Table of Contents

Chapter 1 - General Information ............................................... 2

Chapter 2 – Maintenance / Tune Up ....................................... 70
Chapter 3 – Engines ............................................................... 142
Chapter 4 – Fuel System / Carburetion ................................. 240
Chapter 5 – Clutches .............................................................. 292
Chapter 6 – Body and Steering .............................................. 350
Chapter 7 – Suspension ......................................................... 400
Chapter 8 – Brakes / Final Drive ............................................ 474
Chapter 9 – Electrical ............................................................. 552
CHAPTER 1
GENERAL INFORMATION

Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1998 Bulletin Index . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1999 Bulletin Index ........................... 1.4
Standard Torque Specifications . . . . . . . . . . . . . . . . . 1 .5
Recommended Shop Supplies/Accessories ...... 1.6
Decimal Equivalents .......................... 1.7
Tap Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Measurement Conversion Table . . . . . . . . . . . . . . . . 1.9
Victor Tool Ordering Information . . . . . . . . . . . . . . . . 1.10
GlossaryofTerms ............................ 1.11-1.13
General Service Tips . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
1999 Model Number Identification .............. 1.15
Model Specifications - 340, 340 Dlx, 340 Tour. . . . . 1.16-1.17
Model Specifications - Sport . . . . . . . . . . . . . . . . . . . 1. 18-1 .19
Model Specifications- Sport Touring ............ 1.20-1.21
Model Specifications - TranSport . . . . . . . . . . . . . . . 1.22-1.23
Model Specifications - XCF . . . . . . . . . . . . . . . . . . . . 1.24-1.25
Model Specifications - 440 XCR . . . . . . . . . . . . . . . . 1.26-1.27
Model Specifications - Trail . . . . . . . . . . . . . . . . . . . . 1 .28-1.29
Model Specifications - Trail Touring ............. 1.30-1.31
Model Specifications - Trail RMK . . . . . . . . . . . . . . . 1.32-1.33
Model Specifications - Super Sport . . . . . . . . . . . . . . 1.34-1.35
Model Specifications - 500 . . . . . . . . . . . . . . . . . . . . . 1.36-1.37
Model Specifications - 500 Classic . . . . . . . . . . . . . . 1.38-1 .39
Model Specifications - 500 RMK . . . . . . . . . . . . . . . . 1.40-1.41
Model Specifications - Classic Touring . . . . . . . . . . . 1.42-1.43
Model Specifications - XLT Special . . . . . . . . . . . . . . 1.44-1.45
Model Specifications- XLT Classic .............. 1.46-1.47
Model Specifications - XLT Touring . . . . . . . . . . . . . . 1.48-1.49
Model Specifications- 500 XC, 500 XC SP ....... 1.50-1.51
Model Specifications- 600 XC, 600 XC SP ....... 1.52-1.53
Model Specifications- 700 XC, 700 XC SP ....... 1.54-1.55
Model Specifications - 600 RMK . . . . . . . . . . . . . . . . 1 .56-1 .57
Model Specifications - 700 RMK . . . . . . . . . . . . . . . . 1.58-1.59
Model Specifications- 700 SKS ................ 1.60-1.61
Model Specifications - 700 XCR . . . . . . . . . . . . . . . . 1.62-1.63
Model Specifications - 800 XCR ................ 1.64-1.65
Model Specifications -Wide Trak LX ............ 1.66-1.67
 GENERAL
Publication Numbers

1999 Publication Numbers

Model Model No. Owner's Manual Parts Parts
Supplement Manual Microfiche
Indy 340 099LB3AS 9914669 9914673 9914674
Indy 340 Deluxe 099LD3AS 9914669 9914673 9914674
Indy Sport 099SB4DS 9914853 9914827 9914799
Indy XCF 099SP4AS 9914853 9914828 9914801
Indy Super Sport 099SB5BS 9914853 9914835 9914808
Indy Trail Blue 099EB4ES 9914682 9914834 9914807
Indy Trail Green 099EB4ESA 9914682 9914834 9914807
Indy 500 Black 099EB4BS 9914682 9914683 9914684
Indy 500 White 099EB4BSA 9914682 9914683 9914684
Indy 500 Classic 099ED4BS 9914682 9914830 9914803
Indy XLT Classic 099ED6AS 9914856 9914840 9914813
Indy XLT Special 099AB6AS 9914857 9914839 9914812
Indy 340 Touring 099LT3AS 9914669 9914670 9914671
Indy Sport Touring 099ST4DS 9914853 9915044 9915045
Indy Trail Touring Blue 099ET4ES 9914682 9914833 9914806
Indy Trail Touring Green 099ET4ESA 9914682 9914833 9914806
Indy Classic Touring 099ET4BS 9914854 9914831 9914804
Indy XLT Touring Blue 099ET6AS 9914856 9914838 9914811
Indy XLT Touring Gold 099ET6ASA 9914856 9914838 9914811
Indy 440 XCR 099SX4CS 9914860 9914844 9914817
Indy 500 XC 099SB5AS 9914861 9915015 9915016
Indy 500 XC SP 099SP5AS 9914861 9914845 9914818
Indy 600 XC 099SB6DS 9914861 9914846 9914819
Indy 600 XC SP 099SP6DS 9914861 9914847 9914820
Indy 700 XC 099SB7AS 9914861 9914849 9914822
Indy 700 XC SP 099SP7AS 9914861 9914850 9914823
Indy 700 XCR 099AB7BS 9914858 9914842 9914815
Indy 800 XCR 099AB8AS 9914859 9914843 9914816
Indy Trail RMK 099SR5BS 9914853 9914836 9914809
Indy 500 RMK 099ER4BS 9914682 9914829 9914802
Indy 600 RMK 1.75"Track 099SR6DS 9914861 9914848 9914821
Indy 600 RMK 2"Track 099SR6DSA 9914861 9914848 9914821
Indy 700 RMK 1.75"Track 099SR7AS 9914861 9914852 9914825
Indy 700 RMK 2"Track 099SR7ASA 9914861 9914852 9914825
Indy 700 SKS 099SS7AS 9914861 9914851 9914824
Indy Tran Sport 099SU4DS 9914853 9914826 9914798
Indy WideTrak LX 099SU4BS 9914855 9914832 9914805
1999 Snowmobile Owner's Manual (All) - PN 9914668
Snowmobile Assembly Manual- PN 9913911

Polaris Industries Inc. 1.1 10/98

GENERAL
Paint Codes

1999 Polaris Snowmobile Paint Codes

Model Hood Color Polaris Spring Color Polaris

Description "P" No. Description "P" No.
Indy 340 Bright White P133 Medium Blue P107
Indy 340 Deluxe Rigel Blue P246 Medium Blue P107
Indy 340 Touring Candy Red P259 Candy Red P259
Indy Sport Candy Red P259 Candy Red P259
Indy Sport Touring Candy Red P259 Candy Red P259
Indy TranSport Emerald P210 Gold P227
Indy XCF Bright Red P243 Bright Red P243
Indy Super Sport Bright White P133 Violet C P198
Indy 440 XCR Bright Red P243 Violet C P198
Indy 500 Classic Candy Red P259 Candy Red P259
Indy Classic Touring Candy Red P259 Candy Red P259
Indy 500 Opt. 1 Black Metallic P177 Medium Blue P107
Indy 500 Opt. 2 Bright White P133 Medium Blue P107
Indy 500 RMK Black Metallic P177 Medium Blue P107
Indy 500 XC, SP Black Metallic P177 Racing Red P239
Indy 600 XC, SP Bright Red P243 Bright Red P243
Indy 600 RMK Deep Violet P230 Violet C P198
Indy 700 XC Bright White P133 Racing Red P239
Indy 700 XC SP Black Metallic P177 Racing Red P239
Indy 700 RMK Rigel Blue P246 Medium Blue P107
Indy 700 SKS Rigel Blue P246 Medium Blue P107
Indy Trail Opt. 1 Rigel Blue P246 Medium Blue P107
Indy Trail Opt. 2 Mystic Green P269 Light Teal P169
Indy Trail Touring Opt.1 Rigel Blue P246 Medium Blue P107
Indy Trail Touring Opt. 2 Mystic Green P269 Light Teal P169
Indy Trail RMK Rigel Blue P246 Medium Blue P107
Indy XLT SP Black Metallic P177 Bright Red P243
Indy XLT Touring Opt. 1 Rigel Blue P246 Medium Blue P107
Indy XLT Touring Opt. 2 Gold Mist Metallic P274 Gold P227
Indy XLT Classic Candy Red P259 Candy Red P259
Indy 700 XCR Deep Violet P230 Bright Red P243
Indy 800 XCR Bright Red P243 Bright Red P243
Indy WideTrak LX Emerald P210 Gold P227

Order Polaris "P" Number from Midwest Industrial Coatings (612-934-8252). Mix as directed.

10/98 1.2 Polaris Industries Inc.

