-m) Throttle Block Set Screw 30-35 in. Ibs (.35-.40 kg-m) Ski Pivot Bushing Bolt 2528 ft. Ibs. (3.45-3 .86 kg-m) Choke to Plastic Console 20-25 in. Ibs. (.23-.29 kg-m)
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
Polaris tndustries Inc.
7 .1
9/97
BODY AND STEERING 1996 Steering Specif ications

Model 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 Tourin g 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 Suspension Ty pe Lite IFS-38x7 Reference Width' Front Vertical Travel
37"
T
7.25"
38 #
Std. IFS XTRA -10 CRC XTRA-10 CRC IFS-3B Std. IFS XTRA-10 Std.IFS XTRA-10 XTRA-12 XTRA -10 XTRA-12 XTRA-12
41" Use Max Set Up Width See 1997 XTRA-10 CRC Use Max Set Up Width See 1997 XTRA-10 CRC 38"
41'" 4 1/1
7.25" 8.4" 9.15" 7.25" 7.25 " B.4" 7.25" 8.4" 9.B" 8.4" 9.B" 9.B"
41" 41" 42.5" 41" 42.5" 42.5"
XTRA-10 XTRA-10 XTRA-12 XTRA-12 Std.I FS XTRA-10 XTRA-10 Std.IFS Std.IFS
41" 3B" 42.5" 42.5" 41" 41" 38" 41" 38"
8.4" 7.0 9.8" 9.B" 7.25" 7.25" B.4" 7.0" 7.25" 7.0"
CAUTION :
1996 Models: Reference width is measured from center of spindles near grease fitling 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 0 widest point is when lower radius rod is parallel 1 the ground. Always verify adequate tie rod and radius rod end thread engagement after installing or adjusting front suspensi on or steering components. Refer to page 7.11 . Caster: Camber: Toe-in/Toe-out: Fixed Adjust ed with suspens ion fully extended - front end elevated. Adjusted at Normal Ride Height
NOTE: Precision camber and toe setup can be pertormed on Xtra-10 CRC and XC-10 models. Refer to page 7.18a.
9197
7 .2
BODY AND STEERING Steering Rod End Orien tation 1996 to Current Indy Lite/GTlDeluxe
Illustration depic ts proper orientation of rod ends and bolts on steering componen ts .
Stee ring Post 15-17ft. Ibs. 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 li nk Bell Crank
/
.---"~~
""., -Stee ring Post Arm (Stee ring Frog) Rod End
Steering Tie Rod
28-30 ft. Ibs (3.86-4.14 kg-m )
Ste ering Arm Replace locking faste ners if rem oved. See torq ue chart on page 7.1 for torque specs.
7 .3
9/97
BODY AND STEERING 1996 CRC Steering Assemb ly Exploded View

1996 440 XCR/440 XCR SP
Illustration depicts proper orientation 01 rod ends and bolts on steering components.
Ste ering Post Arm (stee ring l rog) 28-30 It. Ibs. (3.9-4.1 kg-m)
Steering Post
D -Ring
Pitman Arm
Drag Link
I
End
Rdk O;
"'~., /
~-r,~
Idler A rm
~I
35-40 ft. Ibs. (4.8-5.5 kg-m)
Oll}t;::-- - - _
28-3 0 It. Ibs. (3.9-4.1 kg-m)
Rod End
Steering Tie Rod Rod End Steerin Arm Replace locking fast ene rs if removed. See torque chart on page 7.1 l or torque specs.
'-"
,?-~~ D
28- 30 ft. lbs. (3.9-4 .1 kg-m )
9/9 7
7 .4
BODY AND STEERING Steer ing Assembly Exploded View
1996 WideTrak GTIlX

Illustration depicts proper orientation of rod ends and bolts on steering components.
Steering Post
Drag Link
Steering Post Arm (stee ring frog)
Bell Crank
Rod End
Stee ring Tie Rod
Steering Arm Replace locki ng fasteners if removed . See torque chart on page 7.1 for torque specs.
7.5
9197
BODY AND STEERING Steering Assembly Exp loded View 1996 Indy 440 LC/Super Sport/500fTrail
Steering Post
Steering Post Arm (steering frog)
Drag Link
Rod End
Rod End
Bell Crank
Steering Tie Rod
Replace locking fasteners if removed. See torque chart on page 7. 1 for torq ue specs .
Steering Arm
9/97
7 .6

1996 Indy 600XCRl600 XCR SP/Ultra SP/Storm/Storm SKS
Illustration depicts proper orientation of rod ends and bolts on steering 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 It. Ibs (3.86-4.14 kg-m)
Steering Arm
Replace locking fasteners if removed. See torque cha rt on page 7.1 for torque specs.
7.7
9197
BODY AND STEERING Steering Assemb ly Exploded View

1996 XTRA-10 1996 - Current XTRA-12 Models
Illustration depicts proper orientatio n of rod ends and bolts on steering components on models listed above. Refer to c ha rt on page 8.1 for suspe ns ion type .
NOTE: On Xtra 10 and Xtra 12 th ree cy linder mode ls the d rag lin k is on the left side. On twin cy linder models the drag link is on th e right side with the same rod end co nf igu ratio n. Three cylinder configuration shown.
Steering
'<;
Drag Link O r 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)
Steer ing Post Ar m (steering frog)
Bell Crank
Rod End Stee ring l1e Rod
28-30 ft. Ibs (3.86 -4.14 kg -m)
Steering Arm
28-30 ft. Ibs (3.86 -4 .14 kg-m)
Replace locking fastene rs if rem oved. See torque cha rt on page 7.1 for torq ue specs.
9/97
7 .8
BODY AND STEERING Steering Assembly Exploded View

All 1997 to Current Models Except XTRA-12 Front Suspension or CRC
Illust ration depicts proper orientation of rod end s and bolts on steering compone nts.
Steering Post
Drag Link O r Tie Rod End Jam Nuts 24-25 It. Ibs. 3.32-3.46 kg-m Stee ring Post Arm
~"i'" Froq)
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
Rep lace locking faste ners if removed . See torque chart on pag e 7.1 fo r torque specs .
7 .9
9/97
BODY AND STEER ING

Steering Inspection Inspection
Prior to performing steering alignment, inspect all steering and suspension components for wear or damage and replace parts as necessary. Refer to stee ring asse mbly exploded views in this chapte r for identification of components and torque values of fasteners. While disassembling, make notes of what direc tion 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 replacing front end components. The following compo nents 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 whe never 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 / linkage (where applicable) Handleba rs and stee ring post assembly Spindles and bushin gs Trailing arms and bushings Skis and skags Bell crank / Pitman Arm / Idler Arm Steering arms Shock absorbers, shock mounts, springs All related fasteners - check torque. Refer to steering exploded views at the end of this section.
Alignment Bar Specifications

Material: Diameter: .. ... ..... . . . . Length; C-1018 .623" - .625 " (5/8'1 (15.82 - 15.87 mm) 48" (122 cm)
PN 8700231 See General Information Chapter or Service Tool Catalog for ordering information .
48" (122 em)
Alignment Bar PN 8700231
9/97
7.10
BODY AND STEERING Steering Adjustment Guidelines - All IFS Camber Definition - AIIIFS
The following definitions of camber use automotive terminology to describe positive and negative positions. Refer to the illustration at right. 0 (Neutral) Camber - Spindle is 90 (perpendicular) to ground Positive, Negative, and Neutral (0) Camber
+ (Posi tive) 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 Rod End Support <, r----",,------,,,--, d ge E
Mounting Surface Incorrec t Correct
Rod End Engagement Guidelines - AIIIFS
Tie Rod Or Radius Rod End Tie Rod Or Rad ius Rod End Must Engage Rod A Minimum Of 2x Thread Diameter When Ad justment Is Complete EXAMPLE 7/16" Rod End x 2 = 7/8" Minimum Thread Engagement =7/8" 11mm x 2 = 22mm Minimum Thread Engagement =22mm
Jam NUl
(
~
p:
/
~' I I IJII
_ I .1 ' ..!..,
L.!-
-,-,
Tie Rod Or Radius Rod
Diameter Of Rod , End x 2 = Minimum Thread Engagem ent Thread Engagem ent
-- -
7.11
9/9 7
BODY AND STEERING Steering Adjustment - AIIIFS

Quick Reference Camber I Toe C h art - All
IFS
Use the General Instructions and illustrations on following pages to adjust camber and toe. Refer to tables below for spec ificat ions. Suspension Type Lite Adju stment Toe Camber Standard IFS Toe Camber XTRA-10 Toe Cambe r XTRA-12 IFS-38x7 38-RMK Toe Cam ber Toe Ca mber 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 0
1/8 - 1/4" ToeOut 112" (12.7 mm)
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 " (6m m) 361 /2" (92.70 cm)
Refer to rod end engagement guidelines Page 7.11 401 /2" (102.90 cm)
C"'q C':
40 1/2" (102.90 cm)

37 3/8" (94.90 cm)
1/8 - 1/4" Toe Out 0
36 3/4" (93.35 ern)
~ s::
=r;=
' NOTE: All ca mbe r specifications are 5/16" ( 8m m)
Use the General Instructions and illustrations on following pages to adjust camber and toe. Refer to table s below for specifications. Suspension Type 38-RMK CRC Adju stment Toe Camber XTRA-10 CRC (, ) XC-10 CRC (. ) Toe Camber Toe Camber Specifi catio n'
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
Method Ride Height Front Elevated Ride Height Front Elevated Ride Height Front Elevated
Max imum Setup Width 1/4" (6m m) 37" (94.00 cm ) 39 1/4" (99.70 ern)
1" (25.4 mm)
39" (99.00 ern)
=-
' NOTE: All camber specifications are 5/16" ( 8mm) An altern ate method of alignment using the Ca mber and Toe Alignment Travel Bars (Kit PN 28715 37) can be performed on snowmobi les equipped with XTRA-1 0 CRC or XC- 10 CRC front suspension. The trave l bars are not intended for use on 38 RMK CRC or non-CRC models. Refer to page 7.18a .
9197
7.12
BODY AND STEERING Stee ring 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 maxim um 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 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. On 1996 and earlier models, be sure to follow thread engagement guidelines for stee ring tie rod and radius rod ends as shown on page 7.11 . Spindle Centering / Set Up Width 1. 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. 2. Support the front of the machine 1-2" (2.5-5.1 em) off the floor. 3. 4. 5. 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 +/- 1/8" (3 mm) from the center of the chassis after adjusting camber, width, and toe alignment. This measurement is controlled by adjusting radius rod length.
6. 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 proced ure.
o ~O:J(l::======~~
Set Up Width' Measure from cente r of one spindle to center of the other spindle with front end elevated and suspension fUlly extended to determine set up width.
' Do not exceed maximum
7 .13
9/97
BODY AND STEERING Steering Inspectiorr- All IFS
CAMBER INSPECTION
All Models - Elevate front End - Shocks Installed
Typical CRC Shown - Style varies by model Suspension free Hanging With If S Shocks Installed
Upper radius rod
Lower radius rod
Radius Rod End Jam Nuts Attac hing Bolts
--~~~~~~~~~~
Measure Here
Refer to specifications for: I FS type Specified amount of camber See page 7.2 - 7.2b or page 7.12 To adjust. lengthen or shorten appropria te lower radius rod until top of bar is within specified cambe r distance. Measurement should be take n 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 meas uring.
CAMBER - ACCEPTABLE RANGE
EXAMPLE: Specified Camber = 3/4" (19mm) Specified Tolerance = 5/16 " (8mm) Acceptable Range = 7/16 - 1 1/16" (11-27mm) Refer to specifications on page 7.2 - 7.2b or page 7.12
9197
7.14
Potens Industries Inc.
BODY AND STEERING

S teeri n g A djustment - All IFS Camber Adjustment 1. Determine which spindle requires the greatest amo unt of correction by installing the alignment bar through one side to the opposite spindle. Remove the bar and install it through the othe r side to the opposite spindle.
2. Using a 3/8" (1 em) drive 11/16" (1.7 em) crow foot wrench and 20" (51 em) long 3/8" (1 em) 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. 3. 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 camber specifications. On models with neutral camber (0) the bar should slide freely through both spindles ( 5/16" ). CAUTION:
I
Bulkhead
Radius rod ends must remain parallel to the bulkhead after rod end jam nuts are tightened to specified torque. See illustration at right. 4. TIghten all jam nuts. Torque radius rod attac hing bolts to specifica tion. Reinstall adjustable torsion bar linkage (where applicable). On 1996 modelsverify adequate thread engagement of rod ends as shown on page 7.11 .
\
Rod end parallel to mounting surface when jam nut is tight.
Jam Nut
Rod End
WARNING
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 attemptto set suspension wider than the specified maximum set upwidth. If set up width exceeds maximum, adjust upper and lower radius rods equally to main tain camber adjustment.
Rad ius Rod End Jam Nut Torque 25 ft. Ibs. (3.45 kgm)
Radius Rod Attaching Bolt Torque 3/8"(outer) 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 " (inn er bottom) 40-50 ft. Ibs. (5.52-6.9 kg- m)
Adjustable Torsion Bar Attaching Bolt Torque 15 ft. Ibs. 2.07 kgm)
7.15
9/9 7
BODY AND STEERING Steering Adjustment - All IFS 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 (B) (or bellcrank on non-CRC models) should be pointed straight forward. 6. Lubricate ski pivot bushings with Polaris Premium All Season Grease and install in spindle. Follow procedure in Illustration A for steel or B for composite skis. Torque ski bolts to specification. Install new cotter pin in castle nut. 7. Perform Toe Adjustment on page 7.17.
9/97
7 .16

Toe Adjustme nt, 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-10 CRC front suspensio n. 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" (7.6-1 2.7 em) and work suspension to find average 2. To obtain normal ride height of the front suspension, lift the front end 3-5" (7.6-12.7 ern) 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 , asphal t, or carpet which may cause carbide skags to grab or catch and restrict movement. Toe Adju stment Normal Ride Height NOTE: Measurements A&B should 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 "B" at normal ride height
/ \
Toe Alignment: All Models Measurement "A" should be 1/8"1/4" (3.17 6.35 mm) greater than measurement " B" at normal ride height.
~" l" Tr l'"

10"
10"
I I
-
' )))21)))
I.
,,-
S traight / Edge
-2' -
- :--- Track
7.17
9/97
BODY AND STEERING Steering Stop Adjustment

Steering Stop Ad justment
1996 Models 1. Remove alignment bar and turn handlebars tully to the right. Loosen upper radius rod bolt (A) and adjust steering stop (B) 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 fully left.
Uppe r Radi us Rod Bolt to Spindle Torque
28 ft. Ibs. (3.86 kgm )
W
.
"'.f/
Adjust Both Steering Stops
1997 Models Steering slops are not adjustable on 1997-current models.
9/97
7.18
BODY AND STEERING Controlled Roll Center (CRC) Steering Alignment

XTRA-10 CRC an d XC-10 CRC Steer i ng Alignment The following steering alignment procedure can be performed on XTRA-l0 CRC or XC-l 0 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 Ti p s 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 genuine Polaris parts and hardware when replacing front end components. Tools Tools required:
5/8" alignment bar - PN 5333508 6' tape measure Travel location bars -1 3.70" long (PN 5211714) Travel location bars -15.20" long (PN 5211713) Travel location bars -11.65" long (PN 5211822) Chassis stand or blocking
ct. ct.
Gamber - All Years 13.70"
.P
Toe Alignment - 1995 /1996 onlY .p 15.20"
~ . Toe Alignment- i997ffJ 11.65"

NOTE: The CRC Travel Location Bars are included in kit PN 287 1537, along with a 46' alignment bar, and assorted hardware. Kit component s 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-10 CRC and XC-l 0 CRC models. See text on following pages for specific procedures. 1995 -1996 CRC Models When Measuring Set Up Width Travel Location Bar Length Suspension Fully Extended - Shocks Installed To Inspect / Adj ust Camber Install 13.70 Bars To Inspect / Adjust Toe Install 15.20 Bars
1997 - Current XTRA-10 CRC and XC-10 CRC Models When Measuring Set Up Width Trave l Location Bar Length Suspens ion 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 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 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 suspension is set too wide on 1997-current models, the torsion bar can come loose and interfere wi th steer ing. 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 for steering tie rod and radius rod ends as shown on page 7.11.
7.18a
9/9 7
BODY AND STEERING CRC 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-U p Width adjustment(must also be checked after adjust ment) Camber Adjustment Handlebar Centering Toe Adjustment Verify Spindle to Chassis Centering and Set-up width are within limits 1. Securely support the front of the machine high enough to remove the skis. Make sure machine is level. 2. Remove skis.
Spindle to Chassis Centering

3. Follow procedure on page 7.13.
Set Up Width Measurement

4. Follow procedure on page 7.13. 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 steer ing. Do not attempt to set the suspension wider than the specified Maximum Set Up Width. For 1995-1996 models, use rod end thread engagement guidelines as shown on page 7.11.
Camber Adjust ment - 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). Disconnect tie rods from steering arms. NOTE: I! 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. Determin e which spindle requires the greatest amount of correction by installing the alignment bar through one side to the opposite spindle, the n remove the bar and install it through the other side to the opposite spindle. Camber Adj us tment Insta l! 13.70" Travel Location Bar s
"
----'
7.
", ..
..
Loose:n~
--=~~~
Remove
Alignment Bar
9/97
7.18b
BODY AND STEERING

CR C Steering Adjustm ent Camber Adjustment - XTRA-l0 CRC and XC-l0 CRC , (Co nt.)
'---8. Using a 3/8" drive 11 /16" (1 .7 em) crow foot wrench and 20" (51 em) long 3/8" (1 em) 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 throug h both spindles. When adjustment is correct, tighten jam nuts to 24-25 It. Ibs. (3.3 1-3.45 kg-m). Torque radius rod attaching bolts to 28-30 It. 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 tighten ed to the specified torque. See illustration at right. 10. Tighten all jam nuts. Torque radius rod attaching bolts to specification. Bulkhead
\
Rod end par allel to mountin g surface when jam nut is tight.
Jam Nut
11 . Re-check set specifications.
up
width
and
compare
to
Rod End
Handlebar Centering-CRC
12. With alignment bar in spindles and tie rod ends discon nected , center the steering rack by pointing the pitman arm and idler arm straight forward . 13. Cente r the handlebars by adjust ing drag link length. Tighten jam nuts to 24-25 ft. Ibs. (3.31-3.45 kg-m). 14. The steering arms should be paral lel to the ski cente rline or slightly inward . Refer to steering arm orientation on page 7.18g. Handl ebar Centering - CRC
~lry ! ' m.~==-. rr---; ~=--~. -! ' ~ :7 .n ,.,.,....,.,

-0 --
Fs..
,'=, . f~\<
~o,;;;.
;; ---
j ;O
,~
' AdJust D rag L' In To Center Bars
k ,r?""S A
9'
:
Pitman Arm and Idler Arm Point Straight Forward
15. Re-altach 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 instailed 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 complet e. 16. Perform toe adjustment on following page .
7.18c
9197
BODY AND STEERING

CRC Steering Adjustment Toe Adjustment- XTRA10 CRC I XC-10 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 spacer 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 / 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 .
(1\
A
I.J : J ' lh:W~.: ~~~~~ ~,

I I
Straightedge , Against Track
I 1 '-,--+-+~I 1
--'.l
r-,
9/97
7.18d
Polaris Industrie s Inc .

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 with 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.
-~j
~-
- --
Toe Measurement - CRC
23. Hold tie rod and tighten jam nuts. Be sure to position inner and outer tie rod ends parallel to their respective mounting surface as shown. When tie rod ends are prope rly tightened . the tie rod should rotate freely approximately 1/Bturn.
Tie Rod End Support '-J---L.'----.::::,---: dge E
Mounting Surface
Tie Rod Jam Nut Torque Incorre ct Co rrec t
28-30 ft. Ibs. (3.86 - 4.14 kg-m )
7.18e
9/97
BODY AND STEERING Ski Spindle Bushing Replacement

Ski Spind le 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 fitling for ski pivot bushing. The fitling 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 fo r wea r or damage.
4.
Remove old bushings and washe r from bottom of spindle tube with a drift punch. Inspect condition of washe r and replace if worn. Install new bushings. tapered end first.
Bushinqs, -
J ~~ '11
VVasher
~ Ji:
9/97
7 .181

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 filting facing forward (standard and leading spindles) or rearward (trailing spindles).
Standa rd
Leading Type
T railing '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 specitication.
Spindle Bolt Torque
28-30 ft. Ibs. (3.86-4.14 kg-rn)
7.189
9/97
BODY AND STEERING Steering Arm Installati on

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 verily proper steering operation after completing adjustments or repairs.
1. 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 fo rm (approximately) a 90 0 angle or slightly greater.
Forwa rd
Correct
As Close To 90 " As Possible
Thread s tie rod at least 3/4" (19mm ).
eng~" 1
...
\"i" "
Steering Amn Bolt Torque 30 ft. Ibs. (4 .15 kg-m) III. 1
2.
If the stee ring arm is installed incorrectly the threads of the steering tie rod end will not engage the tie rod sufficiently, and the angle formed betwee n ski and ski bolt centerlines is considerably less than 90 ' as shown at right.
Forwa rd
(~l
\
Ii
Ii I
Incorrect
Th reads do not II,-engage tie rod at ~~~ < 90
Imll r,
3.
Reinstall torsion bar linkage (where applicab le). Torq ue attaching bolts to specification.
1/1. 2
9/97
7.1 8h
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. Remove retaining nuts as shown. 2. Push bolt down through ski.
3. 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.
Steel Ski, Steel w/skins, Aluminum -15 ft. Ibs. (2.1 kg-m) , I Plastic Ski - 2~25 ft..lbs. (2.763.45 kg-m) "
Ski Skag Removal EZ Steer

1. Remove the three nuts from the skag. 2. Pull down and rearward to remove the skag.
Ski Skag Installation - EZ Steer

1. Install flat bar as shown. 2. Install IFS carbide skag. 3. 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 Install ation

Ski Skin Installation
1.
Lift and support front end of machine for easier access to skis.
A 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 bolt.

3.
Remove ski bolt and take off ski. Note direction of rubber ski stop.
4. Remove the bolts from the skag. Pry the back of

the skag downward from the ski and remove from the front slot.
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. Che ck to see that the skag holes line up.
7. 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.
8 . Replace skag removed in step 4.

9. Replace ski removed in steps 2 and 3. Refer to Page 7.19b.
10. Repeat proced ure for second ski.
9/9 7
7.19a
BODY AND STEER ING Ski Skag Removal

Ski Installation
SK I INSTALLATION - STEEL SKIS
Install ski over spindle, slightly in front of ski saddle with ski pointing outside. D Slide ski forward until spindle is just behind ski saddle and turn to the forward position. D Slide ski forward so spindle is behind ski saddle. D 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. Push ski back to slide spindl e into place. From outside of ski, install bolt and castle nut. Torque to 36 ft. Ibs. Install cotter pin and bend both legs
SK I INSTALLATION - COMPOS ITE
D Install ski stop

with large portion toward front of ski.
Install cotter pin and bend both legs.
Install ski to spindle. From outside of ski. install bolt, washers and castle nut. Torque to 36 It. Ibs. (4.97 kg-m).
D Carefully lower machine
7.19 b
9/97
BODY AND STEER ING

H a n d leba r To rq ue Handlebar Torq ue and Sequence - Indy Style
1. 2. Remove handlebar cove r 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 1 0 the left or right.
Handlebar Adjuster Block Bolt Torque 11-13 ft. Ibs. (1.5 - 1.8 kgm)
IMPORTANT: When adjusting the handlebar, be sure the serrations in handlebar and adjuster block match before 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.
Socket Screws
Handlebar Torque and Sequence Evo lved and Agg ressive Style
1. Remove two plastic fasteners holding console cover located below handlebar cove r 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 tor access to rear nuts.
2.
3. 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. 4. Torque the handlebar adjuster block bolts evenly to specification. The gap should be equal at the front and rear.
I", I
I!I
,',
. .",
5. Replace console cove r.
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
WARNING
Gasoline Is extremely fl amm abl e and exp losive under ce rt ain co ndit ions . Do not smoke or allow open flames or sp arks in or near th e area where w ork is bei ng performed. If you should get gasoline in your eyes or If you sh ould swa llow gasoline, see your doc tor Imm ediately. If you should spill gasoline on your skin or clothing, Imm ediately wash If off with so ap and wat er and change clothing. Prolonged exposure to petroleum based pr odu cts may cau se paint failures . Always protect finished surfaces and wipe up any spills Immedia tely. Two Pi ec e Fu el Tank/Seat Removal 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. 6. Roll front tank hold-down spring forward off tank saddle. 7. If machine is equipped with a fuel gauge connector, this should be unplugged. 8. Remove two bolts holding rear of seat to tunnel. 1. 2. 3. 4. 5.
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 STEER ING Fuel Tank and Seat Remova l

One Piece Fuel Tank/Seat Remova l
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. "---" 2. Remove seat cus hion assembly as outlined on page 7.22. Remove seat and seat covering to be replaced . Carefully remove staples by loosening with a small flat blade screwdriver. Pull each staple straig ht out with a pliers.
'-....-
3. On some models, it will be necessary to drill out the rivets holding the strap buck les. Reach inside the tool box and rotate the "0" ring buckle which secures the center hold down strap. Push the "0" ring through the slot in the tool box and carefully pull it through the foam cushion . Reass em bly Note: For ease of assembly, hook a wire to the center strap. This will allow you to pull the cente r 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.
e.
~...,#
Seat Bucket Hold Down Strap 3-bar Slide
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 plastic seat base as shown in III. 1A.
CAUTION: I
Apply staples in the stapling channe l 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. 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.
6. 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 compa rtment flap, continue with step 11. Bottom View Of Seat Assembly Stapling Chan\1 Tack Cover Here First
"'
Staples
_/h_ffi~ ""
~~
~~ ::"lI;:-_
Sewn Seams Tack Cover Here Second
A~
"x//#
Location Indicators
. ...
Vinyl Seat Flaps Stapling Channel
lJft
III. 1 8. Staple the remainder of the unattached seat cover to the plastic seal 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. 9. Turn the seat cushion assembly over and inspect for wrinkles or irnperiections. If imperiections are visible, remove the staples in the affected area and staple correctly.
Staple Here First
Staple Here Second
Staple PN 9810341 Stainless Steel
Staple Here Third Staple Sequence
1.2 11
9/97
7 .24
BODY AND STEER ING Seat Cover Replaceme nt

Models W ith 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 Instr uctions
OnelTwo Piece Seat and Tank I Covering Instructions PN 9912521 440 &600 XCR Seat Covering Instructions PN 9912842
'Ii
7.25
9/97
BODY AND STEERING Taillight Ass embly Replacement

Taillight Assembly Replacement Standard Indy
1. After removal of seat cover. drill out three rivets from top of taillight. 2. 3. Remove taillight assembly and wire harness. Install new taillight assembly and rivet into place.
4. 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.
Pull seat cover tightly and evenly into position and re-staple to seat pan.
6. 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
Leng th
2 Up Lit e
XCR
Performance
De luxe 2 Up Tou ri ng
Standard
2 Up
Tour ing
2 Up WideTrak
Lite
Lite Deluxe
Spon
Super Sport
Storm
Storm SKSI RMK 600 XCR SP
Trail
Lite GT
440XCR 600 XCR
Classic Trg.
XLT Trg.
Sport Trg. TranSport
WideTrak GT
WideTrak LX
Indy 440 Indy 500 500 EFI SKSI RMK
500 SKSlRMK 500 EFI

Classic
XLT SP XlT
-<:::.......
r---
~ XLT SKS/RMK
RXl
Ultra SP
~ U l t ra
Ultra SKS RMK

The following chart lists seat interchangeability for 1997 models. Arrows indicate interchangeability. For production seats only.
1 Up
Lite
Standard Length
Mid Leng th
Long Le ng th
2Up
Lite
XC
Pe rform ance
Deluxe 2 Up Touring
Standard
2 Up
Wi deTrak
2 Up
Touring
Lite
Lite Deluxe
Sport
Storm/S E Storm RMK 600 XCRIS E Ultra SPXiS E
500 EFt 700 SKS/RMK XLT l TD

Ultra
Lite GT
440 XC 600 XC XCF (no side pads)
Classic Trg_ Sport Trg.

Xl T Trg. Ultra Trg.
TranSport
Traillrg.
WideTrakGT
Super Sport
Ultra SP
WideTrak LX
RXl
Trail RMK Trail Classic
440 500 XlT
500 SKSIRM~
XLT Special
XLT SKSlRMK
7.27
9197

Th e following chart lists seat interchangeability for 1998 models. Arrows indicate interchangeability. For production seats only.
1 Up Lite
Standard Length
Mid Length
Long Len gth
2 Up Lite
XC Performance
Delux e 2 Up Touring
Standard 2 Up Tour ing
2 Up Wid eTrak
Ute
Lite Deluxe
Sport
XLT Special
600 XC 700 XC
6001700 XCR
500 (Option 2) Classic
LiteTr9
XCF (w/o pads) 440 XCR
Trail Tr9. Classic Tr9.

XLTTrg. Ultra Trg.
Sport Trg.
WideTrak LX
Super Sport
XLT LTD
TranSport
XLT Classic
Storm Trail
440 500 (Dption 3 Trail RMK 500 (Option 3) 500 RMK
6001700 RMK
unra
9/97
7 .27a
BODY AND STEER ING Nosepan Replacement Procedure

Nosepan Replacement Procedure Standard Indy/Aggressive Body Styles
When installing a replacement ASS nosepa n, the followi ng procedures must be closely observed to ensure correct fit to the frame and maximum strength, ASS materia l is not rigid, Consequently, it must be installed in such a manner that it can expa nd or contract with temperature changes . 1. Remove damaged nosepan by driiiing out rivet heads. Engine mountings and other mountings attached to the forward part of the machine should be removed for ease of installation.
2. The following aluminum rivets must be used to attach nosepan: PN 762 1448, 3/16 x .652, Quantity required - 7 PN 7621403, 3/16 x .527, Quantity required - 39
All holes are to be drilled into the nosepan 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 762 1448). See illustrat ion below. All remaining holes require 3/ 16 x .527" rivets (PN 762 1403).
4. Make sure there is 1/4" (.6 em) clearance around the exhaust outlet. 5. Install foil (PN 58 10108) in the same location as the original part.
Rivet PN 7621448
@
8
Rivet PN 762 1403
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 Nosepa n
9
7
. .
15
17 19
29
21
"
23
22
'24
+
>
30 32
31
33
NOTE: 1. When transfer drilling holes do not fo rce 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 1997 Steering Specifications

Mo de l Indy Lite/GT/Deluxe Indy Sp ort / Touring Indy TranS port 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 RM K Indy 500 / 500 SKS Indy 500 RMK Indy 500 EFI Indy Classic / Touri ng Indy XLT / XLT SKS Indy XLT RM K Indy XLT Tou ring Indy XLT S P Indy XLT LTD 1 LTD SP Indy RXL Indy 600 XC R Indy 600 XC R SE Indy 600 XC Indy 700 XC Indy 700 SKS Ind y 700 RM K Indy Ultra SP Indy Ultra SPXlSPX SE Indy Ultra/U ltraTouri ng Indy Storm / Storm SE Indy Storm RMK
1_ CAUTION.
Suspension Type Lite 38x7 XTRA-10 XTRA-10 CRC XC -10 CRC XT RA-lO CRC 38 x7 XT RA-10 38-RMK XT RA- 10 38 -RMK XT RA -12 XT RA-12 XT RA-10 38 -RMK XT RA-12
Ref eren ce W idth
Ma ximum Set Up Wi dth ' ( 1/4'1 36 1/2 (92.70 em) 37 3/8" (9 4.90 em) 39 1/8" (99.40 em)
Cam be r
5/16"(8m m )
0 1/2" (13 mm) 0 3/4" (19 mm ) 1" (25.5 mm )
Vertica l Tr av el
31"
38"
1"
7 1/4" 9 1/2" 9 1/2"
0 0 0
41 "
41"
41 "
39 1/4" (99 .70 em)

39" (99.00 em) 39 114" (9 9.70 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" (93.3 5 em) 40 1/2" (102.90 em) 40 1/2" (102.90 em)
41"
38"
3/4" (19 mm )
1/2" (13 mm)
9 1/2" 7 1/4" 9 1/2" 8 1/4" 9 1/2" 81 /4 "
41 " 38"
41"
a
0
0 0
38"
42.5" 42.5" 41"
a a a
0
10
10"
9 1/2"
39 1/8" (99 .40 em )

36 3/4" (93.35 em ) 401 /2" (102 .90 em)
38"
42 .5"
a a a a
3/4" (19 m m)
81 /4"
10'"
XT RA- 12 XT RA- 10 CRC
42 .5" 41"
40 1/2" (102 .90 em) 39 1/4" (99 .70 em)
10"
9 1/2 "
XC -10 CRC XT RA -10 CRC 38- RM KCRC XT RA-10 CR C XT RA-12 XT RA- 10 38- RM K
41" 41 "
38"
39" (99 .00 em) 39 1/4" (99 .70 em)
1" (25.5 mm ) 3/4" (19 mm ) 3/8" (9.5mm) 3/4" (19 mm) 9 1/2" 8 1/4" 9 1/2" 10" 9 1/2" 8 1/4"
31" (94 .00 em)

39 114" (99 .70 em) 40 1/2" (102 .90 em) 39 1/8" (99.40 em) 36 314" (93.35 em)
41"
42.5"
41"
a a
0
38"
' <I
' 1997 Current models have torsion bar attached to inside of trailing arm - Max imum set up width is listed for these models 10 prevent possible disengagement of the torsion bar from the trailing arm, which could interfere with steering. This measurement must be taken from center of spindles near grease filting on bottom of spindle WITh front of machine elevated and suspension fully extended. See pages 7.13 for measurement method and adjustment procedure.
Indicates upper rad ius rod non-adju stable,
Caster : Fixed Camber: Adjusted with suspension fu lly exte nded - fro nt end e leva ted . Toe-in/Toe-o ut: Ad justed at Normal Ride Height NOTE : Precision cambe r and toe setup can be pe rformed on models equ ipped with Xtra- 1 CRC or XC-1 front suspen sion . Refer to pag e 7.18a.
7.2a
9/97
SUSPENSION 1998 Steering Specifications

Model Indy Lite/Deluxerrouring Indy Sport I Touring Indy TranSp ort Indy Super Sport Indy XCF I Indy 500 Indy 440 XCR Indy WideTrak LX Indy 440 UC Indy Trail Indy Trail Touring Indy Trail RMKl500 RMK Indy Classic I Touring Indy XLT Classic Indy XLT Touring Indy XLT LTD Indy 600 XC Indy 700 XC Indy 600 XCR Indy 700 XCR Indy XLT SP Indy 600 RMK Indy 700 RMK Indy unra Indy Ultra Touring Indy Storm CAUTION: Suspensian Type Lite Reference Width Maximum Set Up Width*( 1/4") 36 1/2" (92.70 em) Camber 5116"(8mm) 0 Vertical Travel 7" 7.25" 9.5" 9.5"
37"
38" 41"
4 1"
38x7
XTRA-10 XTRA- 10 CRC XC-10 CRC
37 3/8" (94.93 em) 39 1/8" (99.40 em) 39 1/4" (99.70 em)

39" (99.00 em)
1/2" (13 mm)

0
0 0 0
3/4" (19 mm)

1" (25.5 mm)
41" 38"
41"
38x7
XTRA -10
37 3/8" (94.93 em) 39 1/8" (99.40 em)
1/2" (13 mm)

0
7.25" 9.5"
0 0 0 0 0 0 0 0
38-RMK XTRA- 12 XTRA-12
38" 42.5" 42.5"
36 3/4" (93.35 em)
0 0 0
8.25"
10"
40 1/2" (102.90 em)

40 1/2" (102.90 em)
10"
XC-10 CRC XTRA-10 CRC 38-RMK CRC XTRA- 12 XTRA-12 XTRA-10
41"
4 1"
39" (99.00 em)
1" (25.5 mm)
9.5" 9 .5"
39 1/4" (99.70 em)
3/4" (19mm )
38" 42.5" 42.5" 41"
37" (94.00 em)
3/8" (9.5mm )
0 0 0
8.25" 10" 10" 9.5"
40 1/2" (102.90 em) 40 1/2" (102.90 em) 39 1/8" (99.40 em)
0 0 0
*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 arm. which could interfere 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 upper radius rod non-adjustable. Caster: Fixed Camber : Adjusted with suspension fully extended - front end elevated . Tee-in/Toe-out: Adjusted at Normal Ride Height NOTE: Precision camber and toe setup can be pertormed on models equipped with Xtra-10 CRC or XC-10 front suspension. Refer to page 7.18a.
____
9197
7.2b
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 III. 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 hinge brace toward bottom of slot in hood brace.
If gap is too lillie at this point. move hole in hinge brace toward top of slot in hood brace .
o
Hood Adjustment - Evolved Style
Check to see that hood and upper hood hinge are properly aligned . To adjust . loosen nuts (A) and align properly. Tighten nuts. See III. 1. 2. With hood open. loosen nut (B). See III. 1. 3. Close hood and remove both rubber plugs. Then. using a 7/16" (.4 em) socket with an 8" (20 em) extens ion. loosen nut (C). Adjust hood to pan gap. Tighten nuts .
c
III. 2
1.
1------- --,
/
I I I l I I I I
/II HOOd ~1I

Upper I Hinge L
0 ' -' :
/ I
r-------/ :
-<l9
A
I I ol> l --- I I
4.
Check outer perimete r alignment and front and rear alignme nt 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 .
Hood and Hinge need not be flush
, ./ D
I I I
L _ __
I 1M I I
5.
III. 1
7.31
9/96
BODY AND STEERING

Hood Adjustment Nosepan, Front Bumper and Side Bumper Adjustment - Evolved Style
1. Open hood remove pane ls. and side
t
Fill Hole wi Rivet & Washer
FORWARD
2.
Remove foil tape cove ring 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 Out 1/2 Move Out 114" mm) as shown in the illust ration below. Be sure to mount the bracket at the same angle as befo re, so the side panel fits squarely agai nst 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.
6. Apply a new section of foil tape (PN 58 10908) ove r the bracket. Repeat this proced ure for the left side with the following excep tions: move the bracket outwa rd 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. Before removing old decal , it is important to note its position by marking it in several locations. 2. Remove old decal completely. NOTE: A small amount of solvent will aid in removing the old decal. 3. The decals are UV based. If heat will not remove decal, gently buff area with a mild abrasive. Use 3M Scotch BriteT " Graphics Removal Discs with a No.1 Roloc and hoider, or an equivalent iow RPM buffing disc.
li\~;2~9;hoN:
;i
Maintain 2500-3500 RPM to prevent damage to hood caused by excessive heat. 4. Remove any remaining decal adhesive with a citrus based cleaner or equivalent non-solvent based cleaner. 5. 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 approximateiy four ounces soap to one gallon water.
3M ScotchbriteT " Graphics Removal Disc 3M PN 0480111 6855 . No.1 Roloc and holde r 3MPN 048 01115408
IIi
Decal Installati on
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. Ii decal does not have a pre-mask, apply additional soapy water solution to top of decal after it is in position. 4. Hoiding decal in position, 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: 6. 7. Fasten a straight edge to tail end of decal. 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. 8. 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 oecal surface. 9. Apply a small amount of heat to the decal to fasten it securely. 10. Carefully remove excess decal material.
7.33
11/95
BODY AND STEERING Troub leshoot ing

Problem "Machine darts from side to side Possible Cause -Incorrect ski toe alignment So lu tion -Adjust to correc t toe alig nment
-Incorrect camber -Loose or wo rn stee ring com ponents or fasteners -Cracked or broken skis, skaqs , or carbides Tie rod hits trailing arm -Stee ring arm installed incorrectly
-Adjust to correct camber -Tighten or replace
-Replace if necessary -Index correctly in relation to -spindle -Replace if necessary -Tighten or replace if necessary
-Tie rod ends wo rn Steering has excessive freeplay -Steering bellcran k bushing worn or loose -Drag link worn or loose -Steering post loose -Steering post bushings worn -Tie rod ends worn -Spindle bushing s 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
-Tighten or replace if necessary -Tighfen as needed -Replace if necessary -Tighten as needed -Replace if necessary -Adjust spring tensio n on shocks -Recha rge. service. or replace -shocks -Remove noseco ne 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