 GENERAL
Bulletin Index - 1998 By Model
1998 Model Bulletin# Type Notes
Storm
700XC S-98-03 Service Exhaust Heat Shield Kit/Float Level Information
700 XCR S-97-05R Safet~ Alert Pitman Arm Weld Failure And Pitman Arm to
Steering Rack Bolt Replacement
S-97-05 Safety_ Alert - Refer To S-97-05R
700 RMK S-97-05R Safet~ Alert Pitman Arm Weld Failure And Pitman Arm to
Steering Rack Bolt Replacement
S-97-05 Safet~ Alert - Refer To S-97-05R
S-97-08 Service Nosepan Heat Damage
S-98-04 Service Exhaust Heat Shield Kit
Ultra
Ultra Touring S-98-05 Service Passenger Hand Grip Heaters
600XC S-98-01 Service Exhaust Heat Shield Kit/Running Quality Up-
grades
600XCR S-97-05R Safety_ Alert Pitman Arm Weld Failure And Pitman Arm to
Steering Rack Bolt Replacement
S-97-05 Safety_ Alert - Refer To S-97-05R
600 RMK S-97-05R Safet~ Alert Pitman Arm Weld Failure And Pitman Arm to
Steering Rack Bolt Replacement
S-97-05 Safet~ Alert - Refer To S-97-05R
S-97-08 Service Nosepan Heat Damage
S-98-02 Service Exhaust Heat Shield Kit/Jet Needle E-clip Posi-
tion
XLT SP S-97-05R Safet~ Alert Pitman Arm Weld Failure And Pitman Arm to
Steering Rack Bolt Replacement
S-97-05 Safet~ Alert - Refer To S-97-05R
XLT Ltd
XLT Classic
XLT Touring S-98-05 Service Passenger Hand Grip Heaters
500
500 RMK
Classic
Classic Touring S-98-05 Service Passenger Hand Grip Heaters
Widetrak LX
Trail
Trail Touring
Trail RMK
440
440XCR
XCF
Sport
Super Sport
Sport Touring
Transport
Lite, Lite Dlx, Lite Trg.

Polaris Industries Inc. 1.3 10/98

GENERAL
Bulletin Index - 1999 By Model
1999 Model Bulletin# Type Notes
800 XCR
700XCR
700XC S-98-06 Service Updates for 1999 Gen II Pilot Builds
700XC SP S-98-06 Service Updates for 1999 Gen II Pilot Builds
700 RMK S-98-06 Service Updates for 1999 Gen II Pilot Builds
700 SKS S-98-06 Service Updates for 1999 Gen II Pilot Builds
600XC S-98-06 Service Updates for 1999 Gen II Pilot Builds
600 XC SP S-98-06 Service Updates for 1999 Gen II Pilot Builds
600 RMK S-98-06 Service Updates for 1999 Gen II Pilot Builds
XLTSP
XLT Classic
XLT Touring
500
500 RMK
500XC
500 XC SP S-98-06 Service Updates for 1999 Gen II Pilot Builds
Classic
Classic Touring
Widetrak LX S-98-06 Service Updates for 1999 Gen II Pilot Builds
Trail
Trail Touring
Trail RMK S-98-06 Service Updates for 1999 Gen II Pilot Builds
440 XCR
XCF S-98-06 Service Updates for 1999 Gen II Pilot Builds
Sport S-98-06 Service Updates for 1999 Gen II Pilot Builds
Super Sport S-98-06 Service Updates for 1999 Gen II Pilot Builds
Sport Touring S-98-06 Service Updates for 1999 Gen II Pilot Builds
Transport S-98-06 Service Updates for 1999 Gen II Pilot Builds
340
340 Deluxe
340 Touring

10/98 1.4 Polaris Industries Inc.

 GENERAL
Standard Torque Specifications
The following torque specifications are to be used as a general guideline when torque value is not specified. There are
exceptions in the steering, suspension, and engine areas. Always consult the torque chart and the specific manual
section for torque values of fasteners.

Bolt Size Threads/In

(MM!Thread)
0Grade 2
0 Grade 5
0 Grade 8

Torgue in. lbs. (kg/m)

#10 24 ............. 27 (.31) ............... 43 (.50) 60 (.69)
#10 32 ............. 31 (.36) . . . . . . . . . . . . . . . 49 (.56) 68 (.78)
Torgue ft. lbs. (kg/m)*
1/4 20 ............. 5 (.7) ................. . 8(1.1) ............... 12(1.6)
1/4 28 ............. 6 (.8) ................. . 10 (1.4) .............. 14 (1.9)
5/16 - 18 . . . . . . . . . . . . . 11 (1.5) ............... . 17 (2.3) . . . . . . . . . . . . . . 25 (3.5)
5/16 - 24 ............. 12 (1.6) .............. . 19(2.6) .............. 29{4.0)
3/8 16 ............. 20 (2.7) .............. . 30 (4.0) .............. 45 (6.2)
3/8 24 . . . . . . . . . . . . . 23 (3.2) .............. . 35 (4.8) .............. 50 (6.9)
7/16 - 14 ............. 30 (4.0) .............. . 50 {6.9) .............. 70 (9.7)
7/16 - 20 ............. 35 (4.8) .............. . 55 (7.6) .............. 80 {11.0)
1/2 13 ............. 50 (6.9) .............. . 75 (10.4) ............. 110 (15.2)
1/2 20 ............. 55 (7.6) .............. . 90 (12.4) . . . . . . . . . . . . . 120 (16.6)
*To convert ft. lbs. to kg/m multiply foot pounds by .138.
*To convert kg/m to N/m move the decimal to the right one position.

Polaris Industries Inc. 1.5 10/98

GENERAL
Recommended Shop Supplies I Accessories

Description Part Number

Synthetic Chaincase Lubricant- One Gallon .......... 2871477
Synthetic Chaincase Lubricant - (12 oz) .............. 2871478
Cable Lubricant ................................... 2870510
Fuel System Deicer (Isopropyl) . . . . . . . . . . . . . . . . . . . . . . 2870505
Loctite Primer T - 6 Oz. Aerosol . . . . . . . . . . . . . . . . . . . . . 2870585
Loctite RC 680 - 1Occ Retaining Compound . . . . . . . . . . 2870584
Loctite 515 Gasket Eliminator- 50cc Tube ............ 2870587
Loctite/Chisel- Gasket Remover- 18 Oz ............. 2870601
Metal Polish - 8 Oz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870632
DOT 3 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870990
Fogging Oil ....................................... 2870791
Corrosion Resistant Dielectric Grease ............... 2871027
Fox Shock Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870995
Premium All Season Grease (141/2 oz) .............. 2871423
Premium All Season Grease (3 oz) .................. 2871322
Premium 60/40 Anti-Freeze/Coolant ................. 2871323
Premium Carbon Clean Fuel System Additive . . . . . . . . . 2871326
Polaris Battery Tender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2871 076
Carbon Clean Fuel System Additive . . . . . . . . . . . . . . . . . 2871326
T-9 Metal Protectant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2871064
Crankcase Sealant 3 Bond 1215 . . . . . . . . . . . . . . . . . . . . 2871557

10/98 1.6 Polaris Industries Inc.

 GENERAL
Decimal Equivalents
1/64 ........................ . .0156
1/32 .................. . .0312 ................ 1 mm = .0394"
3/64 ........................ . .0469
1/16 ............. . .0625
5/64 ........................ . .0781 ................ 2 mm = .0787"
3/32 .................. . .0938
7/64 .1094 ................ 3 mm = .1181"
1/8 ........ . 1250
9/64 ........................ . .1406
5/32 .................. . .1563 ................ 4 mm = .1575"
11/64 ....................... . . 1719
3/16 ............. . .1875 ................ 5 mm = .1969"
13/64 ...................... . .2031
7/32 .................. . .2188
15/64 ...................... . .2344 . . . . . . . . . . . . . . . . 6 mm = .2362"
1/4 ......... . .25
17/64 ...................... . .2656 ................ 7 mm = .2756"
9/32 .................. . .2813
19/64 ...................... . .2969
5/16 ............ .. .3125 ................ 8 mm = .3150"
21/64 ...................... . .3281
11/32 ................. . .3438 ................ 9 mm = .3543"
23/64 ...................... . .3594
3/8 ........ .. .375
25/64 ...................... . .3906 . . . . . . . . . . . . . . . . 10 mm = .3937"
13/32 ................. . .4063
27/64 ...................... . .4219 ................ 11 mm = .4331"
7/16 ............. . .4375
29/64 ...................... . .4531
15/32 ................. . .4688 ................ 12 mm = .4724"
31/64 ...................... . .4844
1/2 ......... . .5 .................... 13 mm = .5118
33/64 ...................... . .5156
17/32 ................ .. .5313
35/64 ...................... . .5469 ................ 14 mm = .5512"
9/16 ............. . .5625
37/64 ...................... . .5781 . . . . . . . . . . . . . . . . 15 mm = .5906"
19/32 ................. . .5938
39/64 ...................... . .6094
5/8 ......... . .625 . . . . . . . . . . . . . . . . . 16 mm = .6299"
41/64 ...................... . .6406
21/32 ................. . .6563 ................ 17 mm = .6693"
43/64 ...................... . .6719
11/16 ............ . .6875
45/64 ...................... . .7031 ................ 18 mm = .7087"
23/32 ................. . .7188
47/64 ...................... . .7344 ................ 19 mm = .7480"
3/4 ......... . .75
49/64 ...................... . .7656
25/32 ................ .. .7813 ................ 20 mm = .7874"
51/64 ...................... . .7969
13/16 ............ . .8125 ................ 21 mm =.8268"
53/64 ...................... . .8281
27/32 ................. . .8438
55/64 ...................... . .8594 ................ 22 mm = .8661"
7/8 ........ .. .875
57/64 ...................... . .8906 . . . . . . . . . . . . . . . . 23 mm = .9055"
29/32 ................. . .9063
59/64 ...................... . .9219
15/16 ............ . .9375 ................ 24 mm = .9449"
61/64 ...................... . .9531
31/32 ................. . .9688 . . . . . . . . . . . . . . . . 25 mm = .9843
63/64 ...................... . .9844
1 .......... . 1.0

Polaris Industries Inc. 1.7 10/98

GENERAL
Tap Drill Charts

SAE Tap Drill Sizes

Thread Size Drill Size Thread Size Drill Size
#0-80 3/64 1/2-13 27/64
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50
5/8-11 17/32
#3-48 5/64
5/8-18 37/64
#3-56 45
#4-40 43 3/4-10 21/32
#4-48 42 3/4-16 11/16
#5-40 38 7/8-9 49/64
#5-44 37 7/8-14 13/16
#6-32 36 1-8 7/8
#6-40 33 1-12 59/64
#8-32 29 1 1/8-7 63/64
#8-36 29 1 1/8-12 1 3/64
#10-24 24
1 1/4-7 1 7/64
#10-32 21
1 1/4-12 1 11/64
#12-24 17
#12-28 4.6mm 1 1/2-6 1 11/32
1/4-20 7 1 1/2-12 1 27/64
1/4-28 3 1 3/4-5 1 9/16
5/16-18 F 1 3/4-12 1 43/64
5/16-24 I 2-4 1/2 1 25/32
3/8-16 0 2-12 1 59/64
3/8-24 Q
2 1/4-4 1/2 2 1/32
7/16-14 u 2 1/2-4 2 1/4
7/16-20 25/64
2 3/4-4 2 1/2
3-4 2 3/4

Metric Tap Drill Sizes

Tap Size Drill Size Decimal Equivalent Nearest Fraction
3 X .50 #39 0.0995 3/32
3x .60 3/32 0.0937 3/32
4x .70 #30 0.1285 1/8
4 X .75 1/8 0.125 1/8
5 X .80 #19 0.166 11/64
5 X .90 #20 0.161 5/32
6 X 1.00 #9 0.196 13/64
7 X 1.00 16/64 0.234 15/64
8 X 1.00 J 0.277 9/32
8 X 1.25 17/64 0.265 17/64
9 X 1.00 5/16 0.3125 5/16
9 X 1.25 5/16 0.3125 5/16
10 X 1.25 11/32 0.3437 11/32
10 X 1.50 R 0.339 11/32
11 X 1.50 3/8 0.375 3/8
12 X 1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32

10/98 1.8 Polaris Industries Inc.

 GENERAL
Conversion Table
Unit of Measure Multiplied by Converts to
ft. lbs. x12 =in. lbs.
in.lbs. x.0833 =ft. lbs.
ft. lbs. X .1383 = kg-m
in.lbs. x.0115 = kg-m
kg-m X 7.233 =ft. lbs.
kg-m X 86.796 = in.lbs.
kg-m x10 =Nm
in. X 25.4 =mm
mm x.03937 =in.
in. X 2.54 =em
mile (mi.) X 1.6 =km
km x.6214 =mile (mi.)
Ounces (oz) X 28.35 =Grams (g)
Grams (g) X 0.035 = Ounces (oz)
cc x.03381 =Fluid Ounces (oz)
lb. X .454 =kg
kg X 2.2046 =lb.
Cubic inches (cu in) X 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) X 0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) X 0.568 =Liters (I)
Liters (I) X 1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) X 1.137 =Liters (I)
Liters (I) x0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) X 1.201 = US quarts (US qt)
US quarts (US qt) X 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) X 0.946 = Liters (I)
Liters (I) X 1.057 = US quarts (US qt)
US gallons (US gal) X 3.785 =Liters (I)
Liters (I) X 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) X 6.895 = Kilopascals (kPa)
Kilopascals (kPa) X 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) X 0.01 = Kilograms - force per square em
Kilograms - force per square em X 98.1 = Kilopascals (kPa)

octo oF: 9 (°C + 40) + 5- 40 = oF

oF to oc: 5 (°F + 40) + 9 - 40 = oc

Polaris Industries Inc. 1.9 10/98

GENERAL
Victor Specialty Tools

PDLRRIS InDUSTRIES InC.

VST Service Tools

FOREWORD

This catalog has been produced to assist Polaris dealers and distributors in ordering Polaris Service
tools from Victor Specialty Tool Company (VST). To keep the information contained in this catalog
current and accurate, Tool Catalog Update pages will be mailed annually. Information on new
service tools will be included in the General section of the monthly Service Team Tips dealer news-
letter.
Tools listed in this catalog as "commercially available" cannot be ordered through VST. The sug-
gested tool or an equivalent can be purchased through most automotive tool suppliers or tool
manufacturers.
Note to new Dealers or Distributors: Suggested new Dealer I Distributor tool kit contents for each
product line (or combination thereof) are listed separately in the Index/Addendum section of this
catalog .. Contact VST for a current tool price list. Inquiries regarding tool availability, sugges-
tions or usage should be directed to VST at the phone number listed below.
Information, photographs, and illustrations contained in this manual are general representations
and actual tools may differ. All information subject to change without notice.

TO PLACE AN ORDER
(Canadian Dealers order directly from Polaris Winnipeg)
TOLL FREE ORDER FAX #
(ORDERS ONLY)
1-800-716-3938
PHONE ORDERS OR INFORMATION
1-716-742-1790

Service Tool Catalog Part Number 9914681

10/98 1.10 Polaris Industries Inc.

 GENERAL
Glossary of Terms
ACS: Alternator control switch.
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 em)
minimum from end of high tension lead to ground. Several testers are available commercially.
Alternator: Electrical generator producing alternating current voltage.
Bore: Diameter of cylinder.
BTDC: Before Top Dead Center.
Bump Steer: When skis toe in and toe out through suspension travel.
CDI: Capacitor Discharge Ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a
capacitor or condenser (in CDI box). At the proper moment a voltage generated by the stator plate pulser coil closes an
electronic switch (thyristor) in the CDI box and allows the voltage in the capacitor to discharge into the primary windings of
the ignition coil.
Center Cylinder: On three cylinder engines, the cylinder between Mag and PTO ends.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 em). 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 TDC.
Compression: Reduction in volume or squeezing of a gas.
Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI 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 PTO. Maximum allowable
run-out is .006" (.02 em).
DCV: Direct current voltage.
Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition. Piston looks
"hammered" through, rough appearance around hole. Possible causes: 1) lean fuel/air mixture; 2) low octane fuel; 3)
over-advanced ignition timing; 4 )compression ratio too high for the fuel octane.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in
the cylinder bore.
Displacement: The volume of the cylinder displaced by the
piston as it travels from BDC to TDC. The formula is: Bore 2 x Stroke x 3.1416
- - - - - - - - - - - =Displacement in
4 CCs

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-lo 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.

Polaris Industries Inc. 1.11 10/98

GENERAL
Glossary of Terms

~ Flat Head Bolt: To be used where finished surfaces require a flush fastening unit. Countersunk.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
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.

t Hex Head Bolt: Standard type of wrench-applied hexagon head, characterized by clean, sharp corners trimmed to
close tolerances. Recommended for general commercial applications.
Hi-Fax: Trademark of Himont Advanced Materials. The special slide material which fits onto the bottom of the suspension
rails.
High Side: Sled pushes or tips up.
High Tension Wire: The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug.
Hole Shot: A term used when machine starts a race from a dead stop.
Holed Piston: Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2} pre-ignition.
Ignition Coil: A type of transformer which increases voltage in the primary windings (approx. 200V) to a higher voltage in the
secondary windings (approx. 14KV- 32KV) through inductions. Secondary voltage is high enough to arc the air gap at the
spark plug.
Ignition Generating Coil: Exciter coil or primary charge coil. Stator plate coil which generates primary ignition voltage. CDI
system uses one ignition generating coil.
Inch Pound: ln. lb. 12 in. lbs. = 1 ft. lb.
Kg/cm2: Kilograms per square centimeter. Metric equivalent of PSI.
Keystone Ring: A piston ring with bevel on upper surface.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. Metric
equivalent of ft. lbs.
L Ring: A wide face piston ring with an "L" shaped cross section. Leg of "L" goes up when installing on piston.
Labyrinth Seal: A pressure type center seal identified by series of grooves and lands. Polaris engines us this type of seal to
separate the cylinders in the crankcase halves.
Left Side: Always referred to based on normal operating position of the driver.
Lighting Coil: Generates voltage for lights, battery charging, etc by electromagnetic induction.
Loose: When the rear of the vehicle slides outward in a turn. The track does not grab sufficiently.
mm: Millimeter. Unit of length in the metric system. 1mm = .040".
Mag End: Flywheel side of engine.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
This is how mechanical energy in our engines is converted to electrical energy in the lighting coil, 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 fuel/air mixture; 2)
improper spark plug heat range.