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 01rod 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
A I
Drag Link
Steering Rack
~~~~::::~p.itman Arm ~ 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 01 boll
Spindle
9/97
7.9a
BOD Y AND STEERING Steering Assemb ly Exp loded View
All 1997 to Current XTRA-10 and 38 Wide (Non-CRC) Models

Steering Post
Drag Link Or Tie Rod End Jam Nuts 24-25 It. Ibs. 3.32-3.46 kg-m
Steering Tie Rod
2830 It. Ibs (3.86-4 .14 kg-m)
Replace locking fasteners if removed . See torque chart on page 7.1 lor torque specs .
Steering Arm 28-30 It. Ibs. (3.86-4.14 kg-m)
7 .9b
9/97
BODY AND STEERING XC-10 CRC Steering Assembly Exploded View

1997440 XCR, 700 XC ; 1998440 XCR, 600 XC, 700 XC
Illustration depicts proper orientation of rod ends and bolts on stee ring components for most models.
'M r\ '"
\ , ~
I
1 ., '
="
35-40 It. Ibs. (4.8-5.5 kgm)
N\." ~I=; '

\.
''0
"
~~ 'dfo ..,
X:Il____ '
..
NOTE: Typical XC-10 shown . Orientation of drag link and placement of pitman and idler arms reversed on some mode ls
'"
\~~, ~'.\ j;'I'

~
I
\"J
Trailing Arm
-se-:
~I
?;, -
L - --
~~
28-30 ft. Ibs. (3.9-4.1 kg-m)
.~
ti
Steering Arm
"'"-Drag Link
Jam Nuts 28-30 ft. Ibs. (3.9-4.1 kg-m) Pitman Arm
Idler Arm n e Rod Ends 28-30 ft. Ibs (3.9-4.1 kg-m)

_@ - --- 0
;~:9'/ - - - _ _1=-~~ ,) ~~ ~R~~~- . l @: J'-' "' ~ , ,

~ '"'-l-'.==-
~ ~_.')~, ~
@:
~ Steering Rack 'I'
-------- ---------==
4=1 .----:jj ~;a=---7' ~ .,1J::::

I =~n=r== -hJ~- .,, ,..
\ Jam Nuts
~
J )
,.: ~- .
'- _~; l} ~ f> -~.c,=_/ ~ -~j . . -=:-~ U~

~ <:> -- -- . - --;;::::I::rfr~ "j." <].:<- --.::::o~~.
Tie Rod
-'~\j--
28-30 ft. Ibs. (3.9-4.1 kg-m)
9/9 7
z.se
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 steering rod end orientation pages in this chapter for diagrams depicting location. orientation. and torque valu es of fasteners. Always use genuine Polar is parts and fasteners. Bolt Size 3/8 7/16 1/2 1/2 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) 24-25 ft. Ibs. (3.31-3.45 kg-m) Radius Rod, Drag Link, or lie Rod End Jam Nuts Bellcrank (Center Steering Arm) (Non-C RC) 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) lie Rod to Steering Arm 28-30 ft. Ibs. (3.86-4.14 kg-m) lie Rod to Bellcrank 28-30 ft. lbs. (3.86-4.14 kg-m) Trailing Arm Rear Support 40-45 ft. Ibs. (5.52-6.21 kg-m) 28-30 ft. Ibs. (3.86-4.14 kg-m) IFS Shock (Top & Bottom) 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. lbs. (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 kg-m) Throttle Block Set Screw 30-35 in. Ibs (.35-.40 kg-m) Ski Pivot Bushing Bolt 2528 ft. Ibs. (3.45-3 .86 kg-m) Choke to Plastic Console 20-25 in. Ibs. (.23-.29 kg-m)
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
Polaris tndustries Inc.
7 .1
9/97
BODY AND STEER ING

Steering Inspection Inspection
Prior to performing steering alignment, inspect all steering and suspension components for wear or damage and replace parts as necessary. Refer to stee ring asse mbly exploded views in this chapte r for identification of components and torque values of fasteners. While disassembling, make notes of what direc tion 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 replacing front end components. The following compo nents 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 whe never 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 / linkage (where applicable) Handleba rs and stee ring post assembly Spindles and bushin gs Trailing arms and bushings Skis and skags Bell crank / Pitman Arm / Idler Arm Steering arms Shock absorbers, shock mounts, springs All related fasteners - check torque. Refer to steering exploded views at the end of this section.
Alignment Bar Specifications

Material: Diameter: .. ... ..... . . . . Length; C-1018 .623" - .625 " (5/8'1 (15.82 - 15.87 mm) 48" (122 cm)
PN 8700231 See General Information Chapter or Service Tool Catalog for ordering information .
48" (122 em)
Alignment Bar PN 8700231
9/97
7.10
BODY AND STEERING Steering Adjustment Guidelines - All IFS Camber Definition - AIIIFS
The following definitions of camber use automotive terminology to describe positive and negative positions. Refer to the illustration at right. 0 (Neutral) Camber - Spindle is 90 (perpendicular) to ground Positive, Negative, and Neutral (0) Camber
+ (Posi tive) 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 Rod End Support <, r----",,------,,,--, d ge E
Mounting Surface Incorrec t Correct
Rod End Engagement Guidelines - AIIIFS
Tie Rod Or Radius Rod End Tie Rod Or Rad ius Rod End Must Engage Rod A Minimum Of 2x Thread Diameter When Ad justment Is Complete EXAMPLE 7/16" Rod End x 2 = 7/8" Minimum Thread Engagement =7/8" 11mm x 2 = 22mm Minimum Thread Engagement =22mm
Jam NUl
(
~
p:
/
~' I I IJII
_ I .1 ' ..!..,
L.!-
-,-,
Tie Rod Or Radius Rod
Diameter Of Rod , End x 2 = Minimum Thread Engagem ent Thread Engagem ent
-- -
7.11
9/9 7

Quick Reference Camber I Toe C h art - All
IFS
Use the General Instructions and illustrations on following pages to adjust camber and toe. Refer to tables below for spec ificat ions. Suspension Type Lite Adju stment Toe Camber Standard IFS Toe Camber XTRA-10 Toe Cambe r XTRA-12 IFS-38x7 38-RMK Toe Cam ber Toe Ca mber 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 0
1/8 - 1/4" ToeOut 112" (12.7 mm)
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 " (6m m) 361 /2" (92.70 cm)
Refer to rod end engagement guidelines Page 7.11 401 /2" (102.90 cm)
C"'q C':
40 1/2" (102.90 cm)

37 3/8" (94.90 cm)
1/8 - 1/4" Toe Out 0
36 3/4" (93.35 ern)
~ s::
=r;=
' NOTE: All ca mbe r specifications are 5/16" ( 8m m)
Use the General Instructions and illustrations on following pages to adjust camber and toe. Refer to table s below for specifications. Suspension Type 38-RMK CRC Adju stment Toe Camber XTRA-10 CRC (, ) XC-10 CRC (. ) Toe Camber Toe Camber Specifi catio n'
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
Method Ride Height Front Elevated Ride Height Front Elevated Ride Height Front Elevated
Max imum Setup Width 1/4" (6m m) 37" (94.00 cm ) 39 1/4" (99.70 ern)
1" (25.4 mm)
39" (99.00 ern)
=-
' NOTE: All camber specifications are 5/16" ( 8mm) An altern ate method of alignment using the Ca mber and Toe Alignment Travel Bars (Kit PN 28715 37) can be performed on snowmobi les equipped with XTRA-1 0 CRC or XC- 10 CRC front suspension. The trave l bars are not intended for use on 38 RMK CRC or non-CRC models. Refer to page 7.18a .
9197
7.12
BODY AND STEERING Stee ring 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 maxim um 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 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. On 1996 and earlier models, be sure to follow thread engagement guidelines for stee ring tie rod and radius rod ends as shown on page 7.11 . Spindle Centering / Set Up Width 1. 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. 2. Support the front of the machine 1-2" (2.5-5.1 em) off the floor. 3. 4. 5. 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 +/- 1/8" (3 mm) from the center of the chassis after adjusting camber, width, and toe alignment. This measurement is controlled by adjusting radius rod length.
6. 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 proced ure.
o ~O:J(l::======~~
Set Up Width' Measure from cente r of one spindle to center of the other spindle with front end elevated and suspension fUlly extended to determine set up width.
' Do not exceed maximum
7 .13
9/97
BODY AND STEERING Steering Inspectiorr- All IFS
CAMBER INSPECTION
All Models - Elevate front End - Shocks Installed
Typical CRC Shown - Style varies by model Suspension free Hanging With If S Shocks Installed
Upper radius rod
Lower radius rod
Radius Rod End Jam Nuts Attac hing Bolts
--~~~~~~~~~~
Measure Here
Refer to specifications for: I FS type Specified amount of camber See page 7.2 - 7.2b or page 7.12 To adjust. lengthen or shorten appropria te lower radius rod until top of bar is within specified cambe r distance. Measurement should be take n 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 meas uring.
CAMBER - ACCEPTABLE RANGE
EXAMPLE: Specified Camber = 3/4" (19mm) Specified Tolerance = 5/16 " (8mm) Acceptable Range = 7/16 - 1 1/16" (11-27mm) Refer to specifications on page 7.2 - 7.2b or page 7.12
9197
7.14
BODY AND STEERING

S teeri n g A djustment - All IFS Camber Adjustment 1. Determine which spindle requires the greatest amo unt of correction by installing the alignment bar through one side to the opposite spindle. Remove the bar and install it through the othe r side to the opposite spindle.
2. Using a 3/8" (1 em) drive 11/16" (1.7 em) crow foot wrench and 20" (51 em) long 3/8" (1 em) 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. 3. 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 camber specifications. On models with neutral camber (0) the bar should slide freely through both spindles ( 5/16" ). CAUTION:
I
Bulkhead
Radius rod ends must remain parallel to the bulkhead after rod end jam nuts are tightened to specified torque. See illustration at right. 4. TIghten all jam nuts. Torque radius rod attac hing bolts to specifica tion. Reinstall adjustable torsion bar linkage (where applicable). On 1996 modelsverify adequate thread engagement of rod ends as shown on page 7.11 .
\
Rod end parallel to mounting surface when jam nut is tight.
Jam Nut
Rod End
WARNING
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 attemptto set suspension wider than the specified maximum set upwidth. If set up width exceeds maximum, adjust upper and lower radius rods equally to main tain camber adjustment.
Rad ius Rod End Jam Nut Torque 25 ft. Ibs. (3.45 kgm)
Radius Rod Attaching Bolt Torque 3/8"(outer) 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 " (inn er bottom) 40-50 ft. Ibs. (5.52-6.9 kg- m)
Adjustable Torsion Bar Attaching Bolt Torque 15 ft. Ibs. 2.07 kgm)
7.15
9/9 7
BODY AND STEERING Steering Adjustment - All IFS 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 (B) (or bellcrank on non-CRC models) should be pointed straight forward. 6. Lubricate ski pivot bushings with Polaris Premium All Season Grease and install in spindle. Follow procedure in Illustration A for steel or B for composite skis. Torque ski bolts to specification. Install new cotter pin in castle nut. 7. Perform Toe Adjustment on page 7.17.
9/97
7 .16

Toe Adjustme nt, 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-10 CRC front suspensio n. 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" (7.6-1 2.7 em) and work suspension to find average 2. To obtain normal ride height of the front suspension, lift the front end 3-5" (7.6-12.7 ern) 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 , asphal t, or carpet which may cause carbide skags to grab or catch and restrict movement. Toe Adju stment Normal Ride Height NOTE: Measurements A&B should 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 "B" at normal ride height
/ \
Toe Alignment: All Models Measurement "A" should be 1/8"1/4" (3.17 6.35 mm) greater than measurement " B" at normal ride height.
~" l" Tr l'"

10"
10"
I I
-
' )))21)))
I.
,,-
S traight / Edge
-2' -
- :--- Track
7.17
9/97
BODY AND STEERING Steering Stop Adjustment

Steering Stop Ad justment
1996 Models 1. Remove alignment bar and turn handlebars tully to the right. Loosen upper radius rod bolt (A) and adjust steering stop (B) 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 fully left.
Uppe r Radi us Rod Bolt to Spindle Torque
28 ft. Ibs. (3.86 kgm )
W
.
"'.f/
Adjust Both Steering Stops
1997 Models Steering slops are not adjustable on 1997-current models.
9/97
7.18
BODY AND STEERING Controlled Roll Center (CRC) Steering Alignment

XTRA-10 CRC an d XC-10 CRC Steer i ng Alignment The following steering alignment procedure can be performed on XTRA-l0 CRC or XC-l 0 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 Ti p s 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 genuine Polaris parts and hardware when replacing front end components. Tools Tools required:
5/8" alignment bar - PN 5333508 6' tape measure Travel location bars -1 3.70" long (PN 5211714) Travel location bars -15.20" long (PN 5211713) Travel location bars -11.65" long (PN 5211822) Chassis stand or blocking
ct. ct.
Gamber - All Years 13.70"
.P
Toe Alignment - 1995 /1996 onlY .p 15.20"
~ . Toe Alignment- i997ffJ 11.65"

NOTE: The CRC Travel Location Bars are included in kit PN 287 1537, along with a 46' alignment bar, and assorted hardware. Kit component s 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-10 CRC and XC-l 0 CRC models. See text on following pages for specific procedures. 1995 -1996 CRC Models When Measuring Set Up Width Travel Location Bar Length Suspension Fully Extended - Shocks Installed To Inspect / Adj ust Camber Install 13.70 Bars To Inspect / Adjust Toe Install 15.20 Bars
1997 - Current XTRA-10 CRC and XC-10 CRC Models When Measuring Set Up Width Trave l Location Bar Length Suspens ion 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 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 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 suspension is set too wide on 1997-current models, the torsion bar can come loose and interfere wi th steer ing. 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 for steering tie rod and radius rod ends as shown on page 7.11.
7.18a
9/9 7

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-U p Width adjustment(must also be checked after adjust ment) Camber Adjustment Handlebar Centering Toe Adjustment Verify Spindle to Chassis Centering and Set-up width are within limits 1. Securely support the front of the machine high enough to remove the skis. Make sure machine is level. 2. Remove skis.
Spindle to Chassis Centering

3. Follow procedure on page 7.13.
Set Up Width Measurement

4. Follow procedure on page 7.13. 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 steer ing. Do not attempt to set the suspension wider than the specified Maximum Set Up Width. For 1995-1996 models, use rod end thread engagement guidelines as shown on page 7.11.
Camber Adjust ment - 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). Disconnect tie rods from steering arms. NOTE: I! 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. Determin e which spindle requires the greatest amount of correction by installing the alignment bar through one side to the opposite spindle, the n remove the bar and install it through the other side to the opposite spindle. Camber Adj us tment Insta l! 13.70" Travel Location Bar s
"
----'
7.
", ..
..
Loose:n~
--=~~~
Remove
Alignment Bar
9/97
7.18b
BODY AND STEERING

CR C Steering Adjustm ent Camber Adjustment - XTRA-l0 CRC and XC-l0 CRC , (Co nt.)
'---8. Using a 3/8" drive 11 /16" (1 .7 em) crow foot wrench and 20" (51 em) long 3/8" (1 em) 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 throug h both spindles. When adjustment is correct, tighten jam nuts to 24-25 It. Ibs. (3.3 1-3.45 kg-m). Torque radius rod attaching bolts to 28-30 It. 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 tighten ed to the specified torque. See illustration at right. 10. Tighten all jam nuts. Torque radius rod attaching bolts to specification. Bulkhead
\
Rod end par allel to mountin g surface when jam nut is tight.
Jam Nut
11 . Re-check set specifications.
up
width
and
compare
to
Rod End
Handlebar Centering-CRC
12. With alignment bar in spindles and tie rod ends discon nected , center the steering rack by pointing the pitman arm and idler arm straight forward . 13. Cente r the handlebars by adjust ing drag link length. Tighten jam nuts to 24-25 ft. Ibs. (3.31-3.45 kg-m). 14. The steering arms should be paral lel to the ski cente rline or slightly inward . Refer to steering arm orientation on page 7.18g. Handl ebar Centering - CRC
~lry ! ' m.~==-. rr---; ~=--~. -! ' ~ :7 .n ,.,.,....,.,

-0 --
Fs..
,'=, . f~\<
~o,;;;.
;; ---
j ;O
,~
' AdJust D rag L' In To Center Bars
k ,r?""S A
9'
:
Pitman Arm and Idler Arm Point Straight Forward
15. Re-altach 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 instailed 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 complet e. 16. Perform toe adjustment on following page .
7.18c
9197
BODY AND STEERING

CRC Steering Adjustment Toe Adjustment- XTRA10 CRC I XC-10 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 spacer 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 / 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 .
(1\
A
I.J : J ' lh:W~.: ~~~~~ ~,

I I
Straightedge , Against Track
I 1 '-,--+-+~I 1
--'.l
r-,
9/97
7.18d
Polaris Industrie s Inc .

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 with 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.
-~j
~-
- --
Toe Measurement - CRC
23. Hold tie rod and tighten jam nuts. Be sure to position inner and outer tie rod ends parallel to their respective mounting surface as shown. When tie rod ends are prope rly tightened . the tie rod should rotate freely approximately 1/Bturn.
Tie Rod End Support '-J---L.'----.::::,---: dge E
Mounting Surface
Tie Rod Jam Nut Torque Incorre ct Co rrec t
28-30 ft. Ibs. (3.86 - 4.14 kg-m )
7.18e
9/97

Ski Spind le 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 fitling for ski pivot bushing. The fitling 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 fo r wea r or damage.
4.
Remove old bushings and washe r from bottom of spindle tube with a drift punch. Inspect condition of washe r and replace if worn. Install new bushings. tapered end first.
Bushinqs, -
J ~~ '11
VVasher
~ Ji:
9/97
7 .181

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 filting facing forward (standard and leading spindles) or rearward (trailing spindles).
Standa rd
Leading Type
T railing '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 specitication.
Spindle Bolt Torque
28-30 ft. Ibs. (3.86-4.14 kg-rn)
7.189
9/97
BODY AND STEERING Steering Arm Installati on

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 verily proper steering operation after completing adjustments or repairs.
1. 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 fo rm (approximately) a 90 0 angle or slightly greater.
Forwa rd
Correct
As Close To 90 " As Possible
Thread s tie rod at least 3/4" (19mm ).
eng~" 1
...
\"i" "
Steering Amn Bolt Torque 30 ft. Ibs. (4 .15 kg-m) III. 1
2.
If the stee ring arm is installed incorrectly the threads of the steering tie rod end will not engage the tie rod sufficiently, and the angle formed betwee n ski and ski bolt centerlines is considerably less than 90 ' as shown at right.
Forwa rd
(~l
\
Ii
Ii I
Incorrect
Th reads do not II,-engage tie rod at ~~~ < 90
Imll r,
3.
Reinstall torsion bar linkage (where applicab le). Torq ue attaching bolts to specification.
1/1. 2
9/97
7.1 8h
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. Remove retaining nuts as shown. 2. Push bolt down through ski.
3. 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.
Steel Ski, Steel w/skins, Aluminum -15 ft. Ibs. (2.1 kg-m) , I Plastic Ski - 2~25 ft..lbs. (2.763.45 kg-m) "
Ski Skag Removal EZ Steer

1. Remove the three nuts from the skag. 2. Pull down and rearward to remove the skag.
Ski Skag Installation - EZ Steer

1. Install flat bar as shown. 2. Install IFS carbide skag. 3. 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 Install ation

Ski Skin Installation
1.
Lift and support front end of machine for easier access to skis.
A 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 bolt.

3.
Remove ski bolt and take off ski. Note direction of rubber ski stop.
4. Remove the bolts from the skag. Pry the back of

the skag downward from the ski and remove from the front slot.
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. Che ck to see that the skag holes line up.
7. 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.
8 . Replace skag removed in step 4.

9. Replace ski removed in steps 2 and 3. Refer to Page 7.19b.
10. Repeat proced ure for second ski.
9/9 7
7.19a
BODY AND STEER ING Ski Skag Removal

Ski Installation
SK I INSTALLATION - STEEL SKIS
Install ski over spindle, slightly in front of ski saddle with ski pointing outside. D Slide ski forward until spindle is just behind ski saddle and turn to the forward position. D Slide ski forward so spindle is behind ski saddle. D 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. Push ski back to slide spindl e into place. From outside of ski, install bolt and castle nut. Torque to 36 ft. Ibs. Install cotter pin and bend both legs
SK I INSTALLATION - COMPOS ITE
D Install ski stop

with large portion toward front of ski.
Install cotter pin and bend both legs.
Install ski to spindle. From outside of ski. install bolt, washers and castle nut. Torque to 36 It. Ibs. (4.97 kg-m).
D Carefully lower machine
7.19 b
9/97
BODY AND STEERING 1996 Steering Specif ications

Model 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 Tourin g 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 Suspension Ty pe Lite IFS-38x7 Reference Width' Front Vertical Travel
37"
T
7.25"
38 #
Std. IFS XTRA -10 CRC XTRA-10 CRC IFS-3B Std. IFS XTRA-10 Std.IFS XTRA-10 XTRA-12 XTRA -10 XTRA-12 XTRA-12
41" Use Max Set Up Width See 1997 XTRA-10 CRC Use Max Set Up Width See 1997 XTRA-10 CRC 38"
41'" 4 1/1
7.25" 8.4" 9.15" 7.25" 7.25 " B.4" 7.25" 8.4" 9.B" 8.4" 9.B" 9.B"
41" 41" 42.5" 41" 42.5" 42.5"
XTRA-10 XTRA-10 XTRA-12 XTRA-12 Std.I FS XTRA-10 XTRA-10 Std.IFS Std.IFS
41" 3B" 42.5" 42.5" 41" 41" 38" 41" 38"
8.4" 7.0 9.8" 9.B" 7.25" 7.25" B.4" 7.0" 7.25" 7.0"
CAUTION :
1996 Models: Reference width is measured from center of spindles near grease fitling 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 0 widest point is when lower radius rod is parallel 1 the ground. Always verify adequate tie rod and radius rod end thread engagement after installing or adjusting front suspensi on or steering components. Refer to page 7.11 . Caster: Camber: Toe-in/Toe-out: Fixed Adjust ed with suspens ion fully extended - front end elevated. Adjusted at Normal Ride Height
NOTE: Precision camber and toe setup can be pertormed on Xtra-10 CRC and XC-10 models. Refer to page 7.18a.
9197
7 .2
BODY AND STEER ING

H a n d leba r To rq ue Handlebar Torq ue and Sequence - Indy Style
1. 2. Remove handlebar cove r 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 1 0 the left or right.
Handlebar Adjuster Block Bolt Torque 11-13 ft. Ibs. (1.5 - 1.8 kgm)
IMPORTANT: When adjusting the handlebar, be sure the serrations in handlebar and adjuster block match before 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.
Socket Screws
Handlebar Torque and Sequence Evo lved and Agg ressive Style
1. Remove two plastic fasteners holding console cover located below handlebar cove r 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 tor access to rear nuts.
2.
3. 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. 4. Torque the handlebar adjuster block bolts evenly to specification. The gap should be equal at the front and rear.
I", I
I!I
,',
. .",
5. Replace console cove r.
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
WARNING
Gasoline Is extremely fl amm abl e and exp losive under ce rt ain co ndit ions . Do not smoke or allow open flames or sp arks in or near th e area where w ork is bei ng performed. If you should get gasoline in your eyes or If you sh ould swa llow gasoline, see your doc tor Imm ediately. If you should spill gasoline on your skin or clothing, Imm ediately wash If off with so ap and wat er and change clothing. Prolonged exposure to petroleum based pr odu cts may cau se paint failures . Always protect finished surfaces and wipe up any spills Immedia tely. Two Pi ec e Fu el Tank/Seat Removal 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. 6. Roll front tank hold-down spring forward off tank saddle. 7. If machine is equipped with a fuel gauge connector, this should be unplugged. 8. Remove two bolts holding rear of seat to tunnel. 1. 2. 3. 4. 5.
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 STEER ING Fuel Tank and Seat Remova l

One Piece Fuel Tank/Seat Remova l
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. "---" 2. Remove seat cus hion assembly as outlined on page 7.22. Remove seat and seat covering to be replaced . Carefully remove staples by loosening with a small flat blade screwdriver. Pull each staple straig ht out with a pliers.
'-....-
3. On some models, it will be necessary to drill out the rivets holding the strap buck les. Reach inside the tool box and rotate the "0" ring buckle which secures the center hold down strap. Push the "0" ring through the slot in the tool box and carefully pull it through the foam cushion . Reass em bly Note: For ease of assembly, hook a wire to the center strap. This will allow you to pull the cente r 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.
e.
~...,#
Seat Bucket Hold Down Strap 3-bar Slide
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 plastic seat base as shown in III. 1A.
CAUTION: I
Apply staples in the stapling channe l 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. 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.
6. 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 compa rtment flap, continue with step 11. Bottom View Of Seat Assembly Stapling Chan\1 Tack Cover Here First
"'
Staples
_/h_ffi~ ""
~~
~~ ::"lI;:-_
Sewn Seams Tack Cover Here Second
A~
"x//#
Location Indicators
. ...
Vinyl Seat Flaps Stapling Channel
lJft
III. 1 8. Staple the remainder of the unattached seat cover to the plastic seal 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. 9. Turn the seat cushion assembly over and inspect for wrinkles or irnperiections. If imperiections are visible, remove the staples in the affected area and staple correctly.
Staple Here First
Staple Here Second
Staple PN 9810341 Stainless Steel
Staple Here Third Staple Sequence
1.2 11
9/97
7 .24
BODY AND STEER ING Seat Cover Replaceme nt

Models W ith 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 Instr uctions
OnelTwo Piece Seat and Tank I Covering Instructions PN 9912521 440 &600 XCR Seat Covering Instructions PN 9912842
'Ii
7.25
9/97
BODY AND STEERING Taillight Ass embly Replacement

Taillight Assembly Replacement Standard Indy
1. After removal of seat cover. drill out three rivets from top of taillight. 2. 3. Remove taillight assembly and wire harness. Install new taillight assembly and rivet into place.
4. 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.
Pull seat cover tightly and evenly into position and re-staple to seat pan.
6. Inspect cover for a wrinkle-free finish before reinstalling on the snowmobile.
11/95
7.26

The following chart lists seat interchangeability for 1996 models . Arrows indicate interchangeability. For production seats only.
1 Up Lite
Standard
Length
Mid Length
Long
Leng th
2 Up Lit e
XCR
Performance
De luxe 2 Up Tou ri ng
Standard
2 Up
Tour ing
2 Up WideTrak
Lite
Lite Deluxe
Spon
Super Sport
Storm
Storm SKSI RMK 600 XCR SP
Trail
Lite GT
440XCR 600 XCR
Classic Trg.
XLT Trg.
Sport Trg. TranSport
WideTrak GT
WideTrak LX
Indy 440 Indy 500 500 EFI SKSI RMK
500 SKSlRMK 500 EFI

Classic
XLT SP XlT
-<:::.......
r---
~ XLT SKS/RMK
RXl
Ultra SP
~ U l t ra
Ultra SKS RMK

The following chart lists seat interchangeability for 1997 models. Arrows indicate interchangeability. For production seats only.
1 Up
Lite
Standard Length
Mid Leng th
Long Le ng th
2Up
Lite
XC
Pe rform ance
Deluxe 2 Up Touring
Standard
2 Up
Wi deTrak
2 Up
Touring
Lite
Lite Deluxe
Sport
Storm/S E Storm RMK 600 XCRIS E Ultra SPXiS E
500 EFt 700 SKS/RMK XLT l TD

Ultra
Lite GT
440 XC 600 XC XCF (no side pads)
Classic Trg_ Sport Trg.

Xl T Trg. Ultra Trg.
TranSport
Traillrg.
WideTrakGT
Super Sport
Ultra SP
WideTrak LX
RXl
Trail RMK Trail Classic
440 500 XlT
500 SKSIRM~
XLT Special
XLT SKSlRMK
7.27
9197

Th e following chart lists seat interchangeability for 1998 models. Arrows indicate interchangeability. For production seats only.
1 Up Lite
Standard Length
Mid Length
Long Len gth
2 Up Lite
XC Performance
Delux e 2 Up Touring
Standard 2 Up Tour ing
2 Up Wid eTrak
Ute
Lite Deluxe
Sport
XLT Special
600 XC 700 XC
6001700 XCR
500 (Option 2) Classic
LiteTr9
XCF (w/o pads) 440 XCR
Trail Tr9. Classic Tr9.

XLTTrg. Ultra Trg.
Sport Trg.
WideTrak LX
Super Sport
XLT LTD
TranSport
XLT Classic
Storm Trail
440 500 (Dption 3 Trail RMK 500 (Option 3) 500 RMK
6001700 RMK
unra
9/97
7 .27a
BODY AND STEER ING Nosepan Replacement Procedure

Nosepan Replacement Procedure Standard Indy/Aggressive Body Styles
When installing a replacement ASS nosepa n, the followi ng procedures must be closely observed to ensure correct fit to the frame and maximum strength, ASS materia l is not rigid, Consequently, it must be installed in such a manner that it can expa nd or contract with temperature changes . 1. Remove damaged nosepan by driiiing out rivet heads. Engine mountings and other mountings attached to the forward part of the machine should be removed for ease of installation.
2. The following aluminum rivets must be used to attach nosepan: PN 762 1448, 3/16 x .652, Quantity required - 7 PN 7621403, 3/16 x .527, Quantity required - 39
All holes are to be drilled into the nosepan 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 762 1448). See illustrat ion below. All remaining holes require 3/ 16 x .527" rivets (PN 762 1403).
4. Make sure there is 1/4" (.6 em) clearance around the exhaust outlet. 5. Install foil (PN 58 10108) in the same location as the original part.
Rivet PN 7621448
@
8
Rivet PN 762 1403
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 Nosepa n
9
7
. .
15
17 19
29
21
"
23
22
'24
+
>
30 32
31
33
NOTE: 1. When transfer drilling holes do not fo rce 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 1997 Steering Specifications

Mo de l Indy Lite/GT/Deluxe Indy Sp ort / Touring Indy TranS port 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 RM K Indy 500 / 500 SKS Indy 500 RMK Indy 500 EFI Indy Classic / Touri ng Indy XLT / XLT SKS Indy XLT RM K Indy XLT Tou ring Indy XLT S P Indy XLT LTD 1 LTD SP Indy RXL Indy 600 XC R Indy 600 XC R SE Indy 600 XC Indy 700 XC Indy 700 SKS Ind y 700 RM K Indy Ultra SP Indy Ultra SPXlSPX SE Indy Ultra/U ltraTouri ng Indy Storm / Storm SE Indy Storm RMK
1_ CAUTION.
Suspension Type Lite 38x7 XTRA-10 XTRA-10 CRC XC -10 CRC XT RA-lO CRC 38 x7 XT RA-10 38-RMK XT RA- 10 38 -RMK XT RA -12 XT RA-12 XT RA-10 38 -RMK XT RA-12
Ref eren ce W idth
Ma ximum Set Up Wi dth ' ( 1/4'1 36 1/2 (92.70 em) 37 3/8" (9 4.90 em) 39 1/8" (99.40 em)
Cam be r
5/16"(8m m )
0 1/2" (13 mm) 0 3/4" (19 mm ) 1" (25.5 mm )
Vertica l Tr av el
31"
38"
1"
7 1/4" 9 1/2" 9 1/2"
0 0 0
41 "
41"
41 "
39 1/4" (99 .70 em)

39" (99.00 em) 39 114" (9 9.70 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" (93.3 5 em) 40 1/2" (102.90 em) 40 1/2" (102.90 em)
41"
38"
3/4" (19 mm )
1/2" (13 mm)
9 1/2" 7 1/4" 9 1/2" 8 1/4" 9 1/2" 81 /4 "
41 " 38"
41"
a
0
0 0
38"
42.5" 42.5" 41"
a a a
0
10
10"
9 1/2"
39 1/8" (99 .40 em )

36 3/4" (93.35 em ) 401 /2" (102 .90 em)
38"
42 .5"
a a a a
3/4" (19 m m)
81 /4"
10'"
XT RA- 12 XT RA- 10 CRC
42 .5" 41"
40 1/2" (102 .90 em) 39 1/4" (99 .70 em)
10"
9 1/2 "
XC -10 CRC XT RA -10 CRC 38- RM KCRC XT RA-10 CR C XT RA-12 XT RA- 10 38- RM K
41" 41 "
38"
39" (99 .00 em) 39 1/4" (99 .70 em)
1" (25.5 mm ) 3/4" (19 mm ) 3/8" (9.5mm) 3/4" (19 mm) 9 1/2" 8 1/4" 9 1/2" 10" 9 1/2" 8 1/4"
31" (94 .00 em)

39 114" (99 .70 em) 40 1/2" (102 .90 em) 39 1/8" (99.40 em) 36 314" (93.35 em)
41"
42.5"
41"
a a
0
38"
' <I
' 1997 Current models have torsion bar attached to inside of trailing arm - Max imum set up width is listed for these models 10 prevent possible disengagement of the torsion bar from the trailing arm, which could interfere with steering. This measurement must be taken from center of spindles near grease filting on bottom of spindle WITh front of machine elevated and suspension fully extended. See pages 7.13 for measurement method and adjustment procedure.
Indicates upper rad ius rod non-adju stable,
Caster : Fixed Camber: Adjusted with suspension fu lly exte nded - fro nt end e leva ted . Toe-in/Toe-o ut: Ad justed at Normal Ride Height NOTE : Precision cambe r and toe setup can be pe rformed on models equ ipped with Xtra- 1 CRC or XC-1 front suspen sion . Refer to pag e 7.18a.
7.2a
9/97
SUSPENSION 1998 Steering Specifications

Model Indy Lite/Deluxerrouring Indy Sport I Touring Indy TranSp ort Indy Super Sport Indy XCF I Indy 500 Indy 440 XCR Indy WideTrak LX Indy 440 UC Indy Trail Indy Trail Touring Indy Trail RMKl500 RMK Indy Classic I Touring Indy XLT Classic Indy XLT Touring Indy XLT LTD Indy 600 XC Indy 700 XC Indy 600 XCR Indy 700 XCR Indy XLT SP Indy 600 RMK Indy 700 RMK Indy unra Indy Ultra Touring Indy Storm CAUTION: Suspensian Type Lite Reference Width Maximum Set Up Width*( 1/4") 36 1/2" (92.70 em) Camber 5116"(8mm) 0 Vertical Travel 7" 7.25" 9.5" 9.5"
37"
38" 41"
4 1"
38x7
XTRA-10 XTRA- 10 CRC XC-10 CRC
37 3/8" (94.93 em) 39 1/8" (99.40 em) 39 1/4" (99.70 em)

39" (99.00 em)
1/2" (13 mm)

0
0 0 0
3/4" (19 mm)

1" (25.5 mm)
41" 38"
41"
38x7
XTRA -10
37 3/8" (94.93 em) 39 1/8" (99.40 em)
1/2" (13 mm)

0
7.25" 9.5"
0 0 0 0 0 0 0 0
38-RMK XTRA- 12 XTRA-12
38" 42.5" 42.5"
36 3/4" (93.35 em)
0 0 0
8.25"
10"
40 1/2" (102.90 em)

40 1/2" (102.90 em)
10"
XC-10 CRC XTRA-10 CRC 38-RMK CRC XTRA- 12 XTRA-12 XTRA-10
41"
4 1"
39" (99.00 em)
1" (25.5 mm)
9.5" 9 .5"
39 1/4" (99.70 em)
3/4" (19mm )
38" 42.5" 42.5" 41"
37" (94.00 em)
3/8" (9.5mm )
0 0 0
8.25" 10" 10" 9.5"
40 1/2" (102.90 em) 40 1/2" (102.90 em) 39 1/8" (99.40 em)
0 0 0
*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 arm. which could interfere 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 upper radius rod non-adjustable. Caster: Fixed Camber : Adjusted with suspension fully extended - front end elevated . Tee-in/Toe-out: Adjusted at Normal Ride Height NOTE: Precision camber and toe setup can be pertormed on models equipped with Xtra-10 CRC or XC-10 front suspension. Refer to page 7.18a.
____
9197
7.2b
BODY AND STEERING Steering Rod End Orien tation 1996 to Current Indy Lite/GTlDeluxe
Illustration depic ts proper orientation of rod ends and bolts on steering componen ts .
Stee ring Post 15-17ft. Ibs. 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 li nk Bell Crank
/
.---"~~
""., -Stee ring Post Arm (Stee ring Frog) Rod End
Steering Tie Rod
28-30 ft. Ibs (3.86-4.14 kg-m )
Ste ering Arm Replace locking faste ners if rem oved. See torq ue chart on page 7.1 for torque specs.
7 .3
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 III. 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 hinge brace toward bottom of slot in hood brace.
If gap is too lillie at this point. move hole in hinge brace toward top of slot in hood brace .
o
Hood Adjustment - Evolved Style
Check to see that hood and upper hood hinge are properly aligned . To adjust . loosen nuts (A) and align properly. Tighten nuts. See III. 1. 2. With hood open. loosen nut (B). See III. 1. 3. Close hood and remove both rubber plugs. Then. using a 7/16" (.4 em) socket with an 8" (20 em) extens ion. loosen nut (C). Adjust hood to pan gap. Tighten nuts .
c
III. 2
1.
1------- --,
/
I I I l I I I I
/II HOOd ~1I

Upper I Hinge L
0 ' -' :
/ I
r-------/ :
-<l9
A
I I ol> l --- I I
4.
Check outer perimete r alignment and front and rear alignme nt 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 .
Hood and Hinge need not be flush
, ./ D
I I I
L _ __
I 1M I I
5.
III. 1
7.31
9/96
BODY AND STEERING

Hood Adjustment Nosepan, Front Bumper and Side Bumper Adjustment - Evolved Style
1. Open hood remove pane ls. and side
t
Fill Hole wi Rivet & Washer
FORWARD
2.
Remove foil tape cove ring 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 Out 1/2 Move Out 114" mm) as shown in the illust ration below. Be sure to mount the bracket at the same angle as befo re, so the side panel fits squarely agai nst 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.
6. Apply a new section of foil tape (PN 58 10908) ove r the bracket. Repeat this proced ure for the left side with the following excep tions: move the bracket outwa rd 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. Before removing old decal , it is important to note its position by marking it in several locations. 2. Remove old decal completely. NOTE: A small amount of solvent will aid in removing the old decal. 3. The decals are UV based. If heat will not remove decal, gently buff area with a mild abrasive. Use 3M Scotch BriteT " Graphics Removal Discs with a No.1 Roloc and hoider, or an equivalent iow RPM buffing disc.
li\~;2~9;hoN:
;i
Maintain 2500-3500 RPM to prevent damage to hood caused by excessive heat. 4. Remove any remaining decal adhesive with a citrus based cleaner or equivalent non-solvent based cleaner. 5. 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 approximateiy four ounces soap to one gallon water.
3M ScotchbriteT " Graphics Removal Disc 3M PN 0480111 6855 . No.1 Roloc and holde r 3MPN 048 01115408
IIi
Decal Installati on
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. Ii decal does not have a pre-mask, apply additional soapy water solution to top of decal after it is in position. 4. Hoiding decal in position, 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: 6. 7. Fasten a straight edge to tail end of decal. 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. 8. 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 oecal surface. 9. Apply a small amount of heat to the decal to fasten it securely. 10. Carefully remove excess decal material.
7.33
11/95
BODY AND STEERING Troub leshoot ing

Problem "Machine darts from side to side Possible Cause -Incorrect ski toe alignment So lu tion -Adjust to correc t toe alig nment
-Incorrect camber -Loose or wo rn stee ring com ponents or fasteners -Cracked or broken skis, skaqs , or carbides Tie rod hits trailing arm -Stee ring arm installed incorrectly
-Adjust to correct camber -Tighten or replace
-Replace if necessary -Index correctly in relation to -spindle -Replace if necessary -Tighten or replace if necessary
-Tie rod ends wo rn Steering has excessive freeplay -Steering bellcran k bushing worn or loose -Drag link worn or loose -Steering post loose -Steering post bushings worn -Tie rod ends worn -Spindle bushing s 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
-Tighten or replace if necessary -Tighfen as needed -Replace if necessary -Tighten as needed -Replace if necessary -Adjust spring tensio n on shocks -Recha rge. service. or replace -shocks -Remove noseco ne 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
BODY AND STEERING 1996 CRC Steering Assemb ly Exploded View

1996 440 XCR/440 XCR SP
Ste ering Post Arm (stee ring l rog) 28-30 It. Ibs. (3.9-4.1 kg-m)
Steering Post
D -Ring
Pitman Arm
Drag Link
I
End
Rdk O;
"'~., /
~-r,~
Idler A rm
~I
35-40 ft. Ibs. (4.8-5.5 kg-m)
Oll}t;::-- - - _
28-3 0 It. Ibs. (3.9-4.1 kg-m)
Rod End
Steering Tie Rod Rod End Steerin Arm Replace locking fast ene rs if removed. See torque chart on page 7.1 l or torque specs.
'-"
,?-~~ D
28- 30 ft. lbs. (3.9-4 .1 kg-m )
9/9 7
7 .4
1996 WideTrak GTIlX

Steering Post
Drag Link
Steering Post Arm (stee ring frog)
Bell Crank
Rod End
Stee ring Tie Rod
Steering Arm Replace locki ng fasteners if removed . See torque chart on page 7.1 for torque specs.
7.5
9197
BODY AND STEERING Steering Assembly Exp loded View 1996 Indy 440 LC/Super Sport/500fTrail
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 torq ue specs .
Steering Arm
9/97
7 .6

1996 Indy 600XCRl600 XCR SP/Ultra SP/Storm/Storm SKS
Illustration depicts proper orientation of rod ends and bolts on steering 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 It. Ibs (3.86-4.14 kg-m)
Steering Arm
Replace locking fasteners if removed. See torque cha rt on page 7.1 for torque specs.
7.7
9197
BODY AND STEERING Steering Assemb ly Exploded View

1996 XTRA-10 1996 - Current XTRA-12 Models
Illustration depicts proper orientatio n of rod ends and bolts on steering components on models listed above. Refer to c ha rt on page 8.1 for suspe ns ion type .
NOTE: On Xtra 10 and Xtra 12 th ree cy linder mode ls the d rag lin k is on the left side. On twin cy linder models the drag link is on th e right side with the same rod end co nf igu ratio n. Three cylinder configuration shown.
Steering
'<;
Drag Link O r 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)
Steer ing Post Ar m (steering frog)
Bell Crank
Rod End Stee ring l1e Rod
28-30 ft. Ibs (3.86 -4.14 kg -m)
Steering Arm
28-30 ft. Ibs (3.86 -4 .14 kg-m)
Replace locking fastene rs if rem oved. See torque cha rt on page 7.1 for torq ue specs.
9/97
7 .8

All 1997 to Current Models Except XTRA-12 Front Suspension or CRC
Illust ration depicts proper orientation of rod end s and bolts on steering compone nts.
Steering Post
Drag Link O r Tie Rod End Jam Nuts 24-25 It. Ibs. 3.32-3.46 kg-m Stee ring Post Arm
~"i'" Froq)
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
Rep lace locking faste ners if removed . See torque chart on pag e 7.1 fo r 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 01rod 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
A I
Drag Link
Steering Rack
~~~~::::~p.itman Arm ~ 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 01 boll
Spindle
9/97
7.9a
BOD Y AND STEERING Steering Assemb ly Exp loded View
All 1997 to Current XTRA-10 and 38 Wide (Non-CRC) Models

Steering Post
Drag Link Or Tie Rod End Jam Nuts 24-25 It. Ibs. 3.32-3.46 kg-m
Steering Tie Rod
2830 It. Ibs (3.86-4 .14 kg-m)
Replace locking fasteners if removed . See torque chart on page 7.1 lor torque specs .
Steering Arm 28-30 It. Ibs. (3.86-4.14 kg-m)
7 .9b
9/97
BODY AND STEERING XC-10 CRC Steering Assembly Exploded View

1997440 XCR, 700 XC ; 1998440 XCR, 600 XC, 700 XC
Illustration depicts proper orientation of rod ends and bolts on stee ring components for most models.
'M r\ '"
\ , ~
I
1 ., '
="
35-40 It. Ibs. (4.8-5.5 kgm)
N\." ~I=; '

\.
''0
"
~~ 'dfo ..,
X:Il____ '
..
NOTE: Typical XC-10 shown . Orientation of drag link and placement of pitman and idler arms reversed on some mode ls
'"
\~~, ~'.\ j;'I'

~
I
\"J
Trailing Arm
-se-:
~I
?;, -
L - --
~~
28-30 ft. Ibs. (3.9-4.1 kg-m)
.~
ti
Steering Arm
"'"-Drag Link
Jam Nuts 28-30 ft. Ibs. (3.9-4.1 kg-m) Pitman Arm
Idler Arm n e Rod Ends 28-30 ft. Ibs (3.9-4.1 kg-m)

_@ - --- 0
;~:9'/ - - - _ _1=-~~ ,) ~~ ~R~~~- . l @: J'-' "' ~ , ,

~ '"'-l-'.==-
~ ~_.')~, ~
@:
~ Steering Rack 'I'
-------- ---------==
4=1 .----:jj ~;a=---7' ~ .,1J::::

I =~n=r== -hJ~- .,, ,..
\ Jam Nuts
~
J )
,.: ~- .
'- _~; l} ~ f> -~.c,=_/ ~ -~j . . -=:-~ U~

~ <:> -- -- . - --;;::::I::rfr~ "j." <].:<- --.::::o~~.
Tie Rod
-'~\j--
28-30 ft. Ibs. (3.9-4.1 kg-m)
9/9 7
z.se
SUSPENSION IFS Specifications
1996 Independent Front Suspension (IFS)

Model Front Suspension IFS 37 IFS 38 IFS38 IFS 38 IFS 41 IFS Xtra 10 CRC IFS Xtra 10 CRC IFS 41 IFS 41 IFS 38.5 IFS 4 1 IFS41 Xtra 10 IFS 41 IFS 41 IFS 41Xtral0 IFS 41 Xtra 10 IFS 42.5 Xtra 12 IFS 41 Xtra 10 IFS 38 IFS 42.5 Xtra 12 IFS 42.5 Xtra 12 IFS 42.5 Xtra 12 IFS 42.5 Xtra 12 IFS 41 xtra 10 IFS 38 IFS 42.5 Xlra 12 IFS 42 .5 Xlra 12 IFS 41 IFS 38 IFS 4 1 Xtra 10 IFS 41 IFS38 Shock PN Shock Desc ription Hyd Hyd Hyd Hyd AirlH ydl Cam IFPIThread Adj . IFPIThread Adj . IFPICam IFP/Cam Hyd Air/HydiCa m Air/ HydiC am Airl HydiCam Airl HydiCam Air/ HydiCa m Airl HydiCa m Airl HydiCam Airl HydiCam Airl HydiCam Airl HydiC am Air/HydiCam Air/HydiCam IFP AirlHydlThread Preload Adj AirlHydlThrea d Preload Adj Airl HydiCam AirlH ydlThread Preload Adj IFP AirlH ydlThread Preload Adj AirlHydlThread Preload Adj IFP IFP IFS Sp ring PW 704126 1 704 1261 7041261 7041261 704 1261 704 1396 704 1489 70 41252 704 135 8 7041261 704 1261 7041405 7041261 704 126 1 704 1405 7041405 704 1396 704 1405 704 1405 704 1396 7041396 704 1396 7041396 7041405 7041396 7041396 704139 8 7041405 704 1396 7041405 704 1358 704 1358 Sprin g Rate 105#/in 105#l in 105#/in 105#/in 105#/ln 50#lin 741125 #I in. 120#/in 160# 105#lin 105#lin 65#l in 105#/in 105#l ln 65#l in 65#/in 50#l in 65#l in 65#/i n 50#l in 50#lin 50#/l n 50#li n 65#l in 50#l in 50#/in 75#li n 65#lin 50#li n 65#(,n 160#lin 160#/in
Indy Litel GTID eluxe Indy Sport Indy Spo rt Touring Indy TranSp ort Indy Super Sport Indy 440 XCR Indy 440 XCR SP Indy 600 XCR Indy 600 XCR SP Indy WideTrak GTILX 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 Class ic Touring Indy XLT Indy XLT SP Indy XLT SKS Indy XLT RMK Indy XLT Touring Ind y RXL Indy Ultra SP Indy Ultra RMK Indy Ultra SKS Indy Slor mlS KS Indy Sto rm RMK KE Y:
~-
7041 284 704 1284 70 41285 704 1284 7041473 70414 01 70 41494 704 1474 7041474 7041284 704 1388 704 1423 70413 88 704 1388 70414 23 7041423 704142 4 70414 23 7041423 7041424 7041427 7041424 7041385 70414 23 7041427 704142 7 7041385 70414 74 704 1427 704 1423 704 1474 704 1494
Hyd - Hydraulic Standard Shock Gas IFP - Gas Charged Internal Floating Piston , Fox Shock Gabriel Select Adjust able Shoc k NOTE: All pounds referred to in the sp ring rate column are 10%
Add a suffix of "-067" to spring part numb er when ordering Polaris Industries Inc.
8. 1
9/9 7
SUSPENSION Rear Suspens ion Specifications
1996 Rear Suspe nsion

Model
Rear
Suspensicn
Indy Ut eiGTIDIx Indy Sport Indy Sport Trg . Indy TranSport Sport Style Sport Style
Xtra 10
Front Track
Sho ck
PN
7041142 7041142 7041430 70 41142 7041430 704 1402 704 1507 704 1402 704 1402 704 128 1 70 4 1281 7041430 704 1430 7041430 704 1430 70414 30 70 41433 7041430 7041433 7041485 7041433 7041386 7041430 7041486 7041386 7041402 7041430 704 1402
Front Track Shoc k Desc.

Hyd Hyd Hyd Hyd Hyd IFP Gas
Spr ing
PW
Spr ing Rate
Rear Trac k Sh ock
Rear Track Sho ck Desc.

Hyd Hyd
Indy Select
Sp ring
PW
Sp ring Ra te
Tors ion
Spring Dia.
.393 .393 .42 1 N/A .406 .406 .421 .406 .406 .468 .468 .406 .42 1 .406 .406 .406 .406 .406 .406 .437 .406 .406 .406 .437 .406 .406 406 .406
PN
7041 127 7041127 7041253 7041127 7041253 7041253 7041 508 704 1253 704 1253 704 1140 70 41140 7041253 7041253 7041253 7041253 7041253 704135 1 7041253 7041351 7041404 7041351 704 135 1 7041253 7041404 704 1351 704 1253 704 1253 7041253
181#/in 181#/in
704115 4 7041154 7041438 70411 54 70 41441 70 41444 70 4 1492 704 1444 704 1444 7041 290 704 1280
N/A N/A N/A N/A N/A N/A N/A NlA
N/A N/A NlA N/A N/A
200/var
181#/in
Sport Style Xtra 10

Xlra 10 Xlra 10 Xtra 10
Hyd Indy Select
Indy Super
Sport Indy 440 XCR Indy 440 XCR SP Indy 600 XC R Indy 600 XC R SP
20D/var
200/var 190#/in
Fox IFP Gas Fox IFP Gas Fox IFP Gas Fox IFP Gas
Hyd (2) Hyd (2) Cam A dj
Indy Select Indy Se lect Indy Se lect Indy Select Indy Select Nitrogen Ce ll Indy Se lect Nitrogen Cell Nitrogen Cell Nitrogen Cell Fox IF? Gas Indy Select Nitrogen Cell Fox IF? Gas Fox IF? Gas Indy Se lect Fox IF? Gas
N/A
NlA
FoxTU Re-
mote
J Gas FP
IFP Gas Hyd Hyd Hy d Hyd Hyd Hy d Hyd
Indy Select Th read Adj
20D/var
Xtra 10
Wide Trak Style WideTrak Style
20D /var
181#/in 18 1 #/in
N/A N/A
704 1261
N/A N/A
N/A
IndyWideTrak
GT
Indy W ideTrak LX
l O #/in 5
N/A N/A N/A
Indy Trail Indy Trail Trg.

Indy 440 LC Indy 500 Indy 500 SKSI R MK Indy 500 EFI Indy 500 EF I SKS/RMK
Indy Cla ssic Indy Classi c Trg .
Xtra 10
200/var 70 4 144 1
200/va r 200/va r 200/va r
200lva r
Xtra 10
Xtra 10 Xtra 10 Xtra 10 Xtra 12 Xtra 10 Xtra 12 Xtra 12
70 4 1438 70 4 1441 704 1441 70 4 1438 704 1440 704 1438 7041440 704148 1 7041440 7041480 7041438 7041481 70 41480 7041444 7041438 7041444
N/A N/A N/A N/A N/A

704 1253 N/A 704 1253 7041482 7041253 7041253
N/A N/A
200Nar #/in
75 125 #/in
200/var
Hyd Indy Se lecl Thread Adj

Indy Sele ct Thread Adj
N/A
200lvar
#fm
75125 #lin 90150 #/in 75125 It/in 75125 #lin

200 /var
250#/in
ZOONar #/in 200lvar #lin
Ind y XLT Ind y XLT SP Indy XLT SKSI RMK Indy XLT Trg .
Xtra 12
Ind y Select Thread AdJ

Fox IF? Gas Thread Adj
xtra 12
xtra 10
Xtra 12 Xtra 12 Xtra 10 Xtra 10 Xlra 10
Hyd Ryde AFX Thread Adj Fox IFP Thread Ad)

Fox IF? Ga s
N/A
7041482 7041253
N/A
250#lin
90150 #/in 75 125 II/in

200/va r 200/va r 200 /va r
Indy RXL
Indy Ultra SP Indy Ultr a SKSI RMK
Indy Storm/ SKS /RMK
200lvar
#lin
Hyd
Fox IFP Ga s
N/A N/A N/A
N/A N/A N/A
Add a suffix of "067" to spring part number when ordering
9/97
8.2
SUSPENSION IFS Specifications
1997 Independent Front Suspension (IFS)

Model Front Susp ension Lile IFS 38x7 IFS 38x7 IFS 38x7 IFS Xtra-10 IFS Xtra- 10 CRC IFS Xtra-10 IFS 38 RMK IFS 38x7 IFS Xtra-10 IFS Xlra -10 CRC IFS XC-10 CRC IFS Xtra-10 IFS 38 RMK IFS Xtra-12 IFS Xtra-12 IFS Xtra-12 IFS Xtra-10 IFS Xtra-12 IFS Xtra-12 IFS 38 RMK IFS Xtra- 12 IFS Xtra-10 CRC IFS Xtra-10 CRC IFS Xtra- 12 IFS Xtra-12 IFS Xtra-12 IFS Xtra-10 CRC IFS Xtra- 10 CRC IFS XC-10 CRC IFS Xtra-10 CRC IFS 38 RMK IFS Xl ra10 IFS 38 RMK Shock PN Shock Descrip tion 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 Th read Adj. Nitrogen Cell Thread Adj. Nitrogen Cell Thread Adj. Indy Select Thread Adj. Indy Select Thread Adj. Nitrogen Cell Thread Adj. Gas IFP Th read Adj. Gas IFP Thread Adj. Gas IFP Th read 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 105#/ln 105#f1n 105#/ln 105#/ln 50#f1 n 80#/in 80#/ln 80#f1n 105#/in 80#/in 120#/in 120#/in 80#/in 80#/in 75#!in 100#/in 75#/in 80#/in 80#/in 100#/in 80#/in 80#/in 120#/in 120#/in 120#/in 120#/in 140#/in 120#/in 120#/in 120#/in 80#/in 80#/in 120#/in 140#/in Select
PW
Indy Lite/GT/ Deluxe Indy Sport Indy Sport Touring Indy TranSport Indy Super Sport Indy XCF Indy Trail/Trail Touring Indy Trail RMK Indy WideTrak GT/LX Indy 440 LC Indy 440 XC Indy 440 XCR Indy 500/S KS 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 SPXJSE Indy 700 XC Indy 700 SKS Indy 700 RMK Indy Storm/SE Indy Storm RMK 7041284 704 1535 7041562 704 1535 7041496 7041523 7041496 7041544 7041535 7041496 7041593 7041494 7041496 704 1544 7041539 7041503 7041539 7041538 704 1503 7041503 7041543 704 1537 7041536 704 1540 704 1524 704 1503 704 1524 7041523 704 1540 704 1494 704 1538 7041543 704 1540 704 1545 704126 1 7041261 704 1261 704 1261 7041396 704 1552 704 1552 704 1552 704 1261 7041552 7041489 704 1489 704 1552 7041552 7041398 704155 1 7041398 7041552 704 1552 7041551 704 1552 7041552 7041550 704 1575 7041550 7041550 704 1549 7041550 704 1575 704 11489 704 1552 704 1552 704157 5 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 column are 10% Ad d a s uff ix of "-067" to sp ring pa rt nu m ber when orde ring
8 .3
9/97
SUSPENSION Rear Suspension Specifications

1997 Rear Suspensi on
Model
Rear
Suspension
Front Track Shock PN
Front Track Shock Desc.
Sp ring
PW
S pring Rate
Rear Track Sho ck PN
Rear Track
S hock
Spring PW
Spring Rate
Desc.
Hyd Hyd Hyd
Indy Select
Torsion Spring Dia.
Indy UlelDlx Indy Ute GT Indy Sport Indy Sport Trg . Indy TranSport
Xtra Lite
7041516 7041516 7041516 7041430 7041142 7041430 7041596 7041430 7041430 7041430 7041281 704128 1 7041430 7041507 or 704164 1 704 1641 704 1430 7041430 7041430 7041586 7041485 704 1586 7041590 7041588 7041486 7041430 7041430 7041386
Hyd Hyd Hyd Hyd Hyd Hyd RydeAFX Hyd Hyd Hyd Hyd Hyd Hyd IFP Gas RA
704 1570 7041127 7041569 7041253 7041127 7041253 7041253 7041253 7041253 7041253 704 1140 704 1140 7041253 704 1508
80#/in
7041515 7041154 7041515 7041438 7041154 7041441 7041597 7041441 7041438 7041577 7041290 7041280 7041 441 7041492
NIA NIA NIA NIA NIA NIA N/A NIA NIA NIA NIA 7041261 NIA N/A
NIA NIA NIA NIA NIA NIA NIA NIA NIA NIA NIA
105# /in
.3 93 .3 93 .3 93 .421 .406 .406 .406 .406 .421 .42 1 .468 .468 .406 .421
Xtra Lite
181#nn
Xtra Lite
Xtra 10 133 .5 Sport Style Xtra 10 121 Xtra 10 121
Xtra 10 121
60#/in
200lvar
lS1#lin
200lvar 200lvar
200/var
Hyd Indy Select Ryde AFX

Indy Se lect Indy Se lect Indy Select
Indy Super Sport

IndyXCF
Indy Trail
IndyTrail Trg.
Indy Trail RMK
Xtra 10 133 .5 Xtra 10 133.5
200lvar 200lvar
181#lin 181 #/in 200 /var 190#/l n

Indy 440 LC Indy 440 XC
WideTrak Style
WideTrak Style Xtra '0 12 1
Hyd (2) Hyd (2 ) Cam Adj

Indy Select IF ? Gas
NIA NIA
Xtra 10 Fox
lV
Indy 440 XCR Indy 500 Indy 500 SKS Indy 500 RMK
Indy Classic Indy Cla ssic Trg.
Xtra 10 Foxa
IFP Gas RA Hyd Hyd Hyd Hyd

Indy Select Indy Sele ct
7041508 7041253 7041253 7041253 704 135 1 704 1404 704 135 1 7041253 7041351 7041404 7041253 7041253 7041351
190 #/in 200 /var 200lvar 200lvar
7041599 7041441 7041567 704 1577 704 1587 7041481 7041587 7041567 7041587 704 1481 7041 567 7041577 7041480
IFP Gas
Indy Select Indy Se lect
NIA NIA NIA NIA 704 1561 704 1484 7041561 NIA 7041561 7041484 NIA NIA 7041561
NIA NIA NIA NIA

85#/in 275#lin 85#/in
.421 .406 .406 .421 .406 .437 .406 .421 .406 .437 .406 421 .406
Xtra 10 12 1
Xtra 10 133.5 Xtra 10 133.5 Xtra 12 121 Xtra 12 133.5
Xtra 12 121 Xtra 10 121 Xtra 12 121
Indy Select Gas Bag Indy Select Gas Bag Indy Select Gas Bag Indy Select Indy Select Indy Select
75/125
ItIin
901150 #/in 751125 #/in

200 lvar
Indy 500 EFI Indy XLT Indy XLT LTDI LTD SP Indy XLT Trg . Indy XLT SKS Indy XLT RMK Indy XLT 5P
Hyd
Indy Select Indy Sele ct
NIA
85# /in
751125 #/in
Xtra 12 133 .5 Xtra 10 133 .5 Xtra 10 133.5
90/150
#l1n
275#lin
NIA NiA
85# /in
Hyd Hyd IFPGas
200Jvar
20 0lvar
Xtra 12 12 1 Foxrv
75/125
#/in
IFP Gas
Add a suffix of "067" to spring part number whe n ordering
9/97
8.4
SUSPENSION Rear Suspen sion Specifi cat ions 1997 Rear Suspension Cont.
Model
Rear Suspension Front Trac k
Sh ock PN Indy 600 XC Indy 600 XCR/ SE xira 10 121 7041584 7041589 704 1559 7041433 704 1590 7041594 704 1589 704 1606 704 1589 704 1589
Fro nt Track Shock Desc.
Spring
PN'
Sprin g Rate
Rear Track Shock
Rear Track Shock
Spr ing
PN'
Spring Rate
Oes c.
IFP Gas IFP Gas Ryde AFX
Gas Bag
Tors ion Spring Dia.
PN IFP Gas IFP Gas AFX Indy Selecl Hyd AFX

IF? Gas
704 1253 7041253 7041351 7041351 7041253 7041404 7041253 7041253 7041253 704 1253
200/var 200/var 75/125 It/in 75/ 125

#l in
704 1585 704 1595 704 1560 7041440 7041567 7041548 7041595 7041438 7041595 7041588
N/A N/A 7041561 7041364 N/A 704 1484 NIA N/A NIA N/A
N/A N/A
.421 .421 .406 .406 .421 .437 .421 .421 .421 .42 1
Fox:1.l
Xtra 10 121
Fox".
x tra 12 121 xt ra 12 121 xt re 10 121 Xlra 12 133.5
Xtra 10 121
Indy RXL
Indy Ultra Indy Ultra SP Indy Ultra Trg. Indy Ultra SPX/ SE Indy 700 SKS/ RMK Indy Storm/SE Indy Storm RMK
85 #/in
126#lin
200/var 90/150
Indy Select Ryde AFX IFP Gas Indy Select

IF? Gas
NJA
275# lin
#nn
200/var ZOO/var
200Nar
N/A N/A N/A NIA
Foxw
Xtra 10 133.5 Xtra 10 121 Hyd IFP Gas
IF? Gas
FoxT '"
Xtra 10 133 .5
200Nar
IFP Gas
, Add a sufflx of "067" to spring part number when ordering
8.5
9/97
SUSPENSION IFS - Torsion Bar

Adjustable To rs io n Bar Operat ion : For high performance applications the torsion ba r can be adjusted for any number of varying condition s. Ad justment: Each side is individually adjustable. 1. Rider must be in positi on on the machi ne. sides. Adjust rod until there is a small amount of free play detectable on all rod ends.
Torsion Bar Suppo rt
Torsion Sar Housing
<!?b / /
(.
2. Loosen rod end jam nuts on both left and right

3.
let
~@.
~~
.>
" '00 "" "0_',

Torsion Bar ,setscrew
4 . Tighten jam nuts sec urely.

Nu t - - ......
Maintenance : Periodi c inspe ction of the support area, set screw and bar arm bolts is recomm ended to prevent arm to spline loosening . Period ic lubrication of the bushings is required using Polaris Low Temp or Premium All Season grea se . NOTE: Refer to kit instru ction s for prope r assembly.
' Nut ............... , Torsion Sar
sraCket~
Jam Nut~ ~
~/'7 Rod Ends

" " Sar Arm
aeu
screw~ - ~
'Washer
Polar is Low Temp Grease PN 2'870577 ",';;, Polaris Premium A ll Season Grease PN 2871423
~/~
Bolt
' Parts for new style liquid twin model s.
Ad justable Torsion Bar Kit PN 2871035
9/97
8.6
Polaris Industries Inc ,
SUSPENSION IFS - Torsion Bar Torsion Bar Removal

1. Remove trailing arm assembly. 2. 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. Punch out the rivet body. Remove support and torsion bar. Repeat procedure for second torsion bar.
4. 5. 6.
Torsion Bar Installation

1.
Rivet support in place using Polaris PN 7621449 rivets. NOTE : These high strength "Q " rivets are the only replacement rivets recommended for this application.
Torsion Bar Support Rivets PN 7621449
2.
Reinstall torsion bar.
3. Reinstall trailing arm assembly. 4. 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 Suspens ion Operat ion
The primary function of the rear suspension is to provid e a comfo rtable ride in all types of riding conditions. It separates the rider from the ground. while allowing for complete vehic le control. The rear suspension also must provid e weight transfer and maintain track tension. The rear suspensio n has many adjustable featu res for fine tuning to achieve optimu m comfort . The suspension can be adjusted to suit rider preference and deliver excellent perf ormance 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 transte r. As engine torque is applied to the drive axle the torque is transferred to the track. pulling it forwa rd. This ene rgy 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 suspe nsion's reaction to the force. Adjusting the length of the limiter strap will change the front torque arm ang le. 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 allows the front of the suspension to extend furthe r; 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 tens ion whenever limiter strap length is changed. Front track shock spring preload also affects weight fransfer. A stiffer spring and/or more preload on the spring transfe rs 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 springs/preload will provide more track pressure (reduced ski pressure). but may result in a less comfortable ride. During acceleration. the rear of the suspension will compres s and the IFS will extend. pivoting the machine. Because of this pivoting effect. rear spring and spring preload also have some effect on weight transfe r. Softer rear springs. or less preload. allow more weight transfer to the track and reduce ski pressu re. Stiffer rear 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 vehic le and rider. as well as to provide enoug h 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 whe n referring to coil springs.
Free length- the length of a coil spring with no ioad 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 compress 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 #/in . Straight rate spring - the spring requires the same amount of force to comp ress the last one inch of travel as the first one inch of travel. For example, if a 150 #/in . spring requires 150 pounds of force to compress it one inch, 300 pounds of force 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 #/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 encountered by the suspension, the force of the bump compresses the spring. If the force were 450 pounds , a 100 #/in . spring would compress 4.5 inches. A 150 #/in. spring would only comp ress 3 inches. If the suspension had 4 inches of spring travel the 100 #/in. spring wo uld bottom out, while the 150 #/in. spring 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 open ing angle
r:o~~' ~-.---~
..
8 .9
9196
SUSPENSION Rear Suspension Tuning

Many factors influence the overall handling characteristics of snow mobile suspensions. Rider weight, riding style, course cond itions , and the condition of suspension components are some of the things that you have to conside r when tuning a suspensi on. On new machines, or whenever new suspe nsion 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 wea r in. The shock springs will also take their initial set and the setup will be mo re accurate .
Suspen sion Tuning

To begin suspens ion tuning, check the condition of shoc ks and other suspensi on parts . Begin by taking the shocks apart, inspecting ail parts for damage , and cha nging the oil. Even new shocks should get an 011 change after break in to clean break -in mate rial from the shocks and valve body. If oil is low, inspect seal cap a- Ring and seals fo r da mage. If ai r or foam is evident in the oil, the a- Ring in the floating piston must be replaced. After changing the oil reasse mble shoc ks, making sure oil level , floating piston depth (IFP), and nitrogen pressure are correct. The use of nitrogen in Fox'" shocks provides consistent dampin g at extrem e temperature s. Don't overcharge the shocks . Excess nitrogen pressure may cause sea l "stlction" 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 free ly. All suspens ion components should be greased when disassembled. Regular maintenance greasing sho uld be done with no weight on the comp onent 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, meas ured at the rear bump er. Bounce on the suspension a couple of times to overcome any "stiction" and settle the sled to an accurate refere nce point. The rider should have their weight placed cor rectly on the machine. Adjust spring preload to achiev e 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" stiffe r 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. The refore, 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 prope r weight transfer. The front suspen sion should sag about 1" (meas ured 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 trave l.
Shock Tuning
The shocks work in two directions. Compression dampin g prevents the shock from bottoming hard while rebound damping keeps the shock from springing back too fast. Both compressio n and rebound damp ing 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 chec k low speed shock valving, drive the machine through rounded, soft bumps. Feel what each area of the snowmob ile 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 vaiving 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. Th e 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.
9196
8.10
SUSPENSION IFS Shock Adju stment Front Shock Spring Preload Adjustment
The XTRA 10 and XTRA 12 suspension systems on Polaris snowmobiles have been designed to provide the rider with a wide range of adjustment. Generally, the softest spring 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 characterist ics. The front shock spring preload can be adjusted by grasping the spring and turning in a clockw ise direction, (as viewed from the bottom), to increase preload.
~
High preload
-w.
NOTE: Access to the cam with the spanner wrench

IS
easiest f rom the inside of the ski.
-s:: ~ Low~ preload
~ :0:
l4!'
Turning clockwise
increases
Ed-
preload
Span ner W rench
(included with some models)
~ /-~ Cam ')f Highest / l

Preload ())
Softest Preload
8 .11
9/96
SUSPENSION Indy Se lect 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 - countercl ockwise). If bottoming occurs, the compression damping should be used in conjunction with the spring preload to achieve the desired ride affect. 1/2 of a turn will affect the ride considerably. There are approximately 3 turns of adjustment available.
Adjustmen Screw
Indy Select I Ryde AFX Rear Track Shock

Snowmobiles equipped with rear adjustable compression damping rear 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 tighten pretoad 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 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-clock wise. 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. 9/96
8. 12
SUSPENSION Rear Suspension Adjustment

The primary function of the rear 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 suspensi on can be adjusted to suit rider preference and deliver excellent performance fora given set of conditions. It should be noted , howeve r, that suspension adjustments involv e a com promise or trade off. A machine set up to perform well in the moguls wou ld not suit the preference of a groomed trail rider. The secondary funct ion is to provide superb handling and stabil ity, such as adjus tments to vary ski pressu re 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). Adju stment procedures for each type are explained later 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 I Ryde AFX adjustable comp ression rate
Rear Suspension Spring preload - front track shock Spring preload rear track shock Rear torsion spring Front rear scisso r stop (FRSS) Rear rear scisso r stop (RRSS) Optional coil springs Optional torsion springs Optional shock valving Limiter strap - front
Limiter strap - rear Indy Select I Ryde AFX adjustable com pression rate
8.13
9/96
SUSPENSION 1996 Tunnel Mounting 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 Tunne l 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 t, I :, o
Front
o
Factory Setting: A-B or BB
A B
o I ,.--1-- B
I
Tunnel Mounting Positions - XTRA 10133"
133" SKS stock mounting position. Optional position - lower hole.

Rear ,. _-
Front
,- '1
, r
, ' I
133" RMK stock mounting position. No optional positions for maximum deep snow perlormance.
Front torque arm stock mounting position. No optional positions.
For improved deep snow perlormance. tighten the front lirruter strap 5/B ' 3/4" (1.59 - 1.91 ern) .
NOTE: XTRA 10 121 ". XTRA 12 121 ". and XTRA 12 133" have no optional tunnel mounting positions. XTRA 12 front limiter strap may be shortened for more ski pressure and lower track approach angle.
9197
8.14
SUSPENSION 1997 Tunnel Mounting Positions 1997 Model Tunnel Mounting Positions
(Upper) 1 Front Re ar
(Mi d)
(Low e r) 3
2_--~;~~~~-~-:L' =========~t::~~~
Suspension Mounting Bolt Torque: 7/16" 60 ft.lbs, (8.28 Kg-m)
(Upper) 1 (Lower) 2
3/8"
Mod el Indy Lite/Deluxe/GT Indy SportlTranSport Indy Sport Touring Indy Super Sport I XCF Indy Trail Indy Trail Touring Indy Trail RMK WideTrak GT/LX Indy 440 I 440 XC Indy 500 Indy 500 SKS Indy 500 RMK Indy 500 ClassidTounnglEFI Indy XLT Indy XLT LTDlTouringiSPI LTDSP Indy XLT SKS Indy XLT RMK Indy 600 XC Indy 600 XCRISE Indy RXL Indy UltraiTouring Indy Ultra SP Indy Ultra SPXlSE Indy 700 SKS Indy 700 RMK Indy StormlSE Indy Storm RMK
40 ft.lbs. (5.52 Kg-m)
Front Torque Arm
Rear Mount Locatio n
Op tional Positions
Tunnel Position 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 Upper
Lower
Fixed
(FrontJRear) None
None
1/2 2/ 1 2/ 1 1/2 1/ 1, 2/ 1,3/2

None
Fixed Fixed Upper

Lower
2/ 1
2/1 2/ 1, 2/2, 3/2 1/1, 2/ 1, 3/2

None
Fixed Fixed Fixed Upper

Lower
2/ 1
None
2/ 1, 2/2, 3/2 1/1, 2/ 1, 3/2 2/ 1

1/1
Fixed Fixed Fixed Fixed Fixed Fixed Upper

Lower
None
None
2/ 1
111 111 , 2/2 , 3/2
1/1. 2/ 1. 3/2
1/1
Fixed
Lower
1/1. 2/ 1. 3/2
CAUTION : Use only combination s specified to prevent track and drive trai n damage, Always install bolts (PN 7517289) and nuts (PN 7542453) in open mo unt ing holes to p revent tunnel damage,
8,15
9/97
SUSPENSION Tunnel Mounting
1998 Rear Su spension Set Up I Tunnel Mounting Positi on s

Model Front Trac k Shock Mo unt Front Torque Ann Tun nel Position Rear Torque A nn Tunnel Mount Fixed Fixed (Below) Fixed Fixed (Below) Fixed Fixed Fixed Fixed Fixed Rxed (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
0
Options
Lite/D lx Lite Trn g Spo rt Sport Tmg TranSport XC F 440 LC 440 XC R Trail Tr ail Trng Trail RM K Super Sport Wi deTrak LX 500 500 RMK C lass ic Classic Trg XLTS P XLT LTD XLT Trng X LT Classic 600 XC 600 RM K 600 XC R Ultra Ultra Trng 700 XC 700 XC R 700 RM K Storm
N /A NlA N /A 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
"C
0 ... o'
:::l
III
N /A N /A
Lower
l: :::l
~ 0
~.
#2
Fixed Fixed Fixed
to
:::l
N /A N /A N /A
Lower Upper Lower
"tI 0
;:;:
:::l II>
II>
o'
#2 #2 #2
Fixed Fixed
N /A N /A
Lower Lower Upper Lower
#2 #2
Fixed
#2
NOTE : There are no opti onal fr ont torque arm m ounti ng p os it ion s. Do not re -Iocate the front torque arm .
9197
8. 15a
Pola ris Industries Inc .
SUSPENSION Hi-Fax Inspect ion I Replacem ent

H i-Fax Replacement - All M odel s Hi -Fax replacement on all Polaris models is similar. When any area of the Hi-Fax is worn to 1/8" (.3 em), it should be replaced. This will save wear on othe r vital components. The slide rail is designed to operate in conditio ns with adequate snow cove r to provide sufficient lubrication. Excessive wear may be due to improper alignment, improper track adju stmen t or machine ope rat ion on surfaces without snow. Replace Hi-Fax when worn to 5/16" (.79 em) on XTRA 12 suspensions; 3/8" (.95 em) on XT RA 10 and Sport style suspensions; 7/16" (1.1 em) on XT RA Lite style suspensions. Hi Fax We ar Limit
r-v _ _
3/8"
-------{---,
XTRA 10 & Sport St Ie
5~_L r-T- A--'i2 l jX

R
==
5/ 16"
Su g ge ste d Hi Fax Wear Limit: XTRA 12 - 5/16" (.79 em) XTRA 10 & Sport St y le 3/8" (.95 em ) XTR A Lite - 7/ 16" (1 .1 em )
XTRA Lite
Hi-Fax wea r patterns are somewhat different on mac hines eq uipped with the XTRA 12 sus pension than on conventional models. (The rear of the rail will wear rapidly at first.) After reaching a certa in point, this rapid wear will cease. Th is area should be checked frequently. however. replaceme nt is not necessary until a thickness of 5/16" (.79 em) 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. H i-Fax Removal 1. Remove suspension from machine.
NOT E: So me models may allow Hi Fax to be removed by slidi ng it through trac k windows with the suspe nsio n mou nted 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 slide rail.
4. With Hi-Fax material at room temperature, install new Hi-Fax by reversing steps 1 - 3.
NOTE: Lightly coat Hi-Fax track clip area with a lubricant such as LPS2 or WO-4D to ease installation. NOTE: Wide Hi-Fax should be narrowed on the leading sides to allow it to fit through narrow windows.
Track Clip Remova l - All Types

1. Position removal tool jaws on edge of clip. 2. Squeeze handles together to spread clip.
3. 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. Place new clip in position on track. 2. Connect clip installation tool on top of clip. 3. Squeeze handles together to crimp new clip.
Track Clip Installation Tool (Camoplast) PN 2871041 Track Clip Installation Tool (Yokohama) PN 2870380
8. 17
9197
SUSPENSION Rea r Suspension Exploded View - 1996 Sport Styl e
Rear Torque Arm Assembly
9/96
8 .18
SUSPENSION Rear Suspension Components - 1996 Sport Style
= = ,)
00 1 1
Torsion Springs
Front Track Shock
Front Track Shock Rear Track Shock
Carrier Wheel Rear Torsion Spring
Pivot Arm Shaft Forward
Bogie Wheel
Slide Rail Pivot Rail Bumper Arm Shaft
---
Idler Wheel
8 .19
9/96
SUSPENSIO N Suspension Adjustment - 1996 Sport Style

The Polaris Sport Style suspension has been designed and set up to del iver a soft ride under average riding conditions. Rider weight. riding styles. trail conditions . a nd vehicle speed each affect suspe nsion actio n. 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 suspe nsion adjustments involve a comp romise or trade off. A machine set up to perform well in the moguls wou ld 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 / Ryde AFX shock) Optional coil springs lo r front track shock Optional torsion spri ngs
Adjustment Procedures
It is a good idea to have custome rs break the suspension in for approxi mately 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 recomm end start ing with factory sett ings and then customizing eac h adjustmen t indivldually to suit rider preference. The machine should be methodically tested under the same conditions after eac h adjustment (trail and snow condit ions. vehicle speed .riding position. etc .) until a satisfactory ride is achieved . Adjus tments should be made to one area at a time. in order to prope rly eval uate the change. The purpose olthe front track shock coil spring is to contro l ride height. It you find that in order to obtain the desired ride effect the spring preload is at its maximum . consider removing the existi ng 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 adjustme nt options which affects ride. Preload is the initia l compression placed on the spr ing. The longer the installed iength of the spring. the less the amou nt of preload; the sho rter the insta lled length of the spring. the more the amount of preload. Increasing preload on the IFS spri ng will result in more bite on the skis. but will require more effo rt to turn. The IFS compressio n spring preload can be increased by adding shims (PN 5210953) under the spring. Alw ays verify ski alignment before makin g adjustments to the IFS. See Body and Steeri ng. Chapter 7 to check alignment. If the skis are misaligned. we recom mend the camber adjust ment be checked as this may also be affected.
9196
8.20
SUSPENSION Rear Suspens ion Adjustme nts 1996 Sport Style

The Indy Lite Deluxe model comes from the factor y with the rear suspension pivot moun ted in the forwardmost hole in the rail. Do not change this mount ing position . The other holes in the rail are for use on different machines utilizing the same rail. Rail Rear Suspension Pivot
#1 - Stock
Optional Suspension Adjustment Springs Torsion Springs
Position
Although your snowmobile suspen sion has the capabi lity of providing you with the best ride possible, the follow ing access ory rear springs are availab le to better suit individual riding preference. Soft .. .. . . . . . . . . . . . . .. . . .. .... . ..... .... . . Firm Part No, LH Part No. RH Wire Size Sport TranSp ort Indy Lite Indy Lite Deluxe Indy Lite GT 7041318 7041319 .375 Option Option Option Option Option 7041119 7041120 .393 Standa rd Standa rd Standard Standard Standard 7041 320 7041321 .406 Opt ion Option Option Option Opt ion
Shock Coil Springs

Changing the rate of the front track shock coil spring can affect handl ing. Heavier spring s will reduce darting and require less effort to steer. However, they will stiffen the ride and give the mach ine a tenden cy to push through corners. Lighter springs will increase ski pressure for positive pressure through curves. PN 7041127 PN 7041140 PN 704 1289 Standard Option Option Light Medium Heavy 181 #/in 181 #/in (longer free length than above) 200#Nariable
8,2 1
9/96
SUSPENSION 1997 XTRA Lite Style Exploded View
Front Torque Arm Assembly
9/96
8.22
SUSPENSION Rear Suspens ion Components - 1997 XTRA Lite Style
=="J
o
0
Carrier Wheel Rear Track Shock
Rail Bumper
Front Track Shock
Bogie Wheel Rear Torsion Spring
Forward
--
Rail Bump er
Idler Wheel
8.23
9/96
SUSPENSION Suspension Adju stment - 1997 XTRA Lite Suspensi on Adjustment

The Polaris suspens ion 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 de liver excellent performance for a given set of conditions. It should be noted , however, that suspens ion adjustments involve a compr omise or trade off. A machin e set up to perform well in the moguls would not suit the preference of a groomed trail rider. Adjustable Features and Adjustment Options IFS compre ssion spring preload Rear torsion spring preloa d Option al 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 customiz ing each adjustment individually to suit rider preference . The machine should be methodically tested under the same condit ions after each adjustment (trail and snow condit ions, 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 cha nge. The purpose of the front track shoc k coil spring is to control ride height and front IFS preload. If you find that in order to obtain the desired ride effect the spring preload is at its maximum , cons ider removing the existing spring and installing the next highest rate spring. See the cha rt on page 8.26. IFS Ad jus t 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 spri ng, the more the amount of preload. Increasing preload on the IFS spring will result in more bite on fhe 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 adjustme nts 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. 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 snowmobiie. Measure the distance between the ground and the same spot on the running board.
Torsion Springs
2.
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" drop 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 stee r around curves and will tend to push, or drive straight through curves. The XT RA 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 capabil ity of providing the best ride possible . the follow ing access ory 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 ------
.... ... .. ..... .. ... . .. .. .. ... ... ..... ....

7041557 7041558 .393/80 ' Standard Standard Opt ion
Firm
7041521 7041522 .406/82 ' Opt ion Opt ion Option
.393f77'
Option Option Standard
Shock Coil Springs

Chang ing the rate of the front tra ck 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 pressu re for positive pressure through curves. PN 7041569 PN 7041570 PN 704 1520 PN 7041571 Standard Standard Option Option Light Mediu m Heavy Light 60 #/in 80 #/in 90 #/in. 70 #/in. Sport Lite/Lite Deluxe All All
Maintenance
A visual inspection of the following item s should be done on a weekl y basis or befo re any long distance trip: Suspension pivot arm bolts for tightness Rear idler wheel bolts for tightness Rear idler adjusting bolt locknuts for tightness Bogie wheels and attaching bolts for tightness Front torque arm limiter strap condit ion Slide rail hi-fax thickness - replace when worn to 7/ 16- (1.1 em).
CAUTION :
If suspen sion 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.
Rear Idler Wheel ~
.~
-r:=-...".
~ Was her
Domed Side of
Out
9/96
8.26
SUSPENSION Suspension Adjustment - 1997 XTRA Lite

Suspens ion Lubrication
To maintain rider comfort and to retard wear of the pivot shafts. the suspension pivot shafts shou ld be lubricated with Polaris Premium All Season Grease, PN 287 1066. at 500 miles (800 km) initially; 1000 miles (1600 km) and before summer storage eac h yea r. The riding characteristics of the snowmobile will be affected by lack of lubrica tion of these shafts , NOTE: A grease gun kit com plete with grease and adaptors is available to lub ricate all fittings on Polaris snowmobiles. Order PN 287 1312. Refer to the diagram below for suspension lubrication points.
Grease at fittin gs
Forward
8.27
9/96
SUSPENSION 1996 WideTrak Style Exploded View
9/96
8 .28
SUSPENSION 1996 WideTrak Style Exploded View
Torsion Springs
Adjuste r Eyebolt Front Track Shock Rail Bumper
Carrier Whee l
Front Track Shock
Front Torque Arm Rear Track Shock
::arrier Whee l Rear Torsion Spring
Hi-fax
/ Bogie Wheel Rail Bumper Pivot Arm Shaft Idler Wheel
Pivot Arm Shaft
Forward
NOTE : Genera l representation only. Models may differ.
8 .29
9196
SUSPENSION Suspens ion Adjustment - 1996 WideTrak Style Models

Th e Polaris WideTrak style suspen sion has been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding style s, trail conditions, and vehicle speed each affect suspensio n action. The suspension can be adjusted to suit rider preference and deliver excelle nt performance for a given set of condi tions. It shou ld be noted. how ever. that suspen sion adjust ments involve a compro mise or trade off. A machine set up to perform well in the moguls would not suit the preference of a groomed trail rider. ..........
Adjus table Features and Adjustmen t Options

IFS compression sprin g preload Rear torsion sprin g preload Optional coil springs for front track shock
Adjustment Procedures It is a good idea to have customers break the suspension in for approxi mately 150 miles (240 km) befo re 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 sett ings and then customizing each adju stment individually to suit rider preference . The machine should be meth odically tested under the same conditions after each adjustme nt (trail and snow conditions, vehicle speed.ridinq position , etc.) until a satisfactory ride is achieved. Adjustmenf s 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. 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 8.37 .
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 insta lled 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 comp ression spring preload can be increas ed by add ing 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 misali gned, we recomm end 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. Slowly lower the machine and measure the distance between the ground and the running board at the rear of the tunnel. 3. Without letting the suspension settle, the rider should carefully mount the snowmobile. 4. 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 Torsion Springs 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.
Forward
8 .31
9/96
SUSPENSION Optional Suspension Adjustment Springs -1996 - Cur rent WideTrak Style Front Track 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 press ure for positive pressure through curves . PN 7041127 Opt ion Standard Opt ion Light Medium Heavy 181 #/in (6.88" free length) 181 #/i n (7.50" free length ) 200#Nariable
PN 7041140
PN 7041289
WideTrak GT
Rea r Torque Arm
,.
, '
.'
9/9 7
8. 32
SUSPENSION 1997 Standard Indy 133.5" /141 " Exploded View
8 .33
9/96
SUSPENSION 1997 Standa rd Indy 133.5" /141 " Exploded View
Torsion Springs
Adjuster Eyebolt Front Track Shock Rail Bumper
Carrier Whee l
Front Track Shock
Front Torque Arm Center Shock
Carrier Whe el Rear Torsion Spring
Hi-fax / Pivot Arm Shaft Slide Rail Rail Bumper Pivot Arm Shalt Idler Wheel
9/96
8.34
SUSPENSION Suspension Adjustment - 1997 Standard Indy 133.5" /141 "

The Polaris suspension has been designe d and set up to deliver a soft ride under average ridin g co nditions. Rider weigh t, riding styles , trail co nditio ns, and vehicle speed each affect suspension action, '-The sus pension can be adjusted to suit rider preference and deliver exc ellent performance for a give n set of co nditions, It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine set up to pe rform well in the moguls woul d not suit the preference of a groomed trai l rider.

IFS compression sp ring preload Rear torsion spring prelo ad 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 ride r to rider, depending on rider we ight, veh icle speed, riding style , and trail conditions. We recommen d starting with factory setti ngs and then customizi ng each adjustment individually to suit rider pref ere nce. The machine sho uld be methodically tested under the same conditions after each adjustment (trail and sno w condi tions, ve hicle speed,ri ding pos ition, etc.) until a satisfac tory ride is achieved. Adjustments should be made to one area at a time, in order to properly eva luate the change. The purpose of the fronttrack shock co il spri ng is to contro l ride height. If yo u find that in orderto obtai n the desi red ride effec t the spring preload is at its maximum, consi de r removing the existing sp ring and installing the next highest rate sp ring. 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 comp ressio n placed on the spring. The lon ger the instal led len gth of the spring, the less the amount of preload ; the sho rter the installed lengt h of the spring, the more the amou nt 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 co mpress ion spring preload can be increase d by adding shims (PN 52 10953) under the spring. Always ve rify ski align ment befo re makin g adjustme nts to the IFS. Se e Body and Steering, Chapter 7 to chec k alignme nt. If the skis are misaligned, we recommend the ca mbe r adjustment be checked as this may also be affected.
8.35
9/96
SUSPENSION Rear Suspension Adjustments - 1997 Standard Indy 133.5" / 141"

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. Slowly lower the machine and measure the distance between the ground and the running board at the rear of the tunnel. 3. Without ietting the suspension settle, the rider should carefully mount the snowm obile. 4. 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 ioads can be made Torsion Springs 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.
Forward
9/96
8.36
SUSPENSION Optional Suspension Adjustment Springs - 1997 Standard Indy 133.5" / 141"
Shock Coil Springs
Changing the rate of the front track shock coil spring can affect hand ling. 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 press ure for positive press ure throu gh curves.
1997 Models
PN 7041127 PN 70411 40 PN 7041289 Option Standard Option Ught Medium Heavy 181 #/in 181 #/in (longe r free length than above) 200#/Variable
An optional shock/spring assemb ly is available for the rear track shock. Order PN 2871042.
8.37
9/96
SUSPENSION Rear Suspension Exploded View - XTRA 10 Style
9/96
8.38
SUSPENSION Rear Suspension Components .. XTRA 10 Style
Limiter Strap
Forward
Rear Torsion Spring Adjuster Cam low position shown CAUTION: Never allo w long side of block to poin t toward rear as breakage will occur. FRSS low position shown
RRSS low position shown NOTE: 1997 models have optional lower RRSShole
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. CA UTION: The rear torsion spring block should never have the long side pointing toward the rear or block break age will occur.
Front Limiter
The front limiter strap controls fhe 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 (Le. the lighter the torsion spring preload , the more weight transfer) . Sett ing Longer Shorter Ski Pressure Decreased Increased Weigh t Transfer Increased Decreased
NOTE: RRSS has greatest affect on weight transfer on XTRA 10 suspe nsions.
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
Piyot Arm Shaft Rear Torqu e Arm
Forward Carrier Wheel Rear Track Shock Rear Torsion Spring
Limiter Strap Idler Wheel
'H--
Bogie Wheel
Slide Rail Front Track Shock Hi-fax
1997 Models have additional hole for movementof RRSS
91 96
8.40
SUSPENSION Rear Suspens ion Components - XTRA 10 133.5" /136" Style
Front Track Shock Limiter Strap Rear Track Shock
Rear Limiter Strap
, 0
Pivot Arm Shaft Forward
Rear Torsion Spring
Pivot Arm Shaft
Carrier Wheel Rear Track Shock Rear Torsion Spring
Front Torque Arm
Limiter Strap Rail Bumper
Idler Wheel
Bogie Wheel
Slide Rail Front Track Shock Hi-fax
8.41
9/96
SUSPENS ION Suspens ion Adjustment - XTRA 10 Style

The XTRNM 10 suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding styles , traii 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 suspen sion adjustments involve a compromise or trade off. A machine set up to perform well in the moguls would not suit the prefe rence of a groomed trail rider.

Independent Front Suspens ion (IFS) Front shock spring preload Optional springs Adjustable compression valving via Ryde AFX I Indy Select shock Rear Suspension Rear torsion springs Front rear scissor stop (FRSS) Rear rear scissor stop (RRSS) Optional coil springs for front track shock
Optional torsion springs Adju stable compression via Ryde AFX I indy Select shock rear track shock Limite r straps - front and rear
Adjustment Procedu res

It is a good idea to have customers break the suspension in for appro ximately 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 should be made to one area at a time, in order to properly evaluate the change.
9197
8 .42
SUSPENSION Suspension Adjustment - XTRA 10 Style Compression Damping Adjustable Shock

Snowm obiles 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 adjus tme nt 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 ciockwise (a small screwdriver or dime work well), the compr ession 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 screw clockwise in 1/2 turn increments until the bottoming stops. Backing off 1/4 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 afte r torsion spring preload has been increased. Riding conditions are ever changing. Keep in mind the Indy Select I Ryde AFX shocks can be adjusted at any time to achieve the best possible ride in any condition.
NOTE: Whene ver 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.
8.43
9197
SUSPENSION IFS Adjustments - XTRA 10 Style

Front Suspens ion 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 spring, 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. The front spring 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 adjusta ble, except by adding shims. To adjust front spring preload on threaded 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 countercloc kwise direction to decrease preload.
Spanner Wrench
i
::aJ'?
High preload
NOTE: Access to the cam with the spanner wrench is easiest

from the inside of the ski. When adjusting, be sure 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 occasional light 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 existi ng spring and install the next highest rate spring.
-1;';1-
B: Lo w ~ preload 'Ji I. ,
--" " d
Turning clockwise increases preload
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 acceleration. To adjust models with quick adjust front limite r straps,turn the eyebolt nut to lengthen or shorten the straps. To shorten the strap, turn the nut clockwise. To lengthen the strap, turn the nut counte rclockwise. Turn nut to adjust
NOTE: Both limiter straps must be adjusted evenly and remain equal in length to avoid improper Hi-Fax and track wea r.
Turning clockwise shortens strap. Turning counterclockwise lengthens strap.
9/9 7
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 alt itude 01 the rear suspension. As the front torque arm (FTA) hits the bump, it forces the rear scisso r to coll apse a pred eter mined amou nt, depending on the FRSS block position. This accompl ishes two important thing s, 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 resilien t mate rial allow inq smooth action and preventing any suspension component damage . This unique feature is applied to the XTRA'" 10 rear suspension. Paten ts are pending.
Rear Scissor Front Torque Arm (FTA) FRSS RRSS
--=----- - - -~~~~ 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 scisso r to collapse with less FTA movement than whe n in short position .
8.45
9/96
SUSPENSIO N Rear Rear Scissor Stop (RRSS) - XTRA 10 Style The RRSS controls weight transfer from the rear susr - - -- - -- - -- - -- - - -- ---,
pension to the skis. It also influences the stiffness of the ride by controlling 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 for maximum weight transfer. However, unless the torsion springs and rear shock valving are changed, the ride will be compromised. Always maintain equal adj ustment on both sides.
RRSS -low position shown
FRSS - low pos ition shown