10/98 1.12 Polaris Industries Inc.

 GENERAL
Glossary of Terms
Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston looks
melted at area of damage. Possible causes: 1)incorrect spark plug heat range; 2} spark plug not properly torqued; 3}
"glowing" piece of head gasket, metal burr or carbon in the combustion chamber; 4} lean fuel/air mixture; 5) Incorrect ignition
timing.
Primary Circuit: This circuit is responsible for the voltage build up in the primary windings of the coil. Parts of this circuit
include the exciter coil, points and condenser, wires from the stator plate to the small primary winding in the ignition coil. In
the CDI system the parts include the exciter coil, the trigger coil, the wires from stator plate to CDI box and to the low
resistance primary windings in the ignition coil.
Primary Clutch: Drive clutch on engine.
Primary Compression: Pressure built up in the crankcase of a two stroke engine.
psi.: Pounds per square inch.
Pushing: When the front of the vehicle does not steer as much as the driver desires. The skis do not grab sufficiently.
R & R: Remove and replace.
RFI: Radio Frequency Interference. Caused by high voltage from the ignition system. There are special plug caps and
spark plugs to help eliminate this problem. Required in Canada.
RPM: Revolutions Per Minute.
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.
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 em) reach plugs.
Static Timing: Ignition timing when engine is at zero RPM.
Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coils.
Stroke: The maximum movement of the piston from bottom dead center to top dead center. It is characterized by 180° of
crankshaft rotation.
Surge Tank: The fill tank in the liquid cooling system.
TDC: Top Dead Center. Piston's most outward travel from crankshaft.
Transfer: The movement of fuel/air from the crankcase to the combustion chamber in a two stroke engine.
Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI systems.
Small coil mounted at the top of the stator plate next to the ignition generating coil.
V Regulator: Voltage regulator. Maintains maximum lighting coil output at approx. 14.5 ACV as engine RPM increases.
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 air/fuel mixture.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.

Polaris Industries Inc. 1.13 10/98

GENERAL
Service Tips

In order to perform seNice work efficiently and to prevent costly errors, the technician should read the text in this
manual, thoroughly familiarizing him/herself with procedures before beginning. Pictures and illustrations have been
included with the text as an aid. Notes, cautions and warnings have also been included for clarification of text and
safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to perform
the seNice work safely and satisfactorily. Use only genuine Polaris seNice parts.

&. Cleanliness of parts and tools as well as the work area is of primary importance.
Dirt and foreign matter will act as
an abrasive and cause damage to precision parts. Clean the snowmobile before beginning service. Clean new parts
before installing.

&. Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel. Protect hands with
gloves when working with sharp components.

&. If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be
found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.

&. Some of the fasteners in the snowmobile were installed with locking agents. Use of impact drivers or wrenches will
help avoid damage to fasteners.

&. Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious
machine damage or, as in the case of steering components, can result in injury or death for the rider(s).

&. If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten.
Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value. When
removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before removing
them.

&. If the condition of any gasket or 0-Ring is in question, replace it with a new one. Be sure the mating surfaces
around the gasket are clean and smooth in order to avoid leaks.

&. 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 other brands are substituted.

&. Grease should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating
grease loses lubricity and may contain abrasive foreign matter.

&. Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion resulting in
serious burns. Always disconnect the negative (black) cable first and reconnect it last. Battery electrolyte contains
sulphuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing. ANTIDOTE:
External - Flush with water. Internal - Drink large quantities or water or milk. Follow with milk of magnesia, beaten egg,
or vegetable oil. Call physician immediately. Eyes- Flush with water for 15 minutes and get prompt medical attention.

10/98 1.14 Polaris Industries Inc.

 GENERAL
1999 Model Identification
MODEL NUMBER IDENTIFICATION

1999 MODEL DESIGNATION

YEAR DESIGNATION----------. ENGINE DESIGNATION
E=European Model - - - - 3 A J S (A) --Color Option

I
S= North American Model
U= European Model
MODEL LINE (4TH DIGIT) MODEL TYPE (5TH DIGIT)
A= Aggressive B= Basic
S= Standard Indy U= Utility
E= Evolved D= Deluxe
L= Lite P= Performance
R=RMK
X= Racer
T= Touring
S=SKS

1999 1999
MODEL DESIGNATION ENGINE DESIGNATION
NUMBERS (Chassis) NUMBERS
LB -Indy 340 3A - 340 F/C Piston Port
LD - Indy 340 Deluxe 4A - 440 F/C Cylinder Reed
LT- Indy 340 Touring 48 - 488 UC Piston Port
SU- Transport!WideTrak LX 4C- 440 UC Case Reed (domestic)
ST - Sport Touring 4D - 440 F/C Piston Port
SB - Sport/Supersport/500 XC/600 XC/700 XC 4E - 488 F/C Piston Port
SP-XCF SA- 497 UC Case Reed 2 Cylinder (domestic)
ER- 500 RMK 58 - 544 F/C Cylinder Reed
EB- Indy 500/Trail/XLT LTD 6A - 597 UC 3 Cylinder
ED- Indy 500 Classic/XLT Classic 6D- 593 UC Case Reed 2 Cylinder (domestic)
ET- Classic Touring/Trail Touring/XLT Touring 7A- 700 UC Case Reed 2 Cylinder (domestic)
SR -Trail RMK/600 RMK/700 RMK 78 - 700 VES UC Case Reed 3 Cylinder
AB- XLT Special/700 XCR/800 XCR 8A - 800 VES UC Case Reed 3 Cylinder
SX- 440 XCR
SP- 500 XC SP/600 XC SP/700 XC SP
SS -700 SKS

MODEL NO. MADE IN U.S.A. POLARIS PATENT NOTICE

Mid. by Polaris Industries Inc.. in Roseau, MN under one or
V.I.N. NO. more of the following patents:
U.S. Patents Patented Canada
THIS VEHICLE CONFORMS TO ALL APPLICABLE 882,491/71
3,605,511 3,613,810 5,050,559
U.S. FEDERAL AND STATE REQUIREMENTS AND 3,580,647 3,867,991 5,048,503 883,694/71
CANADA MOTOR VEHICLE SAFETY STANDARDS 3,483,766 4,793,950 5,056,482 864,394/71
IN EFFECT ON THE DATE OF MANUFACTURE. 3,533,662 5,038,881 5,099,813 Canadian Rd.
3,545,821 5,172,675 5,074,271 34,573171
3,605,510 5,090,386 5,191,531 34,572/71
MFD. DATE: 3,525,412 5,050,564 3,613,811 1,227,823/87
7072133

These numbers should be referred to in any correspondence regarding warranty, service or replacement parts.

The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is
permanently stamped into the tunnel. The model number is embossed on the decal.
Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved
model and serial numbers are located on the crankcase (intake side).

Polaris Industries Inc. 1.15 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY 340 /INDY 340 DELUXE /INDY 340 TOURING
MODEL NUMBER: . 099LB3AS I 099LD3AS I 099LT3AS
ENGINE MODEL: . . EC34-2PM051

CARBURETION JETTING CHART

Type ............... . VM30SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 150 Altitude Below -20°F -20' to +10'F +10'to +40'F Above +40'F
Pilot Jet ............ . 35 Below-29'C -29'to -12'C -12' to +5'C Above S'C
0-900 160
Jet Needle ......... . 5DP7-2 Meters
(Feet) (0-3000)
150 140 135
#2 #2 #2 #2
Needle Jet ......... . 0-6(169)
Cutaway ........... . 2.5AL 900-1800 145 140 130 125
(3000-6000) #2 #2
#2 #1
Air Screw .......... . 1.5 Turns
1800-2700 130 125 120 115
Valve Seat ......... . 1.5 (6000-9000)
#2 #2 #1 #1
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700-3700 115 115 110 105
89 Oxygenated (9000-12000)
#2 #1 #1 #1
Throttle Gap
Under Cutaway
Idle Sync Gap
.219"(5.55mm)
~ - # refers to the clip position from top of jet needle.