Scissor Stop Block Position
Medium
Be sure rear scissor stop face is squa re with the face of the scisso r arm to ensure complete contact.
Low
o
o
High
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 ieg is lifted over the roller and replaced after the block is prope rly positioned. Always maintain equal adjustment on both sides.
A
Soft Tension Long End to Front
~~~ / ~
=-:rf:=--- ~=
0
"~ ~
;1,~
Medium Tension (Short End Up)
Firm Tension (Long End Up)
9/97
8 .46
SUSPENSION Optional Springs - 1996 - Current XTRA 10 Style

The foll owing opt ional springs are available to bette r suit indiv idual ridi ng preference. NOTE: Th ere are no options for the fro nt ski springs.
~
Th e foll owing optional sp rings are available to bette r suit individual riding p refe rence. Front Track Spring Part No. 7041361 -067 7041253-067 7041362-067 7041364-067 Torsion Spring Part No. 7041463-067 Left 7041464-067 Right 7041461-067 Left 7041462-067 Right 7041465-067 Left 7041466-067 Right .406/77'
.406177> .421 177' .421 177' .437177' .437177'
Spring Wire Dia. x Free Length - Rate .343 x 7.0 - 243 #/in. .312 x 7.5 - 200Nar. .261 x 7.0 - 85 #/in. .283 x 7.5 - 126 #/in. Wire DiaJDegrees
The following optional front ski springs are available for the 440 XCR . Front Ski Spring Part No. 7041396-067 7041398-067 7041351-067 7041405-067 Spr ing Wire Dia. x Free Length Rate .283 x 11 .88 - 50#frn. .312 x 11.88 - 75#/ln. .331 x 11.88 - 75-125#frn. .283 x 11.88 - 65#/ln.
NOTE: Sp rings on the front ski sh ocks and front (cente r) track shock are interch an geab le . Th e following optional front ski springs are available for the 600 XCR. Front Ski Sprin g Part No. 7041358-067 7041 359-067 7041360-067 7041366-067
Spring Wire Dia. x
Free Length - Rate .331 x 9.5 - 160#/ln. .312 x 9 - 146#frn. .331 x 9 - 120/170#/in. .331 x 9 - 110 /140#/ln.
The followin g opt io nal front track springs are available for the 44 0 XCR SP. Front Track Spring Part No. 7041509-067 7041510-067 7041511-067 7041512-067 7041513-067 7041514-067 Spring Wire Dia. x Free Length - Rate .343 x 6.18 - 140/240#frn .362 x 6.25 - 165/245#/ln. .225 x 5.25 - 50#/ln. .263 x 5.25 - 85#/ln. .295 x 5.25 - 135#/ln. .297 x 5.25 - 100/180#/ln.
CAUTION : Sp ring s on front skis must be the same rate. Valvin g in sh ocks may have to be changed in some ca ses or loss of contro l co uld result. Ryde AFX shocks also available as an accessory for the IFS or rear track. These shocks offe r more tunin g ability. See the accessory sec tion at the back of thi s manual.
8.47
9/97
SUSPENS ION Optional Springs - 1997 XTRA 10 Style

Following is a list of all avai lable springs for Ihe XT RA 10 fronl and rea r su spension . T hese sp rings ca n be used 1 bett er suit ind ivid ual riding preference. 0 Torsion Spring Part No. 7041463-067 LH 7041464-067 RH 7041461-067 LH 7041462-067 RH 7041465-067 LH 7041466-067 RH Front Ski Spring Part No. 704 1554-067 7041576-067 7041575-067 7041574-067 7041573-067 7041553067 7041552-067 7041551-067 7041550-067 7041549-067 Front Track Spr ing Part No. 704136 1-067 7041253-067 7041362-067 7041364-067 80# Fox 100# Fox 120# Fox 140# Fox 160# Fox 60# GabrieVArvin 80# Gabriell Arvin 100# Gabriel/Arvin 120# GabrieVArvin 140# GabrieVArvin Spri ng Wire Dia. x Free Length Rale .343 x 7.0 - 243 #f1n .3 t 2 x7.5 - 200Nar .261 x 7.0 - 85 #f1 n .283 x 7.5 - 126 #/in .406177' .406177 ' .42 1177' .42117 7' .437177' .437177' Len gth/Rate App lication Wir e DiaJD egrees
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
SUSPENSION Rear Suspension Componen ts - XTRA 12 Sty le
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" RRSS - "Rear Rear Scissor Stop"
8.51
9/96
SUSPENSION Rear Suspension Components - XTRA 12 Style
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 Rea r Track Shock
Front Torque Arm
Rear Torqu e Arm
Slide Rail Pivot Arm Shaft Rail Bumper Idler Whee l
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 pressu re at which the spring is held. The longer the installed length of the spring, the less the amou nt 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 direct ion (as viewed from the bottom of the shock) to increase the preload . Turn in a cou nterclockw ise direction to decrease preload. High preload preload
-F r
zt,
Low ~
'f1
U
Turning clockwise increases preload
CAUTION: I
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, result ing in damage . For the best ride the spring preload shou ld be as low as possible. Set the preload to use the full travel of the ski shoc k with occasiona l light bottoming. To dete rmine if you r machine is using full travel, push the shock jounce bumpe r 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 trave l is full, the bumper will be seated at the top of the shoc k. The purpose of the shock coil spring is to control ride height. The purpose of shock valving is to co ntrol dampi ng. 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 existi ng spring and change the shock valving to obtain the desi red effect. NOTE : Shoc k valving can only be adjusted or changed on models equip ped with Indy Select or Fox' " shocks.
Always leave at least one th read showing above nut
"'I
~
o
QJl
Push jou nce bumpe r down as far as it will go on shock rod
~ ----l ~ .
Shock rod
'y
_
WARNING
Changin g shock valving requires spec ial tools and a sound know ledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Shocks contai n high pressure nitrogen gas. Extreme cautio n 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 maki ng adjustments to the IFS. See page 7 .17 to check alig nment. If the skis are misaligned, we recommend the cam be r adjustment be checked as this may also be affected.
8.53
9/96
SUSPENSIO N IFS Front Torque Arm Limiter Strap Adjustment - XTRA 12 Style
One method of changing ski-to-snow pressu re 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 exte nded posit ion. 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 for changing ski pressure is to move the FRSS to the forwardm ost hole. See page 8.56.
9/96
8.54
SUSPENS ION Suspension Adjustment - XTRA 12 Style

The XTRA T" 12 suspension has been designed and set up to deliver a soft ride under average riding condit ions. Rider weight, riding styles, trail condit ions, and vehicle speed each affect suspe nsion 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.

Independent Front Suspens ion (IFS) Front shock spring preload Optional springs Optional shock vaiving Compres sion adjust Indy Select I 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 Compre ssion adjust Indy Select Ryde AFX shock (see page 8.62)
It is a good idea to have customers break the suspensio n 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, vehic le 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.
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 suspen sion 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 suspensio n. start with the lightest preload setting that will prevent heavy bottoming. Adjustments should be made to one area at a time. in order to properly evaluate the change . NOTE: Rear spring settings will affect ski-to-grou nd 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. Tum in a counterclockwise direction to decrease preload.
Forward
......--
Note direction of bolts
Rear Track Shock Spring

The rear track shock coif spring does not have a threaded adjuster. One option to dec rease 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. Turn 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
@ low
@)
(@)
medium high Forward
CAUTION:
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.
RRSS
Relocate FRSS to forwardmost hole in rail for additional ski pressure
Rear Rear Scissor Stop (RRSS)

The RRSS is not adjustabl e but can be changed to provide less weight transfer on 121" models. See chart below.
XTRA 12 RRSS Production Settings

Suspension 121 " 133" Length Short Long Color Black Gray Part Number 54 10937 5411041
Forward
NOTE: For less weight transfer on XTRA 12 121" use long (gray) RRSS block.
9/97
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 at the spring as shown with the engine spark plug tool. This adjustment is easier if the long spring leg is lifted over the roller and replaced after the cam is prope rly 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
Firm Tension (Long End Up)
8.57
9/97
SUSPENSION Optional Springs - 1996 XTRA 12 Style

The following opt ional springs are available to better suit ind ividual riding preference . Coi l Spring Part No. For Use on Ski or Front Track Shocks 7041405-067 7041398-067 7041404-067 Rear Track Spring Part No. 7041362-067 7041364-067 7041361-067 Tors ion Spring Part No. 7041406067 Left 7041407-067 Right 7041467-067 Left 7041468067 Right Coi l Spring Part No. For Use on Ski (or Classic Front Track) 7041405-067 7041398-067 7041404-067 Rear Track Spring Part No. Classic Only 7041362-067 7041364-067 7041361-067 .261 x 7.0 85#~n. .283 x 7.5 126#/in. .343 x 7.0 243 #/ln. .261 x 7.0 - 85#~n . .283 x 7.5 126#~n .
Spring Wire Dia. x Free Length Rate .306 x 11.88 - 65 #/in. .312 x 11 .88 -75 #/in. .343 (or .362) x 11.88 - 90/150 #An. Spring Wire Dia. x Free Length Rate
.343 x 7.0243 #/in. Wire DiaJDegrees
.421/55' .421 /55' .437/55 .437/55

Spring Wire Dia. x Free Len gth Rate .306 x 11.88 - 65 #~n . .312 x 11.88 - 75 #/in. .343 x 11.88 90/150 #/in. Spring Wire Dia. x Free Leng th Rate
NOTE: A front track spring option kit is available fo r Classic Touring and XLT Touring Models. Order part number 2871349. Th is 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 7041468-067 Ri9ht Wire DiaJDegrees
.421/55 .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 mus t be the same rate. Valving in shocks may have to be changed in some cases or loss of co ntro l cou ld res ult.
9/96
8.58
SUSPENSION Optional Springs 1997 XTRA 12 Style

Following is a list of all av ailable springs for the XTRA 12 front and rear suspension. These springs can be used to better suit individual riding prefe rence. Torsion Spring Part No. 704 1394-067 LH 7041395-067 RH 7041487-067 LH 7041488-067 RH 7041406-067 LH 7041407-067 RH 7041487-067 LH 7041488-067 RH IFS Spring Part No. 7041554-067 7041576-067 7041575-067 7041574-067 7041573-067 7041553-067 7041552-067 7041551-067 7041550-067 7041549-067 Front Track Shock Spring Part No. 7041404-067 7041396-067 704 1484-067 7041405-067 7041398-067 Rear Track Shock Spring Part No. 704 1362-067 7041364-067 704136 1-067 7041561-067 .26 1 x 7.0 - 85 #fln .283 x 7.5 - 126 #fln .343 x 7.0 - 243 #fin .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 #fln .406 x 9.0 - 275 #/in .306 x 11 .88 - 65 #/in .312 x 11.88 - 75 #/in Spring Wire Dia. x Free Length - Rate More Pre-load More Pre-load More Pre-load More Pre-load .406/65' .406/65'
.406f77' .406177'
Wire DiaJDegrees
.421/55'
.421155' .437177' .437177'
Length/Rate - Application
8.59
9/97
SUSP ENSION 1998 IFS Data - Set-Up & Adju stment 1998 Model
Lite/Lite DlxlL ite Trg Sport TranSport Sport Touring XCF Super Sport Trail Trail Touring Trail RMK WideTrak LX 440 LC 440 XCR 500 500 RMK Classic Classic Tou ring XLT LTD XLT Touring XLTSP XLT Classic 600 XC 600 XCR 600 RMK Ultra Ultra Touring 700 XC 700 XCR 700 RMK Storm
Front Suspens ion Type

Lite IFS 38x7 IFS 38x7 IFS 38x7 IFS Xtra-10 CRC IFS Xtra- 10 IFS Xtra-10 IFS Xtra-10 IFS 38 RMK IFS 38x7 IFS Xtra-10 IFS XC-10 CRC IFS Xtra- 10 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- 10 CRC IFS 38 RMK CRC IFS Xtra-10
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 Celi 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
70412 84 7041535 7041535 7041562 704 1523 7041496 7041496 7041496 704 1544 7041535 7041496 704 1692 7041496 7041544 7041539 7041503 7041503 7041503 7041523 7041503 7041697 704 1540 7041543 7041503 704 1524 704 1697 704 1540 704 1543 704 1540
IFS Spring PN*

704126 1 7041261 704126 1 704 1598 704 1552 704 1552 704 1552 704 1683 704 1552 704 1261 704 1552 7041489 704 1552 7041552 7041405 704 1551 7041398 7041550 704 1405 704 1398 704 1613 704 1575 704 1551 7041550 7041549 7041613 7041575 7041551 7041575
Spring Rate
105#/i n 105#/ in 105#/ in 105#/ in 80#/in 80#/in 80#/in
Spring PreLoad
3 Shims 1 Shim 3 Shims
.13"
1.0"
1.0"
.75" .13"
80#fJn
80#/in 105#/in 80 #/in 74 /120# 80#/in 80#/in 65 #/in 100#/in
.3" 3 Shims
.8"
.625
.8"
.6"
.75"
.4"
75#fJn
120#/in 65#/in 75#/in 75#/in 120#/ in 100#/in 120#/ in 140#/i n 75 #/in
.25" .13" .75" .75

.75 "
1.5" .13"
.13"
.63" .75"
1.5"
120#fJn
100#/in 120#/in
.13" 1.55"
9197
8.5a
SUSPENSION 1998 Rear Suspensi on Data
Model
Rear Suspension
Front Trac k Shock
PN
Front Track Shock (Type)
Front Track
Front
Track
Rear
Track
Shock
Rear Track
Shock
Des c.
Torsion Spring Pa rt Num ber "
Tor sion Sp ring Dia meter I Angl e
Sh oc k
Spring
Sh ock
Spring Rate
Left I Right
(Rear Track
PN
(Rear Shock
Spring Rate)
PW
Lile /D lx Lite Tm g Sport Sport Tmg Xna Loe Xtra Lit.. I33
Xtra Ute
(Ib.fln .) 704 1516 704 1516 704 1516 7041516 7041719 7041596 7041430 704 1706 704 1430 7041430 7041430 704143 0 7041711 7041430 704 1586 7041485 7041639 7041586 Hyd Hyd Hyd Hyd Hyd Ryde AFX Hyd FOX IFP Hyd Hyd Hyd Hyd Hyd Hyd Hyd 7041 570 70 41570 704 1569 704 1570 70417 10 7041253 704 1253 7041508 7041 253 7041253 7041 253 704125 3 7041712 7041253 7041 253 70413 51 70414 04 7041253 70 4135 1 7041404 704 135 1 70 41253 7041 253 70 41253 704 135 1 704 140 4 7041253 704 1253 704 1253 7041253
BO#/in
80#/in 60#/in
Shock Spring) 7041665 704 1666 704 1665 704 1666 70411 54 7041667 7041 441 704 1707 704144 1 7041438 Hyd Hyd Hyd Hyd Hyd Ryde AFX
70415571704 1558 704 146 117041462 7041 52 117041522 704 146117041462 7041 320170413 21
.393 .421 .406 .421 .406 .406 .406 .421 .406 .437 .421 .406 .468 .406 .421 .406 (85#nn) .437 (275#" n) .421 .406 (85#(on ) .437 (275#"n) .406 (85#/ln) .421 .421 .421 .406 (126#/ln) .437 (275#" n) .42 1 .42 1 .421 .42 1
80' 77' 82' 77 ' 75' 77' 77' 77' 77' 77' 77' 77' 74' 77 ' 77' 55'
Xtra Ute 133
BO#frn
TranSport
XCF 440 LC 440 XCR
141 GT Xua l 0
181# lln
200/var
200 /var
704146317041464 704146 317041464

704 146 117041462 704 146317041464 7041465170414 66 7041461 170414 62
xna-t o
Xlra 10
Select
FOX IFP
190#/in
20 0/va r 200/var
Trail
Trail Trng Trail RMK Super Sport WideTrak LX
xtra 10
Xaa 10 133.5 Xfra 10 133.5
Sele ct
Select
Select
20D/vaT 704 1577
Xtra 10 WideT rak 156

Xtra 10 Xtra 12
200/var 7041441
18 1 It/in
200/va r
Select
Hyd
Se lect Select Gas Bag
704146 317041464
70 412391704 1240
704 1280 704 1441 7041577 704 1587 704148 1 7041694 70415 87 7041481 7041560 7041640 7041438 7041695 7041440 7041548 7041640 7041695 7041438 7041695
500 500 RMK

Clas sic
7041463170 41464
704146 1170414 62 704 139417041395 (704 156 1) 70414 871704 I 488 (7041484)
Xtra 10 133.5 7041430
2DQ/var
75/12 5
Select Select
Ryde FX Select
Select
Classic Trg XLTSP XLT LTD XLT Trng XLT Classic 600 XC 600 RMK 600 XCR
Ultra Ultra Trng
xna 12 133.5
Xtra-l 0
Xtra 12
901150
Select
#/in
20 0lvar
77' 77' 55' 77 ~
Ryde AFX Gas Bag

Select
7041461/7041462 7041394/704 1395 (7041561 ) 704148717 041488 (704 1484)

704 13941704 1395 (704 156 1)
751125
90/ 150
Xtra 12 133.5 7041486 Xtra 12

Xtra 10 Xfra-f O 136
55' 77" 77' 77' 55'
7041559 7041639 7041606 704 1642 704 1433 7041 594 704 1639 7041 642 704 1606 7041 642
AFXlElecl Ryde FX Hyd FOX IFP

Select Select
75/ 125
200/var 200/var
Ryde A FX RydeAFX
Select
704146117 041462
704 1461170414 62 704146117041462
Xtra 10 Xtra 12 Xtra 12 133.5
200/var 75/ 125 901150

200/var 200lvar 2QQ/var
FOXIFP
Gas Bag
7041394170 41395 (704 1364) 704148717041488 (704 1484)

70 4146117041462
Ryde AFX Ryde AFX FOX IFP

Select
71"
700 XC 700 XCR 700 RMK

Storm
xea-ic
Xtra 10
Ryde FX FOX IFP Hyd FOX IFP
77' 77' 77'J
704 14611 7041462 704146117041462

70 4146 117041462
Xlra 10 136 Xfra 10
200/var
FOX IFP
77 '
' All springs shipped as service parts are black . You must add a suffix of "-067' to spring part number when ordering.
8 .5b
9/9 7
SUSPENSION XTRA 12 Rear Suspension Set Up Rear Suspension Suspension Set Up

The following charts are only guide lines to be used for initial suspension set up. Set up may vary based on your desired riding sty le.
XTRA 12 121"
Rider Weight 110-160 Ibs. (50-73 kg) '1 60-210Ibs. (73-95 kg) 210-260 Ibs. (95-118 kg) 260+ Ibs. (118+ kg) Front Track Sho ck Spring 75 #fin.
75/125 #fin Torsion Spring
Rear Track Shock Spring "" 85 #fin. 85 #/in. Ultra 126 #fin. Ultra 126 #fin. Ultra 126 #fin. Ultra 200 #fin. Variable
.406 Low Setting .406 Low Setting .421 Low Setting .421 High Setting
Low-Medium Preload
75/125 #/in
85 #/in .
High Preload
90/150 #fin Low Preload
126 #fin.
'Indicates produ ction set up for average riderl average conditions . " May be removed if ride is too stiff afte r other adjustments or changed to a lighter rate sp ring. See Rea r Track Spring Options, pag e 8.58.
XTRA 12 133"
Rider Weight Front Track Spring (1)
Torsion
Spring
Rear Track Spring (2)
Front Track Shock (3)
Rear Track Shock (3) 3/4 1.75 1 2 1.5 2.5 2.5 3
11 0-160 With rack plus 30 Ibs.
Soft
75-1 25 #/in . 90/150 #fin.
.421 x 5510w .437 x 77 low .437 x 77 low .437 x 77 low
275 #/in. 3/4 275 #/in. 275 #/in. 275 #Iin. 1.75 1
190 #fin. 160-200 with rack plus 30 Ibs. 200-260 with rack plus 30 lbs, 260+ with rack plus 30 Ibs. 90-150 #/in. 190 #fin.
90 150 #/in .
.437 x 55 high 275 #Iin. 2 .437 x 77 low 275 #fin. 1.5
190 #fin. wi 1.0 " pre-load 90-150 #/in.
.437 x 77 high 275 #Iin. 2.5 .437 x 77 high 275 #/in. 2.5
190 #/in. wl 1.0 "pi .437 x 77 high 275 #/in. 3
(1) Note: Th e front tra ck spr ing preload may be adj usted using the threaded adjuster to the desi red sett ing in combination with the listed co nfiguratio ns. (2) Note : For extreme co nditions up to one inch of preload ca n be add ed to the rear trac k sho ck sp ring using spacer s (PN 5210953 ). (3) Note: This setti ng refers to the com pression adjust scr ew in Indy Sel ect shocks. Settin g indicat es numbe r of turns in clo ckw ise direction.
9/9 7
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 sc rew located nea r 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 spiilage and flooding of the carburetors. By turning the screw clockwise (a sma il screwdriver or dime wo rk weil), the comp ression valving is increased, stiffening the ride. To soften the ride, reduce the comp ression by turning the screw counter-clockwi se. A great deal of ride performance is accomplished with a mere 1/2 to 1 turns. There are approximately 3 fuil turns of adjustment available.
How to Adjust
If the suspensi on is "bottom ing," tighten the comp ression screw clockwise in 1/2 turn increments until the bottoming stops. Backing off 1/4 turn counter-clockwise at this point should give you the best possible ride ensuring use of the fuil travel of the suspens ion. The opposite procedure should be used if the suspension is too stiff upon initial set-up . The adjustme nt of the front track shock should be used in conjunctio n with the shock spring preload . To adjust spring, see page 8.60. If bottom ing continues afte r the screw is botto med out, the torsio n spring should be adjust ed per the adjustment block. See page 8.60. Back the screw out to the original starti ng position after the torsi on spring has been tightened . Riding conditions are eve r changi ng. Keep in mind the compressio n damping adjustab le can be adjusted at any time to achieve the best possible ride in any condit ion.
NOTE: Whenever shocks are replaced or reinstailed for any reason, the adjustme nt screw should be located toward the forward right side of the suspension. Access to the adjuste r is not possible if reversed. Fox' " Shocks should be instailed with the charge fitting up.
9/96
8.62
SUSPENSION
XTRA 12 Suspension - Shock Remova l XTRA 12 Suspension Shock Remova l
'Steps 1-4 (immediately below) may be used for either front 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). 3. 4. '-Remove (4) suspension mounting bolts, Place a protective mat along side of machine. TIp the machine on its side onto protective mat.
Front Track Shock Installation Fox Shocks - Gas fitling positio ned downward (towa rd track) Indy Select Shocks - Adjuster screw positioned upward
5. Note orientation of shacks before removal - gas valve (Fox) or adjuster screw (Select) up or down. C A 6. 7. 8. Remove suspension. Lift rear torsion springs (D) from their lower mounts. Remove top bolt from front track shock.
B D
9. Remove lower front track shock bolt (lift torque arm to gain access ). 10. With front track shock removed , loosen and remove top and bottom bolts from rear track shock. Rear Track Shock Installation Fox Shocks - Gas fitting positioned upward (tow ard rear) Indy Select Shocks - Adjuste r screw positioned upward (toward rear)
XTRA 12 Suspension Shock Installation

1. above for Reverse steps assembly, with the following notes: Use new Flex-LacT " nuts for installation. TIghten shock bolts to 15-18 ft. Ibs. (2.07- 2.48 kg/m ). Be sure 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
SUSPENSIO N
Wheel Kits Wheel Kit Mounting Recommendations
The following illustrations indicate proper installation of optional whe el kits.
XTRA Lile Use kit PN 2871651
Inside
XTRA 10 121"
Inside Kit PN 2870602
Outsid e Kit PN 2871582
8 .65
9/96
SUSPENSION Wheel Kits

. WheeI Kit Mountmg Recom mendat io ns
XTR A 10 133.5"
Oute r 02 Kit PN 28706
Inner 2 Kit PN 287158
Outer Kit PN 2871582
XTRA 10 136"
Inner Kit PN 2871582 Outer Kit PN 2870602
Outer Kit PN 2871582
9/96
8 .66
SUSPENSION
Wheel Ki ts . Wheel Kit Mountmg Recommendations
XTRA 12 121"
Outer Kit PN 2870602 Outer Kit PN 287 1582
XTRA 12 133.5"
No Wheel Kits re.comm ended fo r th is suspension
8.67
9/96
SUSP ENSIO N FOX Shock Data
FOXT Shoc k Specifi cations "

Shock PN Extended Length (in .) Compression (in) St roke (in) IFP Depth (in ) .025 (See NOTE:) 1.142 1. 142
7041385 7041386 704 1387 7041401 704 1402 7041 403 70 41444 70 41 474 70 41480 7 041490 70 4 1492 704 1494 704 1507 704 1536 7041537 704 1540 704 1545 7041584 70 41585 7041588 7041589 7 04 1593 70 41595 7041599 704 16 12 704164 1 7041642 7041692 70 41695 704 1697 70 41706 7041 707
18 .15 18.15 12.32 16.56 11.07 13.56 14 .52 13.25 12:32 12.7 1 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 9.2 1 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 9.8 2 10.47 7.78 9.82
6.37 6.37 3.65 5.8 1 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
.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
-:I
IFP Depth Tool PN 287135 1

I
oC
8.68
&
JHJ
--
Part number stamped on body cap on some shocks.
Body Cap
9/97
SUSPENSION Fox Shock Maintenance

Changing oil on FoxT" Shocks is recommended annually and should be included when performing end of season storage preparation. This oil 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 serv iced more frequently. When performing maintenance on FoxT" 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 Floating Piston (IFP), and Shock Rod Hold ing Tool are not included in the Recharg ing Kit and must be ordered separately. Refer to General Tools, Chapter 1 for part numbers.
Gas Shock Recharging Kit PN 220042 1
WARNING
Extreme caution should be observed while handling and working with high pressure service equipment. Wear a face shie ld, safety glasses . and ear protection during service of these shocks. Care should be observed while handling the inflater needle and pressu re gauges. Maintain your equipme nt and keep it in good cond ition. If injury should occur, consult a physicia n immediately. Extreme cleanliness is of utmost importance during all disasse mbly and reassembly operations to prevent any dirt or foreign particles from getting into the shocks. Keep the parts in order as they are disassembled. Note the directio n and position of all inlernal parts for reassembly. 1 Bleed Screw Body Cap Ref. # 1 2 3 4 5 6 7 8 Part No. 1500005 1500004 7710424 5020617 1500003 1500006 1500002 5020618 oty. 1 2 1 1 2 1 Description Pressure Valve O-Ring Retaining Ring Spring Retainer Body O-Ring Piston Ring (Floating) Piston Ring (Damping) Spring Retainer, Slotted
8
2 Internal Floating Piston (IFP)

Shock Body
6
~4
5
1
1
---Bearing Cap 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 everyo ne by turning Thandle 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. Remove valve and sealing G-ring from body cap. 4. Extend shock shaft by pulling up on shock eyelet. Using a 1" (25 mm) wrench, loosen shaft bearing cap.
9/96
8 .70
SUSP ENSION FOX Shock Mai nten an ce

Disassemb ly, 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 2871 07 1
6.
Pull shock rod and piston straight out to avoid seal or valve damage . Be prepared to catch piston ring when removing the damper rodlva lve piston.
7. Remove shock trom 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 washe rs with electrical contact cleaner. Dry thoroughly with compressed air. Tighten nut and torque to 12 ft. Ibs. (1.66 kg-m).
"
Valve Nul Torque -
12 ft. Ibs. (1.66 kg-m)
8 .7 1
9196
SUSPENSION FOX Shock Maintenance

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 dampe r 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 .
2. 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.
3. Clean seal cavity and inspect bushing for wea r or damage and replace bearing cap if necessary.
4.
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.
5.
6. Inspect damper rod for nicks, scratches or ab rasion. 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 dampe r rod nut (toward IFP). Install rebound stack, washer, and a new nut. Torque nut to 12 ft. Ibs.
Valve NUl Torque -
12 ft. Ibs . (1.66 kg-m)
9/96
8.72
SUSPENSION Fox T" Shock Maintenance

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 .
8. 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! sealant. CAUTION :
Never apply heat to shock body witho ut first depressurizing 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 2871071
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 a- ring in body cap for damage. 11. Note location of Allen screw in internal floating piston (IFP) for reasse mbly in body tube. Remove IFP by pushing with handle of hammer agains t piston towa rd 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 bleeder screw a-ring and IFP sealing a-ring for wear or damage. Replace a -rings upon reassembly . 12. Carefully clean all parts thorough ly with electrical contact cleaner or solvent and dry with compressed air. Inspect shock body for scratc hes or wear.
8 .73
9i96
SUSP ENSIO N FOX Shock Maintenance

Reassemb ly 1. Install bleeder screw in IFP until a-ring is lightly seated. 2. Lubricate IFP a-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 ern). Do not install the IFP to a depth greater than 1/4" (.6 cm) at this time.
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 1/4" (6 mm) from the top of the body. Allow time for air bubbles to rise to the surface.
Suspens ion Fluid PN 2870995
4.
Position bearing cap on damper rod against valve piston. Submerge valve piston in a clean contai ner of 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 three closely spaced slots (on nut side) at the highest point. Rock the dampe r 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

Reassem bly, Cont.
'---6. Wrap a shop towel around shock body and screw bearing cap in until hand tight - enough to seat O-ring. Invert shock and mount bearing cap flats lightly in vise. Caution: Be sure damper rod is fully extended. Pour shock fluid on top of IFP until covered to a depth of about 1/4" (6mm) . Do not remove bleeder screw at this time. Install body cap until O-ring is lightly seated .
7.
CAUT ION:
Do not over-tighten vise or bearing cap may be damaged . 8. Mount shock in vise by top eyelet as shown. Suppo rt shock and strike body cap end 2-3 times with a soft faced hammer to remove all air trapped inside the vaive piston. Allow shock to stand for 3-5 minutes.
9.
Unscrew body cap and remove bleede r 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 air to purge through the bleeder screw hole.
8 .75
9/96
SUSPENSION FOX Shock Main tenance

Reassembly, Cont. 10. Mount shock in vise by bearing cap flats. IMPORTANT: Fully extend damper rod. Set IFP tool to specified depth with a dial caliper as shown .
IFP To ol PN 287135 1
11. Place a Shoptowel overthe end of IFPtool 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. Pour out excess oil. It is not necessary to completely clean all oil from the nitrogen chamber, a small amount of oil will lubricate the IFP. Verify the proper IFP depth to within .025" (.63mm) with a dial caliper. Be sure to measure to the flat portion of the IFP. not to the tapered outer edge. 13. Reinstall body cap with a new O-ring and tighten by hand. Mount shock with body cap end down in the soft jaws of a vise. Torque bearing cap to 8-10 ft. Ibs. (1.10-1.38 kg/m). This will also tighten the body into the body cap.
CAUTION :
Do not over tighten or damage to the bearing may result.
Bearing Cap Torque 8-10 ft. Ibs . (1.10-1.38 kg-m)
9196
8.76
SUS PENSION FOX Shock Maintenan ce Reassembly, Cont.

14. Install pressurizing valve with new O-ring and tighten securely.
15. Set the nitrogen tank pressure regulator to 200 205 PSI.
16. Insert the Fox'" 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 full extension. Shaft movement must be smooth and consistent throughout the entire compression and rebound stroke, without binding or loss of damping .
8.77
9/97
SUSPENSIO N FOX Shock Maintenance

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. 19. Whe n reinstalling shocks on the mach ine, torque only to required specifications. If the shock is ove r tightened it will not pivot, possibly resulting in damage to shaft and seals. 20. When installing IFS shocks. tighten top mount first. Pivot shock body into lower mount and dete rmine 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.
Shack Eyelet Replacement
Top Shock Eyelet
~
_
O [Y
r
I
I
Damper Rod Holding Tool PN 287 1352

If shock eyelet is removed for damper rod replacement, clean threads of eyelet and damper rod thoroughly with Loctite - Primer N. Apply Loctite - 262 to threads before assembly.
~.~
I I
9/97
8.78
SUSP ENSION Fox T" Remote Shock Mai ntenance

1996 Fox T " Remo te Shock
The 1996 Indy 440 XCR SP features a remote shock limiter assembly. The shock length is adjusted by a va riable 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 surface. Clean cloth or paper towels are recommended.
, -,
)
'1 - ~~
L~
II
~~
,..,.,
Disassembly
1. Clean the self-sealing quick-disconnect coupler near the remote limiter knob assembly to avoid contamination. Uncouple the connector. 2. Remove the remote limiter knob assembly and shock from the snowmobile.
1 /
/
)J. s9J,;~
r~Z /
/
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. 4. Inspect hoses for damage. Replace if necessary. 5. Position the main shock reservo ir in a vise with the air va lve facing up. Using the body cap tool cla mp lightly near the hose end, taking care not to crush the reservoir.
Body Cap Tool PN 2871071
6. Remove the Allen screw from the air valve. 7. 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, inse rting 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 Mainte nance

CAUTION:
It is possible fo r some resi dual pressu re to remain in the shock regardless of the gauge reading. Alway s completeIy remove valve fro m body ca p before furthe r disassembly of shock. 8. Push the reservoi r cap into the reservoir until the wi re retai ning ring is exposed. Lig htly tap the cap inward to break it loose if necessary. Using a sc ribe , rem ove the wi re ring. Be ca reful not to sc ratch the bore of the reservoi r since the reserv oir cap O-ring mu st sea l on this su rface. Ligh tly lubricate the reserv oir bore to ea se removal of th e reserv oi r ca p a nd O-ring. Rem ove the reservoi r cap by grabbing the ai r va lve and gentl y wo rking the ca p out of the reserv oir. T ry to kee p th e cap straight wit h the rese rvoi r, bei ng especia lly ca reful w he n passing ove r the groove. Do not remove the air valve .
9.
10. Insure that the reservoir is secu re in the vise. Remove the bleed sc rew fro m the internal floa ting piston (IFP) located inside the reservoir. Lightly lubricate the reservoir bore to ease removal of the IFP. Gently wo rk 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. 11. Drain the oil out of the reservoir into a suitable container. Suspend the reservoi r over a container. With the main shock positioned shaft up above the reservoir, stroke the sha ft 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. 12. Push a clean clo th or pap er towel into the reservoir. 13. Secu re the al umi nu m body cap in a vise with the shaft poi nting up. Position the rem ote limiter knob assembly below the level of the body ca p. Using a 1" wrench , unsc rew the shaft beari ng cap. T he bearing must loosen befo re the body cap. If the body cap loose ns first , tig hte n and try again. Disassem bly via the body cap is not recommend ed . 14. Ge ntly pull the shoc k rod a nd piston straight ou t to avo id sea l or valving damage. Be prepared to catc h the piston ring an d som e oil, using a cle an cloth or pap er towel held aro und the bo dy at the bearing cap . Set the sha ft assembly on a clea n towel.
NOTE: T he a lum inum bod y ca p an d exte rna l threaded by-pass sleeve do not need to be removed for general shock service or revalving. If the y are bei ng removed for replacement, do so now. NOTE: Do not attempt to drain the oil out of the re mote limiter knob assembly. T his oil does not need to be replaced. 15. Clean the shock and reservoir internal surfaces by w iping with clean towels and flus hing the surfaces with clea n shock oil. Put 1" to 2" of sho ck oil in the reservoi r and flush a ll surfaces. Pour into the shock body and flush a ll surtaces. Repeat. Disca rd oil into a suitab le co ntai ner.
CAUTION: I
Do not clea n the internal port ion s of the shoc k body, reservoir, hose s, or adjuste r assemb ly wi th solve nts . It is difficu lt to e nsure that residu al so lvent is flushed from the hoses with out complete disassem bly. 16. Clean the shaft asse mbly (bea ring cap, sepa rato r piston, and valving) in a suitable so lvent. Dry thoroughly. Inspec t the damping piston and va lving for damage and contamination. Inspect the shaft sea ls and shaft bearing (sleeve) fo r damage o r wear. If con dition is in dou bt, replace O-ring seals on bearing ca p and separato r pisto n. Revalve at this time if appl icab le. 17. Reassemb le shaft a sse mbly with valving. Do not ove r torque the damping piston nut.
Damping Piston Nut Torque 15 ft. Ib s. (2.07 kg -m)
9/96
8 .80
SUSPENSION FOX Remote Shock Maintenance 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 beiow the level of the alum inum body cap, insure that the reservoir cap at the hose end is in position aga inst the wire retain ing ring. After remo ving 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 botto ms out. This will purge the air from the reservo ir and hose. Make sure the shoc k does not overfill with oil.
2.
'--
3. Letting the reservoir hang freely, fill the shock body to about 1.5" from the end. Prepare the fully asse mbled shaft bearing cap assembl y by sliding the bearing cap and separato r piston agains t the eyelet. Using a new piston ring on the damp ing piston, slowly and carefully slip the da mping piston into the shock. Be careful not to drag the piston ring ove r the threads and contaminate the oil. 4. 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 va lves open enough to fill the piston cav ities 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. 5. Add enough oil to keep the piston submerged when the top out plate is even with the internal thread s 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.
6. 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-rin g seal on the separator piston. Use a towel to catc h overflowing oil. 7. 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.
Bearing Cap Torqu e 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 diHicult to keep the IFP from rotating while tightening the sealing Allen screw.
Shock IFP Depth 4.57" (11.6 em) f rom end of res ervoir
9. Using a clean reservo ir 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 press urize the shock to 200 PSI. 10. Test the shock for smooth and consistent damping. Inspect for leaks.
8.81
9/9 6
SUSPENSION FOX Rem ot e Shoc k Maintenance

Recharging the Remote Limiter Knob A s s embly 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
Bod y 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. 4. Secure the remote limite r 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. 5. 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. 6. 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 subrnerqed in oil. The oil under the IFP should be free of air bubbles.
Rem ove Limit er Knob Assembly IFP Depth - .625" from end of reservoir
7. Install the Allen screw and O-ring into the IFP. Check the IFP depth. 8. 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' to the threads prior to assembly. 9. Test the adjuster system by tightening the knob and reducing the extended length of the shock. 1O. Inspect for leaks.
9/96
8 .82
SUSPENS ION Typical Shock Valving Arrangement

Shown below is an exam ple of how valving stac ks are arranged. The tables on page 8.84 contain produc tion valvi ng specificati ons and piston orifice sizes for 1996-current FOX '" shocks. Optional valving (by shock part numbe r) is listed in the tables on following pag es. Refer to
Parts in box are an example of standa rd valving. " Note direction of valve pisto n before disasse mb ly. The side with the greater number of slots should face the IFP (nut end of the shaft).
Standard Valving
Compression Stack
~>
~
Typical Valve Stack

Shaft End
r
I I I
I
- ~--- ~ - - I
.800 x .01O .90 0 x .Ol0 1.00x .Ol 0
I ,
l
:
I
1
I
I I I
I
I I I
Toward Shaft (Fewer slots)
I
1.100 X .010 :
Piston" Orifice
1.300 x .010
i
1 :
I
I I
~ 1.300x .012
Orifice must be drilled to required size on replacement valve pistons.
I
I
I
Rebound Stack 1-R :
I
I
I
1.250x .01 0
I I
I
1.10 0x .0 10
I
I I
1.000 x .010
.900 x .010 .800 x. 010 .700 x .010
: @
I I L
I
I J
I
d-..
Nut End
IFP Deeth Adjustment For Limited Travel Setun Spa cer Thickness IFP Depth Modifier .25 .029 (Subtract) .50 .058 .75 .088 1.0 .117 1.25 .146 1.50 .175 Spacer 1.75 .204 PN 2.00 .234 5431355 2.25 .263 2.50 .292 2.75 .321 3.00 .350 3.25 .380 3.50 .409 3.75 .438 4.00 .467 4.25 .496 4.50 .526 4.75 .555 5.00 .584
Changing oil on Fox' " Shocks is recomm ended annually and should be Included when performing end of season storage preparation . For competition use, shocks should be disassembled, inspected and serviced more frequently.
8 .83
9/97
SU SPENSION Shock Valving 1996 Production Valving Specifications

ShockPN
704 1385
IFS
7041386 Front Track X12 0.700X.006
7041 40 1
IFS
704 1403 704 1402 Front Track Rear Track X 10 X 10 1.250X.0 12
7041444 IFP, Rear

Track X 10
7041474
IFS.IFP.
7041480
IFP, Rear T rack X 12
7041490
IFP
Cam
Com pression Stack
6C 5C 4C 3C 2C lC
0.700X.008
1.250X.Ol 0 1.250X.Ol 0
NIA
0.700X.006
N/A
0.800X.008 0.800X.006
0.800X.00 e 0.800X.008 0.eOOx.012 o.eoox .ooe 0.eOOX.008 0.eOOX.006 o.eoox.ooe 0 ,90QX,006 0,900X ,00e 1,000X,006
0.900X,008 0,900X,006 0,900X.Ol0 0.900X,01O 0,90 0X,015 0,900X,00e 0,900X,008 1.000X,008 1.100X,00e 1,300X.00e 0 ,078 1.000X.006 l ,000X,010 l ,000X,Ol0 1.100X.Ol 0 1.000X,012 1.000X,008 l .000X.008
i.ooox.ooa
1.300X.Ol0 N/A 1.250X.Ol 0
1.100X.006 1.100x .00e 1,300X,006 0 ,078 1.250X,012 1.250X.012 1.100X.Ol0 1,300X,00e 0 ,089 1,250X,008 1.300X.012
l .100X.012 1.100X,006 l .100X,008
1.100X,006 l ,100X,008
1.30QX,012 l ,3 00X.012 1,300X,00e 0,075 0 ,072 0 ,067
1.300X,0 10 1.300X,006 0 ,078 1.250X.Ol0 0,067 1.250X.Ol 0
Orifice
Rebound Stack
lR 2R 3R 4R 5R 6R
1,250X,00e 1.100x.00e 1.000X.00e 0.900X.008
1,250X.Ol 0 1.250X.0 12 1.25QX.00e 1.100X.Ol0 1.100X.012 1.100X.008
1.100X.0 10 1.100X.Ol0 1.100X.Ol0 1.000X.Ol0 1.000X,010 0.900X.Ol0 0.900X.01O
1.300X.012 1.000X .Ol0
1.000X.0 12 1.00QX.008 1.000X.Ol0
1.000X.Ol 0 1.300X.0 12 0.900X .Ol0 0.900X.0 12 0.900X.008 0.900X.Ol0
o.eoox.ooe 0.900X.Ol0
1.300X.0 12 0.800X.01O 0.eOOX.012 0.800X.008 o.eoox.ooe o.eOOX.OlO o.eoox.ooe 0.700X,0 10 0.700X.0 12 N/A 0.700X .OOe 0.700X .Ol0 0.700X .00e
0.700X.00e o.eOOX.OlO 0.700X.008
9/96
8.84
SUSPENSION 1997/1998 Production Valving Listed By Shock Part Numb er

Sho ck P N
Compress . Sta ck
7041385 IFS 8C 7C 6C 5C 4C 3C 2C lC
N/A N/A
704149 4 IFS
N/A N/A
70 41536 IFS
N/A N/A N/A
7041 537 IFS

N/A N/A
7041 540 IFS

N/A
704 1545 IFS

N/A N/A
704 1593 IFS

N/A N/A
7041 692 IFS 1.250x .O l0 .800x.008 .900x.Ol 0 1.000x.Ol 0 1.100x.008 1.300x.Ol0 1.000x.006 1.300x.008 0 .08 1 1.250x.Ol 0 1.100x.Ol 0 1.000x.008 .900x.008 .800x.008 .700x.008
N /A
N/A
0.700 X.008 0.800X.008 0.900 X.008 1.000X.008 1.100X.OO8 1.300X.008 0.078 1.250X.008 1.100X.008 1.000X.008 0.900X .008 0.800 X.008 0.700X .008 70 4169 7 IFS
1.250x.Ol0 .800x.Ol 0 .900x.Ol 0 1.000x .Ol 0 1.00x.Ol0 1.300x.Ol 0 0.081 1.25 0x.Ol 0 1.100x.008 1.0 00x .008 .900x.008 .800x.008 .700x.008
.700 x.008 .800 x.008 .900x .008 1.000x.008 1.100x.008 1.300x.008 0.078 1.250x.008 1.100x.008 1.000x.008 .900x .008 .800x.008 .700x.008
N /A
.800x.008 .900x.008 1.000x.008 1.100x.008 1.300x.O l0 0 .078 1.250x.Ol 0 1.100x.Ol 0 1.000x .Ol 0 .900x.Ol 0 .800x.008 .700x.008
1.250x.Ol0 .800x.Ol0 .900x.Ol 0 1.000x.Ol0 1.100x.Ol0 1.300x.010 0.08 1 1.250x.Ol0 1.100x.008 1.000x.008 .900x.008 .800 x.008 .700x.008
.800x.008 .900x.008 1.0 0x .008 1.100x.008 1.300x.Ol 0 0.078 1.250x.Ol 0 1.1 00x.Ol 0 1.000x.Ol0 .900x.Ol 0 .800x.008 .700x.008
.800x .008 .900x.008 1.000x.Ol 0 1.100x.008 1.300x.Ol 0 0.078 1.250x.01 5 1.100x .012 1.000x.Ol 0 .900x.008 .800x.008
Orifice Rebound Stack
lR 2R 3R 4R 5R 6R
N /A
Shock PN
Compress. Stack
7041584 7041589 704 164 1 7041642 704 1706 70 4 1507 Front Track Front Track Front Track Front Track FrontTrack FrontTrack
N/A N/A
8C 7C 6C 5C 4C 3C 2C lC
1.2 50x.Ol 0 800x.008 .900x .Ol0 1.000x.008 1.100x.008 1.300x.008 1.000x.006 1.300x.008 0 .086 1.250x.Ol 0 1.100x.008 1.000x .008 .900x.008 .800x .008 .700x.008
NIA
1.250x.Ol0 .900x.Ol 0 1.000x.012 1.1 00x.01 2 1.300x.012 .900x.006 1.300x.008 0.075 1.2 50x.Ol 0 1.100x.Ol0
1.0 00x.Ol 0
NIA
.7 00x.Ol 0 .800x .Ol0 .900x.Ol 0 1.000x.01O 1.1OOx.O l 0 1.250x.012 1.300x.0 12 0.D75 1.250x.Ol0 1.100x .Ol0 1.000x.012 .900x.Ol 0 .800x.Ol 0
.700x.Ol 0
NIA
N/A
/A N
.700x.Ol 0 .800x.Ol0 .900x.0 1O
1.0 00 x.Ol 0
1.250x .Ol0 .800 x.Ol0 .900x.012 1.000x .0 12

1.10ax.Ol0
1.250x.Ol 0 .800x.008 .900x.0 12 1.000x.01 2 1.100x.01 2 1.300x.0 12 0.075 1.250x.010 1.100x.Ol 0 1.000x.Ol 0 .900x.Ol 0 .800x.Ol 0 .700x.Ol 0 70 4 1492
1.250x.O l0 .800x.008 .900x.0 12 1.000x.01 2 1.100x.01 2 1.300 x.0 12 0.075 1.250x.Ol 0 1.100x.Ol 0 1.000x .Ol 0 .900x.Ol 0 .800x.Ol 0
.700x.Ol0
1.1 00x .Ol0 1.250x.012

1.3 00 x.0 12
1.300x.012 1.000x.006 1.300x .Ol0 0.075 1.250x.Ol0 1.100x.Ol 0

1.000 x.OlO
Orifice Reboun d
1R 2R 3R 4R 5R 6R
0.D75 1.250x .O l0 1.100x.Ol 0

1.0aOx.0 12
Stac k
.900x.Ol0 .800x .O l0
.70 0x.QlO
.900x.Ol 0 .800x.Ol 0 .70 0x.Ol 0
.900x.Ol 0 .800x.Ol 0 .700x.Ol 0 704 1695 704 1707 Rear Track 1.250x Ol 0 .900 x.Ol 0 1.000x .012 1.100x.01 5 1.250x.Ol0 1.300x.01 2 1.000x.006 1.300x .0 12 .072 1.250x.Ol 0 1 250x .Ol0 1.100x .012 1.000x .012 .900x.012 .800 x.012 .700x.012
Shock PN Compress. Stack
7041480 Rear Track 8C 7C 6C 5C 4C 3C 2C lC

N/A N/A
704 158 5
Rear Track
Rear Track
7041 588 Rear Track

N/A
7041595
Rea r Track
7041599 Rear Track 1.250x.Ol0 .900x.Ol 0 1.000x.01 2 1.100x.0 15 1.250x .Ol0 1.300x .0 15 1.000x.006 1.300x.01 2 0.072 1.250x .Ol0 1.100x.012 1.000x.0 12 .900 x.0 12 .800x.0 12 .700x.0 12
Rear Track
1.250x.Ol 0 .900x.Ol 0 1.000x.0 12 1.100x.01 5 1.250x.Ol 0 1.300x.0 15 1.00 0x.006 1.300x.0 12 0.072 1.250x.Ol 0 1.100x.0 12 1.000x .012 .900x.0 12 .800x.012
.700x.0 12
N/A
1.250x.Ol 0 .900x.Ol 0 1.000x.Ol 0 1.100x.01 5 1.300x.01 5 1.000x.006 1.300x.Ol 0 0 .086 1.2 50x .012 1.100x.012 1.00 0x .0 12 .900x0 12 .800x.0 12 .700x.012
N /A
1.250x .Ol0 .900x.Ol 0 1.000x.01 2 1.100x.01 5 1.300x.01 5 .900x.012 1.300x .0 12 0.086 1.250x.01 2 1.100 x.012 1.100x.01 2 1.000x.0 12 .900x.012 .800x.012 .700x.012
1.250x.Ol0 .900x.012 1.000x .008 1.000x .012 1.100x .015 1.300x.01 5 .900 x.012 1.300x.0 12 .086 1.250x.0 12
1.100x .0 12
.700x.008 .800x.008 .900x.O l 0 1.000x .008 1.100x.008 1.250x.008 1.300x.008 0.078

1.250x.0 12
1.10 0x.0 12
0.700X .006 0.800X.006 0.900X.006 1.000X.006 1.100X.006 1.300X.006 0.067 1.250X.Ol0 1.100X.Ol0 1 000X. Ol0 0 .900X.Ol 0 0.80 0X.Ol0 0.700X.O l0
Orifice Rebound Stack
lR 2R 3R 4R 5R 6R 7R
1.00 0x.012 .900x.012 .800 x.012 .700X .012
11 00x .012 1.000x .01 2

.900 x.Q12
.800x.012 .700x.012
N /A
NIA
NIA
N/A
NIA
8.85
9/97
SUSPENSION Optional Shock Valving (By Shock Part Number)
1996/1997 Optional Valving Specifications - Light

Sheck PN
704 1385 IFS N/A N/A 7041386
Front Track
X12 N/A N/A N/A
7041401 IFS N/A N/A 1,250x.008 .800x.008 .900x.008 1.000x.008
704 1402
704 1403
Front Track
X 10
RearTrack
X l0 NlA
7041444 IFP, Rear Track X 10
7041474 IFS ,IFP, Cam @)
7041480 IFP, Rear Track X 12
704 1490 IFP
Compres-
8C 7C 6C 5C 4C 3C 2C lC
N/A N/A N/A
N/A
N/A
sion
Sta c k
N/A
1.250x,0 1O .800x .012 .900x .015 1.0oox .012 1.100 x.Ol0 1.300x .Ol0 1.300X .006 0.067 1.300X .008 0.078 .081 1.250X .O OB 1.100X.O OB
N/A
0.800X .006 0.900X.006 1.000X .006
N/A
N/A
Nl A .800x.008 .900x .OOB 1.000x.008
1.100 x.008 1.300x .008 .089 1.250x.008 .075
1.100x .008 1.300x.008 .08 1 1.250x .01O 1.100x .Ol0 1.000x.Ol0
Ori fice Rabound Sta c k lR 2R 3R 4R 5R 6R
0.078 1.250X.006 1.100X.OO6
0.081 1.250X.010 1.100X.010
.072 1.250 x.012 1.100x.012
t . 100x.008
1.000x.008 .9OOx.008 .800x.008 JOOx.008
1.0oox .012 .900x.0 12 .800x.012 .700x .012
.900x.Ol 0
.800x.Ol 0 .700x.010
N/A
Use existing washer here (no change)
NIA = Not Applicable
OJ Spring In Third Groove

@]
Install Springs PN 7041252 - 8.5" Installed Length
1996/1997 Optional Valving Spec ifications Extra Light

Shock PN 704 1385 IFS Nl A N/A N/A 0.800X.006 0.900X.OO6 1.OO0X.006 1.100X.006 1.300X.006 0.078 1.250X.006 1.100X.006 1.OO0X.006 0.900X.OO6 0.800X.006 704 1386
Front Track
X 12 N/A N/A N/A
704 1401 IFS N/A N/A 1.250x .008 .800x.008 .900x.008 1.000x.008
704 1402
704 1403
Front Track
X 10 N/A NIA 1.250X.01O 0.800X.008 0.800X.008 1.000X.008 1.100X.008 1.250X.008 0.Q75
RearTrack
X 10
704 1444 IFP, Rear Track X 10 N/A N/A N/A
704 1474 IFS,IFP, Cam N/A N/A
7041480
IFP, Rear
Track X 12 NIA NIA N/A
7041490 IFP N/A N/A N/A .800x.008
Compres-
8C 7C 6C 5C 4C 3C 2C lC
N/A
NlA 1.250x.010 .800x.010 .9 00x.012 1.000x.Ol 0 1.100x.008 1.300x .008 .081 1.250x.Ol 0 1.100x .Ol0 1.000x .012 .900x.0 12 .800x .0 12 J OOx.012
slon
Stac k

0.089 1.250X.008 1.100X.008 1.000X.008 0.900x.008 0.800x.008
1.000X.OOB 1.100X.OO6 1.300X.006 0.067
1.000X .006 1.100X.OO6 1.3OOX.OO6 0.078
.900x.O OB
1.0oox .00B 1.100x.008 1.300x.008
1.100x.006 1.300x .008 .093 1.250x.008 1.100x .008 1.000x .008 OB .900x.O .800x.008 JO Ox.008
Orif ice Re bound Stack lR 2R 3R 4R 5R 6R
.089 1.250X .006
.086 1.250x.01O 1.100x.Ol0 1.000x .008 .900x.008 .800x.008 .700x.008
1.100X .006 1.000X.OO6
NIA
OJ OOX.006
N/A = Not Applicable
9/97
8.86
SUSPENSION Optional Shock Valving (By Shock Part Number)
1996/1997 Optional Valving Specifications - Heavy

Sho c k PN 7041385 IFS 7041386 FrontTrack X 12 704 1401 IFS 7041402 FrontTrack X 10 1.250x.Ol 0 .900x.Ol 0 1.000x.012 1.100x.012 1.300x.0 12 .900x.006 1.300x.008 .075
No change No change No change
No change No change No change
7041403 704 1444 Rear Track IFP Rear X 10 Track X 10
704 1474 IFS . IFP. Ca m
7041480 IFP. Re a r
Track X 12
704 1490 IFPi2J
cernpres-
7C 6C 5C 4C 3C 2C lC
sian
N /A N/A
S ta c k
N/A N/A N/A

1.0OOX.008 1.100X.008 1.300X.008 0.Q78
N/A
1.250x.Ol0 .800x.Ol 0 .900x.0 12
N/A
1.250x.Q12 .800x.Q12 .900x.015 1.000x.015 1.100x.012 1.300x.012 .072 1.250x.0 12 1.100x.012 1.000x .012 .900x.012 .800x.012 .700x .012
1.25 0x.Ol0 .900x.Ol 0 1.000x.Ol0 1.100x.015 1.300x.015 1.000x.006 1.300x.O l 0 .072 1.250 x.Ol 0 1.100x012 1.000x.012 .900x.012 .8 00x.0 12 .700x.0 12
N/A
1.25x.Ol0 .800x .Ol0 .900x.Ol 0 1.000x.Ol0 1.100x.008 1.300x.008 .078 I .250x.Ol0 1.100x.008 1.000x.008 .900x .008 .800x.008 .700x.008
N/A N/A
.800X.008 .900X.008 1.000X.008 1.100X.012 1.300X.012 .067
N/A N/A
.800x.O oa .900x.Ol 0 1.00x.Ol0 1.100x.008 1.300 x.Ol0 .078 1.250x.Ol0 1.100x.Ol0
1. 100X.Ol0 1.300X.Ol0 0.078
1.00x.01O 1.100x.008 1.300 x.008 .08 1 1.250x.008 1.100x.008
Orifice Re
bound
lR 2R 3R 4R 5R 6R
1.100X.Ol0
Stack
. .
1.100X.012 1.000X.012
r.ooocooa
.900x.008 .800x.008 .700x.Ooa
.
1.000X.012 .900X.012 .800X.0 12
1.000x .01O .900x.Ol 0 .800x.008 .700x.008
0.900X.012 0.8ooX.012
N/A = Not Applicable
1996/1997 Optional Valving Specifications - Extra Heavy

S ho c k PN 7041385 IFS 704 1386 Front Track X12 704 1401 IFS 704 1444 7041 402 7041403 Front Track Rear Track IFP. Rear X 10 X 10 Track X 10 704 1474 IFS.IFP, Cam 7041480 IFP, Rea r Track X 12 704 1490 IFP
Com-
8C 7C 6C 5C 4C 3C 2C lC
presslon
Sta c k
N/A N/A N/A

0.800X.Ol 0 0.900X.O l 0
NlA N/A N/A

0.800X.01O 0.900X.010
N /A N/A
1.250x.Ol0 .800x.010 .900x.012 1.000x.0 12 1.100x.Ol0 1.300x.Ol0 .08 1 1.250x.010 1.100x.008 1.000x.008 .900x.008 .800x.008 .700x.008
N/A N/A
1.250X.Ol0 0.800X.008 0.900X.012 1.000X.012 1.100X.012 1.300X.012 0.075
N/A N/A
1.250x.012 .800x.012 .900x.015 1.000x.015 1.100x.012 1.300x .012 .067
1.250x.Ol0 .900x.010 1.000X.012 1.100X.015 1.250X.Ol0 1.300X.015 l. OO0X.006 1.300X.012 0.06 7 1.250X.Ol0 1.100X.012 1.000X.012 0.900X.012
N/A N/A
1.250X.Ol0 0.800X.01O 0.900X.Ol0
N/A N/A N/A

.800X.008 .900X.008
N/A N/A
1.250x.Ol0 .800x.01O .900X.Ol 0 1.000x.01O 1.100x.Ol0 1.300x.Ol0 .072 1.250x.0 12 1.100 x.012 1.000x.Ol0 .900x.Ol 0 .800x.Ol 0 .700x.Ol 0
l.OO0X.01O 1.000X.O l 0 1.100X.Ol0 1.300X.Ol0 0.078 1.1ooX.Ol0 1.3ooX.Ol0 0.067
1.000X.01O 1.000X.ooa 1.1OOX.010 1.3OOX.010 0.078 1.250X.010 1.100X.ooa 1.000X.008 0.900X.008 1.100X.012 1.300X.012 .067 1.250X.012 1.250X.012 1.100X.012
O rifice
Rebou nd
lR 2R 3R 4R 5R 6R
1.250X.01O 1.250X.015 1.100X.Ol0 1.250X.015 1.100X.012 1.000X.012 0.900X.012
1.250X.01O 1.250x .012 1.100X.Ol0 1.000X.O l0 0.900X.01O 0.800X.01O 0.700X.01O 1.100x.0 12 1.000x.015 .900x.012 .80 0x.012 .700x.012
Sta c k
0.800X.012 0.800X.008 0.700X.012 0.700X.008
0.800X.01O
Use existing wa sher here (no change)
NIA = Not Applicab le
8.87
9197
SUSPENSION 1997/ 1998 Optional Valving Listed By Shock Part Number

LIGHT
Shoc k P N 704 1S93 1FS X-10 CRC SC 7C SC 5C 4C 3C 2C lC Orific e 704170S Front Track 1.2SX.OW" 0.a x.Ol0
0.9X .OW
HEAVY
7041707 Rear Track 1.2SX.Ol0" 0.9x.00a 1.0X.OW 1. lX .OW 1.25X.00a 1.3X.Ol0 1.0X.00S " 1.3X.00a 0.075 1.2SX.Ol0 " 1.1X.OlO 1.0X.012 " 0.9X.0 12" 0.ax.012" 0 .7X.0 12" 7041S931 FS X-WCRC 704170S Front Track 1.25 x.Ol0" 0.aX.012 0.9X.0 12 " 1.0X.0 15
l.l X.015
7041707 RearTrack
Compression Stack
N /A N /A N /A
N A
N /A
1.25X.OW" 0.9X.012 1.0X.012 " l.l X.01 S" 1.3X.01S" 1.0 X.00S" I .3X.012" 0.075
1.2SX.OW "
o.sx.oio
0.9X.010 1.0X.Ol0 1.1 X.01 2 1.3X.012 1.0X.OOO 1.3X.Ol0" 0.07B I.2SX.Ol0 " 1.lX.012 1.0X.Ol 2 0.9X.Ol0 0.aX.Ol0 0.7X.Ol0
o.sx.ooa
0.9X.OOa 1.0X.OOO 1. l X.OOa 1.3X.00S 0.07a
1.0X.OlO 1. lX .00a 1.3X.Ol0 1.0X.OOO 1.3X.00a
1.3X.012 " 1.0X.00S 1.3X.Ol0 0.075 1.2SX.012

l.lX.012
o.oai
1.2SX.Ol0"
Rebound Stack
1.2SX.Ol0" l.lX.Ol0 1.0X.00B" 0.9X.00B" O.BX.OOB" 0.7X.00a"
i.ix.oro1.0X.Ol0" 0.9X .Ol0"
1.25X .012 l.l X.0 12" 1.0X.012 " 0.9X.012" 0.ax.012" 0.7 X.012"
1.0X.Ol 2 0.9X.Ol0" 0.aX.Ol0" 0.7X.Ol0"
o.sx.oro0 .7X.Ol 0"
N /A
N /A
N /A
N/A
N /A
" Use production washer here (no change) LIGHT

S ho c k P N 704 1692 IFS BC 7C 6C SC 4C 3C 2C lC Orifice 1.25X.00a .a X.OOB" .9X.00 B 1.0X.00B l.lX .OOB" 1.3X.Ol0" 1.0X.OOB 1.3X.00B O.OBl lR 2R 3R 4R 5R 6R 7R 1.25X.Ol0" 1.1X.0 0B 1.0X.00B" 0.9X.00B" O.BX.OOB" O.7X.OOB" 704 1641 Fronl Track 1.25X.Ol0" 0 .aX.Ol0" 0.9X.Ol0 1.0X.OW 1.1X.00B 1.3X.Ol0 1.0X.OOO" 1.3X.00B O.OBl 1.25X.Ol0" 1.1X.Ol0" 1.0X.OW" 0 .9X.Ol0" 0.BX.Ol0" 0.7X.Ol0" 7041599 Rear Track 1.2SX.Ol 0" .9X.00B 1.0X.Ol 0 I .1X.Ol0 1.25X.00B 1.3X.Ol 0 1.0X.006" 1.3X.00B 0.075 1.25X.Ol0" 1.1X.Ol0 1.0X.012 " 0.9X.012 " 0 .BX.012" 0.7X.012" 70 41692 IFS 1.25X .Ol0" 0 .aX.Ol0" 0.9X.012 1.0X.Ol0" 1.1X.Ol0" 1.3X.012 1.0X.OOO" 1.3X.010" O.OBl 1.25X.Ol0 " 1.IX.Ol0 " l .OX.OOB" 0 .9X.00B" O.BX.OOB" 0.7X.OOB"
HEAVY
704 164 1 Front Track 1.25X.Ol 0" 0.BX.012 0.9X .012" 1.0X.015 l.lX .0 1S 1.3X.012" 1.0X.006" 1.3X.Ol0" 0.075 1.25X.0 12 1.1X.0 12 1.0X.Ol2 0.9X.Ol0" 7041599 RearTrack 1.2SX.Ol 0" 0.9X.012 1.0X.012" 1.lX.01S " 1.25X .012 1.3X.0 15 1.0X.006" 1.3 X.012" 0.075 1.2SX.Ol0" 1.2SX.0 12
l.l X.012"
Compression S tack
Rebound Stack
1.0X.012 " 0.9X.012 " 0.BX.012" 0.7X.012"
o.ex.oio0.7X.OIO"
NlA
N /A
N /A
N /A
N/A
Use production washer here (no change)
9/97
8.87a
SUSPENSION 1997/1998 Optiona l Valving Listed By Shock Part Number
LIGHT
Shock PN Comp o Stack
HEAVY
7041695 Rear Track 70415 40
IFS
7041540
IFS
7041595 Rear Track
704 1642 Front Track
7041595 Rear Track
7041695 Rear Track
ac 7C 6C 5C 4C 3C 2C lC
N/A
NIA
N/A
1.25X.Ol 0 0.9X.00a 1.0X.008 1.1X.Ol0 1.3X.012 0.9X.012 ' 1.3X.01O 0.086 1.25X.012' 1.lX .Ol0 1.0X.Ol0 0.9X.Ol 0 0.8X.Ol0 0.7X.Ol0
NIA
N/A
1.25X.Ol0 0.9X.00a 1.0X.008 1.1X.Ol0 1.3X.012 0.9X.012 1.3X.Ol0 0.086 1.25X.012 1.1X.Ol0 1.0X.Ol0 0.9X.Ol0 0.8X.O l0 0.7X.Ol 0
N/A
NIA
NIA
1.25X.Ol 0 0.9X.012 1.0X.Ol0 1.10X.015 1.3X.015 0.9X.008 1.3X.012' 0.086 1.25X.012 ' 1.10X.012' 1.0X.012 ' 0.9X.012' 0.8X.012 0.7X.012'
N/A
0.7X.0W" 0.aX.012 0.9X.012 1.0X.012 1.1X.015 1.25X.012 1.3X.012' 0.075 1.25X.01O' 1.1X.Ol 0' 1.0X.012' 0.9X.O l 0 O.aX.O lO' 0.7X.Ol0 '
N/A
1.25X.Ol0 0.9X.012 1.0X.O l0 1.10X.015 1.3X.015 ' 0.9X.00a 1.3X.012 0.086 1.25X.012 1.10X.012 1.0X.012' 0.9X.012 0.8X.012 0.7X.012
o.zx.ooe
o.ex.oos
0.9X.008 1.0X.008 1.lX .Ol0 1.25X.Ol0 1.3X.008 0.075 1.25X.Ol0' 1.lX .Ol0 ' 1.0X.012 0.9X.Ol0 ' 0.8X.Ol0' 0.7X.Ol0
N/A
0.8X.00a 0.9X.008 1.0X.008 1.1X.006' 1.3X.008' 0.078
N/A
0.8X.Ol0 0.9X.Ol0' 1.0X.012' 1.1X.012 ' 1.3X.012' 0.078 1.25X.015 1.1X.012 1.0X.012 0.9X.Ol0 0.8X.008 0.7X.00a
Orifice
Reb .
Stack
1.25X.012 1.1X.012 1.0X.012 0.9X.Ol0 0.8X.00a 0.7X.008
N/A
N/A
N/A
NIA
N/A
N/A
N/A
NIA
, Use produc tion wash er here (no cha nge)
LIGH T
Shoc k PN
HEAVY
704 1585 RearTrack 7041589 Front Track 7041584 Front Track 7041585 Rear Track
70415a9 Front Track 8C 7C 6C 5C 4C 3C 2C lC
Compression Stack
N/A
0.7X.008 0.a X.008 0.9X.008 1.0X.008 1.1X.01O' 1.25X.Ol0 1.3X.008 0.D75
NIA
1.25x.010' .9x.01O 1.0X.010 1.1X.Ol0 1.3X.Ol0 .9X.008 1.3X.008 0.075 1.25X.OIO' 1.IX.008 1.O X.Ol 0' 0.9X.Ol0' 0.8X.Ol0' 0.7X.O l0'
NIA
1.25X.Ol0' 0.9X.O l 0' I .OX .O l 0' 1.1X.012 1.3X.Ol 0 0.9X.006 1.3X.00a 0.086 1.25X.012 1.1X.Ol0 1.0X.OlO 0.9X.Ol0 0.8X.Ol0 0.7 X.Ol0
NIA
0.7X.Ol0' 0.8X.012 0.9X.012 1.0X.012 1.1X.015 1.25X.012 ' 1.3X.012 0.075 1.25X.0 1O' 1.1X.Ol0' 1.0X.012 0.9X.Ol0 0.8X.Ol0' 0.7X.O l0
N/A
1.25x.Ol0 .9x.012 1.0X.012' 1.1X.015 1.3X.012 ' .9X.006' 1.3X.O l0 0.075 1.25X.012 1.1X.Ol0' 1.0X.Ol 0' 0.9X.Ol0' 0.8X.Ol0' 0.7X.OlO'
N/A
1.25X.Ol0 0.9X.012 1.0X.Ol0' 1.1X.015' 1.3X.015' 1.0X.006' 1.3X.012 0.086 1.25X.012' 1.1X.012 1.0X.012' 0.9X.012 0.8X.012' 0.7X.012'
Orifice
Rebound Stack
1.25X.Ol 0' 1.1X.Ol0' 1.0X.012 ' 0.9X.Ol 0 0.8X.Ol0' 0.7X.Ol0
NIA
N/A
NIA
N/A
N/A
N/A
Use produ ction washer here (no change)

a.a7b
9197
SUSPENSION Fox IFP Depth 1992-1995 an d Kit Shocks

Th e followi ng chart li sts all ?re-1996 Fox' " Shock IFP depths by model and part number for quick reference. Measure
as shown in the illustration using IFP depth/rem oval tool PN 287 135 1 or vernier caliper.
Ty pi cal Shock Show n
c-
For welded dome IF? shocks measure C-D using a di al cali per 10 center of IFP.
For body sl yl c IFP measure from point A-B using IF? depth tool PN 2R7135 1 IFS Shocks Mod el 1992 440 XCR 1993/1994440 XCR; 1993/1994 XLT SP 1994440 XCR SP & 600 XCR 1994 XLT SP 1995 440 XCR & 600 XCR 1995 RXL & XLT SP 1995 440 XCR SP. Model 1992 XCR 1993440 XCR & XLT SP 1994440 XCR 1994440 XCR SP & 600 XCR 1994 XLT SP 1995 440 XCR & 600 XCR 1995 440 XCR SP 1995 XLT SP & RXL Model 1992440 XCR and 1993 XLT SP 1993 440 XCR 1994 440 XCR, XLT SP 1994 440 XCR SP & 600 XCR 1995 440 XCR & 600 XCR 1995 440 XCR SP 1995 XLT SP & RXL Part Number 7041266 LH 704129 1 RH 7041292 7041346 IFP Dept h 2" oil (no IFP) .728" (18.5 mm) .728" (18.5 mm) A-B 704 1385 704 140 1 Front Trac k Shocks Part Num ber 7041254 7041294 704 1344 1.142"(29.0 mm) 1.139"(28 .9 mm) fFP Depth 4.150" (105.40 mm) 4.150" (105.40 mm) 4.150" (105.4 0 mm) A-B A B
Measurement Point
Oil level from top of shock body (C) A-B
C-D C- D C-D
7041402 7041386 Rear T rack Shocks Part Num be r (sis 1 0 7041267

2870979 )
.586"(1 4.9 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 Dep th 1.000" (25.4mm) 1.139"(28.9mm) 1.142"(29.0mm ) 1.I 42"(2.89cm) .633"(16.0mm) .835"(2 1.2mm) 4.I 50" (105.40 mm) .835" (21.2mm)
A B A B A-B A-B A-B A-B A-B A-B A-B

Measureme nt Point
704 1295 704 1347 704 1345 7041403 704 1387
Kit Shocks Kit Part Number / Model Shoc k Part Number 38 - 41" Widening Kil 70416 12 2871711 XTRA-I0 -I FS Shocks 7041401 2871401 7041385 2871396 XTRA-I 2 " IFS Shocks. XTRA-12 121 / 133.5 Track Shocks 7041386-(Fr Track) 2871399 7041480-(RrTrack ) ITS: XC100; XCI01 Rear Track Shock 7041293 287 1077 2870978 ITS; XCl00; XCI0l Front Track Shock 704 1294 1988-1991 Dial Adjust Rear Shock 2870979 7041347
A-B A B A-B A-B A-B A B C-D A-B
9/9 7
8 .88
SUSPENSION Fox Shock Parts

Refer to the appropriate parts manu al fo r a complete listing of Fox shock pa rts. Fox . Registered Trademark of FOX Shox. Val v e Washer Part Numbers
Part NQ. Description Part No. Descriptjon
1500052 1500050 1500049 1500048 1500053 1500054 1500055 1500030 1500051 1500031 1500032 1500033 1500028 1500029 1500062 1500026 1500027 1500045 1500046 1500047 1500044
1.300x 0.006 1.250 x 0.006 1.100 x 0.006 1.000x 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 O .008 1.1 00 x 0.008 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 1.250xO.Ol0 1.100xO.Ol0 1.000 x 0.010 0.900 x 0.010 0.800 x 0.010 0.700 x 0.010
1500079 1500078 1500060 1500059 1500058 1500057 1500056 1500087 1500086 1500085 1500084 1500083 1500082 1500081
1.300 x 0.012 1.250 x 0.012 1.100 x 0.012 1.000 x 0.012 0.900 x 0.012 0.800 x 0.012 0.700 x 0.012 1.300 x 0.015 1.250 x O 5 .01 1.100 x 0.Q1 5 1.000 xO.015 0.900 x 0.Q15 0.800 x 0.015 0.700 x 0.015
SHOCK SHAFT (POLARIS PART NUMBER)
SHAFT LENGTH (INCHES)
SHOCK PART NUMBER
1500068 1500076 150015 3 1500133 1500 140 150015 2
9. 125 6.35 5.57 6.85 7.60 7.45
704 1385 70 4 1387 704 1490 7041 402 7041584 704 1255 7041 545 7041537 7041 256 704 1295 704 1347 7041492 704 1588 704 159 9 704 1593 7041 612 70 41536
704 1386 704 1480 7041 493 704 1589 704 1403
704 1267 7041 293 704 1444 704 1585 7041595 7 041 540 704 1494
1500136
7.73
Shock Travel Li miting Spacer (1/4') - Part Number 543 1355 Note: Subtract .029" from IFP depth for each 1/4 inc h spacer added to the shock dam per rod for limiting . For example : If standard (full shock travel) IFP depth is .835" , and 6 space rs are added to reduce shock travel by 1.5 inches. mu ltiply .029 x 6 to ca lculate the amount to sub tract from IFP dep th. 835 - .174 = .661 ( .025') New IFP Depth
8.89
9/9 7
SUSPENSION Suspension Troubleshooting - WideTrak Style

Problem Sol ution
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) -Install overload kit PN 287 1042 for extreme use -Check for binding suspension shafts and grease all pivot points -Decrease torsion spring preload adjustments -Decrease rear shock co mpression 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 compo nents are free turning -Make sure skags are straight on skis -Check hi-fax and replace if worn -Reduce ski pressure: elncrease front track spring preload eReduce IFS spring preload if shims have been added eRed uce 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 -Chack skags and skis for damage -Reduce ski pressure: el ncrease front track spring preload eReduce IFS spring preload if shims have been added eRed uce rear torsion spring preload -Change worn hi-fax -Lower front and rear torque arms (see Periormance 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
SUSPENS ION Suspension Troubleshooting - Sport Style

Problem Rear suspension bottoms too easily Solution -Increase torsion spring preload -Increase rear shock compres sion valving by turning screw clockw ise (if equipped with optional Indy Select / Ryde AFX shock) -Check for binding suspe nsion 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) -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-tax 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 fo r binding suspension shafts and grease all pivot points -Increase IFS sp ring preioad 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 Rear suspension bottoms too easily Rides too stiff in rear Solutio n -Increase torsion spring preload -Install optional torsion springs -Check for binding suspension shafts and grease all pivot points -Decrease torsion spring pre load adjustments -Make sure skis are aligned proper ly (1/8-1/4" toe out at ride height) -Make sure spindles and all steeri ng components are free turning -Make sure skags are straight on skis -Check hi-fax and replace if worn -Reduce ski pressure: el ncrease front track spring preload (requires shims) eReduce IFS spring preload eReduce rear torsion spring preload eLengthen front limiter strap -Check for worn skags -Check for binding suspension shafts and grease all pivot points -Increase IFS spring preload by addin g washer s -Shorten front limiter strap -Check ski alignment -Check skags and skis for damage -Reduce ski pressure: el ncrease front track spring preload eReduce IFS spring preload eReduce rear torsion spring preload -Change worn hi-fax -Increase front limiter strap length -Increase front track spring preload by adding washers
Front end pushes
Steering is heavy
9/9 7
8.92
SUSPENSION Suspens ion Troubleshooting - XTRA 10 Style

Problem Rear suspension bottoms too easily Solution -Increase torsion spring preload -Increase rear shock compression valving by turning screw clockw ise (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 optiona l 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 Suspens ion Wallchart for Fox equipped models -Set RRSS to lowest position or totally remove -Install optional torsion springs (softer) -Make sure skis are aligned properly (1/8-1/4" toe out at ride height) -Make sure spindles and all steering components are free turnin g -Make sure 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 by adjusting 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 alignmen t -Check skags and skis for damage -Reduce ski pressure: -I ncrease front track spring preload -Reduce IFS spring preload by adjusting cam -Reduce rear torsion spring preload -Change worn hi-fax -Lower rear torque arms -Increase front limiter strap length -Based on rider 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
9197
SUSPEN SION Suspension Troubleshooting - XTRA 12 Style

Problem Rear suspension bottoms 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 model s equipped with Indy Select or Ryde AFX shocks -Check nitrogen pressur e in shoc ks (models equipped with Fox' " shocks) -Change shock valving to heavier setting (models equtpped with Fox ,,' shocks) -Check for binding suspe nsion shafts and grease all pivot points -Decrease spring preload adjustments -Remove rear track shock spring or reduce rate of spring (reter to wallchart) -Change front track shock to lighter spring -Change to lighter shock valving on mode ls equipped with Fox' " or Indy Select / Ryde AFX shoc ks (refer to wallchart) -Make sure skis are aligned properly (1/8-1/4" toe out at normal ride height) -Make sure spindles and all steering compone nts are free turning -Make sure skags are straight on skis and in good condition -Check for worn skags -Check for binding suspension shafts and grease all pivot points -Increase front IFS preload -Change FRSS to low setting or move to forwardmost hole -Install optional carbide skags -Check ski alignment -Check skags and skis for damage -Change FRSS to high setting -Decrease IFS spring preload -Rotate FRSS to lowest setting, dependi ng upon rider preference -Decrease preload on front track spring -Move FRSS to forwardmost hole -Tighten limiter strap one hole
Front end pushes
Steering is heavy
9/97
8.94
BRAKES/FINAL DRIVE Specifications

1996 Brake Specifications
Po lari s Cha incase Lu be Amou nt 9 fl. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 fl. oz. 9 II. oz. 9 II. oz. 9 II. oz. 11 II. oz. 9 II. oz. 9 II. oz. 9 fl. oz. 9 fl. oz. 9 II. oz. 11 II. oz. 11 II. oz. 11 II. oz. 11 II. oz. 9 II. oz. 9 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. 11 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 II. oz. 9 fl. oz. 9 fl. oz. Chainc ase SprockeV 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 18/41/66 18/41/66 21/39/66W 20/3 9/66W 21/39/66 18/39/66 20/39/66 21/3 9/66W 20/39 /66 18/3 9/66 21/39/66W 20/39 /66W 18/39/66W 21/3 9/66W 20/39 /66W 20/35 /64W 21/35 /64W 20/35/6 4W 20/39/66W 23/37/66W 20/35/64W 20/39 /66W
Reverse Ace Ace Ace Ace Ace Ace Ace Ace SId Ace Ace Ace Ace Ace SId SId Std Std Ace Ace Ace Ace Ace Ace Ace Ace Ace Ace Sid Ace Ace Ace Ace Ace Ace Ace Jac kshaft Spline 13 13 13 13 13 13 13 15 15 15 15 15 15 15 Brake Pads Std Std Std Std Std Std Std Std SId Sid HD Race..... HD SId SId Std SId Sid SId HD SId Std Std HD SId Std HD Std SId Std Std Std SId Std SId HD
Model 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 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 Storm RMK
Brake Type 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
22 22
15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15
___
Brake type 1.0 .. M=Me chanical, H=Hydraullc, LC= Liquid Cooled, WT=WideTrak "W" denotes a 13 link wide chain and wide sprocket; others are 11 link wide. Requires 2871296 Instal lation Tool for 15 tooth. 287097 4 1 nstaliation Tool fo r 13 tooth Denotes jackshafts with pressed on left side bearings (no lock collar) Race pad 440 XCR SP can only be used with spec ial caliper assembly and Maqura master cylinder assembly
9. 1
9197
INDY JACKSHAFT SPEED VS. MILES PER HOUR SPROCKET COMBINATION/GEAR RATIO/CHAIN PITCH - STD. CHAINCASE
T he following chart should be used 1 se lect op timum geari ng for special applications. The chart is calculated tor mod els with the 0 for mph and eng ine rpm s.
'"
pas drive clutch at a 1 to 1 ratio between dri ve clutch and driven
c-m Ill:c
('>
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 01jack shalt rpm. Shown on lop is optimum gearing
:Tm
III
-
'0'"
I
17 5 13
19i4 0
Geilnng
''''7
l. lil
201J3 1 2 113!l
I
7<W"
1 15
Rallo
Pilch
J d < t ' ;tH ;l<s
A I~ M
ss
1.67
se
'"
il .14
I..
aa.
'"
781
79.9
..
.....
lQr'J5
2l1:17
1 71;
21139
1
10'35
'0'39
I ,!)!)
19,'39
1!J141
10'39
1&"
2. 19 62
l Wol1 2.28
17/39
2.29
151 35
11140
2.35
11f41
ee
\ ,94
, 0'
66
' 06
1 62
2. 11
ee
G'
I...
I 70.9
72.0
73 I
ce
10 ,6
e a
....
71' j 2.17
166
233 62
2< 1
66
68
68
se
204 4
"""
16140
2 .50
141'35
2.50
1 161<4'
2.56
151 39
' .60
64
00
62
00
..
151 40
-- -14/39 -- -U/41 15141 14/4 0

2.73
2.67
,.ro
64
"Z
Q.
'86
64
2.91
64
=
en en!!
CD CD /II _ <
~"
r C
se
50,4
MILES PER HOUR
W,(1l1
~~
6700
1l'i.5
r..
76.0
7"
7(;1,4
lUl l,
84 7
I 93 7
N'
75. 1
71> .:1
671
668
67,, 8
"8 .9
65 .2
63.7
1634
717
778 73.8 74.9
08 2
69 ."
cc.a
1\72
li4 ,1
65 .7
64 .
6SA
6J.B 65.7 00 '

61.7
1" "'0 "'00
'"
9:J4
es.c
111.;j
I ae.o
86 .2 81.5
81 1
!1.l
.,
68 7 69.'
70.6 71.6 12 ,5
62.
su.a
61> 62'
63.2
64 .1
60 1
61.0
~~ 600 59.5
60.9
60 .'1
51.1
58.0
~ 57.3
StU
55 . ,
,~
55 .9 56.7 51 .6 56 .4
55.9 56.7
.. ,
!:i: B l
55.4 56.2
57. 1 57.9
52. ~
5 \ .6
53. 8 54 .6
52.3
,,,
52 ,0
49~
48 .1
47.0 47,7
48.4
. <
:c
50.1
50.9
51,6
se.a
49.6
62.0 '29
63.6
5B.9
~ J4
00. 92 1
l.It.I 6
~
7100
89.8
I 88.8
90.0 9 1.3
."
64 7 85'
87.1
823
7'3
79.\
a UI
830 !\4.?
85,4
77 .4
74.2 75.3 76 .4
702 11.:1 12.3 133 74<

15.4
69.9
70.9
68.' 69 2 '02
7 1.3
72 .3 733
68.7
luG
110.6
81 ,1 82.9
79.7
'"-
68' 67.3 68.3

69.3
70 .3 71.2
~ ~ 59,7
62 .7 62 .2 00.6
5'.) .0
59 .9
51.6
58,4
55.4
56.2
'"
53.9
547
52.1
60.3
Sl.1
49. 1
76.0
11.1
72.0
73.0 74.0 75.0 16 1 11 1 78. 1 79.:.1 80 ,:?
noo
7:1110
" .7 00.0
91 ,3
'" 92.'
93 .1
808
8:.'.0
11.6
78.6 19 .7
68 ' 69.6
70.6
65.0
659
66.9 67,8
" .7 657 00.'

61 ,5
ee.e
87.1 1 89.0 1102 9 1.4
182 793
"'.
65.4 66.3
61.3
63 '
92.6 93.' "'.1
88 3 89 5
... 0
85 .2
I~
(0 1 1500 1'1 600
95 .0 9<>3
97 ,S
""6
100,0
!IO'
82 0 93 '
9-44
66.3
I\)
f-- -
moo'800 -soo
"00 8200 .300 8400
10 1 :1
'U26
103 u 105.2 106.5 10 1,8
"".
96.'
!'Il,6
98 !)
et.s
88 .6 1 89.8
sac
93 .8 95.0
83.0 -- - 0 '77 "
...
85 .4
..,
83 .1
716
72~
... "'.
64 0 63.3
65 .8
63 . 1
61.5
60.7
6 1,6
59 3 60 1
61.0
61 .8
59.3
60 .1 6 1.0 6 1.8
57.0
57 .8 58 .6 59.5
ss.s
,..,
55. 1 55 .8 56 .6 57 .4 58.2
53.5
52.4
49 .9
" o
III
$:m
:J:
:T
53.1
51.6
52 .6 53 .3
50.'
51.3 52.0 52 .8
.~
59 .6
62.' 63.' .. 2
6!U
~ 57 ,I
57 .9 58 .7 59.5
~
5 4.6 55 .4 56 ,2
::1
" .1 65 0 65.' 00 .
60 '
61.2
60.'
81 ,9
80 '
8 1 0C 82 .5 836
~
77 5
7.~
74 3
15.3 76.3
722
13 .2
68.7
69 .1 70.6
68' 69.4
10.3 11.2
68.7
61 ,6
62 .7
53!.
627
735
14.5
7f> .5 76 .5
68.'
742
75 I 16.1
73.,
745
75.4 l G.4
69'
66.'
69 4
7!1S
77 .:.J
78.3 7!!3
715
72 .4 73 .4 14.3
roo
70.9 11.8 12.1
101 :/.1
88 ,8
89.9
85 ,1
101 4 10? 7 104 .0 105 2
100 '
101.4 102.7 104 .0 105.<' 106.5 10UI
1 000
'"
190.9
1 92. 1 1 93.2 11 j<\.oI
6"
81,3
'" 115.B 86.9
60 . ' 16
62. 6 83 ,7
721
73.0 14 ,0 74,9 158 76.1
71.7
70.3
71,2 12 .1 13.0 73 .9
""
68.'
b ~.4
66 -.0 - - 652 - 64' 64 .' 00.' -.1 - - .... , - 65' 61 00.1
'"
6 7,8
620
62 ,9
~ 6 1. 1
6 1.9 527 6 3,5
569
5 1.7
...
555
56~
54 ,0
53.'
"' 2
.17
645 65.3 66'
& .0 7 61 .8 68.7 69.5 70 ,;)
60.3 -6 1,1
58'
59.1
54.'
55'
sa.
59 ,2 600
57 .0 518
at.a
82.2 83.3
77 '
711.4 79.4 804 814
771
18.1 79.0 60.0 8 10 82.0 82.9 83.9 849
68.6
69.4 10 .3 71.2 12 .0
00.'
67 .8
00.' 68 6
1i9,5 70 ,3 11. 1 72.0
643
65 .2 66 .0 668
~
62.1
63. 4
60.'
6 1.3 62.1
56.'
57 .1
68 '
592
% .8
96.3
07.5 IIB.7 99.9 101 1 H123
9El 0
'"
80.3
8 1.3
77.4
78 .3
10 .3 11.2 72.0
60.7
6 1,S
57.
58 .5 59 .3
92 2 9 3.4
68'
89,5
00,6
IIU O
119.0
75.7
76 .2
73'
74~
686
6!l.5 10.3 71.1
" 2
65 .0 65,8 66,6 67 4
62. 63.6
64.4
60 0 60 7
61 ,S
1092
110 .5
ron 5
107.8
I O~
"'" '.)4
101 .G \02 .9 104 . 1
WS :t
64.7
B5,1
... .3 85.'
66.3
91.4
62.3
83 .3
79.3 60.3
8 1.2
62'
95Ji
96.7 tl7 8 99 ,0 100, 1 10 1,3
102 ,4
"" 95,6
% .11
I fIO l
n,
78. 0 78. g 7 9,9
75.4 76.3
77 :J.
14.8
75.7 766
729
73.8 747 75.6
76 .4
676
6tlA 69,2 70.0 70.9
!j 1.1
I 91 ,;?
aa.a
~3~
V->.b
116.'
Bl .8 63.8
64.3 95.3
8t13
82.3
83.3
I tl500
' 600 ",00
78'
7:HI 14.6 755 76.4
65.2
'lIB
113. 1 \ 144 115,7 117 1 118.4 1197 121 0
'.1:1,8 93 ,9
110.4 , 109.0
111 7
1I1 .!j
1 10 .~1
10"
IOd,7
'76
9':;,0
gs O 00.1
9 1,1 98 ,2
.800
1116 H 2 .!! 114. '

115.4
1l)3 S
llJ7.7 108 .9 110 1
111.:)
IOS .1I 1071

108 .3
100.2
101
""
811.9
~ a9.1t
90.,
91 .5 92 .5 93 .5 94.6
64 3
85.3
873 .. 3
69 .3
... ,
85.1
86 .1 87.0
. 32
'"
10,6 79,5
80 ,4
720
72 .8 137
65.9
".
.. 6 953
66,0
sao
60.0 60.7 6" 622
622
160 ,
18 1.7
82 ,7
78' 791
80.0
80.9 8 1.8
n,
784
79.3
72.
73,7
71.1
72 ,0
68'
6U.O
.....7
67.5 68 .3
.000
9100
90.'
9 1.9
116 3
ss.a
00.
81 .8 888 89 .8
8 1.4
n3
762
79 .1
14.5
74,S
75.4 76.2
114 2 115.5
1IG8
103 6
102 .5 103 6
a
~
en
iii
W "'"
"I:'IUO
1181
119 4
116.7
117.9
10$.9
"'" ,
' 062
ros.s
110 ,7 111 9 113 ,1 114 3 115 .5
104.7
1::'2.:1
12 3.fi
112 5 113.7
107 0
S-
"'00 " 00
9600
120 .6 121 'J 123 2 114.5 125.8 177 1 128.3
110.2 120.5 121,7
107.0
""
. ,--... ....
9 7.7 100 .<4 1015 102 .6 103 ,7 101. 0 102 .1
96 6
93 0 " 0 95.0 96. '

97 .1
00.3
91.J
92~
.. ,
862
87 .2
'12.3 832 ... .1 85.1 96 0
80'
81.1
77.2
63 ' . 45 85.4 00 '

87 .3
88.0 " .0 89 . 00.'

9 1.9 92 .8
927
83.6
82 .0
BOO
80.'
8 1,7
78' 790
79,8
~ 76,2
18.1
,~ ,~
74,04
75 ,]
71.1
1? 5
69 .8 70,6 7 1.-4
68..
6 1.5
'" ...
67 .4
63.7
~
63.' "3
65 .0
65' 65' 00.' 68 1 08.

69.6 70.3 11 .1 71 .8 72 ,6 73 ,3 74. 0
690
69 ,8
13.3
66.3
&9.1 69 .8 70 .6 71 .3 12 .\ 72.9 73.6 74.4 75.1 75 ,9
18.1
71.9 78 11 79 .&
741
722
10.6
71. 4
65. 00.5
6 1,2 67 ,9
00 '
91.2
82.'
83'
... 7
8S6 86 .5
18.'
78,8 796 80 .5
, ~ 74 9
95 ,6 96.6
633
94 ;1
95 .3
90.
91 .7
64' 95.' 96.3

87 .2
607
81 .6
ro.'
71.8
78.&
75 ,1
I~
73 ,8 74 ,5 75.3 16 ,1 76,9 77.1 78.6 7!l,3
771
72 ,9 73 .7
1749
126.3
r~
l 1G.2
1174
100 .3 110,5 111 6 \1 2.8

I1:HI
108 2 109.3
110A
IO U
104.2
9tl.l
977
98.7
~.
tOU
105 .9 10 7.U 100 . 1 100 2
99'
100 .2 101 ,2 !O2.3
96 '
tl7.3 98.3
."
941 95.1 96 1
91 . 1
92.'
92.7
93 .7 94.7 95.6 9G.G 97 ,6
68'
97""
9"'"
'''Hi
1:!8.9
l :l{l ?
123 0
124:3
ue. 7
117.9
119 1 120 .3
res 3
1(>6.4 107 .5 108 .6
m u
100 .7 10 1.8 102.8
"
S-
118.6
W I flo
111.G
~'''''00
12!'> ,!;
126,8
112 7
113.!!
131 5
121 0
lt5.1
103,3
" "
"'.
95.7
93,8
'"
901
91.0 91.9 92 .9
... ."
9 1.5 92.5
86.9
62.' 63.5 643

8!'>,2 116.1 870
16.6
77 .4
9 1.8
..2
89 .1
60.6
."
88.3
". ... ,
83.3
80.'
81.3 812
68.7
69.4 70 ,1 708 71.5 72 ,3
81.3
eaa
U3.0 BJ.9
80 .?
'"
78 ,2 790 79 5 80G 81.4
74.S
75 .2
85.0
630
81.1
76.0
76 .8
00.0
' 97
90 . 1
100 .4
990
96.7
90 '
87.9
"'.
as.s
" 7
... ,
83.9
et.v
" .7
776
(,

1996 Trac k Drive Dat a Mod el Drive No. of Drive Type Sprockets 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' 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-loc' s 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-Ioc" Pressed Pressed Pressed Pressed Pressed Pressed Dr ive Sprocket Diameter 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 DRIVE SPROCKET POSITION Reference Page 9.4 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 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 B 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 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 12.32 16.32 15.97 17.47 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 XCR SP Indy Wide Trak 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
All 1996 models. sprocket positions are measured to sprocket hub and not idler center. See page 9.4.
Denotes driveshafts wit h pressed on left side bearings (no lock coll ar) wit h welde d f1angetle bolts.
9.3
9/96
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 jackshaft 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 "SO). To ensure proper sprocket tooth alignment, be sure the vendor logos are oriented in the same position on all sprockets. Drive shaft sprocket positions are measured to sprocket hub edge. Not idler center.
Logo orientation
S
2 Drive Sprocket Use straight edge against sprocket hub 4 Drive Sprocket
Square
f - - - -- B -
----+I
fo-- -- C - --
dIl
~
Coupler WideTrak GT Left Side
ir- ~ -t~ ~~
Coupler WideTrak LX
~ ~A
-I
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 DR IVE Hydrau lic Brake System Operation
view~
F
End
D---The Polaris snowmobile hydraulic brake system consists of the following comp onents 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 activate d brake lever (A) is applied, it contac ts a piston (B) within the master cyli nder. As the master cylinde r 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 pressu re within the system is increased, the piston (D) located in the brake caliper moves outwa rd and applies pressu re to the movea ble 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 appl ied to the brake pads will cause the pads to wear. As the pads wear, the piston within the caliper self-adjusts and moves furthe r outward. Brake fluid level is critical to proper system operation . A low fluid leve l allows air to enter the system causing the brakes to feel spongy.
Compensating Port
Located within the maste r 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 outwa rd. As the temperature within the hyd raulic syste m 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 impo rtant that the master cylinder reser voir have adequate space to allow for the brake fluid to expand. Master cylinde r reservoirs should be filled to the top of the fluid level mark on the inside of the reservoir, 1/4" - 5/16" (.6 - .8 em) below lip of reservoir opening.
'---
WARNING
Never overfill the reservoir. This could alter brake function, resulting in system component damage or sever perso nal injury or death . This system also inco rporates a diaphragm (E) as part of the cove r 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 functio n. If the reservoir is ove rfilled or the diaphragm vent is plugged , the expanding ffuid may build pressure in the brake system and lead to brake failure. Polaris Industries Inc.
9.5
11/95
BRAKES /FINAL DRIVE

Typ e 3 Maste r Cylinde r Ty p e
3 M a s t er C yli n d e r
The Type 3 master cyl inder assembly is easily recogni zed by the longer (cent ered) brake line mount.
1. 2.
3. 4. 5. 6. 7. 8. 9. 10.
11.
15.
12. 13. 14.
16.
17 .
18. 19. 20.

21.
Cover Screw Cover Cove r Gasket Cylinder Housing Brake Lever Bushing Brake Lever Park Lever Return Spring Pivot Boit Nut Park Leve r Park Leve r Pivot Bolt Park Lever Pivot Bushing Spring Seat Washer Compress ion Spr ing U-Pack Seal Piston O- Ring Sea l Clamp Bolt Atta ching Clamp Lever Pivot Bolt Baffle Baffle Washer
2~
y--1
21
3~
"'/
20
V~
19
~18
~
12
13
17
L-. ~~ ~
5 ---;-<;l
6
7
Optional at customer request
.",. ~ /
o
Ij q K BOU 'lE
,~ .
1 >5
~~16
Ae.J.( _S: eEFC"E
O "Ili o;:l a;ME "UV,

S'f5T E\I fAUi R
C" ",REMAY
;<E SUL . J.l'f'i.V t 81'1"-,[ LE 'f!:Fr 10 qELEASl:
Pa rk Brake L e v er Lock
WARNING
Release park brake lock be fore drivin g or brake system failure or fire may result. Ap ply brake leve r to release. Ty p e
3 Master
Cylinder Removal
1.
Position clean sh op cloths to catch spilled fluid and remo ve brake hose. CAUTION:
I
3.
Brake fluid will d amage fin ished surfaces. Do not allow brake fluid to come in contact with finished surfaces.
2. Remove brake clamp attaching bolts (Item 17).

Rem ove park brake leve r (Ite m 9) and brake mas te r cy linder lever (Item 6) , noting po sition of bushing, spri ng , etc., for proper reassem bly. Using the master cylin der service tool , posi tion push rod through small hole in spring seat washer (Item 12) as shown. Remove piston assembly, spring and wa sher.
4.
Master Cylinder Service Tool K it PN 2870962
9196
9.6
BRAKES/FINAL DRIVE Type 3 Maste r Cylinder Inspecti on and Assembly

1996440 XCR SP Brake System Description Component Part Number Differen ce from Standard Brake System
Magura Master Cylinder Brake Line Caliper Assembly Calipe r/Piston Kit Brake Pads Disc
2050074 1930773 1930772 2200764 2200763 1910197
-5/8"compared to 3/4" -Requires less hand effort for the same braking -Uses a flare fitting instead of threaded fitting -.080" 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 (.008")
The Magura master cylinder must be used with the correct brake line. To upgrade to the Magura master cylinder, order the following : PN 20500 74 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 pads/vented disc, order the following: PN 2200 763 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 thoroughiy 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 cyli nder bore for scratches , score marks, or corrosion and replace any worn or damaged parts.
Assembl y
1. Always replace a-Ring seal, U-pack seal and cover gasket (diaphragm) upon reassemb ly. Use only genuine Polaris service parts. 2. Apply clean DOT 3 brake fluid on piston, piston seals and cyli nder bore. Install seals onto piston positioning U-pack seal lip (A) toward s spring. Snap spring into place on piston.
-,
3.
Install piston assembly into master cylinder service tool until U-pack seal is covered by tool as show n. 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

Assem bly, Cont. 4. 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 nul. 6. Reinstall master cylinder onto handlebar and reconnect brake line. Partially insert fittings (one to two threads) and apply LoctiteTN 242 to remaining threads of fittings. Torque brake line fittings to specification.
Brake Line FItting Torque Master Cylinder End Finger tight plus 2 turns
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 1/4" - 5/16" (.6 - .8 ern) below lip of reservoir opening while bleeding brakes. Do not allow air into system while bleeding. See bleeding procedure on page 9.10.
-:
Master Cylinder Fluid Level

114" 5/16" (.6 .8 em) below top of master cylinder
11/95
9.8
BRAKES/FINAL DRIVE Type 3 Master Cylinder Assembly

Assembly, Cont.
9. Field test machine before puttinq 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 em) from handlebar.
10. 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
11195
BRAKES/FINAL DRIVE Brake Bleed ing - Fluid Change

Brake Bleed ing Fluid Change
This procedu re should be used to change fluid or bleed brakes dur ing regular maintena nce. 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 immed iately. Cover parts to avoid damage. 1. 2. Clean reservoir cover thorou ghly. Remove screws, cover, and diaphragm from reservo ir. Inspect vent slots (A) in cover and remove any debris or blockage. If chang ing fluid, remove fluid from reservo ir with a Mity VacT pump or similar tool.
C
3. 4.
~
A
NOTE: Do not remove brake lever when reservoir fluid level is low.
Mlly VaeT PN 2810975
5. Add brake fluid to within 1/4-5/16" (.6-.8 ern) of

reservo ir 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 diaphra gm (C) in reservoir to prevent spills. Do not install cover.
7. 8.
9.
Slowly pump lever (D) until pressu re builds and holds. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. Do not release lever before bieeder 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.
! CAUTION: R
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.
>, . _ .. .. . ,, _ ....
-0
~~
Reservoir Cover Torque

;'h
~ i ;~
-t
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 firmiy applied, lever reserve should be no less than 1/2" (1.3 em) 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 fitling. 3. Loosen brake line fitting and tighten lightly. 4. Pump brake lever slowly 2-3 times. 5. 6. Loosen fitling 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 connect ion at caliper to purge air from brake lines.
8. When all air has been purged from line and caliper. tighten all connections and add brake fluid to proper level.
9.11
11/95
BRAKES/FINAL DRIVE Brake Bleeding - System Rebuild

Brake Bleedi ng - Fluid Change, Cant.
9. Install diaphragm , cover, and screws and torque to specification .
10. Field test machine before puttinq 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 em) from handleba r.
"--.-'
Brake Lever Reserve Limit Not less than 1/2 " (1.3 em) from handlebar
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 js 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 Thl ckneas - Type H4
,
"';;."
',Servlc.e. Li mit ,, 250" (6.35mm) : c ,

.
.... .
".'
, :",,: , ~ : : . : ~
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
~l---2
The rider's safety depends on correct installation. Follow procedures carefully. CAUTION:
Protect eyes from brake fluid. 1. Clean any dirt from mount bracket and bolts. Brake cleaner may be used to aid in cleaning of components. 2. With a 9/16" socket, remove two 3/8 hex bolts and washe rs from bracket. Remove rope guide. NOTE: Do not disconnect brake line. 3. 4. 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 paos, apply press ure 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 nse in the reservoir and possibly overflow. Remove excess fluid and discard. CAUTION:
P'SlOn 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.
Polaris Indusrries Inc .
9 .13
9/96
BRAKE S/FIN AL DRIVE

Typ e H4 Brake System 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.
.:>
7. Slide brake assembly into bracket until both clips snap into grooves in bracket. 8. Clean brake mount on top of chaincase. 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 calipe r. Caliper assembl y must fit freely onto disc and chaincase. 10. Replace 3/8 bolts , washers. and rope guide. Torque to specif ication .
11 . Actuate brake several times to set brake pads to prope r 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 assembl y.
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 4
~1}.....-2
The rider's safety depends on correct installation. Follow procedures carefully.
Refer to the exploded view above while performing the follow ing 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.
r
7.
CAUTION:
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. 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 inlet 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.
i
9.
CAUTION:
To avoid scratching bore or burring edge of seal groove , do not use a metal tool such as a screwdriver. Discard old seal.
9.15
11/95

Type H4 Cleanin g and Inspection
Check all parts for wear or damage and replace as required . Alwa ys replace caliper piston seal and dust seal (where applicable). 1. Clean all parts with denatured alcohol and wipe dry with a clean, lint free cloth . 2. Using compressed air, blowout the drilled passages and piston bore. Be sure piston seal groove is thoroughly clean and free from corros ion or brake fluid build up. 3. Inspect piston bore for scoring, pitting or corrosio n. A corroded or deep ly scored casting should be replaced. Light scores and stains may be removed by polishing with a crocus cloth only. Use finger pressu re 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 ab rasive cioth. 4. Check piston to see if it is pitted, scored or worn. If so, discard and replace the piston. -..../
! CAUTION: l
Do not attempt to polish or sand piston. 5. 6. 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. Be sure bleeder screw is clear.
7.
Inspect brake line seat for damage and replace calipe r if necessary.
Type H4 Assemb ly
1. 2. Reassemble by reversi ng disassembly proces s. 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 piston bore. Seal should be positioned at one point in groove and then gently worked arou nd the groove by hand until properl y seated .
~ CAUTION:
I I
Never reuse an old seal. 3. Coat piston thoroughl y with brake fluid and work down into bore by hand carefu lly until bottomed .
CAUTION:
Apply even pressure to avoid cock ing the piston in the bore.
11/95
9.16
BRAKES /FIN AL DRIVE Type H4 Brake System

Type H4 Assembly, Cant.
4. Examine pads for wear or damage. If pad thickness is less than 1/32" (.08 em) 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. 5. Connect hose or line to caliper. 6. Place new pads with friction material facing each other into housing. Hold in piace using clips. 7. Slide brake assembly into bracket until both clips snap into grooves in bracket. 8. Separate pads for installation over disc. 9. Place brake assembly over disc and push bracket into chaincase.
'--
10. Replace 3/8" bolts, rope guide, and washe rs. 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 equ ipped with a brake cooler. NOTE: Repla ce pad s when wo rn beyond service limit.
Brake Pad Thickness Type H5LC

;; w
,S er vice
l.im it
",;;c,) : :ijifi:: d~},
.250- (6.35m!")
Minimum Pad Th ickness .250(6.35mm)
Ty p e H5LC Friction Pad Replacement
1. 2. 3.
4.
5. 6. 7.
8.
9. 10. 11. 12. 13.
Carrier Bracket Atta chin g Bolts Carrier Bracket Piston Piston Sea i Spring Clip Stop Light Switch Brake Pad s Brake Line Bleeder Screw Caliper (Liquid Cooled) Rope G uide Water Cooler Manifold Screws (Cooler Manifo ld)
NOTE: 1996440 XCR SP - items 3&7 are un ique to this modei
A WARNING
The rider's safety depends on correct installation . Follow procedures carefully. . CAUTION:'
'I
Protect eyes from brake fluid. 1. Clean any dirt from moun t bracket and bolts. 2. 3. 4. With a 9/16" sock et, remo ve two 3/8 hex boils and washers from bracket. Remove rope guide. NOTE: Do not disco nnect bra ke line. Remove hos e clamp from engine side of cooler. Twist and remove hose from cooler, catching and disposing of antifreeze prope rly. Use a drop clot h to protect surfaces from brake fluid spillage . Remove reservoir cover. Using a large hardwoo d dowel, or a C clamp vise grip on the center of the old pad s, appl y pressure toward the cali per piston. Compress pisto n back into cali per assembly. Appl y pressure slowly to pre vent exces sive spillag e fro m mast er cyl inder assembly.
NOTE: Pushing the piston back into the bo re will ca use the fluid level to rise in the reservoir and possibly overflow. Remo ve excess flUid and di scard . 5. Lift bracket and bra ke assembly off vehicle. Raise open end of cooler and pad assembly to trap antifree ze in cooler and plug the opening of both coo ler and engine hose open end .
9/96
9.18
BRAKES/F INAL DRIVE Type H5LC Brake System

Type H5LC Friction Pad Replacement, Cont.
'---6. 7. 8. 9. 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 cha incase where brake mounts. Separate pads for installation over disc . If brake assem bly does not slide easily over the disc with loose pads the piston is not comp ressed 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 coo ler assembly. 11 . Replace 3/8" bolts , washers, and rope guide. Torque to specifi cation .
12. Actuate brake several times to set brake pads to proper operating position. 13. Check for proper fluid level in maste r cyiinder 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
11195

1 997 Brake Specifications Po laris Cha incase Lube Amount 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 fi. oz. 9 II. oz. 11 II. oz. 11 fi. oz. 20 fi. oz. 11 fi. oz. 11 fi. oz. 9 II. oz. 9 II. oz. 9 fi. oz. 9 fi. oz. 9 II. oz. 9 fi. oz. 9 II. oz. 9 fi. oz. 9 fi. oz. 11 fi. oz. 9 fi. oz. 9 fi. oz. 9 fi. oz. 9 II. oz. 9 fi. oz. 9 II. oz. 9 fi. oz. 9 fi. oz. 9 fi. oz. 9 fi. oz. 9 II. oz. Chaincase Sp rockeV Chain Length 16/39/64 17/35/62 16/39/64 15/39/64 20/39/66 21/39/66 21/39/66
22/41170
Model Indy Lite, Deluxe , GT Indy Sport Indy Sport Touring Indy TranSp ort 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 / LX Indy Classic Indy Classic Tourin g Indy 500 Indy 500 SKS Indy 500 RMK Indy 500 EFI Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT SP Indy XLT LTD / SP Indy XLT Touring Indy 600 XC Indy 600 XCR Indy RXL Indy Ultra / Ultra SP Indy Ultra SPXlSE Indy Ultra Touring Indy 700 SKS Indy 700 RMK Indy 700 XC Indy Storm / SE Indy Storm 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
Sp rockeV Cha in Width 11 11 11 11 11 11 13 3/4 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 3/4 15 15
Reverse Acc Acc Acc Acc Acc Acc Acc Acc Acc Acc Sid Acc Sid /LR Std Std Acc Acc Acc Acc Acc Acc Acc Acc Acc Sid Acc Acc Acc Acc Acc Std Acc Acc Acc Acc Acc Jacksh aft Sp line 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 Bra ke Pads Std Std Std Sid Sid Std HD HD Sid Sid Sid Sid Sid Sid Sid Sid Sid HD Std Std Std HD Std Sid Std HD HD Std Sid Sid Sid Sid HD HD Sid HD
21/39/66 21/39/66 20/39/66 19/40/66 19/41/66 21/39/66 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 21/35/64 20/35/64 21/35/64 21/35/64 20/35/64 20/35/66 20/39/68
24 /40170
23/37/66 20/39/66
Brake type I.D. - M=Mechanical, H=Hydraulic. LC=liquid Cooled, WT=WideTrak Requires 2871296 Installation Tool l or 15 tooth. 2870974 Installation Tool for 13 tooth
9/97
9 .1a
BRAKES/FI NAL DRIVE Spec ifications
1998 Chain Case I Brake Spec ifications

Polar is Cha incase Lube Amou nt** 7 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. 9 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. 9 11.0z. 7 II. oz. 20 II. oz. 9 II. oz. 9 II. oz. 7 II. oz. 7 II. oz. 1.0z. 91 7 II. oz. 7 fl. oz. 9 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. 9 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. 7 II. oz. Chaincase Sproc ket! Chain Length 16/39/64 16/39/64 16/39/64 17/35/62 17/41/66 15/39/64 19/39/66 22/41/68 21/39/68 22/41/68 22/4 1/68 20/40/66 18/41/66 19/41/66 22/4 1/68 19/40/66 22/4 1/68 17/41/66 22/41/68 22/4 1/68 22/4 1/68 20/40/ 66
22 /40170
Model Indy Lite Indy Lite Delu xe Indy Lite Touring Indy Sport Indy Sport Touring Indy TranSp ort Indy XCF Indy 440 LC Indy 440 XCR Indy Super Sport Indy Trail Indy Trail Touring Indy Trail RMK Indy Wid eTrak LX Indy Classic Indy Classic Touring Indy 500 Indy 500 RMK 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 Tour ing Indy 700 XC Indy 700 XCR Indy 700 RMK Indy Storm
Sprocket! Chain Width 13 13 13 13 13 13 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4"
Reverse Opt. Opt. Opt. Opt. Opt. Std. Opt. Opt. Opt. Opt. Opt. Std. Opt. Sld.wlH-L SId. Std. Opt . Opt. SId. Opt. Opt. SId. 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 SId SId SId Std Std Std HD Std Std Std Std HD Std Std Std Std Std HD HD Std Std SId HD HD SId
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
23/40/68 19/40/68 23/40/68 22/40/68

24/40170
24/40/68 21/41170
25 /40170
Brake type I.D. - M=Mechanical. H=Hydraulic. LC=Liquid Cooled, WT=WideTrak Requires 2871296 Installation Tool for 15 tooth, 2870974 Installation Tool for 13 tooth All 1998 Models with P8S Clutch System use HYVO "' Chain and Sprockets (3/4" wide)
711.02 . = 210cc "-..... 9 1\.02. = 265cc 20 f1.02. = 590cc Polaris Industries Inc.
9 .1b
9/97

Type H5LC Caliper Disassembly
1. Carrier Bracket Attaching Bolts 2. Carrier Bracket 3. Piston 4. Piston Seal 5. Spring Clip 6. Stop Light Switch 7. Brake Pads 8. Brake Line 9. Bleeder Screw 10. Caliper (Liquid Cooled) 11. Rope Guide 12. Water Cooler Manifold 13. Screws (Cooler Manifold)
12
2
NOTE:
WARNING
The rider's safety depends on correct installation. Follow procedures carefully.
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. Remove bracket bolts. Disconnect brake line. Drain brake fiuid into appropriate container and dispose of proper ly. Disconnect and plug coolant lines, catching and disposing of antifreeze properiy. Disassemble on a clean bench.
5. Open bleed screw. Drain brake fluid into appropriate conta iner and dispose of properly.
['lJCAUTION: 1
Protect eyes from brake fluid. 6. Slide brake assembly out of bracket and remove old pads and clips. 7. 8. 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 inlet port.
CAUTtON: ,
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.
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 denatu red 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 deep ly 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 pressu re. 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
6. 7.
CAUTION:
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. Check iniet and bleeder hole threads for damage. Inspect seat insert for damage and replace if necessary.
Type H5LC Assembly

1. Reassembie by reversing disassemb ly process. reassembling the unit. 2. Be sure all parts are clean and servic eable before
Coat a new piston seal in clean DOT 3 brake fluid and place in groove in the caliper bore . Seai 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.
I
4.
CAUTION:
Apply even pressure to avoid cocking the piston in the bore. Examine pads for wear or damage. If pad thickness is less than 1/32" (.08 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.
5. Connect hose or line to caliper. 6. Place new pads with friction material facing each other into housing. Hold in place using clips.
7. Slide brake assembly into bracket until both clips snap into grooves in bracket. 8. Separate pads for installation over disc. 9. Place brake assembly over disc and PUSh bracket into chaincase.
Polaris Indusfries Inc.
9.21
11195
BRAKES/FINAL DRIVE Type H5 LC Brake System

Type H5LC Assembly, Cont.
10. Install coolant lines and hose clamp s and tighten secure ly. 11. Replace 3/8" bolts , rope guide, and washers . Torque to specification.
Caliper BoltTorque.
25-30 ft. lbs. (3.45-4.14 kg-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 Maintenanc e Section for adjustment procedure. 1. Brake Cable and Jam Nuts 2. Bracket, Brake 5 3. Washer 6 2 4. Washer, Spring Lock 7 I 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 16 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 24. Adjuster Bolt
~1
20
21 23
NOTE: Replace pads when worn beyond service limit.
Brake Pad Thlckness - Type M3 Service Lim it
.250 (6.35mm)
Type M3 Brake Disassembly

I< C)\I.JTIC>N:
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. Open adjuster bolt jam nut locking tab (A). Loosen jam (B)nut and remove adjuster bolt (Item 24). 2. Mark location of actuating lever (C) and worm gear (D). 3. Remove actuating lever (C) and return spring (1 3). Do not detach cable from lever arm. 4. Remove top mount bracket and brake assembly mounting bolts (Item 5). Remove washers (Items 3 and 4) and alignment spacers (Item 9). Remove oraxe assembly. NOTE: Be prepared to catch brake oaos as assembly is lifted out. 5. Remove brake pads and inspect for wear and damage. Replace if necessary. 6. Inspect rotor disc and replace if worn , galled, or warped.
9.23
9/96
BRAKES/FINAL DRIVE Type M3 Mechanical Brake System

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, L T Bolt, Caliper Retaining Ring Brake Disc Seal Jackshaft O-Ring Adjuster Bolt
~1
18 7
5 2 3 4 6 7 8
13 16
10
24
12
11
22
~7
19 20 21 23
Type M3 Assembly to Chaincase

1. Clip moveable brake pad into positio n under holder clip. Hold moveable and stationary pads in place with a rubber band while placing asse mbly over rotor disc and mounting to chaincase. Remove rubber band s once system is bolted into place. 2. Install alignmen t space rs (Item 9), washe rs (Items 3 and 4) and bolts (Item 5). Torque assembly to specification.
3. Loosen cable sleeve jam nuts (Item 1) and adjust brake cable sleeve to its shortest position.
11/95
9.24
BRAKES/FINAL DR IVE Type M3 Mechanical Brake System

Type M3 Brake Adjustment
WARNING
The following step is critical for proper positioning of the actuating arm to the caliper helix shaft. Improper position ing will result in minimal resista nce 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 adjust er bolt. Reiease brake arm slightly to index iever for installation on helix shaft. Insert a .015" (.04 ern) feeler gauge between brake disc and moveab le brake pad . Release brak e lever. Install return spring (Item 13) and finger tighten bolt (Item 24). Set adjuster bolt jam nut, bend locl<ing tab and remove feeler gauge.
5.
6.
Fieid 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 Mec hanical Brake System

The Type WT system is the mecha nical brake system used only on Ind y Wid eTrak models.
1. 2.
3. 4. 5. 6.
7. 8.
9.
10. 11 . 12. 13.
14 . 15. 16.
17.
18.
19.
2 1.
20.
21.
Brake Cable and Jam Nuts Bracket, Brake Cable Was her Washer, Spring Lock Bolt, Top Mount Bracket. Brake Top Moun ting Bushin g Nut, Bi-Lock Adjuster Bolt Ca liper, Stationary, Cast Pad , Brake Puck, Mov eable Brak e Spri ng, Brake Return Nut Bushin g, Brake Arm Bolt, Cable Swivel Clevis, LT Bolt, Caliper Brak e Disc Seal Caliper (Moveable Puck) Transmission
5----f
4----<5>
b 3 ---- - -
10
11
12
20
NOTE: Replace pads w hen w orn beyond service limit.
Minim um Pad Thickness
.250"
(6.35mm )
Type WT Brake Disassembly
Whenever inspection reveals worn, da maged or defective part s, replacement is necessary in order to avoi d serious da mage to the mach ine or injury to the ope rato r. 1. 2. 3. 4. 5. 6. 7. Ope n adjuster bolt jam nut locking tab (A). Loosen jam nut (B) and rem ove adjuster bolt (9) . Mark locatio n of actuat ing leve r (C) and worm gear (D). Remove actua ting leve r (C) and return spring. Do not disconnect lever arm fro m cab le. Remove cali per bolts , spacers, bracket nuts (Ite ms 18, 2 , 7. & 8) . Remove stationary ca lipe r casting and stationary pad (Items 10 & 11 ). Remove top mo unting bolts and washers (Items 3, 4, & 5). Pull outward on disc w ith the balance of the caliper assembly. On ce disc is free of shaft sepa rate co mponents. Re move brake pad s and inspect for wea r ana damage . Re pla ce if necessary. If stationary pad (Item 11) is stuck to station ary casting, tap on th e sid e of the pad w ith a pu nch and ham mer to break it loose. Inspect roto r disc ana rep lace if worn , galle d or wa rpea .
9/96
9.26
BRAKES/FINAL DRIVE Type WT Mechan ical 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.
3. Assemble bolts, spring washer, and flat washers to transmission and top mounting bracket (Items 3, 4, 5, & 6). Finger tighten.
4. 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.
8 fllbs. (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. 3. Insert a .015' (.04cm) 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 feeier gauge.
'fu,
Friction Pad Air Gap
tLL
"'"
.015' {.38 mm}

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 WideTrak)
The Type 3 drive system is used on all models except the WideTrak. This system consists ot a right side mounted chaincase with 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 01 used chaincase oil properly. 2. Tum 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 s kwez-loc' style jackshaft bearings; Some models are equipped with press-fit bearings which have no locking device.
Set Screw Style Bearing
~ -.~
~==-"'" /./
-.;::,,::
%1~
~
/
Loosen screw. Remove collar from bearing
Press-Fit Bearing
----- ---
~~
. /
-"0.
skwez -toc' Bearing
5. Remove two upper flangette attaching bolts.
9/97
9.28
BRAKES/FINAL DRIVE
Type 3 Dr ive System Type 3 Drive System Disassembly, Cant.
\........ 6. 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. l. Remove four suspension mounting bolts.
8. Place a protective mat on floor and tip machine onto left side. 9. 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.
10. Position track as shown and remove third jackshalt 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 and/or burrs.
NOTE : Some models are equipped with set screw or Skwez-Ioc'" style driveshaft bearings; Some models are equipped with press-fit bearings which have no locking device. On these models the bearing must be removed after the drive shaft has been removed 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 chain 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
BRAKES/FINAL DRIVE J ackshaft Speed vs. MPH Chart (Long Chain Case)
1997700 XC, 440 XCR; 1998440 XCR, 600 & 700 Domest ic Twins (Longer Chain Case)
Top Sprtlkect
25
41
23 39
1.70
'3 '0
1.74
'3
22
22
41
20
J9
21
19
19
'8 '0
2.22
18
41
17
41
l o wer Sprol<et Ra tio

Chain Length
1.8' 72
"
'0
1.82
1.78
1.86
70
1.95 '8
" 1.95
70
39
'0
2.11
'05
68
2.28
58
2.0 11
'8
70
70
70
70
.8
68
Jace snan
RPM
MILES PER HOUR
'000 6100 6200 6300 8'00 6500

6600
76 .8 78 . ,
74.3
75.6
72.5 73 .7 74 .9 76 .1
70.7
7 1.9 73.1
69.3
70.5
67.6
64,6
8'.'
65.6 66.7 67 .8
8 1.4
62.4
59.9
60.9 61 .9
56.7
57.7
55 .3
52 .3
687
69 .9
71 .0
65.7 66 .8
56 2
57.2
53 .1
79.4 eO.7
82.0
76 .8
71 .6 12 .8
73 .9
75.1
78.0
79.3
7<2
75. 4 76 .6
71.8
67 .9
""
58 .6 59.5 60.5
61.4
" .0
54.9
64.5
62 .9 63 .9
58.1 59.0
59 .9
77.3
7B.5
72.1
73.3
74 .4
689
70.0 71.1
68.9 69.9
71.0
72.1
65.5
55.7 56 .6 57.5
53'
80 .5 81.8 83. 0
84.2
66.
67.5 66.6
8" 65 . 66.'
67.8
' '5
85 .8 81 .1
79.7
80,9
76 .2
77 .4
62' '33 8'3

65 .2
60.'
61 .8
6700
6800
78 .9 60 .1
75.5
76.6
72 '
73 .2
58.3
59.2 601
6 1.0
82 .1
78.6 79.7
73.2 7<'
753 76.4
69.6
62 7
'900 7000 7'00 7200 7= 7<00 7.00 7600

7700 1800
88 4
69.6
85 .5
533
84 .5 55.7 87.0 882
8 1.3
82.5 83 .7 84.8 86 .0 87. 2 88 .4 89. 5 90.7 9 1.9
71'
78.9
7'3
75 ,4 76.5
70.6
71 .S 72 .7 73,7
68. "8
70 .8 71 ,8 72 .8 73.e 74,8 75.8 76 ,8 77.8
8S7
879 89.2
SO.9
82 .0 83 .2 8 4.3 85 .5 86 ,6 87. 8 88.9
66.2
67 .1
'" 8"
65'
66.<
67 .3
90.
BOO
81.1 82 .3 83, 4 845 85. 7 88,8 97 ,9 89 .0
61.8
922
93.5 94.8
71.6 786
79 .1 808 8 1.9 829 8 4.0
71.'
78 .5
68.1
690 69.9
62.7
90 '
91 .7 92 .9 94 1
7<7
75.7 767 77.8 78. 8 79.8 80 .8 81 .9 829
8" SO,
9 1.8
796 '07
81.8
68' 692
70 1 11.0 71 .9 728 73.8 74 ,7 75 .6 76,S
S4.4 65 .3 66 .2 67.1 67 .9
""
96'
97.3 986
70 s
71 .8
99'
1012 102.5 103 .7 105 .0 106 3 107 .6 1089
110.1
'" 96.'
97' 99' ' 00 3
101.6
930
942 95.4
528 83.9
12 .8
73.8 74 ,7 75 .6 76 .6
90.\ 813
92 .4 93 ,6 94.7 959 97 .0 982
7900 .000 8100

8200 6300
931
94.3 954
55'
88' 8"
es 0
8S.1 87 .1
78'
79 .8 80 .8 81 .8
68'
69.7 70 5 7 1.4 72.3
96' 97 a 990
1002 101 .4
90.2
91 .3
968
97 .8
92 '
' 02
eeoc
es00
8600 8700 '800 '900
9000 9 100 9200
104 .0 105 ,3
990
100 .2 101.3 1025 103 .7 1049 1060 1072 108 4 1096 110 ,8
1119
102 7
1039 105. 1 106 .3 107.5 108,7 109,9 111 1 112.3 1135 n4 7 115 9 1171 118 ,4 119.6
.,
9<.7 96.9
935
."
9<.' 959 96.
883
68.'
89.3
83.9
84 .9
77'
75.4 79.4
eO.3
8'8
90.
. 16
926 93 7
'06
993
100,5 1017 102 .8 104.0 105 .1 106 .3 1074 10 8.6 1097 110.9 112 1 113.2 114 4 115.5
."
92 .5 936
90'<
96.0
87 .0 66 .0 890
111.4 112.7 114 0 115.3 1165 1178 1191 120 .4 121 7 122.9 124 2 125 ,5 126.8 128. 1
107 ,8 109.0 110 2 111.5 112,7 114 0 ,,5 2 116.4 117.7
."
."
83 .8 85 .6 86 .8 87 8
17.'
7' , 793
732
740 74.9
61 .3 82.2 83.2 34 .1 65 .1 86 0 67.0 87,9

88,8
992 1003
10 1.4 102 6 103 7
9<.7 95.7 96.' 97 9 99 0

100 .0 101.1 1022 103.3 '04.4 105 .4 106. 5 1076
90.0
91 .1
"" 811
aa r
83 .0 83 .9
7B.
76 .6
'8 ,
89.8
77 '
78.4
.21
93 .1 94.1 952
980 99\
100.2 1012 102 .3
90.'
9 1.8 92 .8 93 .8
792 SO.,
."
858 86 .7
9300 9<00 9.00

9600
'''' 8
105 9 107 1 108.2
sr.o
81 .9 82.7 83 ,6
96.' 9i 2
ne.s
' 202
12\.4
122.6
1131 11.01 J 1155

116 6
103 4
9700 9BOO
9900 '0000
' 09 3
110.4 111 6 1127
''''
105 .6
."
95 .8
89. 9
'7 ' 88.
98'
99 3
1(Xl3 101 3 102. 3
90.7 917
:i2.6 93 6 94 .5
96 '
97 .8 98 .8
89'
90'
" s
85.3
106 6
107 .7
'13
92'
'52
87 .1
123 .9
120 .
1178
99.8
9.2a
9/9 7
BRAKES/FINAL DRIVE Chain Case Sprocket Part Numbers
Top Sprockets - 13 Spline (Except La rge Diameter Jackshaft)

11L Drive System 13T 14T 15T 16T 17T 18T 19T 20T 21T 3222059 3221036 3221031 3221032 3221033 3221037 3221034 3221053 3221035 13L Drive System 19T 20T 21T 22T 23T 3221059 3221055 3221054 3221056 3221057
Top Sprockets - 15 Se line (La rg e Diamete r) Jackshaft

11L Drive System 15T 16T 17T 18T 19T 20T 21T 22T 23T 3221067 3221068 3221069 3221079 3221071 3221065 3221066 3221072 3221073 13L Drive System 15L Drive System 17T 18T 19T 20T 21T 22T 23T 3221075 20T 3221076 21T 3221060 22T 3221061 23T 3221062 3221063 3221064 3221080 3222077 3222078 3222079
Bottom Sprockets 11 L Drive System 33T 35T 3222039 3222036 llL Reverse 35T 39T
Steel
13L Drive System
13L Reverse Gear
15L Drive System 3222073
15L Reverse 35T 1341173 13411 72
1341054 35T 1341053 37T 13411 63 1341198 39T
3222053 35T 3222056 37T
1341110 35T 1341114 37T
3222074 37T
39T PM 39T 3222034 40T 3222052 39T

Steel
1341111 39T 1341163 1341197
3222075
39T
1341171
39T PM 41T 3222037 41T 134111 2 40T 41T 1341117
Drive Chain 11 L Drive System 64P 66P 68P 3224023 3224024 3224025 13L Drive System 64P 66P 15L Drive System 3224057 3224058 3224052 64P 3224051 66P
9/97
9.2b
HyVo
BRAKES/FINAL DRIVE Sprocket Part Numbers
HYVO
17T 18T 19T 20T 21T 22T 23T 24T 25T
1M
Sprocket Part Numbers

Drive Systems
3221084 3221085 3221086 3221087 3221088 3221089 3221090 3221091 3221092
Top Sprockets For 3/4" HYVO '"
HYVO Drive Chain

Chain Length (Pitch) Part Number
66P 68P 70P
3224071 3224070 3224069
Bottom Sprockets For 3/4" HYVO Drive Systems

Standard Bo tt om Sp ro ck ets Rev er se Sprockets
39T 40T 41T
3222105 3222094 3222095
40T 41T
1341224 1341225
9.2c
9/97
BRAKES/FINAL DRIVE Sprocket / Chain Combinations Sprocket / Chain Comb inations - 6.625 Chain Case
Acceptable gearing I chain combinations are listed below for the 6.625 (cente r distance) chaincase. Do not use this chart for 1997 - 1998 models with domestic twin cylinder engines (7.050 chai ncase), refer to page 9,2e , Combinations listed as "not recommended" should not be installed. Upper Sprocket (# of Teeth )
16 16 16 16 16 17 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
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
Chain Length (6.625 Cha in Case)

NOT RECOMMENDED NOT RECOMMENDED
66 66 62 64 64 66 66 64 64 66 66 66 64 64 66 66 66
64
NOT RECOMMENDED NOT RECOMM ENDED NOT RECOMMENDED
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 RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED
NOT RECOMM ENDED
NOT RECOMMENDED NOT RECOMMENDED
NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED
9/97
9.2d
BRAKES/FINAL DRIVE Sprocket / Chain Combinations Sprocket / Chain Comb inations - 7.050 Center Distance Chain Case
'Acceptable gearing / chain comb inatio ns are listed below for the 7.050 (center distance ) chaincase used on all 1997 - 199B 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 Sp ro cket (# of Teeth)
16 16 16 16 16
17 17 17 17 17
Lower Sprocket (# of Teeth)

3S 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 66 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 70 72 72
Chain Length
NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMENDED
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 RECOMMEND ED
NOT RECOMMENDED
NOT RECOMMENDED NOT RECO MMENDED NOT RECOMM ENDED NOT RECOMMENDED
NOT RECOMMENDED NOT RECOMMENDED NOT RECOMMEND ED NOT RECOMM ENDED
NOT RECOMMENDED
NOT RECO MMENDED NOT RECOMMENDED
9.2e
9/97
BRAKES/FINAL DRIVE Type 3 Drive System

Type 3 Drive System Disassembly, Cont.
17. Remove two bolts securing caliper carr ier bracket to chalncase (A).
NOTE: Inspect brake pad condition and repiace if worn to less than 1/2 the originai thick ness. See Brake Pad Replacement in this chapter.
18. Remove three chaincase to bulkhead attaching nuts

and bolts.
NOTE : On some mach ines it may be necessary to remove the rea r exhaust bracket prior to lifti ng chalncass or removing drive shaft asse mbly. Watch for alignment shims between chai ncase and bulkhead . Save for realignment of chai ncase and [ackshaft asse mbly to buikhead during reassembly.
19. Remove chaincase.
.-../
20. Remove oil tank attac hing bo lt (A) . On liquid cooled

models. remove coolant recovery tank bolt (B).
21. Raise jackshaft asse mbly 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 bea ring 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, Cant.
'-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 1hey 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. Ifbearing appears tight, use heat to expand chaincase bore. Aiways 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 WideTrakj
1. Apply Loctite 680 to outer race of beari ng and press into position .
LoctlteTU 680
PN 2870584
2. Reinsta ll snap rings.
3. 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.
4.
Install drive shaft and jackshaft as shown with new seal sleeves (A) and a-Rings.
NOT E: Recessed area on seal sleev e 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 necess ary to install the chaincase to bulkhead attaching bolts.
7.
Install jackshaft alignment tool (B) 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 Alignment Tool
, :.>..
PN 2870399 13 Tooth Jackshafts PN 2871535 15 Tooth Jackshafts
11/95
9.32
BRA KES/F INA L DRIVE Type 3 Drive System

Type 3 Drive System Assembly, Cant.
8. Slide a bearing onto driven clutch end and check shaft alignment to bulkhead opening (A). Modeis with pressed jackshaft bearings will require the chaincase to be shimmed since the bearings cannot be moved for alignment. Equal spacing around the bearing is critical. NOTE: This step is critical to the prevent ion of bearing preload, which can cause premature bearing andlor 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 standa rd nut and flat washer for this alignment process will simplify the process as well as preserve the locking features of the lock nut for reassemb ly.
10. Once correct [ackshaft alignment has been achieved, install lock nuts on chalncase retentio n bolts and torque to specification . Remove alignment tool from chaincase .
11. Install track and drive shaft into unit. Pull jackshaft into chaincase and seat in bearing . Install track in proper direction of travel.
9.33
9196
BRAKES/FIN AL DRIVE Type 3 Drive System

12. Install alignment washers and sprocket spacer on drive shaft and [ackshaft. Install top and bottom sprockets and secure. Using a straight, flat piece of 1/4" (6mm) bar stock 9" (22.86 ern) long check sprocket alignment. Add or subtract washers to bottom sprocket to achieve alignment.
13. Once alignment has been achieved, install

sprockets with chai n. 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 cnalncase.
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.
11/95
9.34

Type 3 Drive System Assembly, Cont.
12. Install jackshaft bearing, flangettes, and gasket.
Align grease hole (A) in bearing with hole or fitting in flangette (B) to within .100 " to ensu re greasability. Torque nuts to specification. Do not lock set screws on reta iner ring (if so equipped). NOTE : Ultra, Storm , and 600 XCR SP models do not have set screw s. RXL mode ls have a Skwez-loct type retaining ring .
Flangette Nut Torque -
15 - 17 It. Ibs. (2.07 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).
",q~{;rU#;
Flangette Nut Torque.
s kwez-roci - Bearing
NOTE : On Ultra, Storm, and 600 XCR models with pressed beari ngs, place inner flange ttes with welded bolts inside tunnel , install gaske t f1angette and angle drive with new adaptor key into assembly. Install Flex Lac'" nuts and torque to specification. Flangette with studs must be assembled on driveshaft prior to press ing bearing on shaft and assem bly of driveshaft into unit.
Flex Lac'" Nut Torque -
15 - 17 It. Ibs. (2.07 - 2.35 kg-m)

.
..
14. When reinstall ing drive shaft flangettes and

speedometer angle drive , always replace drive key (A) and install a new gaske t (B). Align holes
9.35
9/96

20. Check cable routing and lubricate with Polaris cable lube.
21. Grease angle drive and bearing with Polaris grease.
22. Torque bottom chalncase specification.
sprocket bolt to
23. Torque jackshaft nut to specification. On models with castle nut, if colter pin does not align, tighte n nut until it does. It may be necessary to apply brake to hold jackshatt 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 em) 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
BRAKES/FINAL DRIVE Type 3 Drive System Type 3 Drive System Assembly, Cent.
'--...-
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 andlor 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 cnaincase oil to the chaincase.
Polaris Synthetic Gearcase Lube PN 2871477 (Gallon) PN 2871478 (12 ounces)
18. Install chaincase cover gasket in chaincase with gap at the top. Install chaincase cover and torque cover bolts to specification.
!
chalncase' Cover Bolt
n(~
19. Torque bearing driveshaft and jackshaft set screws to specification (if so equipped).
Drlveshafl and Jackshafl Bearing Set Screw Torque -
80 In. Ibs. (.92 kg-m)
20, Lubricate bearing with Polaris Premium All
Season grease.
Polaris Premium All Season Grease PN 2871423
9 .37
9196

Type 3 Drive System Assembly, Cont.
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 jack shaft. This is done by adding or subtracting spacer washers (PN 755573 4) to the clutch retaining bolt. When properiy adjusted, the driven clutch will have .020 - .100" (.5 - 2.5 rnrn) float.
Incorrect float can cause jacks haft bearings to be side loaded, resultin g in prematu re 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 siide shaft out left side without removing chaincase. 36. For reassemb ly, use jacks haft installation tool (A). Grease tool and guide jackshaft through brake disc hub , seal sieeve, O-Ring and beari ng.
NOTE: Jackshaft with tool installed must siide 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.
318 suspemi{6n Bolt Torque " 35-40 ft. Ibs (4.83-5.52 kg m)

7/16" Suspension BoltTorque 45-50 fllbs. (6.21-6.9 kg m) '"
.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 puttinq into service.
9.39
11/95

1997 Track Drive D ata Model Drive No . of . Type Drive Sp rockets 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 3 3 3 3" 3" 3" 3" 3" 3" 3" 3" 3" Drive Shaft Bearing Lock Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Screw Set Sc rew 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 Drive Sproc ket Diameter 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 DRIVE SPRO CKET POSITION Reference Page 9.4 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 B 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 7.4 8 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 7.48 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 12.32 16.32 C D
Indy Lite Indy Lite Deluxe Indy Lite GT 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 XC Indy 600 XC Indy 600 XCR Indy WideTrak GT Indy WideTr ak 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 SP X/SE Indy Ultra Touring Indy 700 SKS Indy 700 RMK Indy Storm Indy Storm SKS Indy s torm RMK
All 1996 mode ls, sprocket positions are measured to spr ocket hub and not idler center. See page 9.4.
15.97
17.47
Skwez-lcc'
Pressed Pressed Pressed Pressed Set Screw Set Screw Pressed Pressed Pressed
Denotes driveshafts with pressed on left side bearings (no lock collar) with welded f1angette bolts .
9196
9.3a
BRAKE S/FINA L DRIVE Specificati ons

1998 Track Drive Data
Model No. of Driv e Sprockets 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 Dri ve Type 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' T 4' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' 3' Driv e Shaft Bea r in g Loc k 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 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 DRIVE SPROC KET POSITION Refere nce Page 9.4
Indy Lite Indy Lite Deluxe Indy Lite Touring 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 Wid eTrak LX Indy Class ic Indy Classic Touring 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 Tou ring Indy 700 XC Indy 700 XCR Indy 700 RMK Indy Storm
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
B 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
9/9 7
BRAKES/FINAL DRIVE Track Specifications

1996 Track Speci fications
Model Leng th x Wid th Co nt act Len gt h 35" 41" 35" 4 1" 45" 35" 44" Patlern Lu g Height .66" .82" .71" Wheels Bogie! Idle r 6/3 6/3 6/3 6/3 8/3 6/3 8/4 6/4 8/4 /4 /4 6/3 6/3 6/3 6/3 6/3 4/3 6/3 6/3 4/3 6/3 6/3 6/3 6/3 4/3 6/3 6/4 8/4 4/4 6/4 8/4 8/4 6/4
Wea r Strips
Indy Lite/De luxe Indy l.ite GT Indy Sport Indy Sport Touring Indy TranSport Indy Super Sport Indy 440 XCR Indy 440 XCR SP Indy 600 XCR/SP Indy WideTrak 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 Tou ring Indy XLT/SP Indy XLT SKS Indy XLT RMK Indy XLT Touring Ind y RXL Indy Ultra SP Indy Ultra RMK Indy Ultra SKS Indy Storm Indy Storm SKS Indy Storm RMK
121 x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 14 1 x 15" 12 1 x 15" 121 x 15" 121 x 15" 121 x 15" 141 x 20" 156 x 20" 121 x 15" 133.5 x 15" 121 x 15" 12 1 x 15" 133.5 x 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" 133.5x15" 133.5 x 15" 133.5 x 15" 121 x 15" 121 x15" 133.5 x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 133.5x 15"
Block Lightning Block lightning Wiper Lightning Logo Logo Lightning Wiper Block Lightnin g Lightnin g Lighlning Lightning Lightning Deep Lug Lightn ing Lightn ing Deep Lug Lightning Lightning Lightning Lightning Deep Lug Lightning Lightning Lightni ng Deep Lug Lightning Wiper Wiper Deep Lug
N/A N/A Ace Ace Ace Ace SId SId SId Std Std Ace Ace Ace Ace Ace N/A Ace Ace N/A Ace Ace Std Ace N/A Ace Std Std N/A Ace Std Ace N/A
.82"
1.13" 82" .73" .73" .82" .9 1" .71" .82" .82"
.82 "
44"
44" 45" 52.5" 44" 50" 44" 44" 50" 50" 35" 50" 41" 35" 41" 35" 41" 41" 44" 35" 35" 41" 41" 44" 50" 50"
.82"
1.0" 1.25" .82" 1.0" 1.25" .82" .82" 1.0" 1.0" 1.5" .82" 1.0" .82" 1.5" 1.0" .9 1" .91" 1.5"
9.3d
9/97
BRAKES/FINAL DRIVE Track Specifications 1997 Track Specifications

Model Length x Width Part No. Pattern Lug Height .66" .82" .71" .82" 1.13" .725" .82" .82" .82" 1.25"
.9 1"
Wheels Bogie/ Idl er 6/2 6/3 6/2 6/3 8/3 6/3 6/3 6/3 6/3 4/3 6/4
6+214
Wea r Strips
Indy LitelDe luxe Indy Lite GT Indy Sport Indy Sport Touring Indy TranSp ort 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/XC R Ind y RX L Indy UltraiSP/SPX Indy Ultra Touring Indy Ultra SPX SE Indy 700 SKS Indy 700 RMK Indy Sio rm Indy Sto rm SE Indy Sto rm RMK
121 x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 141 x 15" 121 x 15" 121 x 15" 121 x 15" 133.5 x 15" 133.5 x 15" 141x20" 156 x 20" 121 x 15" 121 x 15" 121 x 15" 133.5 x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 121 x 15" 121 x 15" 133.5 x 15" 133.5 x 15" 133.5 x 15" 121 x 15" 121 x 15" 12 1 x 15" 121 x 15" 133.5 x 15" 12 1 x 15" 136x 15" 136 x 15" 121 x 15" 121 x 15" 133.5 x 15"
54107 92 54 11171 5410736 54111 71 5410801 5411183 5411168 5411168 54 111 71 54 1102 1 54 10748 5411040 5411168 54111 68 5411168 54 11166 541102 1 5411168 5411091 54111 68 5411167 541109 1 54111 66 541092 1 5411167 5411167 54 111 67 5411057 5411176 5411183 5411193 54 11194 54 11057 5411183 54 1092 1
Block Lightning Block Lightning Wiper Lightn ing Lightning Lightning Lighln ing Deep Lug Wipe r Lightn ing Lighlning Lightning Lightnin g Lightnin g Deep Lug Lightnin g Lightnin g Lightnin g Lightn ing Lightning Lightn ing Dee p Lug Lightnin g Lightn ing Lightn ing Lightning Lightn ing Lightning Lightn ing Deep Lug Lightning Lightning Deep Lug
Ace Ace Ace Ace Ace Sid Ace Ace Ace N/A Std Std Ace Std Ace Ace N/A Ace Ace Ace Ace Ace Ace N/A Si d Std Sid Si d Ace Si d Ace N/A Si d Si d N/A
1.0" .82" .82" .82"

1.0"
1.25#
6/3 6/4 6/3 6/3 4/3 6/3 6/3 6/3 6/3 6/3 6/3 4/3 6/3 6/4 6/4 6/4 6/4 6/4 6/4 4/4 6/4 6/4 6/4
.82" .82" .82" .82" .82" 1.0" 1.5" .82" .82" .82" .82" .82" .725" 1.0" 1.5" .82" .725" 1.5"
9 /9 7
9.3e
BRAKES/FINA L DRIVE Track Specif ications

1998 Track
Mo del Length x Wid th Part No. Patt ern Lug Height .66" .66" .82" .71" .725" 1.125" .82" .82" .82" .82" 1.25" .82" .82" 1.0" .82" 1.25" .82" .82" .91" .82" .82" .82" .82" .82" 1.75"
.82'"
Whee lsBogiel Id ler
Wear Strips .75" Ace .75" Ace .75" Ace 1.05"Ace 1.05"Ace
Wind ow
Ind y Lit e Indy Lit e Del uxe Ind y Lit e Tou ring Indy Sp ort Indy XCF Indy Tran Sport Indy Sport Touring Ind y Su per Sport Ind y Trail Indy Trail Tourin g Indy Trail RMK Indy 440 LC Indy 440 XCR Indy WideTrak LX Indy 500 Indy 500 RMK Indy Classic Indy Classic Tour ing Indy 600 XC Indy 600 XC R Indy XLT LTD Ind y XLT Classic Indy XLT SP Indy XLT Tou ring Indy 600 RMK Indy Ult ra Indy Ultra Touring Indy 70 0 XC Indy 700 XCR Indy 700 RMK Indy St orm
121" x 15" 121" x 15" 133.5" x 15" 121"x 15" 121" x 15" 141" x 15" 133.5" x 15" 121" x 15" 121" x 15" 133.5" x 15" 133.5" x 15" 121" x 15" 121" x 15" 156" x 20" 121" x 15" 133.5" x 15" 121"x 15" 133.5" x 15" 121"x 15" 121" x 15" 121" x 15" 121" x 15" 121"x 15" 133.5" x 15" 136"x 15" 121"x 15" 133.5" x 15" 121" x 15" 121" x 15" 136"x 15" 121" x 15"
5410792 5410792 5411171 5410736 5411183 5410801 54111 71 5411168 5411168 5411171 541102 1 54 11168 5411475 5411040 54 11168 5411021 54 11168 541109 1 5411369 54 11344 5411167 54 11167 5411379 54 11 091 5411237 5411344 5411176 5411369 5411344 5411237 5411344
Block Block Lightning Block Lightning Wiper Lightning Lightning Lightning Lightning Deep Lug Lightning Lightning Lightning Lightning Deep Lug Lightning Lightning New New Lightning Lightning New Lightning Deep Lug New Lightning New New Deep Lug New
4/2
4/2 6/2 4/2
1.25" 1.25" 1.5"

1.5 "
6/4
8/3
1.25" 1.25" 1.5" 1.25" 1.25"
NIA
.75" Ace .75" Ace .75" Ace .75" Ace
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 6/3 6/3 6/4 6/3 4/3 6/4
6/3
1.5#
1.25" 1.25" 1.25" 1.25" 1.25"
NIA
.75" Ace Coolers
NIA
.75" Ace
NIA
.75" Ace .75" Ace Coolers .75" Std .75" Ace .75" Ace .75" SId .75" Ace
1.25"
1.25" 1.5" 1.25" 1.25" 1.25" 1.25" 1.25" IS 1.25" 1.25" 1.5" 1.25" 1.25" 1.25" 1.25"
NIA
.75" Std .75" Ace
.82" .91" .82" 1.75" .82"
6/4 6/4 4/3 6/4
Coolers
.75" Std
NIA
.75" SId
Po laris Industries Inc .
9.31
9/9 7
BRAKES/FINAL DRIVE Transmission, Suspension and Track Remova l - WideTrak Models

1. Mark hood hinges for ease of alignment when reassembling unit. Remove hood assembly and set aside to prevent damage. 2. Remove battery (if so equipped). 3. Turn off fuel valve. Move oil tank for access. 4. Remove air intake and coolant recovery bottle from its mounting (WideTrak LX models only - do not remove entirely). 5. Remove drive belt. 6. Remove driven clutch retaining bolt assembly and drive clutch. Note number of spacers which are behind driven clutch for installation during reassembly procedures. 7. Remove muffler springs and muffler from unit. 8. Loosen brake cable jam nut (Al and remove cable boil, nut and spacer (B). Use care not to loose spacer. 9. Remove cable from transmission.
10. Note location of shift linkage on transmission (Al 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
Polaris Indusfries Inc.
BRAKES/FINAL DR IVE Transmission, Suspension and Track Remova l - WideTrak Models

12. Loosen rear idler wheels and bolts. 13. Loosen jam nuts on adjustment bolls on both sides. Back out adjustment bolts to allow rear idler assembly to come forward , relieving track tension. 14. Tighten idler wheel bolls 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'' handle Allen wrench, loosen set screws on lock collar. 18. Remove (2) bolts, nuts, and f1angettes 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 . 2. Remove angle drive housing, adaptor key, f1angettes, gasket, and bearing from drive shaft and tunnel.
NOTE: It is not necessar y to remove speedometer cable from angle drive. Replace adaptor key any time drive train assembl y is serviced.
3. Tip machine back onto floor.
4. 5.
Remove right side bumper plug (A). Remove bolt retaining rear of bumper to foot rest.
6. Bend muffler mount out of the way to allow transmission removal. 7. Remove three transmissi on retaining bolts. Note all alignment shim quantities and locations for reassembly.
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 transmission to free drive shaft coupler.
9. Lower drive shaft and remove lower front bolt. 10. Maneuver transmission until it can be removed from the unit. Use care not to damage coolant lines on LX models. 11. With transm ission removed , tip unit onto right side. Notice direction of track rotation for reassemb ly. The arrow in the photo at right indicates track bottom, rear of unit. 12. Remove front and rear carrier shafts .. 13. Remove suspensio n by pulling rear of track out of tunnel. Slide suspension forward to driveshatt. Lift up and out at the rear.
NOTE: On some models it may be necessary to unhook rear torque arm springs to allow torque arm to lower
14. Inspect transmission , brakes , suspension and track tor excessive wear. cnecx bearings for excessive movement or rougn feeling. Replace if necessary.
9/96
9.42
Po/ans Industries Inc.
BRAKES/FINAL DRIVE Transmission, Suspension and Track Assembly - Wide Trak Models - 1996
Assembly 1. Tip unit onto right side. 2. 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, flanqette , bearing , gasket , and flangelle 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.
3.
4.
5. 6. 7.
8.
9. Tip machine onto its left side. 10. Replace a-rings on input and output shafts. Apply Polaris All Purpose Grease to drive shaft coup ler splines.
~ : , :: : ,)
Polaris A II. ~urpose Grease

-,0
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 bolt is started into transmission housing, align coupling with drive shaft and jack shaft splines. Keep transm ission flat and lower gradually to prevent binding of couplers. 13. Install remaining transmission mounting bolts. Reinstall shim washers in original positions and tighten 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 features of the lock nut for reassembly. , 4 Tip machine onto its right side.
9.43
9/96
BRAKES/FINAL DR IVE Transm ission, Suspension and Track Assembly - WideTrak Mode ls - 1996
Assembly, Cont.
15. Loosen set screws and seat drive shaft in transmission coupler stub shaft. For ease of assemb ly, make sure track has no pressure against drive shaft. 16. Tlqhten nuts retaining angle drive housing to tunnel. Torque to specification .
17. Using "T" handle Allen wrench , torque set screws to

specification.
-- ~- ~> -n ~: {Y':'; "LL t ::::6S~;;; _; Sel Screw Torque';
SOin. Ibs. (.92 kg-nil
,>c-
t.,"., ;. " ! : ,'
,:"" : : : . :, ~ :? ,,
;_~_ ' <''';(_''(_' _H,q ;,
_ ~):f-~U::-;{~;} ~
0;:;
18. Reinstall suspension inside track and align with tunnel mounting holes.
19. Install and hand tighten suspension bolts (8). 20. Install front carrier shaft assembly inside track and mount to tunnei with bolts. Hand tighten bolts. 21. Install rear carrier shaft assemb ly. Make sure bolts are not cross threaded and hand tighten (A).
22. Tip machine back onto floor and tighten all suspension bolts to specification .
9196
9.44
BRAKES/FINAL DRIVE Transm ission, Suspension and Track Assembly - WideTrak Models 1996
Assemb ly, Cont.
23. If jackshaft was removed from unit, grease coupler spline with Polaris Premium All Season Grease and install on transmission.
24. Check for bearing to bulkhead alignment and shim transmissi on as required to center [ackshatt in bulkhead mount. Shims may be required 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.
27. Install bolts and nuts securing flangettes to bulkhead. Torque to specification .
28. Set lock ring at transmission coup ler and torque to specification .
o
9.45
9/96
BRAKES/FINAL DRIVE Transmission , Suspension and Track Assembly - Wi deTrak Models - 1996 Assembly, Cant.
29. Reattach transmission shift iinkage and brake light connecto r. Check transmission fluid levei and fill if necessary.
30. Attach brake cable to transmission mounting with bolt, nut and spacer. 31. Install bumper onto footrest bolt and tighten. 32. Reinstaii bumper plug. 33. Reinstaii and secure muffler. 34. Instaii battery (if so equipped), air box, oil tank, and cooiant recovery bottle (if so equipped). 35. Loosen rear idler bolts. 36. Reinstall driven ciutch and spacers onto jackshaft and tighten. 37. Reinstaii clutch offset washe rs on jacksh aft and install driven clutch. Using the clutch alignment tool adjust driven clutch to achieve proper offset.
38. WideTrak models have no float on driven clutches. Use shim washers (PN 7555734) to create gap between shaft and cover washe r only.
9196
9.46
BRAKES/FINAL DRIVE Transmission, Suspension and Track Assembly - WideTrak Models - 1996
39. Torque driven clutch retaining bolt to specification.
Dr ive n Clutch Retaining Bolt Torque12 ft. Ibs. (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/FINA L DRIVE Transmission Disassembly 1997 to Current WideTrak Disassemblyllnspection

1. Drain transmission oil into suitable container.
2. Remove snap ring, spacer washer, and brake disc.
NOTE: Note position of spacer washers behind disc for proper aiignment upon reassembly.
3. Remove detent spring and ball.
4.
Remove case bolts evenly in a criss-cross pattern.
9/96
9.47a
BRAKES/FI NAL 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.
..
7. Remove shift arm
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
9196
BRAKES/FINAL DRIVE Transmission Disassembly 1997 to Current WideTrak

10. Remove shift fork shaft from gear cluster. Inspect surface of fork for wear or bending.
11. Remove chain from input and reverse shaft. Inspect gear teeth for damage. Inspect chain for worn, cracked, or broken link plates.
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.
9/96
gA7e
BRAKES/FINAL DRIVE Transmission Disassembly 1997 to Current WideTrak

Gear, shaft , and chain cluster asse mbly shown.
Low gear output power flow...
High gear output powe r flow...
Reverse outp ut power flow...
9.47d
9i96
BRAKES/FINAL DRIVE Transmission Disassembly 1997 to Current WideTrak Low I Reverse Shaft Disassembly
13. Press bearing from end of shaft using a bearing separator.
14. Remove snap ring and spacer washer.
9196
9.47e
BRAKES/FINAL DRIVE Transmission Disassembly 1997 to Cur rent WideTrak

15. Remove low reverse shaft low gear... Low/Reverse dog gear needle bearing, thrust washer, low/reverse dog gear...
Thrust washer
Needle bearing
snap ring, thrust washer (.OSON), reverse idler, needle bearing, and thrust washer (.06S
N ) .
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 Alf
9/96
BRAKES/FINAL DRIVE Transm ission Disassembly 1997 to Current WideTrak

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 for wear. Replace parts as required. NOTE: The spring must be pre -load ed upon installation. Refer to photo and illust ration below. Locate spring in retainer slot as show n
Hook spring he re
Detent area
Arm of detent plate must be positioned betw een end s of spring. Install key.
Transmission Assembly
Lub ricate all parts before assembly with Premium Synthetic Chaincase Lubricant. 1. Install cha in on input and reverse shaft. Photo 1. 2. Add output gear assembly with cha in. Photo 2.
Photo 1
Photo 2
3. Add shift 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). 6. Apply 3 Bond T 1215 Sealant to case halves. 7. 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 install acce ss plug (where appl icable). 8. Install tran smission. Add 20 oz. Premium Synt hetic Chaincase Lubricant. 4.
5.
Transmission Case Bolt Torque-
8-10 ft. Ibs. (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 Gall on PN28i14n 12 oz. PN 2871478
Brake Caliper Removal - Type WT2

1. 2. Remove brake cable. 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.
':'..,:., .~,:~:;. ,:.hf:(U-tt.,.'. '.: . ,.':':" ""'"
Brake Pad Thi ckness - Typ e WT2 " ~:~'~;;;::;i}:~;ri;:,} _ Utr l:S( ' :' : : ; /i ,~ [;: : i:;, Service Li mit .250 (6.35mm) ;,-,-,; :.
m
4. 5. 6.
With actuating arm facing up, carefully remove tensio n 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

Assembly
1. Apply a light film of grease to balls and ball spacer. Install in caliper housing. 2. Install lifter ramp. NOTE: Ramp may be installed in any position.
3.
Install spring and arm with arm located in 8:00 position as shown in photo at right. 4. Install lower guide bushing and both spring clips. Place pads against lower bushing spring clip and tip into position. 5. Install upper guide bushing.
Installation
6. Install hex head bolt with washer in top guide bushing. Install Allen head bolt in recessed bushing as shown. 7. Reinstall brake actuating cable and adjust as outlined on page 2.2Sa of the Maintenance Section. Tighten cable lock nuts securely. Bracket Lock Nuts
Move cable up or down in bracket to adjust freeplay
9/96
9.471
BRAKES/FINAL DRIVE Track Remov al - Two Sprocket Drive Shaft

1. Remove rear suspension bolts. 2. Remove front suspension bolts. 3. 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 Remova l Two Sproc ket Drive Shaft
Track Removal Two Sprocket Drive Shaft

1. Remove three cap screws holding lIangette and bearing in place on left side of machine .
2. 3.
Remove bearing and lock collar from drive shafl. Remove chaincase cover.
4. Loosen chain adjuster bolt lock nut and back all adjuster bolt until chain has maximum slack. 5. Remove bottom sprocket in chaincase. 6. Remove drive shaft by pulling shaft first from chaincase and then from left side of machine. 7 . Reverse process for reassembly. Be sure to install and torque lower chaincas e sprocket before locking lock collar.
NOTE: Cotter pin must be positioned so it will not hit the chaincase cover. Lowe r Chaincase Sprocket Torque -
50 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 thrott le cable and brake hose. Remove two phillips screws securing air intake silencer. Taking care not to damage throttle cable. litt silencer out.
3. Remove secondary clutch and loosen jackshaft lock collar set screw. Using a hammer and punch, unlock the lock collar. Remove three cap screws holding jackshaft left hand bearing and flangelies in place. Remove bearing from jackshaft.
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. Carefully tip machine on its left side onto a mat. Lift chaincase up until drive shaft is out of lower chaincase bearing. 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, replacement is necessary in order to avoid serious damage to the machine or injury to the operator. 6. After inspecting all parts, reverse process for reassembly. The lower forward chaincase mount bolt (C) must be in place before installing drive shaft. Drive sprocket interterence will not permit installation after drive shaft is installed. The lower chaincase sprocket must be installed and torqued before locking lock collar.
9/9 7
9.50
BRAKES/FINAL DRIVE Series 300 Transmission Overhaul

Transmission overhaul should also include drive system overhaul. After removing drive shaft and [ackshatt, proceed as indicated below. "-1. Remove four caliper carrier attaching bolts (A). 2. Remove two caliper bridge bolts (B), 3. Remove brake caliper and brake disc.
4. Remove shift linkage (A) and stop light switch wires (B). 5. 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
BRAKES/FINAL DRIVE Series 300 Transmission Ove rhaul

8. Place transmission as shown and remove shift lever and key (A), neutral light switch (B), 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

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 transmis sion 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 LoctiteT" 515 Gasket Eliminator on one of the case halves.
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.
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 turns. 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 t.octitet 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 rnrn)
9/96
9.54
Polaris tnaustnes Inc .
BRAKE S/FIN AL DRIVE Se ries 300 Transmission Overh aul

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.
Drain Plug
9.55
11195
BRAKES/FINAL DRIVE Reverse Kit Serv ice Tips

The followin g 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 _ _ ; _
Reverse Position
_ =/
Top Sprocket
~---
Drive Chain
--~
Chain Pinion Gear (Narrow Face)
Chain Pinion Gear ~ Chain Pinion Gear (Wide Face) --.- (Narrow Face) Chain Pinion Gear (Wide Face)
-,
Spur Pinion Gear
"<, Spur Pinion Gear
Shift Fork Groove Reverse Kit Option Sprocket Reverse Kit Option Sprocket Drive Coupler
11/95
9.56
BRAKES /FIN AL DRIVE Reverse Kit Maintenance

15 tooth [ackshaft spacer washer PN 7555917 / 13 tooth jacks haft spacer washer PN 7555876 13 wide top sprocket with 15 tooth [ackshatt requires (1) PN 7571620 11 wide top sprocket with 15 tooth jackshafl requires (1) PN 7555864 and (1) PN 7571620
/~\~ @(i
v.gq .
~
~
-6,?l ~ ,: - - - ~ 'd-~ _ " -'~_
: @-~:
Chain - - - t - - --t; ,.
Top :~.. . . ; Sprocket/.'

I '
'"
-h~
:.
@............
11 wide top sprocket with 13 tooth [ackshaft requires (1) PN 7555863 and (1) PN 7571620
' a.t
............
!,. @,
'@
~~
~ JIf.
L // @........
Bottom Sprocket
/
O-R ing
(i
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 adjuste r bolt.
2. 3.
Loosen adjuste r bolt 1/2 turn. Hold adjuster bolt in position and tighten locknut.
Oil Level
1. Using Polaris cha incase lubricant, maintain proper oil level. Proper level is checked by removing dipstick .
9.57
9/96
BRAKES/FINAL DRIVE
Reverse Kit Maintenance
8. Wipe off any metal particles from the dipstick. Small amou nts of particles will be commo n.
9. Add lubricant until the level is in the "safe" zone on the dipstick (11 oz.) Do not mix or use other types of lubricant.
Oil Change
1.
Change annually, prior to off season storage .
Adjustment
Due to break-in or replacement of compo nents, the reverse shift mechanism may require adjustme nt. Adjust with the shifter in the forward position .
Standard Indy Style

1. Loosen jam nuts on lower end of cable .
2 . Adjust cable until endplay movement of cable housing at the handlebar bracket is 1/32" (.08 em). Do not adjust beyond this point. 3 . Tighten jam nuts and re-check adjustment.
Reve rse Cab le End Play 1/32" (.OB em) 1/32" Adjustme nt (.08 em)
Evolved and Aggressive Style

1. Lift shift lever slowly while observing shift 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.
sri~-L
1-1 1/2" (2.5-3.8 em) free play Chaincase
Shift Lever
3 . Loosen jam nuts on lower end of cable. 4 . Adjust cable end at transmission until the end of the shift lever has 1 - 1 1/2" (2.5 - 3.8 em) of freeplay before the cable starts to move the shift arm. Do not
cove~r
Shift Arm
/'
Il~
a
5. Ti
Reve rse Shift Lever Freeplay 1 1 1/2" (2.5 3.8 em) measured at end of shift leve r
~~~~I I
/~ ' 'n
. c
~'>'J
~ f2
9.58
r~
9/97
BRAKES/FINAL DRIVE Traction

The amount of tractio n required varies depe nding upon the type of riding and the snowmobile's horsepower. Studs are desi gned specifically for eac h riding category. They're made in vario us lengths, shapes, and materials. Improperly applied studs can cause poor traction and premature wear. Studs which are too long ca n ca use dam age to the tunnel and heat excha ngers . 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 . Scoo pe rs are used on softer surfaces . Material contributes more to stud life and cost than to functionality. Carbide is the most durable and lasts much longer than steel. Studs should be installed no closer than 1"from the edges of the track . Avoid the ce nter of the track because there is poor suppo rt in this area. The track 's cente r be lt cont rols acce leratio n. The two smaller outside track belts contribu te to acceleration, but the more studs installed in these belts, the harde r it is to corner. The chart on page 9.60 is a guide line for the qua ntity of studs to install.
Be sure to check allowable clearance between the track and tunnel or heat exc hangers, facto ring 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 patte rns with the least repetiti on work best. Studs shou ld cove r as man y diffe rent lines in the ice as possible. Studs closest to the slide rails provide the most effectiveness, because the we ight of the sled is concent rated in this area .
9.59
9/96
SUSPENSION
Traction
Polaris Push-Through Stud and Skag Recommendat ions
Trail Mode l Lite Lite Deluxe Lite GT Sport Sport Touring TranSport XCF 440 XC Super Sport Trail Trail Touring Trail RMK WideTrak GT WldeTrak LX 440 500 500 SKS 500 RMK Classic Classic Touring 500 EFI XLT XLT Touring XLT SKS XLT RMK XLT SP XLT LTD 600 XC/XCR 600 XCR SE 700 SKS 700 RMK RXL Ultra Ultra SP/SPX Ultra SPX SE Ultra Touring Storm Storm SE Storm RMK Trac k Leng th 121 x 15" 121 x 15133.5 x 15" 121 x 15133.5 x 15" 141 x 15" 121 x 15" 121 x 15" 121 x 15" 121 x 15133.5 x 15" 133.5 x 15" 141 x 20" 156 x 20" 121 x 15" 121 x 15" 133.5 x 15" 133.5 x 15" 121 x 15" 133.5 x 15" 121 x 15" 121 x 15" 133.5x 15" 133.5 x 15" 133.5 x 15" 121 x 15" 121 x 15" 121 x 15" 121 x 15" 136x 15" 136x 15121 x 15" 121 x 15" 121 x 15" 121 x 15" 133.5 x 15" 121 x 15" 121 x 15" 133.5 x 15" 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 0.9 1 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 Tun ne l Pro tector 2871689 2871689 2871543 2871544 2871543 N/A Std Std 2871544 2871544 2871543 N/A Std Std 2871544 2871544 287 1545 N/A 2871544 287154 1 287 1544 287 1545 287154 1 2871542 N/A SId 2871544 Std Std 287 1542 N/A Std Sid Std Std 2871541 Std Sto 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 0.875 1.000 1.000 1.000 1.000 N/A 48 48 48 48 53 Stud Siz e 0.750 0.750 1.000 0.750 1.000 St ud Qty. 48 48 53 48 53 SkagAggress iv e Trail Stud Size 0.750 0.750 1.000 0.750 1.000 St ud Qty. 72 72 80 72 80 SkagD N D D D
B
C D D D D orM 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 NIA 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
48 53 48 96 80 80
-
72 80 72 120 106 106
J
P N/A
120 120 120 120 106
96 96 96 96 80
J J
P S P N/A
96 96 96 96 80 96 96
120 120 120 120 106 120 120
J J
P S
J
P
S
NIA
- Refe r to chart on pa ge 9.62 .
9/96
9 .60
1998 Push-Through Stud & Skag Recommendations