Under Cutaway .240"(6.1 mm) c::J - Production Setting

CLUTCH
Type ................ P-90
Belt ................. 3211058 CLUTCH CHART
Belt Width (Projected). 1.250" (31.75mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chaincase
Outside Circumference 43.313 Weight Spring Spring Helix Gearing

Center Distance . . . . . . 11" (280mm) Meters Q-900

10 Silver/Gold Silver
36.5° 17-41 66 p
(Feet) (0-3000) A-1 3/4 HYVO
Shift Weights . . . . . . . . 10
900-1800 17-41 66 p
Primary Spring . . . . . . . Silver/Gold (3000-6000) 10MB Gold Silver 36.5°
A-1 3/4 HYVO
Secondary Spring . . . . Silver 1800-2700 17-41 66 p
Silver 36.5'
10MW Gold
Driven Helix . . . . . . . . . 36.5° A-1 (6000-9000) A-1 3/4HYVO

10MW 17-41 66 p
2700-3700 36.5'
or Blue Gold Silver
(9000-12000) A-1 3/4 HYVO
10MR

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 339 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.4528" (62.3mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.1889" (55.6mm)
Piston I Cylinder Clearance . . . 0.0031" - 0.0055"(0.08 - 0.14mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 34A
Piston Ring Marking . . . . . . . . . RN
Piston ring end gap ...........008"-.014"(.20mm-.36mm)
Head cc's (Uninstalled) . . . . . . 21.1 cc
Head cc's (Installed) ......... 17.3cc
Operating RPM±200 . . . . . . . . . 7000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 4100 RPM
Cylinder Head Torque . . . . . . . . 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.16 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: ............ INDY 340 /INDY 340 DELUXE /INDY 340 TOURING
MODEL NUMBER: ... 099LB3AS I 099LD3AS I 099LT3AS
ENGINE MODEL: . . . . EC34-2PM051

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP-5439 Fuel Tank ........... 8.8 gallons (33.31iters)
CDI Marking ....... CU6409 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 180 Watts Coolant ............. NI A
Ignition Timing . . . . . 26.5° BTDC@ 3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
.145" BTDC (.129"-.161")
3.67mm BTDC (3.28-4.08mm)
Operating Timing 15.5° @ 7000 RPM
Spark Plug I Gap ... NGK BR8ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts (9 watts Touring)
Brake . . . . . . 18 watts (18 watts Touring)
Voltage Regulator .. LR9 All (LR9 and LR2 for Deluxe)*
Electric Start ....... Option (Std. on Deluxe)
*LR9= Half wave voltage regulator
*LR2=Rectifier only for battery charging

SUSPENSION I CHASSIS CHAIN CASE

Body Style ........ Indy 340 Sprockets I Chain .... 17-41, 66 P 314 HYVO
Front Suspension . . 37 IFS Reverse ............ Option
Maximum Width . . . . 37.25"(94.62cm) Brake Pads ......... Std Mechanical
Camber . . . . . . . . . . . 0"±5116"(8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out ........... 118"-114"(3-6.35mm) Driveshaft Sprockets . 2 drivers
Front Shocks ...... Nitrex Brake Type ......... Mechanical Disc
IFS Spring Rate .... 105#lin.
Front Spring Preload 3 shims
Front Vertical Travel 7 in.(17.78cm)
Rear Suspension ... XTRA Lite (121", 133.5")
Rear Travel . . . . . . . . 10.0 in.(25.4cm) I (1 0.875 in.(27.62cm)Touring)
Front Track Shock . . Nitrex
Spring Rate . . . . . . . 80#Iin.
Rear Track Shock . . Nitrex
Rear Springs . . . . . . .393" I 80° (3401340 Dlx)*
Rear Springs . . . . . . .359"(sq.) I 84° (Touring)
Track Type . . . . . . . . 15"x121 "x.66"(15"x133.5"x.82"Touring) I 38.1 x307.34x1.68cm (38.1 x339.09x2.18cmTour)
Track Tension ...... 318"-112" (9.65-12.7mm) slack with 10#(4.54kg) weight 16"(40.64cm) ahead of rear idler shaft
* The stock springs are the softest available for the Indy 340 and Indy 340 Deluxe.

OPTIONAL REAR TORSION SPRINGS

INDY 340 AND INDY 340 DELUXE INDY 340 TOURING

MEDIUM FIRM SOFT FIRM

.393" diameter 17r .406" diameter I 82° .347" diameter 17r .359" diameter 177°
L.H.- 7041555-067 L.H. - 7041521-067 L.H.- 7041627-067 7041629-067
R.H.- 7041556-067 R.H.- 7041522-067 R.H.- 7041628-067 7041630-067

Polaris Industries Inc. 1.17 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY SPORT

MODEL NUMBER: . 099SB4DS
ENGINE MODEL: . . EC44-3PM025

CARBURETION JETTING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 185 Altitude Below -20°F ·20" to+ 10"F +10"to +40"F Above +40"F
Pilot Jet ............ . 35 Below·29"C ·29"to ·12"C ·12" to +5"C Above 5"C
0-900 195
Jet Needle ......... . 6FJ6-3 Meters
(Feet) (0·3000)
185 175 165
#3 #3 #3 #2
Needle Jet ......... . P-8(166)
Cutaway ........... . 2.0 900-1800 185 170 160 150
(3000-6000) #3 #3 #2 #2
Air Screw .......... . 1.0 Turns
1800·2700 165 155 145 135
Valve Seat ......... . 1.5 (6000-9000)
#3 #2 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700·3700 150 145 135 125
89 Oxygenated (9000-12000)
#2 #2 #2 #2
Throttle Gap
Under Cutaway .180" - (4.57mm) ~
~ • # refers to the clip position from top of jet needle.
Idle Sync Gap
Under Cutaway .200" -(5.1 mm) ~ ·Production Setting

CLUTCH
Type ................ P-90
Belt . . . . . . . . . . . . . . . . . 3211 059 CLUTCH CHART
Belt Width (Projected). 1.250" (31.75mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shih Clutch Clutch Driven Chaincase
Outside Circumference 45.125 Weight Spring Spring Helix Gearing
Center Distance . . . . . . 12" (305mm) Meters ()-900
Red/White Red
36.5° 19·39 66 p
(Feet) (0·3000) 10AL
Shift Weights . . . . . . . . 10 AL B-2 3/4 HYVO

Primary Spring . . . . . . . Red/White 900-1800

(3000-6000) 10 Red/White Red
36.5' 19-39 66 p
B-2 3/4HYVO
Secondary Spring . . . . Red
1800-2700 36.5' 19-39 66 p
Driven Helix . . . . . . . . . 36.5° B-2 (6000-9000)
10Al Gold Red
B-2 3/4HYVO
10MB 19-39 66 p
2700-3700 Red/White 36.5'
or 10 Red
(9000-12000) Gold B-2 3/4 HYVO
Bushed

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 432 cc
Bore ....................... 2.6661" (67.72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance ... 0.0035"- 0.0055"(0.09- 0.14mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Identification Marking . . M-6
Piston Ring Marking . . . . . . . . . R
Piston Ring End Gap .........008"-.019"(.20-.49mm)
Head cc's (Uninstalled) . . . . . . 28.6cc
Head cc's (Installed) . . . . . . . . . 23cc
Operating RPM±200 . . . . . . . . . 7000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 4000 RPM
Cylinder Head Torque ........ 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.18 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY SPORT

MODEL NUMBER: . 099SB4DS
ENGINE MODEL: . . EC44-3PM025

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP-5446 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking . . . . . . . CU6416 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 200 Watts Coolant ............. NI A
Ignition Timing ..... 26° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
.150" BTDC (.133"-.167"}
3.81 mm BTDC (3.39-4.25mm)
Operating Timing . . . 16° @ 6500 RPM
Spark Plug I Gap . . . NGK BR8ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 19-39, 66 P 314 HYVO
Front Suspension .. 41 IFS Reverse ............ Option
Maximum Width ... . 41.00"(104.14cm) Brake Pads ......... Type 69
Camber .......... . 9116"±5116"(14±8mm) Chaincase Center Dist. 6 518"(16.83cm)
Toe Out .......... . 0-118"(0-3mm) Driveshaft Sprockets . 2 drivers
Front Shocks ..... . Nit rex Brake Type ......... Polaris HPB
IFS Spring Rate ... . 105#1in.
Front Spring Preload 1 shims
Front Vertical Travel 7.56 in.(19.20cm)
Rear Suspension .. . XTRA Lite
Rear Travel ....... . 10.00 in.(25.40cm)
Front Track Shock .. Nit rex
Spring Rate ...... . 80#Iin.
Rear Track Shock .. Nit rex
Rear Springs ..... . .406" I 82°
Track Type ....... . 15"x121 "x.71"(38.1x307.34x1.80cm)
Track Tension ..... . 318"- 112" (9.67-12.7mm) -slack with 10#(4.54kg) weight16"(40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM (STD) FIRM

.393" diameter /7r .406" diameter /82° .406" diameter /77°
L.H. 7041555-067 L.H. 7041521-067 L.H. 7041463-067
R.H. 7041556-067 R.H. 7041522-067 R.H. 7041464-067

Polaris Industries Inc. 1.19 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY SPORT TOURING

MODEL NUMBER: . 099ST4DS
ENGINE MODEL: . . EC44-3PM025

CARBURETION JETTING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 185 Altitude Below-20°F -20' to+ 10°F +10.,tO +40°F Above +40°F
Pilot Jet ............ . 35 Below-29°C -29oto -12°C -12° to+5°C Above 5"C
Q-900 195
Jet Needle ......... . 6FJ6-3 Meters
(Feet) (0-3000)
185 175 165
#3 #3 #3 #2
Needle Jet ......... . P-8(166)
Cutaway ........... . 2.0CH 900-1800 185 170 160 150
(3000-6000) #3 #3 #2 #2
Air Screw .......... . 1.0 Turns
1800-2700 165 155 145 135
Valve Seat ......... . 1.5 (6000-9000) #3 #2 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700-3700 150 145 135 125
89 Oxygenated (9000-12000) #2 #2 #2 #2
Throttle Gap
Under Cutaway
Idle Sync Gap
.180" - (4.57mm) ~ - # refers to the clip position from top of jet needle.