Trail
M od e l
Trac k
Ag gre ssive Trai l

Sk ag
Performance Stud
Size Stud
Length
Lug Height 0.66 0.66 0.71 0.82 082 082 082 0 82 0.82 0.82 0.82 0.82 0.725 0.91 0.82 0.9 1 0.82 0.82 0.82 0.82 0.82 0.82 0.82 0.82 1.25 1.25
1.7 5
Tunnel
Prote ctor
Stud Size
Stud
Stud
e ly,
Size
B
Stud ely,
Ska g
Sk ag
D
ely
96 96 96 96 96 96 120 120 144 144
144
Ute
Lite Deluxe Sport Super Sport
T rail
121 x 15"
12 1
12 1
2871689 2871689 28719 11 287 1544 287 1544

287 1544
287 1544
0.750 0.75 0 0750 1.000 1 000 1.000 1000 1.000 1.000 1 000 1.000 1.000 0 .875
1.075
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 1000 0.875
1,07 5
72 72 72 72 72 72 72 72 120 120 120 120 72 120 120 120 120 120 72 80 80 80 106 106
0.750 0 .750 0.750

1.000
x 15" x 15"
C
D D
N
D D
J
P
P
121 x 15"
12 1 x 15"
44 a
12 1 x IS" 12 1 x 15"
12 1
N N
D
N N
D
1.000 1.000 1.000 1 000 1.000 1.000 1.000

1,000
J J
P
500
Classic
x 15 "
287 1544 SId

287 1544 287 154 4
N
R
N
S
J
S
XL[ S P XLT LTD

X LT ClaSSIC
(D
12 1 x 15"
12 1 x 15" 12 1
x 15" x 15"
x 15"
Ultra
121
SId 287 1911 SId SId SId SId SId 287 1543 287 1543 287 1543
287 1541
N N N
R R
J J J
R S S S S S
J J J
R S S S S S
144 96 144 144 144 144 144 96 106 106 106 132 132
(J)
XCF 600 XC 600 XCR 700 XC 700 XCR

Storm
12 1 x 15"
0.875 1.075 1.000 1.075 1.000 1.000 1.000 1.000 1.000 1.000 1000 1.000
III
12 1
12 1
x 15" x 15"
1.000 1 075 1.000 1.000 1.000 1 000 1.000 1.000 1.000 1000
12 ' x 15"
12 1
R R
R
1000 1.075 1.000 1.000 1.000 1000 1.000 1.000 1.000 1.000
121 x 15"
133 .5 )( 15"
R
C
Lite Touring
N
D
J
P
Sport Touring
133 .5 133 .5
x 15"
Irall Tounng
Classi Tounnq c
x 15"
N
R
N
R S S 'R
J
S S S S S S S
133.5 x IS"
133.5 x 15"
133 .5
XLT Touring
Ultra Touring
T rail R MK
287 1541 287 1541
x 15"
w
R .R
'R 'R 'R 'R
Dor M
133 5x1 5"

133.5 x 15
136 x 15" 136
NIA
N/A
500 RMK 600 RMK 700 RMK

TranSport W ide Tlak LX
15"
1.75 1.125 1.0
141 x 15"
1!J6)( 20'"
NIA N /A N/A NIA
NIA NIA NIA N/A
N IA
N/A
N.'A
'R 'R
'R
N/A
NIA NIA NIA N/A
en c en
-i m
-C
J or P
, Slandard on RMK Models
:I Z
o en ...'0 0
ill z
BRAKES/FINAL DRIVE Traction
A WARNING
'-A proper balance of traction produ cts on the skis and track must be maintained to obtain proper vehicle control on hard packed snow and ice. Loss of control can resu lt in severe personal injury or death . Track studd ing will enhance braking co ntrol on hard packed snow or Ice. but extreme caution is still requ ired on such surfaces . Use extra caution when track studding is employed as steer ing ability ma y be reduced on hard packed snow or ice. The add ition of carbide skags (if not already installed) is recommended with studded tracks to aid in maintaining proper veh icle steering and control. Proper balance must be maintained between the number of studs and the length and sharpness of carbide on skaqs ,
If you are add ing studs to the track of a machine it will probab ly be advisable to add carbide skags or change to more aggre ssive skags in order to maintain proper vehicle control wh ile turn ing on hard pack ed snow or ice. If
the machine is equipped with carbide skags or if you are add ing them or changing to mor e aggressive skag s tha n standard equipment. it may also be necessa ry to add track studs in orde r to maintain proper vehicle cont rol wh ile 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 pag e 9.60 should be used as guidelines in achieving a prop er balance of ski and track traction products on Polaris snowmobiles.
;;.1
9.6 1
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 7/16
Stud Kits 2871112 Traction Master Carbide Push Through .75 (Pkg of 24 w/bacKe rs) "287 1404 Traction Ma ster Carbide Push Through .875 (Pkg of 24 w/oackers) "2871405 Traction Master Carbide Push Through 1.0 (Pkg of 24 w/backers) "2871414 Traction Master Carb ide Push Throu gh 1.075 (Pkg of 24 w/backers) "2 871 649 Traction Master Carbid e Push Through 1.175 (Pkg of 24 w/backe rs) 287 1243 Traction Master Carbide Push Through .75 (Pkg of 96 no backe rs, use 7mm washer ) 2 871244 Traction Master Carbide Push Through .875 (Pkg of 96 no backers, use 7mm washer) "287 1245 Traction Master Ca rbide Push Through 1.0 (Pkg of 96 no ba ckers, use 7mm washer) "28714 15 Traction Master Carb ide Push Throu gh 1.075 (Pkg of 96 no back ers , use 5/16 washer) "2871 650 Traction Master Carb ide Push Through 1.175 (Pkg of 96 no backers, use 5/16 washer) 287 1598 Tracti on Master Push Through Carb ide Wedge .875 (Pkg of 24 w/back ers) 2871599 Traction Master Push Through Carbide Wedge1.0 (Pkg of 24 w/backers) 287 1241 Traction Master Backer Plates, Aluminum, 7mm (Pkg of 48) 2871242 Traction Master Backer Plates, Steel, 7mm (Pkg of 48) 287 1430 Traction Maste r Backer Plates, Aluminum , 5/16" (Pkg of 48) 2871 43 1 Traction Master Backer Plates, Steel, 5/16 " (Pkg of 48) 287 1374 Drill Bits, Track Studding , 7mm and 5/16" 2870768 Track Studding Kit (T Nut Puller)
J
N P
x 6" 60'
EZ, 2871416
7/16 x 4" 60' EZ, 287 1603

1/2 1/2
x 6" 60',287 160 1 x 8" 60' , 2871602
Polaris Composite Ski
R 7/16 x 4" 60' , 2871688

S
1/2
x 6" 60', 287 1687
SLP Sk i
7/16 x 4" 60' , 2871 717

1/2
x 6" 60' , 287 1718
Wear Strip Kits"" 28715 40 287 1541 287 1544 2871542 2871543 287 1545 287 1689 1 piece tunnel SKS .625 1 piece tunnel SKS .75 12 1" .75 2 piece tunnel SKS .625 2 piece tun nel SKS .75 121" .625 .75 Indy Lite
" Patent Pending Carb ide 60' Point Production set up of wear strips will be located over the windows of the track. An optional position is ava ilable for using hooker plates. Only the outer end holes are punche d in the tunnel. The wear strip will serve as the temp late for drill ing the remain ing holes.
9/96
9 .62
BRAKES/FINA L DRIVE Traction

Stud Installation
1. Mark the stud pattern on the track. 2. Drill stud holes with a 1/4" (or 7mm) hollow-core drill bit. Make sure the drill is sharp for a clean hole. 3. Spin the non-eutting 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 J-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 80-100 in. Ibs. and let dry for 24 hours at room temperature. 6. Check for loose studs after each event.
Push Throug h Studs

Push stud through track hole from inside track. Hand tighten domed support plate and Nyloc nut on the exposed stud. 2. 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. 3. Inspect for loose nuts after each event. 1. Refer to the diagrams below for stud length recommendations. Penetration A = Stud Height B = Washer Thickness C = Track Lug Height A + B - C = Penetration Stud Length Max imum Penetration Maximum St ud Length
I
,-...-J
A
'-
Standard Low Profile Track 3/8"
'Ulf 'U
Deep Lug Track
.750-
~ ---.-,I
~ trf1
L..,
3/8-
r
I
-r
T
"J lf"J
Steel Cleated Track
.875-
Backer Plates Steel .195 Aluminum .220 Stud Mate .' 48 Hooker Washer .025
,..., ,
I
3/8"
IV'
.700"
{1 y
Alum. Shim .055
Polaris tnausuies Inc.
9.63
9/96
SUSPENSION Traction
Ideally when going through a turn, the vehic le 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 balan ced to mainta in a good line through the corner. Too few studs will allow the track to spin, result ing in excess ive wear or damage to the studs . A loose cond ition 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 carb ide skags to ensure maximum steering control. See the diagrams below. Loose - not enough rear traction or too much carbide Pushing - too much rear tract ion or not enough carbide
Correct balance
Carb ide Placement
~ _ 50%
60%
" ,..
9/96
9.64
ELECTRICA L Lighting Specifications

1996 Mode ls
Model Type Headlight Watt s Hi/Low 60/60 60/60 60/60 60160 60/60 60/60 Tail lig ht Brake Li ght
Wa tts
Handwarmer
Watts HI/Low
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
Indy lite/Deluxe
Indy Lite GT Indy Sport
Indy TranSport
Inca"
13.3 23.0 13.3 13.3 13.3 t3 .3 13.3 13.3 13.3 26.9 13.3 13.3 13.3 13.3 13.3 13.3 13.3
Ace
IS
LR9 LR9 LR9 LR9 LR9 LR9 LR9 LR9 LR7 LR9 LR9 LR7 LR9 LR9 LR9 LR9 LR9 LR7 LR7
Incan Incan
Incan
15 15
IS IS
Indy Super Sport Indy Sport Touring Indy 440 XCRl600 XCR Indy 440 XCR SP Indy 600 XCR SP Indy WideTrak LXlGT IndyTrailrTouring Indy 440 LC Indy XLT Touring Indy 500/SKS/RMK Indy 500 EFI/SKS/RMK Indy ClassiC/To uring Indy XLT/SP/SKS/RMK Indy RXL Indy Ultra SP/SKS/RMK Indy StorrnlSKS/ RMK
Incan
Incan
Halogen
60/55
60/55
1517.5 1517.5 1517.5 1517.5 1517.5 1517.5 1517.5 1517.5

15/7.5
Halogen Dual Halogen

Halogen
2x601 2x55 60/55

2<37.5 2x37.5 2x37.5 2x37.5 2x37.5
Halogen Halogen Halogen Halogen

Halogen
Halogen
Halogen
60155 60/55 60/55 2x601 2x55
1517.5
15/7.5
Halog en Dual Halogen
13.3 13.3
1517.5 1517.5
10.1
9/96
ELECTRICAL Lighting Specifi cations

1997 Models
Mode l Typ e IndyLite/Deluxe Indy Lite GT Indy Sport Indy TranSport Indy Super Sport
Indy Sport Touring
Headlight
Watt s
Tailli ght 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 HIILow
Brake Lig ht Watt s 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.
Hi/Low
Incan lncan Incan

lncan
60160 60160
Ace
15 15 15 15 15
LR9 LR9 LR9 LR9 LR9 LR9 LR9 LR9 LR? LR9 LR9 LR9 LR7 LR9 LR9 LR9 LR9 LR7 LR9 LR7 LR7 LR7 LR7
60/60
60160
lncan
lncan
60/60
60160 601 55 60155 2,601 2,55 60/55
Indy 440 XC/600 XC Indy XCF Indy 600 XCRISE Indy WideTrak LX/GT
Halogen
15/7 .5
1517.5
Incan Dual Halogen Halogen Halogen

lncan Halogen Halogen
15/7.5
151 7.5 15/7.5 1517.5
IndyTrailfTouring
Indy 440 LC Indy Trail RMK Indy XLT Touring Indy 500lS KS/RMK Indy 500 EFI
2,37.5/60 2,37 .5/60 2'37.5/60

2,37.5/60 2,37.5/60 2'37.5/60 60155 60/55 60/55
1517.5
15/7.5
Halogen Halogen Halogen

Halogen
15/7.5
15/7.5
Indy ClassicfTouring
Indy XLT/SPILTD/SP LTD/SKSI RMK Indy 700 SKS/RMK Indy RXL Indy UltraiSP Indy UltraTouring Indy Ultra SPX/SPX SE Indy SlormiSEiRMK
15/7.5 15/7.5 15/7.5 15/7.5

1517.5
Halogen Halogen Dual Halogen

Dual Halogen
60155
2, 45/ 2'45 60155 2,601 2,55
15/7.5 15/7.5
Dual Halogen
9/96
10 .1 a
ENGINES I ELECTR ICAL Lighting Specifications 1998 Models

Mod el Type Headlight Watts Hi/Low 60160 60160 60/60 60/60 60/60 60/60 60/60 2,38/1 x60 60155 2,38/ 1,60 2,38/1,60 60/60 60/60 60/55 2,38 /1,60 2,38 / I ,60 2,38/ 1,60 2 , 38 /1x60 2'60/2,55 2,38 /1,60 2,38 /1,60 2,38 /1,60 60/55 60/55 2'60 /2'55 60/55 2'45 /2'45 60155 2, 60 /2' 55 60/55 2,60 /2'55 Taillight Watts Brake Light
Watts
Alternator output (In Watts) @ 4000 RPM

150 '50 '50 200 200 200 200 200 280 200 200 200 200 200 200 200 200 200 280 280 280 280 280 280 280 280 280 280 280 280 200
Volta ge Reg .
IndyLite IndyLite Deluxe Indy Ute Touring

Indy Sport Indy Sport Touring Indy Transport Indy XCF Indy 440 UC Indy 440 XCR Indy Trail
Incandescent
x 3 Watts
8 Watts
18 18 29 18 18 29 18 18 18 18 18 18 18 29 18 18 18 2, 18 2, 18 18 2, 18 18 2"8 18 2, 18 18 2, 18 2, 18 2, 18 18 2 x 18
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 LR7 LR7 LR7 (LR56) LR7 (LR2 & LR56) LR7 LR7 LR7 LR7
Incandescent Incandescent
Incandescent Incandescent
2 x 3 Watts
2 x 3 Watts
2' 3 Watts 8 Watts
Incandescent Incandescent Halogen Halogen Halogen Halogen

Incandescent
2 x 3 Watts 2 x 3 Wa tts 2 x 3 Watts

2' 3 Watts 2,3 Watts
Indy Trail Touring

Indy Trail RMK Indy SuperSport Indy WideTrak LX Indy 500 Indy 500 Classic Indy 500 RMK
2 x 3 Watts
2,3 Watts 8 Watts
Incandescent Halogen Halogen

Halogen
Halogen
2 x 3 Watts
2 x 3 Watts
2 x 3 Watts
2,9 Watts 2,9 Watts

Indy XLT SP Indy XLT LTD Indy XLT Touring Indy XLT Classic Indy 600 XC Indy 600 RMK Indy 600 XCR Indy Uttra Indy Intra Touring Indy 700 XC Indy 700 XCR Indy 700 RMK
Indy Storm

Halogen
2 x 3 Watts
2,9 Watts 2,3 Watts
Halogen
Halogen
2 x 9 Watts
2,3 Watts
Halogen
Haloge n
2 x 9 Watts
2 x 3 Watts 2,9 Watts

Halogen
Halogen
2 x9Watts
2,9 Watts 2 ,3 Watts
Halogen
2 x 9 Watts
LR7: Full Wave Voltage Regulator LR9: 1/2 Wave Voltage Regulator LR2: Rectifier Only, For Battery Charg ing LR56: For Exhaust Thermal Sensing System (ETSS)
10.1b
9/97
ELECTRICAL Ignition Specifications

1996 Models
Machine Mo del Eng ine Mo del EC34-2PM02lE 02 EC44-3PM0 1/02 EC50PM041E 04 EC50PM03 EC45PL06 EC45PL07 EC45PL08 EC50PLEll /11I14115 EC50PLE12 EC50PL13 EC58PL02l0310 7 EC58PLE05 EC5802 EC59PLOl EC65PL05 EC68PL01/04 EC80PL04/05 Alternato r Wattage 150 200 200 200 200 200 200 200 200 250 170 200 170 200 180 200 200 Spark Plug NGK Pl up, Gap
MMI nches
Champion
RN-3C RN-3C RN-3C RN-3C RN-3C RN-2C RN-2C RN-3C RN-3C RN-3C RN-3C RN-JC RN2C RN-2C RN2C RN-2C RN-2C 0.7/.028 0.71 .028 0.71.028 0.71.028 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 0.71.028 0.7/.028 0.71.028 0.71 .028 BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR9ES BR8ES BR8ES BR8ES BR8ES BR8ES BR9ES BR9ES BR9ES BR9ES BR9ES
C Ol Bo x Identification Number CU6409 CU6416 CU6413 CU6413 CU6417 CU6417 CU6418 CU6417 CU6417 CU64 17 CU2194 CU219 4 CU2 194 CU7303 CU2 193 CU7301 CU7302
Flywheel 1 # 0 FP5439 FP5446 FP5441 FP5441 FP5445 FP5510 FP5517 FP5445 FP5445 FP5508 FP8312 FP8314 FP8312 FP9306 FP6392 FP9304 FP9305
IndyUte Models Indy SportModels
Indy Trail Models Indy WideTrakGT

Indy 440 LC Indy 440 XCR Indy 440 XCR S P
IndySOQ/SKS/RMKlClassic
Indy WldeTrak LX
Indy 500 EFI
Indy XLT(Except Touring) Indy XLTTouring

Indy XCR 600 1 XLT S P Indy 600 XCR SP Indy RXL Indy Ullra SPISKSIRMK
Indy Storm/SKSfRMK
Running Ignition Timing at 3000 RPM

Engine Mode l MM BTDC
Inches
BTD C
Defr ees
B DC
Acceptabl e Variances
MM Inc hes .129 .161 .133-.167 .133 .167 .167-.204
.156-,19 1
0r,eratln% Ti m n?p' BT C R M
EC34-2PM02/E02 EC443PMOI /02 EC50PM04/E04 EC50PM03 EC45PL06/07 EC45PL08 EC50PLE11111 /E1211 4/15 EC50PL13 EC58PL02l03/ E05107 EC65PL05
3.67 3.81 3.81 4.71 4.40 5.69 4.40
.145 .150 .150 .185 .173 .224 .173 .185 .173 .139
26.5 1.5
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 3.91-4.87 3.13-4.01
15.5'@7000 16'@6500 16'@6500 19'@7500 16'@7500 16'@7500 16'@7500 17' @ 7500 20 ' @ 7500 19' @7500
261.5 261.5
291.5
261.5 32 1.5 281.5
.2 17-.242
.156. 19 1 .167 .204 .156' .191 .123.156
4.7 1
4.40
291.5
281.5
25 1.5
3.53
Run n ing Ig n iti on Timi ng at 3500 RPM ' Engi ne
Model
MM BTOC
Inches BTOC
Def rees
B DC
Acceptable Variances
MM
0r,eratln% Tim n?p'BT C R M
Inches
.168-.200 .144-.180 .144 .180 .144. 180 .144-.180 10' @8500 16'@8000 16'@8000 16'@8000 16'@8000
EC59PLOl EC68PLOl EC68PL04 EC80PL04 EC80PL05
4.74
.187 .162 .162 .162 .162
28 1.5 26 1.5
261.5 26 1.5
26 1.5
4.26-5.24 3.66-4.67 3.66-4.57 3.664 .57 3.66-4 .57
4.10 4.10 4.10 4.10
Engine at room temperature

10.2
9/96
ELECTRICAL Coli Resistance Specifications

Ignition system components can be individually tested by measuring the ir internal res istance and insulati on to ground. These checks mu st be done with a digital volt/ohm meter. Compare the readings obtained to the values listed on the c hart. Actua l val ues may vary upto 10% between like components. Any read ings outside the span should be considered questionable. NOTE: The stator coils can be checked without rem oving them from the engine . Simpl y disconnect the con necto r, plug in the stator-to-CD I wir e, and ch eck the res istance va lues between th e wire colors listed below. For further information, co nsult the wiring diag rams at the end of this chap ter. Model 1996 EC34PM EC44PM EC50PM EC45PL EC50PL11,12,14,15 EC50PL13 Exciter Call Wire Color BrnNJ to BlklR BrnNJ to BlklR BrnNJ to BlklR BrnlW to BlklR BrnNJ to Blk R BrnNJ to BlklR Ohms 164 164 164 164 164 164 Trigger Call Wire Color Ohms Light Call Wire Color Y to Brn Y to Y to Yto Ohms 0.3-0.6
0.2.Q.5 0.2.Q.5
'--
Charge Coil Wire Col or Ohms
Ignit ion Coil Primary Secondary
5700 5700 5700 5700 5700 5700
Y/R Y/R
0.4.Q.8
&
Y/R Y/R Y/R
0.2-0.5 0.2-0.5
0.2.Q.5
Gry to
Y to Yto
GryNJ
&
0.2-0.4
BrnlW to Gryl W EC58PL02,03,07 EC58PL05 EC65PL05 BlklR to R BlklR to R BlklR to Grn

&
4.6 4.6 288

&
W/R
W to
100 100 96
Yto
Y/R
0.2-0.5
0.2.Q.5
Gry to
0.4-0.8
&
0.4 0.4 0.4
4000 4000 7500
W/R
W to
Wto
Y to
Y/R
W/R
Y to Brn
0.2-0.4
GryNJ
&
20
0.3-0.5
R to Grn EC68PL01 ,04 Grn to BlklR

&
BrnNJ to Gryl W 500

&
W/R
W to
100
Yto Y/R
0.17
0.34
7900
15.5
Grn to R EC80PL04,05 Grn to BlklR

&
500
&
W to
100
W/R
Y to Y/R
0.17
0.34
7900
15.5
Grn to R Resistance should be checked with the coil at room te mpe rature Coils must be isolated from the system to check resistance Plug cap resistance is 3700-6300 Ohms (measu red separately) Measure resistance from Mag plug lead to PTO plug lead Secondary coil res istance is measured w ith 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
11195
10.4
ELECTRICAL Routing Diagram - Indicator Lights

1996 WldeTrak LXlSportlTranSport/Super Sport/Sport Touring Models
BROWN ORANGE
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
ELE CTRI CAL Routin g Diagram - Indicat or Lights 1996 Lite GT Models
Rocker Switch and Indicator Lights
BLACKlR ~ ~
~
Q
/' lVYELLOW
<,
~I
I~ <,
<""i
I~ <,
BLACKI~ /' ~ ~
BROWN
C'C'
Bl ue~ "'-.
~ a7" Yellow
~,'~
--./
I~
199 8 Lite Delu xe
~ Blue~ / ~~ ~ ~I
~ "
. ~
A.C
Brown
~ purPle
<. B / 7
10 .7
9/9 7
ELECTRICAL Multimeter Usage

Multimeter Usage
The easiest and most accurate method for testing modern electrical components is with a digital multiteste r. Any good quality multitester 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
DiAl
RED LEAD HE FORVOLTS AND REDLEAD HERE

FOR AMPS
COMMON
(BLACK LEAD)
v- = Volt s AC - measuring alte rna to r outp ut

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.sag.e
Test unregulated voltage output of a stator coil Test regulated voltage to the lights and handwarmers
V -:-:-::-
=Volts DC measurin g battery voltage, vo lt dro p, etc.