Under Cutaway .200" -(5.1 mm) c=J -Production Setting

CLUTCH
Type ................ P-90
Belt . . . . . . . . . . . . . . . . . 3211 059 CLUTCH CHART
Belt Width (Projected). 1.250" (31.75mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chaincase
Outside Circumference 45.125 Weight Spring Spring Helix Gearing
Center Distance . . . . . . 12" (305mm) Meters 0-900
10 Brown Red
36.5° 17-41 66 p
(Feet) (0-3000) B-2 3/4HYVO
Shift Weights . . . . . . . . 10
Primary Spring . . . . . . . Brown 900-1800
(3000-6000)
10M
Brown Red
36.5" 17-41 66 p
Bushed B-2 3/4 HYVO
Secondary Spring . . . . Red
1800-2700 10M 36.5° 17-41 66 p
Driven Helix . . . . . . . . . 36.5° B-2 (6000-9000) Bushed
Gold Red
B-2 3/4 HYVO

2700-3700 10MB 36.5° 17-41 66 p

Gold Red
(9000-12000) Bushed B-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 432 cc
Bore ....................... 2.6661" (67.72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0035" - 0.0055"(0.09 - 0.14mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . M-6
Piston Ring Marking . . . . . . . . . R
Piston Ring End Gap .........008"-.019"(.20-.49mm)
Head cc's (Uninstalled) . . . . . . 28.6cc
Head cc's (Installed) . . . . . . . . . 23cc
Operating RPM±200 . . . . . . . . . 7000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 3500 RPM
Cylinder Head Torque ........ 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.20 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . INDY SPORT TOURING

MODEL NUMBER: . 099ST4DS
ENGINE MODEL: . . EC44-3PM025

ELECTRICAL CAPACITIES
Flywheeii.D. . ..... FP-5446 Fuel Tank ........... 11.8 gallons (44.7 liters)
COl Marking ....... CU6416 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 200 Watts Coolant ............. NI A
Ignition Timing ..... 26° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
.150" BTDC (.133"-.167")
3.81 mm BTDC (3.39-4.25mm)
Operating Timing . . . 16° @ 6500 RPM
Spark Plug I Gap ... NGK BR8ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 17-41, 66 P 314 HYVO
Front Suspension .. 41 IFS Reverse ............ Option
Maximum Width ... . 41.00"(1 04.14cm) Brake Pads ......... Type 69
Camber .......... . 9116"±5116"(14±8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out .......... . 0-118"(0-3mm) Driveshaft Sprockets . 2 drivers
Front Shocks ..... . Nitrex Brake Type ......... Polaris HPB
IFS Spring Rate ... . 105#1in.
Front Spring Preload 0.13" Thread Adjust
Front Vertical Travel 7.56 in.(19.20cm)
Rear Suspension .. . XTRA Lite
Rear Travel ....... . 10.875 in.(25.40cm)
Front Track Shock .. Nitrex
Spring Rate ...... . 80#Iin.
Rear Track Shock .. Nit rex
Rear Springs ..... . .359"(sq.) I 84°
Track Type ....... . 15"x133.5"x.82"(38.1 x339.09x2.08cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm)slack with 10# (4.54kg)weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM (STD) FIRM

.347" (sq.) diameter I 77o .359"(sq.) diameter I 84° .359" (sq.) diameter /77°
L.H. 7041627-067 L.H. 7041763-067 L.H. 7041629-067
R.H. 7041628-067 R.H. 7041764-067 R.H. 7041630-067

Polaris Industries Inc. 1.21 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY TRANSPORT

MODEL NUMBER: . 099SU4DS
ENGINE MODEL: . . EC44-3PM025

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 185 Altitude Below ·20°F ·20" to+10"F +10°tO +40°F Above +40°F
·29"to ·12oC
Pilot Jet . . . . . . . . . . . . . 35 Below -29°C ·12" to +5"C Above S"C
Q-900 195
Jet Needle . . . . . . . . . . 6FJ6-3 Meters
(Feet) (0·3000)
185 175 165
#3 #3 #3 #2
Needle Jet .......... P-8(166)
Cutaway . . . . . . . . . . . . 2.0 CH 900-1800 185 170 160 150
(3000·6000) #3 #3 #2 #2
Air Screw . . . . . . . . . . . 1.0 Turns
1800·2700 165 155 145 135
Valve Seat . . . . . . . . . . 1.5 (6000·9000) #3 #2 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700·3700 150 145 135 125
89 Oxygenated (9000-12000) #2 #2 #2 #2
Throttle Gap
Under Cutaway .180"- (4.57mm) DE] · # refers to the clip position from top of jet needle.
Idle Sync Gap
Under Cutaway .200" -(5.1 mm) c::J · Production Setting

CLUTCH
Type ................ P-90
BeH ................. 3211059 CLUTCH CHART
Belt Width (Projected) . 1.250" (31.75mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chain case
Outside Circumference 45.125 Weight Spring Spring Helix Gearing

Center Distance . . . . . . 12" (305mm) Meters 0·900

10 Brown Red
36.SO 16·39 64 p
(Feet) (0-3000) 3/4 HYVO
Shift Weights . . . . . . . . 10 B·2

16-39 64 p
Primary Spring . . . . . . . Brown 900-1800
(3000-6000)
10M
Brown Red
36.5°
B-2 3/4 HYVO
Bushed
Secondary Spring . . . . Red
1800-2700 10M 36.5° 16·39 64 p
Driven Helix . . . . . . . . . 36.5° B-2 (6000·9000) Bushed
Gold Red
B-2 3/4 HYVO

2700·3700 10MB 36.5° 16·39 64 p

Gold Red
(9000-12000) Bushed B-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 432 cc
Bore ....................... 2.6661" (67.72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0035" - 0.0055"(0.09 - 0.14mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . M-6
Piston Ring Marking . . . . . . . . . R
Piston Ring End Gap . . . . . . . . .008"-.019"(.20-.49mm)
Head cc's (Uninstalled) . . . . . . 28.6cc
Head cc's (Installed) . . . . . . . . . 23cc
Operating RPM±200 . . . . . . . . . 7000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 3500 RPM
Cylinder Head Torque . . . . . . . . 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.22 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . INDY TRANSPORT

MODEL NUMBER: . 099SU4DS
ENGINE MODEL: . . EC44-3PM025

ELECTRICAL CAPACITIES
Flywheel I.D. . . . . . . FP-5446 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking ....... CU6416 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output ... 200 Watts Coolant ............. NIA
Ignition Timing . . . . . 26° BTDC@3000RPM±1.5o Chaincase Oil ....... 9 fl.oz(265cc)
.150" BTDC (.133"-.167")
3.81 mm BTDC (3.39-4.25mm)
Operating Timing . . . 16° @ 6500 RPM
Spark Plug I Gap . . . NGK BR8ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75/60 watts
Tail ........ 8 watts
Brake . . . . . . 29 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 16-39, 64 P 3/4 HYVO
Front Suspension .. 41 IFS Reverse ............ Standard
Maximum Width ... . 41.00"(104.14cm) Brake Pads ......... Type 69
Camber .......... . 9/16"±5/16"(14±8mm) Chaincase Center Dist.6 5/8"(16.83cm)
Toe Out .......... . 0-1/8"(0-3mm) Driveshaft Sprockets . 2 drivers
Front Shocks ..... . Nit rex Brake Type ......... Polaris HPB
IFS Spring Rate ... . 105#/in.
Front Spring Preload 5 shims
Front Vertical Travel 7.56 in.(19.20cm)
Rear Suspension .. . 141 GT
Rear Travel ....... . 7 in.(17.78cm)
Front Track Shock .. Nit rex
Spring Rate ...... . 181 #/in.
Rear Track Shock .. Nit rex
Rear Springs ..... . .406" I 75°
Track Type ....... . 15"x141 "x1.125" (38.1 x358.14x2.86cm)
Track Tension ..... . 3/4" - 1" (19.05 - 25.4mm)slack with 10# (4.54kg)weight 16" (40.64cm)ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM (STD) FIRM

.375" diameter /75° .406" diameter I 75° .468" diameter /74°
L.H. 7041318-067 L.H. 7041320-067 L.H. 7041239-067
R.H. 7041319-067 R.H. 7041321-067 R.H. 7041240-067

Polaris Industries Inc. 1.23 10/98

GENERAL
1999 Model Specifications

MODEL: .......... XCF

MODEL NUMBER: . 099SP4AS
ENGINE MODEL: .. EC45PM011

CARBURETION JEITING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 270 Altitude Below ·20"F ·20" to+10"F +10"to +40"F Above +40"F
Pilot Jet ............ . 40 Below-29"C -29"to -12"C -12" to +5"C Above 5"C
0-900
Jet Needle ......... . 6DP1-3 Meters
(Feet) (0-3000)
290 270 250 230
#3 #3 #3 #3
Needle Jet ......... . P-8(480)
900-1800 250 240 220 195
Cutaway ........... . 3.0 (3000·6000) #3 #3 #3 #2
Air Screw .......... . 1.0 Turns
1800-2700 220 200 180 165
Valve Seat ......... . 1.5 (6000-9000) #3 #3 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700-3700 180 170 150 135
89 Oxygenated (9000-12000) #3 #2 #2 #2
Throttle Gap
Under Cutaway
Idle Sync Gap
.218" - (5.54mm) ~ - # refers to the clip position from top of jet needle.

Under Cutaway .240" -(6.1 mm) c::J - Production Setting

CLUTCH
Type ................ P-85
Belt ................. 3211070 CLUTCH CHART
Belt Width (Projected} . 1.375" (34.93mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chaincase
Outside Circumference 47.25 Weight Spring Spring Helix Gearing
Center Distance . . . . . . 12" (305mm) Meters 0·900 10-58
Dark Blue Silver 36" 19-4066 p
(Feet) (0-3000)
Shift Weights . . . . . . . . 10-58 Bushed #-2 3/4 HYVO

Primary Spring . . . . . . . Dark Blue 900-1800

(3000-6000)
10-56
Dark Blue Silver 36" 19-40 66 p
Bushed #-2 3/4 HYVO
Secondary Spring . . . . Silver
1800-2700 10 56 Silver 36' 19-4066 p
Driven Helix . . . . . . . . . 36° #-2 (6000-9000) Bushed
Dark Blue
Blue #-2 3/4 HYVO

2700-3700 10 54 Silver 36' 19-40 66 p

Dark Blue
(9000-12000) Bushed Blue #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Cylinder Reed
Displacement . . . . . . . . . . . . . . . 431 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.559" (65mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.559" (65mm)
Piston I Cylinder Clearance . . . 0.0039" - 0.0053"(0.1 0 - 0.135mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 4MB
Pistn Ring Marking . . . . . . . . . . N
Piston Ring End Gap .........009"-.017"(.24-.45mm)
Head cc's (Uninstalled) . . . . . . 26.2 cc
Head cc's (Installed) . . . . . . . . . 23.2 cc
Operating RPM±200 . . . . . . . . . 6500 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 4000 RPM
Cylinder Head Torque ........ 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.24 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... XCF

MODEL NUMBER: . 099SP4AS
ENGINE MODEL: . . EC45PM011

ELECTRICAL CAPACITIES
Flywheel I.D. . . . . . . F004T32971 Fuel Tank ........... 10.5 gallons (39.71iters)
CDI Marking . . . . . . . F6291 A Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output . . . 240 Watts @ 4000 RPM Coolant ............. NIA
Ignition Timing . . . . . 27° BTDC@ 3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.175" BTDC (0.157"-0.195")
4.45mm BTDC (3.97 -4.93mm)
Operating Timing . . . 17° @ 6500 RPM
Spark Plug I Gap . . . NGK BR9ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 19-40, 66 P 314HYVO
Front Suspension .. XTRA-10 CRC Reverse ............ Option
Maximum Width ... . 41.00"(104.14cm) Brake Pads ......... Type 69
Camber .......... . 314"±5116"(19.05±8mm) Chaincase Center Dist. 6 518"(16.83cm)
Toe Out .......... . 318"-112"(9.65-12.7mm) Driveshaft Sprockets . 2 Drivers
Front Shocks ..... . Indy Select Brake Type ......... Polaris HPB
IFS Spring Rate ... . 80#Iin.
Front Spring Preload .06" Thread Adjust
Front Vertical Travel 9.30 in.(23.62cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 10.0 in.(25.4cm)
Front Track Shock .. Ryde FX
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Ryde AFX
Rear Springs ..... . .406" I 7JO
Track Type ....... . 15"x121"x.82" (38.1x307.34x2.08cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT(STD) MEDIUM FIRM

.406" diametern7o .421" diametern7o .437" diametern7o
L.H .7041463-067 L.H. 7041461-067 L.H. 7041465-067
R.H. 7041464-067 R.H 7041462-067 R.H. 7041466-067

Polaris Industries Inc. 1.25 10/98

GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . 440 XCR

MODEL NUMBER: . 099SX4CS
ENGINE MODEL: .. S44-44-98A1

CARBURETION JETTING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 360 Altitude Below-20°F -20° to +10°F +10°!0 +40°F Above +40°F
Pilot Jet ............ . 45 Below-29°C -29°to -12°C -12° to +5°C Above soc
0-900
Jet Needle ......... . 6DH7-3 Meters
(Feet) (0-3000)
380 360 340 320
#3 #3 #3 #3
Needle Jet ......... . P-4(286)
900-1800
Cutaway ........... . 2.0CH (3000-6000)
340 320 300 280
#3 #3 #3 #3
Air Screw .......... . 1.25 Turns
1800-2700 300 290 270 250
Valve Seat ......... . 1.5 Viton (6000-9000) #3 #3 #3 #3
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700-3700 270 250 240 220
89 Oxygenated (9000-12000) #3 #3 #3 #3
Throttle Gap
Under Cutaway
Idle Sync Gap
.189" - (4.80mm)(3/16") [Jt] - # refers to the clip position from top of jet needle.

Under Cutaway .208" -(5.3mm)(13/64") C:=J - Production Setting

CLUTCH
Type ................ P-85
Belt ................. 3211074 CLUTCH CHART
Belt Width (Projected) . 1.438" (34.93mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shitt Clutch Clutch Driven Chalncase
Outside Circumference 47.625 Weight Spring Spring Helix Gearing
Center Distance . . . . . . 12" (305mm) Meters 0-900 S-53 Almond Silver/ RS 20-3968 p
(Feet) (0-3000)
Shift Weights . . . . . . . . S-53 Red Red Gold Blue #-2 3/4 HYVO

Primary Spring . . . . . . . Almond Gold 900-1800

(3000-6000)
S-53 Almond Silver/ RB 20-39 68 p
Blue Gold Blue #-2 3/4 HYVO
Secondary Spring . . . . Silver/Blue
10M
Driven Helix . . . . . . . . . R-8 #-2 1800-2700
(6000-9000) Blue
Almond Silver/ R8 20-39 68 p
Gold Blue #-3 3/4 HYVO .
Bushed
10M 20-39 68 p
2700-3700 Almond Silver/ R32
(9000-12000) White
Gold Blue #-3 3/4 HYVO
Bushed

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed
Displacement . . . . . . . . . . . . . . . 438 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.598" (66mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.520" (64mm)
Piston I Cylinder Clearance . . . 0.0023" - 0.0037"(0.06 - 0.095mm)
Service Limit . . . . . . . . . . . . . . . . 0.0059" (0.15mm)
Piston Marking . . . . . . . . . . . . . . EK2185B
Piston Ring Marking . . . . . . . . . "o" faces upward
Piston Ring End Gap . . . . . . . . .008"-.020"(.20-.51 mm)
Head cc's (Uninstalled) . . . . . . 19.6 cc
Head cc's (Installed) ......... 18.5 cc
Operating RPM±200 . . . . . . . . . 8250 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 5000 RPM
Cylinder Head Torque . . . . . . . . 20-24 ft.lbs(2.8-3.3 kgm)
Cylinder Base Nut Torque .... 30-34 ft.lbs(4.15-4.7 kgm)
Crankcase Torque (8mm) . . . . 20-24 ft.lbs(2.8-3.3 kgm)
Crankcase Torque (10mm) ... N/A
Flywheel Torque ............ 90 ft.lbs(12.4 kgm)