H
meter termina l
Used to measure DC voltage produced by a battery or rectifier. Test Method 1. Connect black lead to Com 2. Connect red lead to Vo. (+) meter terminal. 3. Turn selector dial to V -:-:-::- setting. 4. Connect test leads parallel with test component. Observe polarity.
UsaQll
Test battery voltage Test DC regulator Test voltage drop for bad connecti ons Test supply voltage to electric fuel gauge EFI electrical testing
11/95
10.8
ELECTRICAL Multimeter Usage

Q
= Ohms, resistance - measurin g compon ent resi stance values - test ing co il s, 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. Connect black lead to Com (-) meter terminal 2. Connect red lead to VQ (+) meter terminal. 3. Turn selector dial to Q setting. 4. Isolate test component from the rest of the electrical circuit by disconnect ing 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 li ghting co il output Used to test the power of an alternator coil. Test Method 1. Discconnect engine harness from system . 2. Connect red lead to 10A (+) 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. NOT E: Amperage readings are not dependent upon engine RPM. The reading you obtain at idle is essentially the same as the reading that woul d be obtained at higher RPMs. NOTE: Although the meter connection is labeled 10A it will correctly read higher AC amperage (without damage to your meter) for periods of time not exceeding 10 seconds.
10.9
9/97
ELECTRICAL Multim eter Usage

A :-:-::
= Amp s DC - used to check
battery charge rate, system draws, etc.
Used to check the current flow to and from the battery. Test Method 1. 2. 3. 4. Make sure red lead is in the 1OAterm inal of the meter and the black lead is in the Com (- ) term inal olthe meter. Disconne ct battery ground wire(s} from battery Connect red meter lead to batte ry (-) terminal.
terminal.
Connect black meter lead to harness ground wires and cable. CAUTI!?,,!; ]
Do not operate electric starter (if equipped ) or meter damage may occur.
Testing key off curren t 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 1OA socket on the front of the instrument.
11/95
10.10
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 tem perature only (68" F / 20 G) and at the proper RPM. TD obtain the best iqnition timing accuracy and reduce the chance ot error, the ignitiDn timing specification is given at a "ftat" portion ot the advance curve. This flat portion on the curve is at 1500, 3000 or 3500 RPM on all current style iqnltlon systems. lqnition timing must be checked at the specified RPM, or inaccurate timing will result. Refer to timi ng specifica tions at the beginning of this chapter. If eng ine damage has occurred due to a suspected ignitiDn related problem, verify the ignitiDn timi ng 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 attempting to adjust the ignitio n 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 S tDPS rotating and reverses direction. This will be T OG (Top Dead Center). 3. While hDlding the crankshaft with the piston at TDC, zero the indicator by rotating the bezel until the a on the dial and the pointer align. 4. Rotate the crankshaft opposite the directio n of rotation abou t .250 BTDG (2 1/2 pointe r revDlutiDns). 5. Determine the correct ignitiDn 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 BTDG, 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 revofutlons betore tDP center, or .150 BTDC. While holding the crankshaft at the correct timing position, mark the flywheel (With chalk Dr a white marker) directly in-line with the stationary pointer (or line) Dn the fan Dr recoil housing through the timing inspection window. 1. 2.
",
6.
10 .11
9/9 7
ENGINE Timing Curves Tim ing Curve 1998 Domestic 600 Twins
20 18
16
14 12 10
8 6 4
2
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,,
,,
r:
. . . .. . .. .
I
1000 2000 3000
.. 4
. .
,
'
4000
5000
6000
7000
8000
Ti ming Table 1998 600 Twin RPM

Degrees
600 2000 4500 5000 6000 7500 8000 8500
6 6 12 17 19 13 11 6
9/97
10.11 a
ENGINE Timing Curves

Timing Curve 1998 700 XC 20
18
16
14
12
10
8
6
4
r:
- 1000
, , ,
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.4
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2000
3000
4000
5000
6000
7000
8000
Timing Tabl e 1998 700 XC
RPM
600 2000 4500 5000 6000 7500 8000 8500
Degrees 6 6 12 17 19 16 15 11
10.11b
9/97
ENGINE Timing Curves Timing Curve 1998 700 RMK
20 15 10
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.. '
.. ' - i-"
II
...
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 18,50
0
23 16 15.5 5.5
0
9(97
10.11 c
EN GINE Timing Curve Template
20
18
16
14
12
10
6
4
2
o o
1000
2000
3000
4000
5000
6000
7000
8000
Timing Table RPM
Degrees
10.11 d
9/97
ELECTRICAL Convers ion Chart - Degrees to Piston Position - B.T.D.C.

Engine EC443PM Model EC45PL EC50PL
EC50PM EC58PL EC65PL
EC59PL EC68P L EC80P L 125 MM ROD 65 MM ST ROKE

MM
EC342PM
S N44LCDCSpOl SN4444LCDCSP -Ql 128 MM ROD 64 MM S TRO KE

MM
SN70LCDCSP-QlI02 SN60-7OLCDCSPOl102 SN7D-7OLCDCSP-Q1102 136 MM ROD 68 MM STR OKE

MM
DEG. BTDC
112 MM ROD 60 MM STROKE

MM
103 MM ROD 55.6 MM S TROKE

MM
INCHES 0 .0002 0.0009 0.0021 0.0036 0.0057 0.0082 0 .0112 0.01 46 0.0184 0.0227 0.0 275 0 .0327 0.03 83 0 .0444 0.0509 0.05 78 0.0652 0.0 729 0 .0811 0.0898 0.0988 0. 1083 0.1181 0 .1264 0 .1390 0. 1500 0 .1615 0 .1733 0.1854 0.1980 0.2109 0.224 1 0.23 77 0.25 17 0.2660 0.2806 0.2955 0.3 108 0.3263 0 .3422
INCHES 0.0002 0 .0010 0 .0022 0.0039 0.006 1 0 .0088 0 .0120 0 .0157 0 .0198 0 .0245 0 .0296 0.0352 0.0 4 12 0 .0478 0.05 48 0.0622 0.070 1 0.07 85 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 0.24 14 0 .2560 0 .2710 0.2864 0.3022 0.3183 0.334 7 0.35 15 0.3686
INCHES 0 .0002 0.0008 0.00 19 0.0034 0.0053 0.0076 0.0 104 0.0 135 0.0171 0.02 11 0 .0255 0 .0303 0.0355 0.0412 0.0 472 0.0 536 0.0605 0 .0677 0.0 753 0 .0833 0 .09 17 0. 100 5 0 .1096 0.1191 0 .129 0 0 .1393 0 .1498 0.1608 0 .172 1 0.183 7 0.19 57 0 .2080 0 .2206 0 .2336 0 .2468 0.2604 0.2742 0.288 4 0.3 028 0 .3176
INCHES 0.0002
INCHES 0.0003 0 .0010 0.0023 0004 1 0.0064 0.0092 0.0 125 0.0163 0.0206 0 .0254 0 .0307 0.0365 0.0428 0.0496 0.0568 0.06 46 0 .0 728 0.08 15 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 0.281 4 0.2974 0 .3 138 0.3305 0.3476 0.36 50 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 0.052 1 0.0926 0.1447 0.2083 0 .2833 0.3698 0.4677 0 .5770 0 .6976 0.829 4 0.9724 1.1265 1.2917 1.4678 1.654 8 1.8526 2 .0611 2.2802 2.5098 2.7497 3.0000 3.2603 3.5307 3 .8110 4.1010 4.4 007 4.7098 5.0282 5.3559 5.6926 6.0381 6.392 4 6.7552 7.1263 7.5057 7.8931 8.2883 8.69 12
0 .0062 0 .0249 0 .056 1 0 .0997 0 .1558 0.22 42 0.3050 0 .3981 0.5036 0.6212 0 .75 10 0.8930 1.0470 1.2129 1.3908 1.58 04 1.7818 1.9948 2.2 193 2.45 52 2.702 4 2 .9608 3.2303 3.51 07 3.801 9 4.1038 4.4 161 4.7389 5.07 19 5.4149 5.7679 6. 1306 6.5028 6.8 845 7.2754 7.6753 8 .0840 8.5 015 8 .927 4 9.3 616
0.00 54 0.0215 0 .0484 0.0860 0 .1343 0.1933 0 .2630 0.3432 0.434 1 0.5355 0.6474 0.769 8 0.9025 1.0456 1.1989 1.3624 1.5359 1.719 5 1.9130 2.1163 2.32 94 2.552 1 2.7843 3.0260 3.2769 3.5370 3.8062 4.0843 4.37 12 4.6667 4.9708 5.2832 5.6039 5.9326 6.2693 6.6 138 6.9658 7.3253 7.692 0 8.0659
0 .0061 0 .0244 0.05 48 0 .0974 0.1522 0.2190 0 .2979 0.3889 0.4919 0.6068 0.7336 0.8723 1.0227 1.184 9 1.3586 1.5439 1.7406 1.9487 2. 1681 2.398 6 2.6402 2.8927 3. 1560 3.4300 3 .7146 4.0096 4.3 149 4.6303 4.9558 5.2911 5.6361 5 .9907 6 .3546 6 .7278 7.1099 7.5010 7 .9007 8 .3089 8 .72 54 9 .150 1
0.0065 0.0259 0.0582 0.1035 0.1617 0.232 7 0.3166 0.4132 05226 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 .353 2 3.6 444 3 .9467 4.2602 4.5846 4.9197 5.2655 5.62 18 5.988 4 6.365 1 6.75 18 7.1482 7.5543 7.9698 8.39 45 8 .8282 9.2708 9 .7220
0.00 10 0.0022 0 .0038 0.00 60 0 .0086 0 .0117 0 .0 153 0 .019 4 0.0239 0.0289 0.03 43 0 .0403 0 .0466 0.0535 0.0608 0.0685 0.0767 0.0 854 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 0.3 111 0 .3271 0 .3435 0.36 02
9/97
10.12
ELECTR ICA L Twin Cylinder Fan CDl lgnition (Adjustable) - Exploded View - Tim ing Timing Procedure
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120 Walt Pulse Type
150 and 200 Walt Pulseless
NOTE: Always verify timing of engine at room tempe rature only (68 0 F/20 ' C) . Refer to ignition t im ing procedu re on page 10.17.
Blower Housing Stationary Lines
NOTE: Acceptable variance is usually one line on either side of the dial indicated blower housing stationary line.
Flywheel Mark
10.13
9/97
ELECTRICAL Twin Cylinder Liquid COl Ignition (Pulse, Pulseless) - Exploded View - Timing Timing Procedure
120 Watt Pulse Type COl NOTE: Always verify timing of engine at room tempe rature only (68 0 F/20 C). Refer to ignition t iming procedure on page 10.17.
200 Watt Pulseless COl
Acceptable Variance Flywheel Rotation Flywheel Lines Stationary Pointers
NOTE: Acceptable variance is usually one line on either side of the dial indicated timing mark.
9i97
10.14
Three Cylinder COl Ignition Tim inq
>
ELECTRICAL Exploded View (Typical)
Lighting Coil Flywheel
Charging Coil
Secondary Colis
NOTE: Always verify timing of engine at room temperature only (68' F/20' C) . Refer to ignition ti mi ng procedure on pag e 10.17.
NOTE: Acceptable variance is usually one line on either side of the dial indicated li ming mark.
10.15
9/97
ELECTRICAL Three Cylinder COl Ignition Exploded View
Pulser Coil
:----,-7-"--- RFI Spark Plug Cap
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' F/20 C). Refer to ignition timing procedure on page 10.17.
NOTE: Acceptable variance is usually one line on either side of the dial indicated timing mark.
9/97
10.16
ELECTRICAL COl Ignition Timing
Timing P roce d u re - All Mo d els 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. 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). 3. 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 cente r 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 advance it. NOTE:Rotate stator plate approximatety the same distance as the marks must move. Blower Housing NOTE:ln most cases. the recoil starter housing. recoil Stationa 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 flywhee l. Flywh eel 8. Torque stator plate screws and flywheel nut to Mark specified torque. Apply Loctite 262 (red) to crankshaft flywheel taper if required. Refer to the Engine section for torque specifications and Fan Co ole d flywheel installation procedure for engine type.
Polaris Industries tnc.
10.17
9/97
ELECTRICAL Operating RPM Timin g Check - All Models
Due to the high RPM necessary and the possi ble danger involved , special ca re must be obse rved whe never per forming an operating RPM timing check to avoid serious personal injury. This check need not be performed unless symptoms iead ing to poor performance and poss ible engine damage are present. Neve r ope rate 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 proionged periods of engine free-rev.
Operating RPM Timing Test Procedure

1. 2. Using the charts at the beginning of this unit, determine the ignitio n advance BTDC at the operating RPM. Remove the mag side spark plug and install a dial indicator in that cylinder.
3. Zero the dial indicator as explained on page 10.11 . 4. Turn the crankshaft in the opposite direction of rotation to a point appro ximately .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 cha rts only indicate degrees BTDC. This fig ure must be converted using the tabies on page 10.12 . Example : The ope rating 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 instailed and zeroed dial indicator, back the engine up to approxi mately .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 hous ing using a piece of chalk or marker. 7. 8. Remove the dial indicator and reinstall spar k plug. Start the engine. Advance and ho ld 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 ope rating RPM timing gre atly varies from the speci ficatio n, but the 3000 or 3500 RPM ignition is cor rect , refer to th e ignition tro ubles hooting section in this unit for corrective action.
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 prope r initial servicing. To serv ice a new battery, the foliowing steps must be taken. NOTE: Do not service the batte ry unless it wili be put into regular serv ice with in 30 days . 1. 2. 3. 4. 5. Remo ve vent plug from vent fitting . Fill battery with electrolyte to the upper level marks on the case. Set battery aside and aliow it to coo l and stab ilize for 30 minute s. Add electro lyte to bring the level back to the upper level mark on the case. NOTE: This is the last time that elect rolyte should be added. If the level bec omes low after this point, add only distill ed water. Charge battery at 1/10 of its amp/hour rating. Example:1/10 of 9 amp batte ry = .9 amp s, 1/ 10 of 14 amp battery = 1.4 amps , 1/ 10 of 18 amp battery = 1.8 amps (recommended charging rate s). Check specif ic gravity of each celi with a hydrometer to ensure each has a reading of.1.270 or higher.
6.
Battery Testing
There are three easy tests which can determine batte ry condition. Whenever the complaint is related to either the starting or charg ing system s, the battery should be chec ked first. Lead-acid batteries shoul d be kept at or as near fuli charge as possible. If the battery is stored or used in a partialiy charged condition , hard cry stal sulfali on will form on the plates , reducing the ir efficiency and possibly ruin ing the battery.
Open Circu it 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 measu re elect rolyte strengt h or specific gravity. As the battery goes through the charge/discharge cyc le, the electrolyte goes from a heavy, more acidic state at fuli cha rge to a light , more wate r stat e whe n discharged. The hydro meter can mea sure state of charge and differences between celi s in a multi-ee li battery. Readings of 1.270 or greater shou ld be observed in a fuliy charged battery. Differences of more than .025 between the low est and highest celi reading s indicate a need to replace the batte ry. Slate Of Charge 100% Charged 75% Charged 50% Charged 25% Charged 0% Charged Slate Of Charge" 100% Charged 75% Charged 50% Charged 25% Charged 0% Charged "at 80 F NOTE: Subtract .0 1 from the specific gravity for electrolyte at 40 F and compare these values to the chart. Polaris Indu stries Inc. Conventional Lead-acid 12.60V 12.40V 12.10V 11.90V 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 1.1 35 Less Than 1.11 5
Detail A
"I I
10.19
11/95
ELECTRICAL
Battery Service
Load Test
NOTE : This test can only be performed on machines equipped wit h electric start . This test cannot be pe rformed if the engine or starting system is not wo rking properly. A battery may indicate a fully charge condi tion on the OCV tes t and the specific grav ity test, but still not have the storage capacity nec essary to properly functi on in the electrical system. For this reason , a batte ry capacity or load test should be condu cted whenever poor battery performance is encountered. To perform the test, hook a mult itester to the battery in the same manner as in the OCV te st. The reading should be 12.6 vo lts or great er. Engage the electric starter and view the registered batte ry voltage while cran king the engine. Contin ue the te st for 15 seconds. During this cranking period , the obse rved voltage should not drop be low 9.5 volts. If the beginning voltage is 12.6 or higher and the cran king voltage drops below 9.5 volts during the test, replace the battery.
Refill ing a Low Battery

The norm al charge/disc harge cycle of a battery causes the cells to give off gases. These gases, hydrogen and oxyge n, are the components of water. Because of the loss ofthese gases and the low ering of the electrol yte leve l, it will be necessary to add pure , clean distilled water to bring the fiuid to the proper leve l. After filling, charg e the battery to raise the specific gravity to the fully charged positi on (1.27 0 or greater).
Off Season Storage

To prevent battery damage during extended periods of non-u se , the following bas ic mainte nance items must be performed. 1. Remove batter y 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 batte ry or the acid will be neutralized. Using a wire brush or knife, remove any corrosion from the cables and term inals. 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 cap acity until the electro lyte's specific gravity reaches 1.270 or greater.
2. 3. 4.
5. The batte ry may be stored either in the machine with the cab les disconnected, or on a piece of wood in a cool place . NOTE : Store d batteries lose their cha rge at the rate of 1% per day. They should be fully recharged eve ry 30 to 60 days during a non-use pe riod . If stored during winter months, the electrolyte wili freeze at higher temperatures as the batte ry discharges. The chart indicates freezing points by specific gra vity. Specific Gravity of Electro lyte 1.265 1.225 1.200 1.150 1.100 1.050 Freezing Point -750 F -350 F -1 7" F
+5 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 large r 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 batte ry are explosi ve. Any spark or open flame near a batter y can cause an exp losion which will spray batte ry acid on anyone close te it. If battery acid gets on anyone , wasn the affected are a with large quantities of coei water and seek immediate med ical attenti on.
Batteries produce explosive gases. Keep sparks, flame, 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 .
11/95
10.20
ELECTRICAL Dynamic Testing of Electric Starter System

Conoltlon: 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 (-) term inal and tester red lead on battery positive (+) termina l. Reading should be 12.6V or greater. Is it? NoYes! (A) Page 10.22 Disconnect red 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? NoYes! Reconnect solenoid, connect tester black lead to battery positive term inal and red tester lead to solenoid end of battery to solenoid cable . Turn key to start position. The reading must be less than .1V 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 posltion. The reading must be less than .1V DC. Is it? NoYes! (C) Page 10.22 Connect black tester lead to solenoid end of solenoid to starter cable and red tester lead to starter end of same cable . Turn key to start position . The reading must be less than .1V DC. Is it? NoYes! (D) Page 10.22 Connect black tester lead to starter frame. Connect red tester lead to battery negative (-) termina l. Turn key to start position. The reading should be less than .1V 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. 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 term inal .. circu it breaker in and out terminals, and across both sides (red and redlwh ite) of the ignition switch with switch on start. Repair or replace any defective parts .
Clean battery to soleno id cable ends or replace cable.
Replace starter solenoid.
Clean solenoid to starter cable ends or replace cable .
Clean ends of engine to battery negative cable or replace cable .
10.21
11/95
ELECTRICAL Electri c Starter System Testing (Static)

Starter Motor Static Testing
IGNIT ION SWITCH
IGN ITION SW ITCH
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STARTER RELAY
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A-E See page 10.21 1. Remove starter motor and disasse mble. Mark end covers and housing for proper reassembly. 2. 3. 4. Remove pinion retaining snap ring, spring and pinion gear. Remove brush end bushing dust cover. Remove housing through bolts.
5. Slide brush end frame off end of starter. NOTE: The eiectrical input post must stay with the field coil housing. 6. Slide positive brush springs to the side, pull brushes out of their guides and remove brush piate. 7. Clean and inspect starter compo nents. 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 comm utator needs cleaning, use only an electrical contact cleaner and/or a non-metallic grit sandpaper. Replace brush assemb ly when worn to 5/16" (.8 em) or less.
Starter Housing and Field Coil Inspect ion

1. Using a digital multitester, measure resistance between starte r input terminal and insulated brushes. The reading should be .3 ohms or less. 2. Measure resistance between insulated brushes and field coil housing. The reading should be infinite. 3. Inspect insulated brush wire and field coil insulation for damage. Repair or replace components as required.
Armature Testing
1. Using a digital multitester, measure resistance between each of the segments of the commutator. The reading should indicate .3 ohms or less. 2. 3. Measure resistance between comm utator and armature shaft. Reading should be infinity. Place armature in a growler. With the growler on, position a hacksaw blade lengthwise 1/8" (.03 em) 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
'" ""'- "", &
.r>:
/'
/'
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 hoiders and correctly position the springs on top of the brushes.
6. Using a non-petroleu m grease, lubricate brush end

bushing and slide it onto end of armature.
7. Align threaded holes in brush piate and install dust

cover and screws.
8. Reinstail through bolts and properly tighten all

screws.
9. Lightly grease pinion shaft and instail pinion, spring

stopper and snap ring.
10.23
11/95
ELECTRICAL St arter Install ation Starter Solenoid Bench Test

It is difficult to test the high amp side of the solenoid accurateiy 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 Jess than .100' clearance between the ring gear and the starter motor pinion gear. Torque 8mm drive end mount bolts to specification.
.100 Ring Gear
2.
3. Torque Gmm brush end mount bracket to engine bolts to specification.
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 2. 3. 4.
(V~)
position .
Disconnect the alternator to main harness connector at engine. Connect one of the tester leads to the yellow alternator wire and the other lead to the brown alternator wire. Start the engine. While observing the voitage 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 li ghti ng co li output Test Method 1. Discconnec t engine harness from system. 2. Connect red lead to 10A (+) meter terminal. 3. Connect black lead to Com (-) meter terminal. 4. Start engine and let it idle. 5. Observe and record the meter readi ng. 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 essentiall y the same as the reading that would be obtained at higher RPMs. NOTE: Although the meter connection is labeled 10A it will correctly read higher AC amperage (without damage to your meter) for periods of time not exceeding 10 seconds . RegUlated Vo ltage 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 . 1. Disconnect the yellow wire from the regu lator. 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 regulator 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 wou ld indicate excessive system loads , poor flywhee l magnets, lighting coil problems, or wiring harness problems . 6. The other possibility is too much voltage. Light bulbs that continuall y burn out wou ld 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 connectio ns 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
9/97
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 GraylWhite and BrownlWhite.
NOTE: Gray, GraylWhite, BrownlWhite are Bullet Type Connectors
11/95
10.26
ELECTRICAL Typical Exciter, Purser or Lighting Coli Replacement

1. Remove coil retaining screws and spacers. 2. Using a pliers, remove epoxy from solder joints (A) on the coil to be replaced.
3.
Unsolder connection from coil.
'~
,0
4.
Clean solder terminais (8) on the replacement coil and re-soider 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 resista nce of each coil prior to stator piate installation. NOTE: Lighting and pulseless coils are replaced in a similar manner.
IMPORTANT: After the stator plate is reinstalle d on the engine, check placement of all coil leads to prevent possible contact with the flywheel. Polaris Industries Inc.
10.27
11195
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 term inal blades at
the 9, 12 and 3 o'clock position, connect the black multitester lead to the 9 o'clock blade.
4. Touch the red tester lead to the 12 o'clock terminal and then to the 3 o'clock termina l, noting the resistance value of each. A reading of between 2 and 5 ohms Is good. An open reading indicates a bad element.
HilLo Beam Switch Testing

1. Set the multitester dial to the ohms (Q) position . 2. If the Hil l o switch has not been removed from the machine, disconnect the switch to harness plug in connector. 3. With the Hil l o switch in the Lo beam position, check the resistance between the yellow and the green switch wires. The reading should be less than .4 ohms. 4. Turn the Hil lo switch to the Hi beam positio n and the multitesler shouid indicate an open circuit (Ol ) reading. 5. Move one of the tester leads from the green to the red switch wire. The multitester should now read less than .4 ohms. 6. Turn the Hi/lo Switch back to the Lo beam position and the meter should again read an open circuit (Ol).
Low
H' h IqT
Grn
Yel Yel/Rd
Seat Harness Troubleshootin g

1. Remove the taillight lens. 2. Remove the two taillight bulbs and the brakelight bulb. 3. Separate the seat harness from the main harness by unplugging the connector at the right rear of the tank . 4. 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. 8. TIp the seat over and remove the right side seat cover staples, locate and repair the harness problem. Reinstall the staples and re-check the seat harness.
High/Low Switch
.
-
.~
, - . 0
.
.
11 .
.' ~
..... 'S
.,.
'.
11/95
10.28
ELECTRICAL Electrical Testing

Ignition Sw itch Testing (Non-Electric Start)
1. Set the multite ster dial to the ohms (0) 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.
Off On
I::8
Ignition Switch
Ignition Sw itch 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 diai to the ohms (0 ) 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 rnultitester should

now read an open circuit (OL).
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. 6. 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.
Bm
Blk
R!W
Ign ition Switch - Electric Start
10.29
11/95
ELECTRICAL Ignition Specificati ons 1997 Models

Machine
Mode l
Engine M odel
EC34-2P M02(S ) EC44 3PM02 EC44-3PM02 EC50PM 03 ECSOPM 04(S) EC 50PM05 EC50PM06 EC45PL08 SN44LCOCSP-01 EC45PL09 EC50PL16 EC50PLE17 EC50PL11 EC50PL1 8 EC50P L19 EC50PL20 EC58PL03 EC58PL07 EC58PL08 EC58PL09 EC58PL12 EC59PLOI EC65PL05 EC68P LOI EC68PL03 EC80PL05 EC80PL04 SN70LCOCSPOl SN70LC OCSP02 SN70LC OCSPOl
Alternator
Wattage
Spark Plug NG K
Plug Gap
Champi on
AN3C AN-3C AN3C AN3C AN3C AN3C AN3C AN2C AN2C AN3C AN3C AN3C AN3C AN3C AN3C AN3C AN3C AN3C AN2C AN3C AN2C AN2C AN-2C AN 2C AN2C AN2C AN-2C AN2C AN2C AN2C
MMnnches
0.71 .028 0.7/.028 0.7/.028 0.7/.028 0.7/.028 0.7/.028 0.7/.028
COl Box Iden tifica tio n Number CU8409 CU84 16 CU84 16 CU84 13 CU8413 CU84 13 CU84 13 CU84 18
Flywhee l
1 # 0
FP5439
FP5 446
Indy Lite Models IndySportlTranSpor'VSpon Touring

Indy XCF Indy WideTrak GT Indy Trail/Trail Touring Indy Trail RMK Indy Super Sport Indy 440 XC Indy 440 XCR
Indy 440 LC
150
BA8ES BA8ES BA8ES BA8E S BA8E S BA8ES BA8E S BA9ES BA9ES BA8ES BA8ES BA8 ES BA8 ES BA8 ES BA8E S BA8ES BA8ES BA8ES BA9ES BA 8ES BA9ES BA9 ES BA9ES BA9ES BA9ES BA9ES BA 9ES BA9ES BA9ES BA9E S
200
200 200 200 200 200 200 200
FP5446
FP5 44 1
FP5441 FP5441
FP5441
0.71.028
0.71 .028 0.7/.028 0.7/.028 0.7/.028
FP5517
40601 41
4060 163
CU84 17
CU64 17 CU64 1?
200
200 200 200 250 200 200 170 170 170 200 170 200 180 200 200 200 200 280 280 280
FP544 5 FP5445 FP5445
Indy 500 RMK Indy 500lS KS
Indy Classic
Indy 500 EFI
0.71.028
0.71.028
CU6417 CU8417
FP5445
FP550B
FP544 5

Indy WideTrak LX Indy XLT/S KS Indy XLT AMK Indy 600 XC Indy XLT Touring/L TD Indy XLT SP Indy 600 XCAISE Indy AXL
0.71.02 8
0.7/.028 0.7/.028 0.7/.028 0.71 .028 0.71 .028 0. 7/.028 0.71 .028
CU6417
CU64 17 CU2194 CU2194 CU2194 CU2194 CU2194 CU7303 CU2 193 CU730 1 CU7307 CF7302 CF7302
40601 44
FP5 445
FP83 12 FP8312 FP8312 FP8314 FP8312 FP9306 FP6392 FP9304

FP9 104
0.71.028 0.71.028 0.71.028

0.7/.028 0.7/.028 0.7/.028 0.7/.028
Indy UllralSPlTouring
Indy Ultra S Px/SP X SE
IndyStormJSE
Indy Storm RMK Indy 700 SKS Indy 700 AMK Indy 700 XC
FP9305 FP9305
4060141
4060 144 4060 144
4060 14 1 406014 1
0.71 .028
9/97
10.2a
ELECTRICAL Ignition Specifications

1997 Models
Runn ing Ign ition Timing at 3000 RPM ' Engine Model MM BTDC
Inches
0r,eratln~
BTDC
OerDC B
ees
Tim nlJ,'BT C R M
MM EC34-2PM02(-S) EC44-3PM02 EC50PM03 EC50PM04(-S) EC50PM05 EC50PM06 EC45PL08 EC45PL09 EC50PL16 EC50PL17 EC50PL18 EC50PL19 EC50PL20 EC58PL03 EC58PL07 EC58PL08 EC58PL09 EC58PL1 2 EC65PL05 3.67 3.81
4.7 1
Inches
.145 .150 .185 .150 .150 .150 .211 .173 .173 .173 .185 .173 .173 .173 .173 .173 .173 .173
.139
26.5i l .5
26%1.5
3.28-4.08 3.39-4.25 4.25-5.20

3.39-4.25
.129-.161 .133-.167 .167-.204 .133-.167 .133-.167 .133-.167
15.5'@7ooo 16' @ 65OO 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
29i1.5 26i 1.5 26i1.5 26i 1.5
3.81 3.81
3.8 1
3.39-4.25 3.39-4.25 4.87-5.86 3.91-4.87 3.91-4.87 3.91-4.67 4.25-5.20 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 3.13-4.01
5.36 4.40 4.40 4.40 4.71 4.40 4.40 4.40

4.40
31:1.5
28i1.5 28i l. 5 28i 1.5
29.1.5
.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
28i l .5
281 .5
28i1.5
28., .5 28. 1.5 28.1.5

281.5 25i1.5
4.40 4.40
4.40
3.53
Running Ig nitio n Timing at 3500 RPM' Engine

Model
MM BTDC
Inches
BTDC
Defrees
B DC
Tim ng ' BT C RPM
0r,eratln~
MM EC59PLO I EC66PLOI EC68PL03 EC80PL04 EC80P L05 SN70LCDCSP-{)1 SN70LCDCSP-{)2

4.74
4.10
Inches
.187 .162 .070 .152 .152 .0365 .0365
281.5
4.26-5.24 3.68-4.57
1.49-2 .11
.168-.200 .144-.180 .059-.087

. 144 . 180
13'@ 8000
16'@7500
26. 1.5
17i 1.5
26 1.5
1.78 4.10 4.10 .9268 .9268
18'@8000 14' @ 8000 14'@5OO0 16'@ 5OO0 16' @5OO0
3.58-4.57 3.68-4.57 .71-1.17

.7 1- 1.17
25i1.5
.144-.180 .028-.045 .028-.045
12.1.5
12 1.5
Engine at room tempe rature
10.2b
9/96
FUEL SYSTEM/CARBURETION Ignition Specifications
1998 Engine Electrical

Machine Model
Engine Mod el
Alternator
Wattage
Spark Plu9 NGK 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
Plu9 Gap
MM/lnches
COl Box Identif ication
Flywhe el
Number
10 #
Lite Models Spo rtfTranSporti Sport TouringlXCF Super Sport
EC34-2PM02A EC44 -3PM024 EC50PM 061 EC50PM043 EC50PM05 1 SN44-44LCDCSP-Ol EC45PL091 EC50PL161 EC50PL17 1 EC50PL171 EC50PL191 EC50PL20 1 EG58PL140 EC58PL130 EC58PL130 EC58PL150 SN60-70LCDCS P-01 SN60 70LCDCSP-02 EG59PL020 EC68PL050 EC68PL060 SN70-70LCDCSP-02 SN70-70 LCDCSP-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
RN-3C RN-3C RN-3C RN-3C RN-3C RN2C RN-3C RN-3C RN-3C RN-3G RN-3G RN-3G RN-2C RN-3G RN-3C RN-2C RN-2C RN-2C RN-2C RN-2C RN-2C RN-2C RN-2C RN-2C
0.7/.028
CU6409 CU6416 CU6413 CU6413 CU6413 4060190 CU64 17 CU6417 CU6417 CU6417 CU6417 CU641 7 CU2552 CU2552 CU2 194 CU2552 4060186 4060186 CU7308 CU7306 CU7307 406018 1 406018 9 CU7302
FP5439 FP5446 FP5441 FP544 1 FP5441 4060 141 FP5445 FP5445 FP5445 FP5445 FP5445 FP5445 FP9 102 FP9102 FP8314 FP9 102 4060 141 4060 14 1
0 .71.028
0.7/.028 0.7/.028 0.7/.028
TrailfTrail Touring
Trail RMK 440 XCR 440 LC 500 RMK 500
0.71.028
0.7/.028
0.71.028
0.7/.028
Classic Classic Touring

WideTrak LX XLTSP XLT LTD XLT Touring XLT Classic 600 XC 600 RMK 600 XCR UltraITouring 700 XCR 700 XC 700 RMK Storm
0 .71.028 0.71.028
0.7/.028 0.7/.028
0.71.028 0.71.028 0.71.028 0.71.028 0.71.028

0.7/.028 0.71.028 0.71.028 0.7/.028 0.7/.028 0.7/.028
FP9103 FP9104 4060141 4060 141 FP9305
9/97
10.2c
ELECTR ICAL Ignition Specifications
1998 Ignition Timing Specifications

Running Ignition Timing at 3000 RPM *
Engin e Model Operatin g Tim ing ca T Oe
MM BTDC
3.67 3 .8 1 3.8 1 3.81 3 .81 4.40 4.40 4.4 0 4.4 0 4.4 0 4.40 4.40 4.4 0
Inches
BlOC
.145 .150 .150 .150 .150 .173 .173 .173 .173 .173 .173 .173 .173
Def rees
B DC
Acceptabl e Variances
RPM
MM
EC34-2PM0 2A EC44 -3PM024 EC50PM043 EC50PM 051 EC50PM061 EC45P L091 EC50PL 161 EC50P L171 EC50PL191 EC50 PL201 EC58PL1 30 EC58PL140 EC58PL 150 26.51.5 26 1.5 26 1.5 26 1.5 261.5 28 1.5 28 1.5 28 1.5 281.5 281.5 28 1.5 281.5 28 1.5 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 3.9 1-4 .87 3.9 1-4.87 3.9 1-4.87 3.9 1-4.87 3.9 1-4 .87 3.9 1-4 .87
Inches
.129-.16 1 .133-.167 .133-.167 .133-.167 .133-.167 .156-.19 1 .156-.19 1 .156-.191 .156-.19 1 .156-. 191 .156 -.19 1 .156-.19 1 .156-.19 1
15.5 ' 16 ' 16' 16" 16' 16" 16' 16 ' 16 ' 16" 20 ' 20 ' 20 '
@ @ @ @ @ @ @ @ @ @ @ @ @
7000 6500 6500 6500 6500 7500 7500 7000 7500 7500 7500 7500 7500
Running Ignitio n Timing at 3500 RPM *

Engin e Model
Operating Timing "BT OC
MM Bl OC
3.72 4 .74 4 .10 1.78 4.10 .93
Inc h es
BlOC
.146 .187 .162 .070 .162 .037
Degrees
BlOC
RPM
MM
SN44LCDCSP-Ol ECS9PL020 EC68 PLOSO EC68P L060 EC80P LOS2 S N70-70LCDCS P-02 2S1.S 28 1.S 26 1.S 171.S 26 1.S 121.S 3.2 9-4 .16 4.26-5.24 3.66-4.57 1.49-2.11 3.66- 4.57 .71 - 1.17
Inches
.130-.164 .168-.200 .144-.180 .059-.087 .144-.180 .028-.045 13 " 16' 18' 14 ' 16 "
@ @ @ @ @
80 00 7500 8000 8000 8000
Running Ignition Timing at 1500 RPM *

Eng ine Model
Operating Tim ing ~ B T D C
RPM
MM BTDC
.22 .22
Inches
BTDC
.009 .009
Degrees
BlOC
Accept able Variances
Ope rat ing
Timing "Bl OC
RPM
@ @
SN60-70LCDCSP-0 1l02 SN70-70LCDCSP-Ol
61.S 61.S
.13-.34 .13-.34
.005-.0 14 .005-.014
11' 15"
8000 800 0
Engine at room temperature
10.2d
9/9 7
ELECTRICA L Electrical Testing

Ignition Sw itch Testing (Fuel InJ ected Models)
1.
Disconnect wires. Set the multitester dial to the ohms (Q) position.
Off
On
2. With the key in the off position , connect one of the tester leads to the G terminal. 3. Randomly connect the other tester lead to the other terminals. The only terminal that should show other than an open circuit (O l ) is the M terminal. The M terminal should read less than .4 ohms.
Start
RlGrn VIGrn Brn Blk
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 (a ll . 5. Return the key to the off position. 6. Connect a tester lead to the B terminal. Randomly connect the other tester lead to each terminal. The readings must be an open circuit (a ll . 7. Turn the key to the run position and repeatlhe test. All of the readings must be an open circuit (a ll, except between the B and l terminals. This reading must be less than .4 ohms. 8. With one tester lead connected to the B terminal and the othert o the S terminal and with the switch in any position except start, the reading should be an open circuit (a ll . In the start position, the reading must be less than .4 ohms.
RIW
RlBlu
R/B LU R/GRN
I SOLENOID I
"-+- R / W
Y- GRN BRN BLK WIRE CONNECTS TO TAB ON IGN. SWIT CH
11/95
10.30
ELECTRICAL Coolant High Temperature Indicat or Testing
Circuit Power In - Yel
- -- ;;:J
Il
k
Temp]
BlkIW- - -- ,
Ground the BlacklWhite wire here (with the engine running) to test the light.
Engine Ground
The indicator light is controiled by a temperature/warning switch installed into the engine coollng system . When engine coolan t tempe rature reaches approxi mately 205 0 F, the switch closes, completing the circuit through the indicator light to ground. The system shouid be tested period ically for proper operation.
Lamp Circuit Test

1. Remove wire from temperature sensing switch located under thermostat housing. 2. With engine idling, ground wire to engine. The temperature warning iamp on the console should light. If not, replace the lamp asse mbly or inspect wiring for shorts or open circuit.
Temp Light Temperatur e Sensor Test

The temperature/warni ng switch is normaliy open . 1. Set the multitester on the ohms (0 ) scale . 2. 3. Disconnect the lamp wire . Connect one test probe to the switch terminal and the other to engine grou nd. The meter should show an open circuit (Ol) . This indicat es a normally open switch . If the switch were heated to appro ximately 205 0 F, the contact in the switch would close and the reading would be iess 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 res ult.
10.31
11/95
ELECTRICAL
Speed Contro l Assurance Operation

Auxiliary Kill Switch Contacts Off Idle Switch Insulator
Ignition Primary
Idle Switc h Engine Ground
~ - --~
01
Plungers Outward
8
Throttle Control Cutaway The speed contro l assurance consists of two series con nected switche s. 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 plunge r is inward. The top switch circuit is closed, and the plunger is outward. The speed control circui t 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 circu it will close (both switch plungers out), groundin g the ignition system and causing the engine to stop.
Speed Control Assurance Adjustment

Throttle lever free play must always provide a specified clearance between throttl e lever (A) and throttle block (8) . This clearance is controlled by the throttle cable sleeve(s) and the idle speed screw(s).
"'.:',',:.'"
Throttle Lever F~eeplay
?" ,'7
" " : " ~ <U~: L /1
,:n :;;\,, ;~;:::~
RegUlar Throttle .010 ,030' (.25 .8mm) EZThrottle .050 .060' (1.271.5 mm)
If the idle speed screw(s) is adjusted inward and the cable
sleevets) is not adjuste d to take up the throttle lever to

throttle block clearance, the engine may misfire or kill upon initial throttle opening.
CAUTlqN: '
After any idle speed adjustments are made, the throttle lever to throttle block clearan ce 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, Carouretlon, for proper carb uretor synchronization adjustments.
111 95
10.32
ELECTRICAL Speed Control Assurance Testing

1. Set the multitester in the ohms (0) 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 biock cleara nce is adjuste d properiy , the switch assemb ly must be replaced.
Test 2 Closed Circuit - Kill The two speed cont rol switches must make a complete circuit to kill the engine. To check the switc hes, 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 Au xiliary ShutOff The multitester should read less than .4 ohms in the OFF position and an ope n 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 handleba r pad andl or 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 assura nce switches. Remove the switches noting their placeme nt in the throttle block. Replace the assembly and check its operation.
10.33
11/95
ELECTRICAL Electric Fuel Gauge Testing

1996 RXL Mode l
Use the multitester's ohmmete r to test the resistance of the fuel sende r. Position Empty Full Ohms
Range
0 -30 85.5 - 94 .5 0
00 900
The supply voltage on the RedlWhtte send er wire should be higher than 2 VDC, and less than 5 VDC.
All Other Models

Use the multitester ohmmeter to test the resistance of the fuel sender. Position Empty Full Ohms Range
950 70
90 - 97.5 0 4.5 - 130
The supply voltage to the gauge should be 13.5 VAC. Fuel Gaug e
Diode Fuse (0.2A)
PurlWh
Brn
Yel
11/95
10.34
ELECTRICAL
Handlebar Warmer Testing

High-Low Handwarmer Toggle Switch
'--Below are the correct wire to PIN numbers :
1. Blue 2. Yellow 3. Blue/Red 4 . Blank 5. Blank 6. Blank 7. Brown 8. Blank
High Circuit Regulated Power (A.C.) Low Circuit
HANDLEBAR HARNESS WIRE CONN. BLUE
Ground Circuit
YELLOW
'--
J.esli.ng 1. Disconnect handwarmer connector at the handwarmer.
BLUE/RED
..
BROWN
2. Measure the low range resistance between the

Blue and Brown wires . The resistance should be 19.2 Q. 3. Measure the high range resistance between the Brown and Blue/Red. The resistance should be 9.6 1.
SWITCH - HANDWARM ER HI -LOW
Thumbwarmer Toggle Switch

Below are the correct wire to PIN numbers: 1 2. 3. 4. 5. 6. 7. 8. White/Gray Yellow White/Gray Blank Blank Blank Brown Blank To Thumbwarmer Regulated Power (A.C.) To Thumbwarmer
WHITE/G RAY YELLOW
I!~~~L-
BROWN
Ground Circuit
J.esli.ng Disconnect handwarmer and check resistance at nandwarrnar, The resistance between the Blue/ Red and Brown wires is 9.6 Q .
WHIT E/G RA SWITCH - THUMBWARMER
10.35
9/96
ELECTRICAL 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 condi tion. Is proper spark being generated? Yes
No
Failure is not with ETSS system. Reference ignition system troubleshooting.
Disconnect tem perature probe from stop system module and check conti nuity 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 snould 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 CDI box oracx kill wire.
9/96
10.35a
Poleris tnoustries Inc.
ELECTRICAL Exhaust Therma l Sensi ng System (ETSS)

Exhaust Thermal 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 condition, which causes the engine to stop operating, is rare and generally results after prolonged wide open throttle 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. IlII:CA UTION: i
Disconnect black wire for testing purposes only. Do not operate the snowmobile with the ETSS system disconnected.
'"
OL"
~.
10.35b
9/96
ELECTRICAL Ignition System Troubleshooting

Condition: No Spark
Discon nect the single black (black/white) wi re from th e COl Module to the ignit ion kill cir cuit. Does it have a spark? Yes-.. C heck the ignition swi tch, wire harness, throttle safety switches an d kill switch for proper adj ustment or short to ground . Repa ir or repl ace as necessary.
NOj
Disconnect the stator t o COl module wires. Test the resis tance va lues of the sta tor cons as per the charts o n page 10.3. Are the resistance values within specs? All except 3 cylinders: If the pa rts of the ignition system under the flywheel check OK. the only rema ining component is the coli/COl module assembly. Replace the module with another wi th the same CU number. (Se e ignition data ) All 3 cylinders: Disconnect and check the secondary ignition co il resistances. Refer to the resistance values listed on page' 0.3 . If the co il resis tance val ues are within specs , replace the C Ol module.
Yes-
NOl
Isolat e which component's res istance is not w ithin specs . R emove the flywh eel and stator, Recheck the resistances: loo k for pinched or bare harness wires; or rep lace the coil. Refe r to pa ge 10.27 for co il rep lacement procedures.
Condition: Incorrect Advance/Retard

Follow the engine tim ing procedu re for che cking run ning tim ing at 3000 RPM . Is the timIng within limits? Adjust the ignition liming by rotating the stator plate to co rrect the tIming. Afte r adjusting the 3000 RPM timing, continue with operating RPM timing jf poor perfo rmance exists. (Continue on with left column.) See ignition timing page' 0.1 ' . If the 3000 a nd operating RPM timing are within limits, no other testIng is necessary.
Ne>-
Yo51
Follow the engi ne timing procedure for checking operati ng RP M timing from page t 0.18. Is the timing within limits ? Yes_
No ~
Rem ove the ignition kill circ uit by disconnecting th e sir,gle blac k wi re between the COl module and the machine harness. Is the tim ing now correct? Yes_
Check th e ig nition switch , th rottle safety switches, kill sw itch and ha rness for damage wh ich can cause intermittent shorting problems . Correct the problem.
No;
Verify the correct C Ol module by co mpanng the CU code on the box to the information listed in the ignition data charts at the beg inning of thi s sect ion. Is it the right module? Rep lace the module with the co rrect part and readjust the ignition liming.
No_
Yes L Check the resista nce of the coi ls under the flywheel. Com pare these values to the charts on page 10.3. Are they within limits? Check the wi ring connecting the coils and/or replace the coils as nece ssary .
NoYesl II the 30DORPM timi ng is within limits but the ope rating RP M timi ng is no t acceptabl e, rep lace the COl mod ule.
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 capable of handl ing these RPMs may provide an inco rrect operating RPM timing reading. Use timing light PN 2870630 or equivalent.
9196
10.36
Polans Industrtes Inc.
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CHAPTER 1 GENERAL INFORMATION

Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . .. 1.1 - 1.1 b Service Bulletin Index By Bulletin Number 1996 Service Bulletin Index By Model 1997 Service Bulletin Index By Model 1998 Service Bulletin Index By Model Service Videos 1996 Model Identification I General Specification s 1997 Model Identification I General Specifications 1998 Model Identification I General Specifications Paint Codes Torque Specifications Decimal Equivalents Conversion Table Glossary of Terms Service Tips Warranty Policy Special Tool Information 1.2 - 1.2c 1.2d - 1.2h 1.2i - 1.2j 1.2k - 1.21 1.3 1.4 - 1.13 1.13a - 1.131 1.13m - 1.13u 1.14 - 1.1 4b 1.15-1.16 1.17 1.18 1.20-1.22 1.23 1.24 1.25
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19
CHAPTER 2 MAINTENANCE I TUNE UP

Maintenance Inspection Forms ' " Recommended Maintenance Product s Lubrication Chaincase Lubrication / Chain Adjustme nt Suspension Lubrication Cooli ng System Track Maintenance/Alignment Spark Plugs Spark Plug Charts Drive Belt Removal/Installation Backrest Adjustment Headlight Adjustment Handlebar Adjustment Brakes Exhaust System Reverse Cable Adjustment Off Season Storage Variable Exhaust System (V. E.S.) Maintenance Routing Diagrams 2.1 - 2.2 2.3 2.4 - 2.6 2.7 - 2.8 2.9 - 2.10 2.11 2.12- 2.16 2.17 2.17a - 2.17b 2.18 2.19 2.20 - 2.22 2.23 2.24 - 2.25a 2.25 2.25b 2.26 - 2.28 2.28a - 2.28e 2.29 - 2.70
CHAPTER 3 ENGINES
Spec ifications Torque Spec ifications Piston/Cylinder Clearance Specifications Fuel Recomm endation Engine Removal. Typical Engine Installation. Typical Fan Cooled Twin Service Liquid Twin Service Three Cylinde r Monoblock Service RXL Service EC59PU EC68P L Service 600 / 700 Case Reed Service 800 Case Reed Service 440 Case Reed Service General Inspection Procedu res Cooling System - EC45/50PL Cooling System - EC65PL05 Cooling System - EC58PL Cooling System - EC 59 / 68PL Cooli ng System - EC80PL Recoil Service Troubleshooting 3.1 - 3.4 3.5 - 3.6 3.7 3.8 - 3.9 3.10 - 3.13 3.14 - 3.18 3.19 - 3.27 3.28 - 3.34 3.35 - 3.44 3.45 - 3.51 3.52 - 3.59 3.60 - 3.71 3.72 - 3.78 3.78a - 3.78j 3.79 - 3.90 3.91 & 3.93 3.92 3.94 - 3.95 3.96 - 3.97 3.99a 3.100 3.101 - 3.102
Cooling System - SN60 / SN70 Domestic Twins .. 3.98 - 3.99
CHAPTER 4 ELECTRONIC FUEL INJECTION (EFI)

Ope ration Battery Maintenance Battery Testing Power Up Testing Alternator Controlled Switch (ACS) Testing Basic Operation - System II EFI Fuel System Maintenance and Testing System III - Electronics Operation System III - Electronics Testing EFJElectronics Wiring Diagram - 1996 / 1997 RXL 4.1-4.3 4.4 4.5 4.6-4 .7 4.8 4.9 4.10-4.15 4.16-4.17 4.18-4.27 4.28-4 .32 4.33
Wiring Diagram - 1996 / 1997 500 EFI/SKS/ RMK . 4.34-4.35
CHAPTER 5 FUEL SYSTEM I CARBURETION

Jet Part Numbers 1996 Condensed Data 1997 Condensed Data 1998 Condensed Data Exploded View - Keihin Exploded View - VM30SS Exploded View - VM34SS Exploded View - VM38SS Exploded View - VM34SS with ACCS 1996 Jetting Compensatio n Charts 1997 Jetting Compensatio n Charts 1998 Jetting Compensation Charts Gaso line Volatility Systems Component Functions Component Effect vs Throttle Opening Jetting Guidelines Oxygenated Fuel - Carb ureted Models Oxygenated Fuel - EFI Models ACCS System Mikuni Carburetor Service Mikuni Carburetor Float Level /Adjustment Keihin Carburetor Service 1996 Synchronization Specs 1997 Synchron ization Specs 1998 Synchronizatio n Specs Synchronization Procedure Choke Adjustment (All) Fuel Pump Operation Water Trap Service Troubleshooting ,.., , , .......... , 5.1 - 5.1a 5.2 - 5.3 5.3a - 5.3b 5.3c 5.3d 5.4 5.5 5.6 , .. 5.7 5.8 - 5.15 5.15a - 5.15j 5.15k - 5.15p 5.16 5.17-5.23 5.24-5.27 5.28 5.29 5.30 5.3 1 5.32-5 .34 5.35-5 .37 5.38 , . . 5.38a-5 .38e 5.381 5.39 5.39a 5.39b-5.39c 5.40 , . . 5.42-5.45 , . . 5.46 5.47-5.48
CHAPTER 6 CLUTCHES
Clutch Service Tools Torque Values 1996 Specifications 1997 Specifications 1998 Specifications Drive Clutch Weight Identification Drive Clutch Spring Rates Drive Clutch Spring Data Driven Clutch Spring Data / Rates P-85 Drive Clutch, Exploded View P-85 Driven Clutch, Exploded View P-90 Drive Clutch, Exploded View P-90 Driven Clutch, Exploded View Clutch Operation Drive Clutch Removal Drive Clutch Disassembly/Inspection Spider Roller Removal Spider Roller Installation Spider Bulton Shimming Drive Clutch Assemb ly Drive Clutch Installation Spider Indexing Driven Clutch Removal Driven Clutch Disassembly Driven Clutch Asse mbly Driven Clutch Helix Ramps Driven Clutch Installation Drive Belt Data Drive Belt Inspection Drive Belt Deflection Clutch Offset/Alignment Torque Stop Adjustment Belt to Sheave Clearance P-85 Clutch Bushing Service P-90 Clutch Bushing Service Troubleshooting 6.1 6.2 6.3 - 6.5 6.6 - 6.8 6.8a - 6.8b 6.9 - 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.22 6.23 6.24 - 6.25 6.26 6.26 - 6.27 6.27 - 6.28 6.29 6.30 6.30 - 6.31 6.32 6.33 6.34 - 6.35 6.36 6.37 6.39 6.40 6.4 1 6.42 6.43 6.44 6.45 6.45 6.46 6.47 6.52 6.53 6.60 6.61 . 6.63
CHAPTER 7 BODY AND STEERING

Torque Specification s Steering Specifications Steering Assemb ly, Exploded View Steering Inspection Cambe r Definition Rod End Torque Procedure Rod End Engagement Guideli nes Steering Adjustment - All Models Steering Stop Adjustment (1996) XTRA-10 CRG / XC-10 CRG Adjustment (Using Travel Bars) Ski Spindle Bushing Removal / Replacement Steering Arm Orientation Ski S!<ag Removal /Installation Ski Skin Installation Ski Installation Handlebar Torque Fuel Tank and Seat Remova l Seat Cover Replacement Seat Interchangeability Chart Nosepan Replacement Procedure - Standard Nosepan Replacement Procedure - Evolved Nosecone Alignment - Standard Hood Adjustment - Evolved Decal Removal and Installation Troubleshooting , ,., 7.1 7.2 - 7.2b 7.3 - 7.9c 7.10 7.11 , . 7.11 7.11 7.13 7.18 7.18 7.18a - 7.18e 7.18f - 7.18g 7.1 8h 7.19 7.19a 7.19b 7.20 7.21-7.22 7.23-7.25 7.27 - 7.27a 7.28 7.29 7.30 7.31-7.32 7.33 7.34
CamberfToe Quick Referenc e By Front End Type . 7.12
Taillight Assembly Replacement - Stand ard Indy .. 7.26
CHAPTER 10
ELECTRICAL
Lighting Specif ications . . .. . . .. . .. .. . .. . . . .. .. .. .. Ignition Specif ications 10.1 - 10.1 a 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 Timing Marks Convers ion Chart - Degrees to Piston Position 10.11 10.1 2
Ignition System Exploded Views . . . . . . . . . . . . . . . . . . . . . . 10.13 - 10.16 Ignition Timing Inspection I Adjustment . . . . . . . . . . . . . . . . 10.17 High RPM Timing 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 Starter Installation Lighting System Output Test Typical Exciter, Pulser or Lighting Coil Replacement Eiectrical Testing Speed Contro l Assurance Operation Electric Fuel Gauge Testing Exhaust Thermal Sensing System (ETSS) 1996 Wiring Diagrams " . . . . . . . . . . . . . . . . 10.23 10.24 10.25 10.27 10.28 - 10.30 10.32 10.34 10.35a - 10.35b 10.37-10.48
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Coolant High Temperature Indicator Testing . . . . . . . . . . .. 10.31 Speed Control Assurance Testing . . . . . . . . . . . . . . . . . . . . . 10.33 Handlebar Warmer Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35 Ignition System Troubleshooting . . . . . . . . . . . . . . . . . . . . .. 10.36 1997 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49 - 10.62b 1998 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.63 - 10.72
CHAPTER 8 SUSPENSION
IFS Specifications Rear Suspens ion Specifications IFS - Torsion Bar Service Rear Suspension Tuning IFS Shock Adjustment Rear Suspension Adjustment Tunnel Mount ing Positions Hi-Fax Replacement 1996 Sport Style Suspension Service 1997 XTRA Lite Style Suspension Service 1996 WideTrak Style Suspension Servic e 1997 Standard Indy 133.5 /14 1" Service XTRA 10 Suspension Service XTRA 12 Suspension Service Rear Suspens ion Set Up Compression Adjustab le Shocks XTRA 12 Shock Installation 8.1 8.2 8.3 8.5 8.6 8.7 8.10 8.11 8.13 8.14 - 8.15 8.1 6 - 8.17 8.18 - 8.21 8.22 - 8.27 8.28 - 8.32 8.33 8.37 8.38 - 8.48 8.49 - 8.60 8.61 8.62 8.64
Rear Suspens ion Operation. . . . . . . . . . . . . . . . . . . . . . . 8.8 8.9
Indy Select Shock Adjustment . . . . . . . . . . . . . . . . . . . . . 8.12
XTRA 12 Shock Remova l . . . . . . . . . . . . . . . . . . . . . . . .. 8.63 Wheel Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.65 - 8.67 FOX Shock Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8.68 FOX Shock Maintenance FOX Remote Shock Maintenance 8.698.78 8.79 - 8.82
Shock Valving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.83 - 8.87 Additional Fox'" Shock Hardware . . . . . . . . . . . . . . . . . . 8.88 - 8.89 Troubleshooting 8.90 - 8.94
CHAPTER 9 BRAKES I FINAL DRIVE

Specifications Jackshaft Speed vs. MPH Chart Chain / Sprocket Part Numbers Chain / Sprocket Comb inations Track Drive Data Track Specifications Drive Shaft Sprocket Installation Tips Hydraulic Brake System Operation Type 3 Master Cylinder Removal / Inspection / Assembly Brake Bleeding Type H4 Brake Friction Pad Replacement Type H4 Caliper Disassembly Type H4 Cleaning and Inspection Type H4 Assembly Type H5LC Brake Friction Pad Replacement Type H5LC Caliper Disassembly Type H5LC Clea ning and Inspection / Assembly Type M3 Brake Disasse mbly Type M3 Assemb ly to Chaincase Type M3 Adjustment Type WT Brake Disassembly Type WT Assembly to Transmiss ion / Adjustment Type 3 Drive System Disassembly Type 3 Drive System Assemb ly Transmission, Suspension and Track Removal - WideTrak Transmission Disassembly 1997 to Current WideTrak Transmission Assembly 1997 to Curren t WideTrak Track Removal - Two Sprocket Drive Shaft Track Removal - Four Sprocket Drive Shaft Series 300 Transmission Overhaul Reverse Kit Service Tips Reverse Kit Maintenance Traction 9.1 - 9.1a 9.2 - 9.2a 9.2 - 9.2c 9.2d - 9.2e 9.3 9.3c 9.3d - 9.3f 9.4 9.5 9.6 9.9 9.10-9 .12 9.13-9.14 9.15 9.16 9.16-9. 17 9.18-9.19 9.20 9.2 1-9.22 9.23 9.24 9.25 9.26 9.27 9.28-9.31 9.32-9.39 9.40- 9.42 9.47a - 9.47g 9.47g - 9.47h 9.48-9.49 9.50 9.51-9.55 9.56 9.57-9.58 9.59 - 9.64
Transmiss ion , Suspension and Track Assembly - WideTrak . . 9.43-9.47
INDEX
A
ACCS Sys tem ......... . ................... 5.325.34 Adjusting B elt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . 6.43 Air/Fuel Mixture Ratio . . . _, . . . . . . . . . . . . . . 5.25 Alignment Bar Specifications .... ........ _. 7. 10 Alignment Bar, Ski. Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 Alignment Kit. Crankshaft. Snow . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 Alig nment Tool, Clu tch Offse t. 5/8", Snow . . . . . . . . . . . . 1.25 Alignment Tool. Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 Align ment Tool, P 90 Clutch Offset. Snow ... , . . 1.25 Alt ernato r Contr oll ed Switc h (ACS) Testing . . . 4.8 Alternato r Output Test . . . . . ....... .. , 0.26
Amp Draw Test . . . , ... , . . .. . , . . , . . . . . .
4.11
B
Backres t Adjus tment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 Barometric Pressure Sensor . . . . .. . . . .. . . . . . . . . . . . . . . . . . 4.26 Battery Cha rging 10 .20 Battery Cha rging System Testing ....................... 4.5 Battery Maintenance , EFI 4.4 Battery Service. . . .. ....... . . . . . . . . . . . . 10.19-10.20 Battery Service , EF I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.4 . . . . . . . . . . . . . . . 4.4 Battery Tender .... .... . .... Battery Testing 10.19 Belt Deflection . ..... ..... ...... .. ....... ... ... .... .. 6.42 Belt Inspec tion . . . . . . . . . . . . . . . . . . 2. 18 6.63 Belt Wea r I Bum Diagnosis Bell to Sheave Clearance Inspection 6.46 Bleeding, Brak e . . . . . . .. ... . . ,.. . 2.2 4 Bleeding , Brak e, Fluid Change . . . . ,.. . . 9. 10-9. 11 Bleeding, Brak e, System Rebuild . . 9 .11 Ble eding, Cooling Syste m ... " ...... .. .. .......... .. .. 2.11. 3 .563.57,3.913 .92 Bleed ing. Oil Pump . , . 3.89 Block, Fox Shoc k Body . Snow . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.29 Brake Adjustment . . ... . . .. ... .. . . ... .. ... ... .. .... 2.25 B rake Adjustment. Type M3 . . . . . . .. .. . . . .. . 9.25 B rake Adjus tment, Type WT ... ... _. . . . . . . . . . . . . . . . . . .. 9.27 Brake Assembly to Cha incase . Type M3 ..... . . . . . . . . . . . . . 9.24 Brake Assembly, Type H4 ..................... ..... 9.169.17 Brake Assembly. Type HSLC .. . ... . ........ 9 .2 1-9.22 Brake Assembly. Type WT . . . . . . . . . . . . .. . . . . . . . . . . . . .. 9.27 Brake Bleed ing . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 Brake Bleeding. Fluid Change 9. 10-9. 11 Brake Bleedin g. Sys tem Rebuild 9. 11-9.12 Brake Clea ning and Inspection. Type H4 . . . . . . . . . . . . . . . . . . . 9. 16 Brake Clea ning and Inspection. Type H5LC 9.21 Brake Disassembly. Type M3 ,. . ... ... . .. ... . . . 9.23 Brak e Disass embly, Type WT . . . . . . . ... . . . . . .. . . .. . . . . , . 9.26 Brake Fluid Replenishment . .. , .. , ., , .. . . . . . . . . . 2.24 Brake Specificati on s. 1996 . . , . ... .. .... ... . . .. . . . . . . " 9.1 Brake Specifications, 1997 . . . . . . 9.1a Brake System, 44 0 XCR SP 9.7 Bu lletin Index By Mod el . ... . .. 1.2d 1.2k Bushing End Play. Oil Pump . ...... .. .. ..... ... ..... 3.543.55
Carb uretor Assembly. Keih in 5.38d 5.28 Carb uretor Component Effect vs . Throttle Ope ning . . . . .. Carb ure tor Component Function .... ........... ...... 5.25-5 .27 Carburetor Function _. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 5.24 Carburetor Leak Testing Needle and Seat . . . . . . . . . . . . . . .. 5 .38 Carburetor Service . . . . . . . .. . . . . . .. . .. . . . . . . . . . 5 .35-5 .37 Carbu retor Service, Keihin . .. . . . . . . . . . . . . . . . . . . . . . 5 .38a-5.38e Carburetor Se rvice , Mikun i . . . . . . . . . . . . . _. . ... 5 .35-5 .37 Chaincase Oil Level 2.7-2 .8 Cha rge Coil Test Specifica tions ... . ...... ........ ... ...... 4 .1 Charging Needle Replacement. Snow . . .. . . . _. . . . . . .. . 1.29 Cho ke Adj ustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5.40 Ch oke and Cable LUbrication ,. . . . . . . . . .. 2.6 Cl utch Alig nm ent . . . . . .. , .. , . . . . .. .. .. . .. . .. 6.3 1 Clu tCh Ali gnment Adjustm ent . . . . . . . . . . . . . . . . . , . . 6,45 Cl utch Alignm ent Inspection .. ..., ,... 6,45 Cl utch Bushing Replace ment Tool Kit Snow 1.26 .. . . . . 6.31 Clutch Off set . . . . . . . . . Clutch Offs et Adjustment 6.44 Clutch Offset Inspection 6 .44 Clutch Service Data. 1996 _. . 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. Sn ow 1.24 Coil Replacement .. . . . . .. . . . . . . . . . ...... ...... .... 10 .27 . . . . . . . . . .. . . . . . . 4.8 Co ld Sta rting , EF I . .. ....... Co mpressio n Adjustable Shocks 8 .62 _. 1.26 Co mpression Tool. Clutch. Snow Co mpressio n Tool, Shock Spr ing , Snow 1.29 Co nnecting Rod (Big End) Inspection . . ,.. .......... .. . . .. 3 .82 Connec ting Rod (Small End) Inspec tion 3.82 Conv ersion Chart, Degrees to Piston Position BTD C 10.12 Conversion Tabl e . . . . .. . .. .. ... . . . . .. . . . .. . 1.18 Coo lant High Temperature Indica to r Testing ,.. .. . . 10.31 Coo lant Le vel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 Cooli ng System .. .. . . . . . .. . . ... . . . . . . . ... . .. . . . . . . . . . 2.11 Coo ling Syste m Diag rams . . . . . .. . .. . . .. . . . . . . . . . . 3 .91-3 .99b Cra nkcase Inspection . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . 3 .81 Crankcase Tempe rature Se nsor . . . . . . . . . . . . . . . . . . . . . . . . .. 4.25 Crankshaft Bearin g Inspection . . . . .. . .. . .. .. . . . . . . . . . . . 3.81 . 3 .84-3 .85 Cranks haft Indexing Crankshaft Straightening 3 .83 Crankshaft Truing . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48 Cylinder Clean ing 3.80 Cyli nde r Head Inspection . . . . . . .. . . . . . . . . . . . . . . . . . .. 3.86 Cy linder Hon ing ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.79 Cyli nde r Measuremen t 3.86
D
Decal Installation . . .. . . ,. .. . . ... .. ... .. 7.33 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 7 .33 Decimal Equivalent Cha rt . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . 1.17 De-glazing . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . 3 .79 Dial Indicator, Ignition Timing , Sno w . . . . . . . . . . . . . . . . . . . . .. 1.32 Drive Clutch Weight Identification 6.9-6 . 12 Drive Belt . . . . . . . . . .. . . . . . . . .... . .. . . . . . . . . .. . . . . . . . . 6.40 Drive Belt Adj ustment , 6.29 Dnve Belt Deflection ............ ..... ............... 6.32 Drive Belt Installation . . . . . . .. . . . .. . . . . . . . . 2.18 Drive Belt Part Num bers , . . . . . . . . . . .. 6.29 Drive Belt Removal ... ....... ....... . ......... ..... . 2.18 Drive Chai n Tension 2.7-2 .8 Drive Clutch Assembly . . . .. . . . . . . . .. . . . . . . . . . .. . . ... . . . 6.29 Dnve ClutCh Bushing Service 6.54-6.55 Drive Clutc h Disassembly . . . . .. .. . . ...... . . . . . . . . . .. ... 6.24 Drive Clutch Iden tification . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.23 Drive Clutch Installa tion . . . . . . . .. ... . . . . . . . . . . 6.30 Drive Clutch Ope ration ,. ... ..... . , . 6.20-6.21
c
Caliper Disass embly. Type H4 . 9.15 Calipe r Disassembly. Type H5LC .. .. ... . 9.20 Cambe r Adjustment, All IFS 7.9d Camber Adjustment- (Trave l Bar Method) XC 10IXtra 10CRC . 7.18a Cam be r J Toe Specifications Quick Reference . . . . . . .. . 7. 12 Carburetion Condensed Data. 1996 5.2- 5.3 Carburetion Conde nsed Data. 1997 5.3 a-5 .3b Ca rbureto r Adjust ment 5.38 -5.39c Carbu retor Adjustm ent. Mlkuni ... . . . . .. . . ... . . .. ... . , 5.38
INDEX
Drive Clutch Removal . . . . . . . . . . . . . . . . , 6.23 Drive Clutch Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.1 Drive Clutch Spring Comp ression Rate Cha rt . .. . .. . .. . . . 6.13 Drive Clutch Spring Data 6.14 Drive Clutch Spring Rate Chart _. . . . . . . . 6.15 Drive Clutch Spring Rates . . . _. . . . . . . . . . . . . . . . . . . . . . . . . .. 6.13 Drive Clutch Weight Identification . . . . . _ _ 6.6-6.9 Drive Gea r End Play. Oil Pump . . . . 3.89-3 .90 Drive System Assemb ly, Type 3 , , 9.32-9.37 Drive System Disassembly. Type 3 . .. . 9.28-9.3 1 Driven Clutch Assembl y 6.36 Driven Clutch Disas semb ly . , . . __. . _. . . . . . . . . . . . . . . . 6.34 Driven Clutch Installat ion . . _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39 Driven Clutch Operat ion _. . . _. . . . 6.22 Driven Clutch Removal _. . . . . . . . . . . . . . . . . . . . . . . . . 6.33 Driven Clutch Springs . . . . . . . . _.. .. 6.15 Driver, Transmiss ion Sea1JBearing. Snow 1.32 Driveshatt Sprocket Installation _. _ _" 9.4 Dropping Resistor _ 4.29
E
ECU Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30 EFI Accessory Note 4.2 EFI Electronics .. .. . . . . . .. . .. . . . .. .. . . . . . . .. . .. .. . . 4.28-4 .32 EFI Fuel System Maintenance 4.10-4.14 EFI Fuel System Testing 4.10-4.15 EFI Operation . . . . . . . , 4.14 .3 EFI System II Operation . . 4.9 EFI Troubleshooti ng . . . . .. .. . 4.22 Electric Fuel Gauge Testing . . . . . . . . . . . . 10.34 Electric Starter Asse mbly . ... .. . 10.23 Electric Starter System Testing 10.21-10.22 Electronic Control Unit _.. . . . . . . . . . . . . . . . . . . . . . 4.19 Electronics Operation. EFI System III . . .. 4. 16-4.17 Electronics Testing. EFI System III . 4.18-4.27 Engine Assembly, 3 Cylinder MonobJ ock ... . ... .... 3.4 1-3.44 Engine Assem bly. 60 01700 Case Reed . . . . . 3.66 -3 .71 . 3.75-3. 78 Engine Assembly, 800 Case Reed . ... . _.. Engine Assemb ly. Fan Cooled Twin Cylinder 3.24-3.27 . 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 . _. . _... ... ..... 3.253.28 Engine Assemb ly. PL Twin Cylinder _ 3.14-3.16 Engine Assembly . RXL .. . 3.48-3.51 Engine Disassemb ly. 3 Cylinde r Monoblock 3.353.40 Engine Disassembly, 6 001700 Case Reed _ 3.60-3.65 Engine Disassembly. 800 Case Reed 3.72-3.74 Engine Disassembly, EC59PU EC68PL . . . . . . . . . . . . . 3.36-3.59 Engine Disassembly. Fan Cooled Twin Cylinder 3.19-3.23 Engine Disassembly. Liquid Twin Cylinder . . ..... . .. . . 3.28-3.31 Engine Disassembly. Monoblock. EC58Pl 3.17-3 .18 Engine Disassembly. Pl Series Reed Valve 3.29-3.31 Engine Disassemb ly. PL Three Cylinder _... _ 3 .22-3.24 Engine Disassemb ly. PL Twin Cylinde r 3 .10-3.13 Engine Disassemb ly. PM Twin Cylinder 3.8-3.9 Engine Disassembly. RXL 3.453 .47 Engine Installation. Typical 3.14-3.18 Engine Removal. Typical 3.103 .13 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 Exhaust The rmal Sensing System (ETSS) . . . . . .. . . . . .. . 10.35a
Fluke Meter. Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' .20 Flushing the Cooling System " 2.11 .. . 8.81 Fox Remote Shock Assembly . . Fox Remote Shock Disassembly 8.79-8.80 Fox Remote Shock Recharging _ 8.82 Fox Shock Assembly 8.74-8.78 '-.-/ Fox Shock Data , . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.68 Fox Shock Disassembly , _. 8.70-8 .71 Fox Shock Hardware _ 8.88-8.89 Fox Shock Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8.69 Fox Shock Seal Replacement .. . . . . .. . . . .. ... . . ... 8,72-8.73 Friction Pad Replacement. Type H4 . . . _..... ... ... .. . . . .. 9.13 Friction Pad Replacement. Type H5LC 9.18 Front Rear Scissor Stop (FRSSI - XTRA 10 Style . . . . 8.45 Front Rear Scisso r Stop (FRSS), XTRA 12 Style . . 8.56 Front Shock Spring Preload Adjustment . _. . .. 8.11 Front Shock Spring Preload Adjustment - XTRA 7.15 Front Track Shock Spring. XTRA 12 Style 8.56 Fuel Delivery System. Typical _ __ . 5.18 Fuel Injecto rs ... _ _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.29 Fuel Pressure Test 4.11 ""Fuel Pump Exploded View 5.43-5.45 Fuel Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42 Fuel Pump Operation _ _. . . . . . . . . . . . . . . .. . . . 5.42 Fuel Pump, EFI , ., 4.10 Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 Fuel Recommendation . . . .. . .. . . .. . . .. . .. . . . . 3.6-3.8 Fuel Hecommendation-f asb EFI Models .. . . 3.9 Fuel System .. . .... .... .... ... ... .. . . _ 2.20 Fuel System Deicers . . . . . 3.9,5.3 Fuel Tank/Seat Removal ...... . 7.21-7,22 Fuse Link . . . . .. .. . ....... 4.7
G
Gasoline Volatility .... . .. ... .. 5.16 Gauge. Cylinder Comp ression. Snow 1.22 Gauge. Pressure. Snow . . . . . . . . . . . 1.31 Gearing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.1 Glossary of Terms _.. . . . .... .... ..... ... 1.33-1.35 2.5 Greasing Driveshaft Bearing . . . . . . . .. . . .. . . . . . . . . Greasing Jacks haft Bearing _. 2.5
H
Handlebar Adjustment _. . . .. 2.23 Handleb ar Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 Handlebar Centering - XTRA . . . . . . . . . . . . . . . . . . . . 7.16 Handlebar Centering CRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7.18c Handlebar Torque - Aggressive Style . . . . . . . . . . . 7.20 ,. Handlebar Torque - Evolved Style .. .... . .. .. . .. . . . . . . .. . . 7.20 Handlebar Torque - Indy Style 7.20 --../ Handlebar Warmer Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . _. 10.35 Headlight Adjustment . . . . .. . ... . . . ... . . . . . . . . . . . 2.202.22 Headlight Bulb Filament Continuity Test 10.28 Headlight Bulb Installation . . . . . . . . . . . . . . . . . . 2.202.22 Headlight Bulb Removal . . , , 2.20-2.22 Hehx Angles and Effects . . . . . . . . . . . . . . . . . . . . _. . . . 6.28 Helix Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.37 Hi La Beam Switch Testing 10.28 Hi- Fax Replacement 8.16-8.17 Holding Fixture . Drive Clutch. Snow . . . . . . . . . . . . . . . . . . . . . . . ~ ~4 Holding Tabs. Replacement. Snow . . . . , .24 Hone Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.79 Hone . Cylinder. Snow . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21 _ Hone, Replacement Set. Snow .... . ........... 1.22 Honing Oil, Snow . . . . . . . . . . . . . . . . . ... . .. ... . 1.22 ....-/ Honing Procedure 3.80 Honing to Oversize .... .. .. . 3.79
F
Final Toe Adjustment (Except CRC) Float Chamber Venting . .. . . Float Level Adjustment . . . . Float System . 7.15 5.t7 5.38 5.24
INDEX
Hood Adjustment - Evolved Style Hydraulic Brake System Operation Hydrometer. Battery. Snow ..... . . 7.31-7.32 . . . . 9.5 1.32 . 7.30 Nosecone Alignment - Indy Style ... ... ... . . , Nosepan Replacement - Evolved Style ... . . . . . . . . . . .. . . . 7.29 "., ,. 7.28 Nosepan Replacement - Indy Style
o
IFS Adjustment - XTRA 10 Style . . . . . . . . . . .. . . . .. . 8.44 . 8.53 IFS Adjustment, XTRA 12 Style . . . . . . . . .. . . . . . . IFS Speci ficat ions. 1996 . .... . ..... ............. . _ 8. 1 IFS Speci ficat ions, 1997 8.2 IFS Spec ificati ons . 1998 . . . . . . . . . . . . . . . . . . . . .. 8.2a Ignition Switch Testing 10.29 -10.30 Indy Select Shock . . ... . . ... ...... .... ........ . .. .. 8.43 .8.62 Information Bulle tins ............. ......... ........ .. 1.21 .29 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 Installation Tool. Clutch Spider Roller. Snow. . . . . . . . . . . . . . . . 1.24 Installation Tool, Jacksnett, Snow. . . . . . . . . . . .. 1.28 Installation Tool, Piston CC lip, Snow , 1.2 1 . ,,... 2.21 Installing the Center Bulb , . ". Installing the Side Bulbs ... " ". ... . . 2.21 ,.,........ 4.25 Intake Air Temperatur e Sensor : . . . . . . . . . . .. 3.89 . . . . . . . .. 3.89 Oil Pump Bleeding. . . . . . . . . . . . . . . . . . . . . . au Pump Bushing End Play Adjustment . .. . . 3.54-3 .55 Oil Pum p Drive Gear End Play Adjustment ' , . . , . . , 3.89-3.90 Oil Pump Ope ration 3.88 . . . . . . . 10.19 Open Circ uit Voltage Test . . , ... , , . . . , . . . Operating RPM Timing Check , 10.18 Operation. Rear Suspension . , , 8.8-8 .9 " , _, . " " " , . . , . . 4.11 Out put Volume Test , .,., Oxygenated Fuel .. .. ....... .. .... . ... , , . , . , . . 3 .9 Oxygenated Fuel - Carbureted Models ... .. .... , .. . . . .. 5.30 5.31 Oxy genated Fuel EF1 Models Oxy gena ted Fuel-Carbureted Models . . . . . . .. 3.8
all Pump Adjustment
p
J
Jackshah Speed vs. MPH Chart _ __ , 9.2 Jet Needle . . . . , ' ,., , . . . . . . . . . . . . . . . . .. 5.26 Jet NeedlelN eedle Jet , , , , .. , . , . . . . . . . . . . . . . . .. 5.22 . .. ", ... " . . , ... ,., 5.1 Jet Part Num bers , .. "" . . ,.. .. . , , . . . .. 5. 1a Jet Part Numbers, Kethln .. .. . , , ' . . Jet Part Numbers, Miku ni . . . . . . . . . . . . . 5.1 JettIng Compensation Charts, 1996 . , ,,,.., 5,8-5. 15 . 5.15a-S.15j Jetting Com pensa tion Charts, 1997 , .,.. . .. Jetting Compensa tion Cha rts, 1998 . . , ' . ' , , , 5,15k-5. 15o Jetting Guideli nes . , , , , . . .. 5.29 P-85 Clutch Bushings . . . . . . . , 6.47-6 .52 P85 Driv e Clutch Exploded View , 6,16 P-85 Drive Clutch Movable Sheave Bushing Installation .. .. 6,50 P-85 Drive Clutch Movable Sheave Bush ing Removal 6.49 P85 Driven Clutch Cove r Bushing Installation , . . . . . . . . .. 6.48 P-85 Driven Clutch Cover Bushing Removal 6.47-6 .48 PBS Driven Clutch Exploded View , 6.136.17 P-B5 Driven Clutch Movable She ave Large Bushing Installation 6.52 P-85 Driven Clutch Movable Shea ve Large Bushing Removal 6.5 1 P85 Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.27 P-90 Clutch Bushin gs 8.53-6 .60 P90 Drive Clutch Exploded VIew , .. , . . . . .. 6.18 P90 Driven Clutch Exploded View 6.19 , . . . . .. 6.30 P90 Driven Clutch Service Pain t Codes. 1996 , , .. .. . . ... 1.14 Paint Codes, 1997 . . .. ....... , . . . . . . . . . . . . . . . . . . . . . .. 1.14a , ... . . .. .. . 5.25 Pilot Air Screw . . '.' Pilot Jet ,......... . ' . . . . . . .. 5.25 PH System ot , . . . . . , . .. " . , .. , .... .. . . . ". ..... .. 5.20 Piston Inspection/Measurement 3.87 , . . . 3,82 Piston Pin Inspe ction . . . . .. . . . . . . . .. . . , . ... . 3.2-3.4 Piston Ring End Gap , Installed .. .. . , ... .. . . . 3.87 Piston Ring Install ation . . . . . . . . . . . .. . . . . .. . . Piston Ring Installed Gap , , " 3.87 Piston/Cylind er Clearance Measu rement 3.7 Port Cha mfering ... . . .. ... ' . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.80 4.7 Power Up Component Testing " , .. , . . . . . . . . . . . 4.6 Power Up Testing " . . . . . .. . . . . . .. . . . . . . . ,. .. ......... . 4 .2 Powering Up. EFI , , Preliminary Toe Adjust men t , " , 7.10b Pressure Regulat or " . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.12 Publication Numb ers. 1996 . . " . . ", . . . . . ,.' "." . .. . . .. , 1.1 . . . . . . . . . . . . . . . . . . . . .. 1.1a Publication Numb ers. 1997 . . .. 1.24 Puller. Drive Clutch. T'H andle , Snow ... , . . . .. Puller, Driven Clutch, Snow . . . . . . . . . . . . . . . . . . . . . . . .. 1,26 Puller. Flywheel, Snow . . . . . . . . . .. 1.23 Puller. Piston Pin . Snow ............ 1.21 Pum p Kit. Vacuum. Snow , ' , . . . . . . . . . 1.32
L
Lighting System Outp ut ".,., 10.25 .. 10.20 Load Test ,., . . , , . ... " 2.5-2.10 Lubr ication , Lubrication . Suspension , ... . . . . ...... . , ... , , . , . 2.9-2.10
M
Main Jet . . . . . . . . , , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 Main System . . . . , . .. . .... , ' , . . . . .. . . . . . . . . , . . .. 5.23 Maintenan ce Inspection. 1000 Mile .,.... ... ..... .......... 2.2 Maintenance Inspection , 150 Mile . . . , . . . . . . . . . . . . . . . . . 2.1 Maintenance Inspection. 2000 Mile . . .. .. . . . .. .. . . . .. .. . . . 2.3 " " .. , ,.,.,.. 2.4 Maintenance Products , . ,' " , 9.7-9.9 Master Cylinde r Asse mbly. Type 3 .. , , . 9.7 Master Cylinder Inspection , Type 3 . , . . . . . . . . . . . . . 9.6 Master Cylinde r Removal. Type 3 . . , ., Master Cylinder Service Tool Kit, Snow , , 1.3 1 Measuring Belt Deflec tion ......... .. .. 6.43 Model Identification . 1996 1.4- 1.13 1.13a-1. 131 Model Identification. 1997 ... ... .... .... ,...... MR Adjustments , .. , ,.. . .. 4.27 10.a-1O.10 Multimeter Usage . . , .. , Multites ter. Snow , , . . . . . . .. . . . . . . . . . . . . .. 1.20
R
Reamer. Tapered, Drive Clutch Bore. Snow Rear Rear Scissor Stop (RRSS) - XTRA 10 Style . . . . . Rea r Rear Scisso r Stop (RRSS). XTRA 12 Style . . . . . Rear Suspension Adju stments, XTRA 12 Style Rear Suspension Op eration , 1.25 8.48 8.56 8.56-8.57 , . . , 8. 13
N
Needle Bearing Inspection Needle Jet , , . . 3.82 5.26
INDEX
Rear Suspension Specific ations, 1996 8.2-8 .3 Rear Suspension Specifications , 199 7 . . . . . . . .. . . . . . . 8.4-8 .5 Rea r Suspension Tun ing 8.10 8.57 Rea r Torsion Spnng , XT RA 12 Style .. _... ... . Rear Track Shock Spring. XTRA 12 Style. . . . . . 8.56 Recharging Kit. Gas Shock . Snow . .. __ . . . . . . . . . . . . . .. . . 1.29 Recoil Assembly 3.97-3.100 Recoil Disassembly 3 .96 Recoil Starte r Spring Replacement 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 RetumHose ........ ...... , , 4.12 Reverse Kit Maintenance 9.57-9 .58 Reverse Kit Service Tips , _ 9.56 Rivet Tool, Tunnel. Snow . . . . . . . . . .. 1.30 2.21 Removing the Side Bulbs . . . . . . . . . . . . .. . . . . . . . . . 4.20 ROM Chip Removal . .. ROM Identification . . . . . . . . . . . . . . . . . . . . . . . .. ...... . 4.1 Roubng - Carburetor Vent Line 2.59-2.66 Routing - Fuel Line 2.4 1-2.44 Routing - Handlebar Harness _ 2.45-2 .47 cator Lights 10.4-10 .7 Routing - rncn Routing - Miscellaneous 2.67-2.70 Routing - Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.482.49 Routing - Oil Vent Line . 2.50-2.5 1 Rouling - Speedometer Cable . . . ... . . . .. ... .. .. . ... . 2.292.30 Routing - Vent Lines .. . . ....... . . . 2,52-2.58 Routing - Wire Harn ess/Fuel Line . , . , . . , . . . . . . . . . 2.36-2. 40 Hounnq - Wire Harn ess/Sp eedom eter Cable . . , .. .. . 2.3 1-2.35 .. 4.23 RPM Senso r ,,..... Rubber Track Clip Replacement . . 8. 10 Specifications, Rear Suspension. 1997 8.4 -8.5 Speci fications. Shock Valving , ......... .... . . . . .. . .. 8.848 .87 Spec ificat ions, Stee ring . . .. . . . . . . . . . . . . . . . . . . . . .... 7.2-7.2b Speci fication s, Torque 1.15-1.16 Spec ifica tions , Torq ue, Body and Steer ing . . . . . . . . . . . . . . . . . 7.1 3.3-3 .6 Spec ifications, Torq ue, Engine Specifications , Torque, Suspension 8.14-8.15. 9.3b Speci fica tions. Track Drive Data , .... ... . . ... .. ....... 9.3-9.3b Specificatio ns. Track. 9.3d-f Speed Con trol Assurance Adjus tment . . . . . . . 10.32 Speed Con trol Assura nce Operation 10.32 10.33 Speed Control Assu rance Replacement ,......... . Speed Control Assurance Testing . . . . . . . . . . . . . . . . . . . . .. 10.33 Spider Assembly 6.22-6.24 __ . . . . . . . . .. 6.27 Spide r Button Shimming Spider Indexing 6.32 6.26 Spider Roller instanauon . . . . . . . . . . . .. . . . . . .. . . . . . . . . .. Spider Aoller Removal . . . . . . . .. . . . . .. . .. ... 6.26 Spindle Centering, IFS 7.10a 7.18a Spindle to Chassis Centering - CAC Spring Tension. Aear, XTAA 10 Style . 8.46 Springs . Acc essory. XTRA Lite . . .. . . . . . . . . . . . 8.26 Springs. Coil. XTRA U te _. . . 8.26 Springs , Optional. Spo rt Style 8.21 Springs. Optional. WideTrak Style 8.37 Springs, Op tional . XTRA 10 Style 8.59 Spri ngs. Optional . XT RA 12 Style 8.58 10.24 Start er Installation . . , . . . . . .. .. . ... . .... . . .. Starte r Solenoid Bench Test 10.24 Starter Syst em , . . . . . . . . . . . . . . . . . . . . . . . 5.19 Stee ring - Standard IFS .. 7.10-7.14 , ... . . . . . . 7.15-7. 17 Steering XTRA10 and12 . . . .. 7.18g Stee ring Arm Installatio n . . . . . . . . . . . .. . . . . . . . . . Stee ring Assembly Exploded View . . . . . . . . . . . . . . . . . 7.4a-7 .98 7.10 Steering Inspection - Standard tFS ..... . ... . Steering Insp ection . - All Mod els . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Steering Rod End Orien tation , .. 7.3 Steering Specifications 7.2-7 .2b Steeri ng Stop Adjustment . ... 7. 16 Steering Stop Adjus tme nt - Standard IFS . .. ..... .... ..... 7.14 , . . 7.16 Steering Stop Adjustment - XT AA Stor age 2.26 -2.28 Stud Install ation . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . .. . . . . . . 9.63 Suppo rt Block . Piston, Snow . . . . . .. 1.21 ,.... .. ........ . .. 8.24 Suspe nsion Adjus tment Suspe nsion Adjustment - Sport Style . . . . . . . . . . . . 8.20 Suspension Adjustment - Standa rd Indy Style 8.35 -8.36 Suspension Adjustment - WideTrak Style 8. 138.14 Suspension Adjustment - XT AA 10 Style . . . . . . .. . . . . 8.42-8.43 Suspension Adjustment Features . . . . . . . . . . . . . . 8.24 8.21 Suspension Adjustment. Spo rt Style Suspe nsion Adjustment. XTRA 12 Style 8.55 .. . 8.25-8 .27 Suspension Adjus tment . XTRA Ute Style . Suspension Adjustments. Rear. . . . . . . . . . . . . . . . . . . . . . . . . .. 8.25 Suspe nsion Components - Sport Style . . . . . . . . . . . . . . 8.19 Suspension Components - Wide Trak Style . . . . . . . . . .. 8.12 Suspension Com ponents. XTAA 10 Style ........... 8.39-8.41 Suspension Compo nents, XT AA 12 Style ... ........ 8.51-8 .52 8.18 Suspension Exploded View. Sport Style Suspension Exploded View. Stan da rd Indy Style .. ..... 8.33-8.34 Suspension Exploded View , WideTrak Style . . . . . . . . . . . 8.28-8 .29 8.38 Suspension Exploded View. XTAA 10 Style . . . . ... Suspension Explod ed View, XTRA 12 Style, 8.28. 8.49. 8.50 Suspension Exploded View. Xtra Ute Style. 8.22 Suspension LUbrication. 2.9. 2.10 . 8.27 Suspe nsion Set Up. Aear, XT AA 12 Style, 8.36. 8.60 Suspension , Rear Components. Xtra Ut e Style . 8.23
---..
s
Seat Cove r Replacement 7.237.25 Seat Length Matrix 7.27-7.27a .. . . .. . . . . . . . . . . . 7.217 .22 Seat Removal ,..' Select Monitor Scrolling . . .. . . . . . .. . . . .. . . . . . . . . . . . . . . 4.22 . . . . . . . . . . . . . 1.20 Select Monitor. Snow . _. . . . . . . . . . . . Service Bulletms 1.2-1.2g . , 1.37-1.38 Service Tips ... .... . . . ..... .. Service Videos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.3 Set Up Width , Maximum . . . . . . . . ., 7.10a SetUpWidthCRC 7.18a Shock Installation. XTRA 12 Style 8.64 .. 8.63 Shock Removal. XT RA 12 Style . .. .. . .. . Shock Tuning 8.10 Shock Valving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.83 1.16 Shop Supplies/Accessories ... .... . .. ..... .... .. .. . .. .. . .. . .. . 7.17 Ski Alignment - XTRA . .. .. 7.14 Ski Installation ..... 7.19 Ski Skag Removal-IFS . ... Ski Skin Installation . . .. . . . . 7,19a . 7.18e-7 .18f Ski Spindle Bush ing Replacement . .. 5.2 1 Slide Cutaway . . . . . . . . .. .. Socket. Dnve Clutch Spide r Nut, Snow 1.25 . . . . . . . . . . . .. . . 2.17 Spark Plug Selection. .. . . . . . . . . . . Specific Gravity Test 10.19 Specifications . Alignment Bar 7.10 Speci fications. Brake . 1996 9.1 Specifica tions. Brake, 1997 , 9.1a Specifica tions, Charge Coil Test _ _. .. . . 4. 1 Specifications. Clutch, 1996 6.3-6.8 Specifica tions . Coil Resistance . . . . , . . . . . . . . . . . . . . .. 10.3 Specifica tions, Engin e, . 3.1-3.4b . 8.2 Specifications ,I FS. 1997 Specifications, Ignition. 1996 . , . . . . .. . .. . . . . . . 10.21 0.2b , 10.110.1a Specifications, Lightin g, 1996 . . . .. . . . . . , Specifications, Rear Suspensio n, 1996 . .. . 8.2-8.3
,. ...../
, -./
INDEX
Track Removal , Two Sproc ket Driveshaft _. 9.48-9 .49 ,... . ........ . . . " . , , 2.13-2 .16 Track Tension Track Tension Data . . . . . . .. .. . . .... . . . . . . . . . . . . . . . . . . . 2.13 Traction . . . .. .. ... , .. . .. . . . ... .... . . . . . . . . .. 9.59-9.64 Transm ission Overhaul. Series 300 9.51-9 .55 Transmission, Sus pension I Track Asse mbly, WideTrak . . 9.43-9 .47 Transmission . Suspension I Trac k Removal, WideTrak . 9.40-9.42 Troubleshooting . Body and Sleering . . . . . . . . . . . . . . . . . . . . . .. 7.34 Troubleshooting. Carburetion 5.47-5.48 Troubleshooti ng, Clutch 6.61-6.62 .. , . , . . . , . .. 4.22 Troubleshooting. EFI , . .. .. . . . Troubleshooting, Engine , ,. . . . . . 3.1013.102 . . . . . 10.36 Troubleshooting , Ignition Syste m . .. .. .. Troubleshooting . Oil Pump . . . . . . . . . . . . . . . . 3.88 Troubleshooting. Seat Harn ess . . . . . . . . . . . . . . . . 10.28 . . . 8.90-8 .94 Troubleshooting. Suspension , .. . ,. Tunnel Mounting Positions . . . . . . . . . . . . . . . . . . . . . . . . 8.14
T
Taillight Asse mbly Replacement Indy Style . . . 7.26 2.22 Taillight Bulb Replacement . ... . _. . . . . . . . . . . . . . . . . . . 1.19 Tap Drill Chart __ . 4.15 Thr ottl e Body Throttl e Cable Lubrication . , .. 2.6 Th rottle Opening vs . Fuel Flow 5,26 Th rottle Position Sensor , .... . . ... . . .. . . .... " 4.24 Thro ttle Synch ronization . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5.39 ThroWe SynchronizationKeihin 5.39c Throttle Synchronizaticn-Mikuni . . ... ... .. . . . . . . . . . . 5.39b Throttle Valve . _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 10.11 TIming Advance Curves . Typical . . . .... _ 1.20 TIming Light. Snow . .. . . _. . . . . . . . . . . . . . . . . . . TIming Procedure , Three Cylinder COl 10.15-10 .17 Timing Procedure, Twin Cytinder Fan COl . . . . . . . .. . .. . 10.13 Timing Procedure , Twin Cylinder Liquid COl . . .. ... . . .. . . 10.14 Toe Adjus tment - Standard IFS . . . ... .. . .. . . . . .... .. . . 7.13 Toe Adjustment, Final (Except CRC) . .. . . . . . . .. . . . . . . . . . 7.15 ,., 7.10b Toe Adjustment. Preliminary , , Toe Alig nment-C RG , , , ,.. 7.18c Torque Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.45 Torsion Bar , ,.. ... .. . . . . . . . . . . . 8.6 . " 8.7 Torsion Bar Install ation . . ,.. . . , . . , , , . 8.7 Tor sion Bar Removal. . . . . . . . . . . . . . . . . . . . , . . . . . . . . 2.12 Track Alignment. . . .. . . . . . . . . . . . . . .. 8.17 Trac k Cli p Removal . . . .. , . . . Track Clip Removal Tool, Snow ,. 1.27 Track Clip Replacement , . . . . . . . . . . . . . . . . . . . . . . . . . 8.17 Track Clip Tool. Camoptast. Snow ,...... ... . . . .... .. . . .. . 1.27 . . . . . . . . . . . . . . . . . . . . 1.27 Track Clip-Tool. IOL, Snow. . . . . . . . Track Maintenance .. . . . . . . . . .. ......... . . . . . . . . . . . " 2.12 Track Maintenance/Alignment 2.12-2 .16 Track Removal. Four Sprocket Drivesh aft . . . . . . . . . . . . . . . . . . 9.50
v
VM30SS VM34SS VM34SS VM38SS Exploded Exploded Exploded Exploded View View View View . . . . . . .. .. . . . . . .. . . . . . . .. . 5.4 5.5 . . .. . . .. . . . .. . .. .. . . .. . . .. .. .. . . . . . . . . . . .. 5.7a with ACCS . . 5.6a . . . , .. . . .. . .
w
Warranty Policy . . . . . . . . . . . . . .. . . . . . . . . . . 1.36 Water Pump Rebu ild . . . . , . . . . , . . . . . . . . . . . . . .. 3.53-3.55 Water Trap Service .. . ..... .. . ..... . .. ...... . . . . . .. 5.46 . 8.658 .67 Wh eel Kits .. .. .. .. . .. ... .. .. ... . . . 7.10a Width. Maximu m Se1 Up . . . . . .. . . . .. . . . . . . . 4 .344.35 Wiring Diagram, 1995500 EFI I SKS I RMK Wiring Diagra ms, 1996 10.39-10.44 Wiring Diagram . 1997 . , .. .. . . . . . . . ..... ..... ... 10.54 -10.62a Wiring Diagra m. 1998 .. .. . .. . . . . . .. . .. . .. .. . .. .. . 10.63-10.72 Wrench. Spanner, Snow , . . .... . . . ... . . . , . . . . . . . . . . . . . 1.30 . . . . . . . . . . . .. 1.31 Wrench. Strap , Snow .. . .. .. . ,.. . .. .
.-

1996-1998 Polaris Snowmobile

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1996-1998 Polaris Snowmobile

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GENERAL INFORMATION Publication Numbers

1996 Publication Numbers

Polaris Industries Inc.

GENERAL INFORMATION 1997 Publication Numbers

Polaris Industries Inc.

GENERAL INFORMATION 1998 Publication Numbers

1998 Publication Numbers

Indy WideTrak LX 0982065

Polaris Industries Inc.

Inform ation Bulletins

Polaris Industries Inc.

GENERAL INFORMATION Bulletin Index - By Number

Polaris Industries Inc.

Polaris Industries Inc .

GENERAL INFORMATION Bulletin Index - By Number Information Bulletins, Cant.

1 -95-03 1 -95-04 1-95-05 1 -95-06 195-07 1 -9508 1 -95-09 1 -95-10

1-96-01 1 -96-02 1-96-03 196-04 1 -96-05 1 -96-06 1 -96-07

Polaris Industries Inc.

GENERAL INFORMATI ON Bulletin Index -1996 By Model

1996 Indy 5torm 5K5

1996 Indy Storm RMK

Service Info Info Info Info Service Safety

1996 Indy Ultra SP

S-96-10 S-96-06 5 -95-22 S-95-18 S-95- 17 S-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 Servi e c Service

Service Service Service Service

S-96-10 S96-06 S9602 S9522 1-96-10 1 9609 1 9608 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

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

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

Heavy Steenng Fronl Muffler Dampe r Installat ion Location

1996 XLT Touring

S-96-08 S-96;05 S-96-01 1-96-13 1 -96- 12 1-96-04 1 -96-03 1 -95- 13 1 -95-10

Info Info Info Info Info Info

Poleris Industries Inc.

GENERAL INFORMATION Bulletin Index - 1996 By Model

1996 Class ic 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

Increased Rear Handwarmer Heat

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 EFI/SKS (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