10/98 1.26 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... 440 XCR

MODEL NUMBER: . 099SX4CS
ENGINE MODEL: .. S44-44-98A1

ELECTRICAL CAPACITIES
Flywheeii.D ....... 4060141 Fuel Tank ........... 10.5 gallons (39.7 liters)
CDI Marking ....... 4060190 Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 Quarts (2.8 liters)
Ignition Timing ..... 25° BTDC@3500RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.146" BTDC (±0.017")
3.72mm BTDC (±0.435mm)
Operating Timing . . . 16° @ 8250 RPM
Spark Plug I Gap ... Champion RN-2C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@2 watts
Brake . . . . . . 1 @17 watts
Voltage Regulator . . LR7
Electric Start . . . . . . . NlA
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 20-39, 68 P 314 HYVO
Front Suspension .. XC-10, CRC Reverse ............ Option
Maximum Width ... . 41.00"(104.14cm) Brake Pads ......... Type 69
Camber .......... . 1.05"±5/16"(26.67±8mm) Chaincase Center Dist. 7.05"(17.90cm)
Toe Out .......... . 0-118"(0-3mm) Driveshaft Sprockets . 2 Drivers-wide
Front Shocks ..... . Fox™ IFP Brake Type ......... Polaris HPB Liquid Cooled
IFS Spring Rate ... . 74-120#Iin.
Front Spring Preload 0.75" Thread Adjust
Front Vertical Travel 9.0 in.(22.86cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 8.0 in.(20.32cm)
Front Track Shock .. Fox™ IFP
Spring Rate ...... . 190#/in.
Rear Track Shock .. Fox™ IFP with Remote Reservoir
Rear Springs ..... . .359" (sq.) I 77°
Track Type ....... . 15"x121 "x.82" (38.1x307.34x2.08cm)
Track Tension ..... . 318" -1/2" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diametern7o .359"(sq.) diametern7o .375"(sq.) diametern7o
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.27 10/98

GENERAL
1999 Model Specifications

MODEL: .......... TRAIL

MODEL NUMBER: . 099EB4ES(A)
ENGINE MODEL: . . EC50PM044

CARBURETION JETTING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 230 Altitude Below·20°F -20° to +10°F +10°tO +40°F Above +40°F
Pilot Jet ............ . 40 Below-29°C -29°to -12°C -12° to +Soc Above soc
0-900
Jet Needle ......... . 6DH7-3 Meters
(Feet) (0-3000)
240 230 220 210
#3 #3 #3 #3
Needle Jet ......... . P-8(166)
Cutaway ........... . 3.0CH 900-1800 220 210 200 190
(3000-6000) #3 #3 #3 #2
Air Screw .......... . 1.0 Turns
1800-2700 200 195 185 180
Valve Seat ......... . 1.5 (6000-9000) #3 #3 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700-3700 190 180 180 180
89 Oxygenated (9000-12000)
#3 #2 #2 #2
Throttle Gap
Under Cutaway .219" -(5.55mm) [TI - # refers to the clip position from top of jet needle.
Idle Sync Gap
Under Cutaway .240" -(6.1 mm) C=:J - Production Setting

CLUTCH
Type ................ P-85
Belt ................. 3211070 CLUTCH CHART
Belt Width (Projected) . 1.375" (34.93mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chain case
Outside Circumference 47.250 Weight Sprtng Sprtng Helix Gearing

Center Distance . . . . . . 12" (305mm) Meters Q-900 10AL Red/White Silver 36° 22-41 68 p
(Feet) (0-3000) 3/4 HYVO
Shift Weights . . . . . . . . 10 AL Bushed Bushed #-2

Primary Spring . . . . . . . Red/White 90Q-t800

(3000-6000)
10M
Red/White Silver 36° 22-41 68 p
Bushed #-2 3/4 HYVO
Secondary Spring . . . . Silver
1800-2700 10MB 36 22-41 68 p
Driven Helix . . . . . . . . . 36° #-2 (6000-9000) Bushed
Red/White Silver
#-2 3/4 HYVO

2700-3700 10MB 36° 22-41 68 p

Red/White Silver
(9000-12000) Bushed #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 488 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346" (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0039"- 0.0063"(0.1 0 - 0.16mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking .............. M-1
Piston Ring Marking . . . . . . . . . R
Piston ring end gap ...........008"-.019"(.20-.49mm)
Head cc's (Uninstalled) ...... 26.7cc
Head cc's (Installed) . . . . . . . . . 24.1 cc
Operating RPM±200 . . . . . . . . . 7000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 3600 RPM
Cylinder Head Torque . . . . . . . . 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 30-34 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.28 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . TRAIL
MODEL NUMBER: . 099EB4ES(A)
ENGINE MODEL: . . EC50PM044

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP5441 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking . . . . . . . CU6413 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 200 Watts Coolant ............. NIA
Ignition Timing ..... 26° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.150" BTDC (±0.017")
3.81 mm BTDC (±0.43mm)
Operating Timing ... 16° @6500 RPM
Spark Plug I Gap ... NGK BR8ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Evolved Sprockets I Chain .... 22-41, 68 P 314 HYVO
Front Suspension .. XTRA-10 Reverse ............ Option
Maximum Width ... . 42.50"(1 07.95cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0±8mm) Chaincase Center Dist. 6 518"(16.83cm)
Toe Out .......... . 118-114"(3-6.35mm) Driveshaft Sprockets . 2 drivers
Front Shocks ..... . Nitrex Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 80#Iin.
Front Spring Preload 0.5'' Thread Adjust
Front Vertical Travel 10.0 in.(25.4cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 10.0 in.(25.4cm)
Front Track Shock .. Nit rex
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Indy Select
Rear Springs ..... . .406" I 77°
Track Type ....... . 15"x121 "x.82" (38.1 x307 .34x2.08cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT(STD) MEDIUM FIRM

.406" diameternr .421" diametern7o .437" diametern7o
L.H 7041463-067 L.H. 7041461-067 L.H. 7041465-067
R.H. 7041464-067 R.H 7041462-067 R.H. 7041466-067

Polaris Industries Inc. 1.29 10/98

GENERAL
1999 Model Specifications

MODEL: .......... TRAIL TOURING

MODEL NUMBER: . 099ET4ES(A)
ENGINE MODEL: . . EC50PM044

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 230 Altitude Below -20"F -20" to +tO"F +tO"to +40"F Above +40°F
Pilot Jet . . . . . . . . . . . . . 40 Below -29"C -29"to -t2"C -t2" to +5"C Above soc
0-900
Jet Needle . . . . . . . . . . 6DH7 -3 Meters
(Feet) (0-3000)
240 230 220 210
#3 #3 #3 #3
Needle Jet . . . . . . . . . . P-8(166)
Cutaway . . . . . . . . . . . . 3.0 CH 900-t800 220 210 200 190
(3000-6000) #3
#3 #3 #2
Air Screw . . . . . . . . . . . 1.0 Turns
t800-2700 200 195 185 180
Valve Seat . . . . . . . . . . 1.5 (6000-9000)
#3 #3 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700-3700 190 180 180 180
89 Oxygenated (9000-t2000)
#3 #2 #2 #2
Throttle Gap
Under Cutaway
Idle Sync Gap
.219" - (5.55mm) ~ - # reters to the clip position !rom top ot jet needle.

Under Cutaway .240" -(6.1 mm) ~ -Production Setting

CLUTCH
Type ................ P-85
BeH ................. 3211070 CLUTCH CHART
Belt Width (Projected) . 1.375" (34.93mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shitt Clutch Clutch Driven Chain case
Outside Circumference 47.250 Weight Spring Spring Helix Gearing
Center Distance . . . . . . 12" (305mm) Meters 0-900 tO
Red/White Silver 36" 20-40 66 p
(Feet) (0-3000)
Shift Weights . . . . . . . . 10 Bushed Bushed #-2 3/4 HYVO

Primary Spring . . . . . . . Red/White 900-t800

(3000-6000)
tOM
Red/White Silver
36" 20-40 66 p
Bushed #-2 3/4 HYVO
Secondary Spring . . . . Silver
t800-2700 tOMB 36' 20-40 66 p
Driven Helix . . . . . . . . . 36° #-2 (6000-9000) Bushed
Red/White Silver
#-2 3/4 HYVO

2700-3700 tOMB 36' 20-40 66 p

(9000-t2000) Red/White Silver
Bushed #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Fan Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 488 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346" (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0039" - 0.0063"(0.1 0 - 0.16mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . M-1
Piston Ring Marking . . . . . . . . . R
Piston Ring End Gap .........008"-.019"(.20-.49mm)
Head cc's (Uninstalled) ...... 26.7cc
Head cc's (Installed) . . . . . . . . . 24.1 cc
Operating RPM±200 . . . . . . . . . 7000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 3600 RPM
Cylinder Head Torque ........ 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 30-34 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) . . . . 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.30 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... TRAIL TOURING

MODEL NUMBER: . 099ET4ES(A)
ENGINE MODEL: . . ECSOPM044

ELECTRICAL CAPACITIES
Flywheeii.D. . ..... FP5441 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking . . . . . . . CU6413 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 200 Watts Coolant ............. NlA
Ignition Timing ..... 26° BTDC@3000RPM±1.5° Chaincase Oil ....... 9 fl.oz(265cc)
0.150" BTDC (±0.017")
3.81 mm BTDC (±0.43mm)
Operating Timing . . . 16° @ 6500 RPM
Spark Plug I Gap . . . NGK BR8ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR9, LR2
Electric Start . . . . . . . Standard
*LR9= Half wave voltage regulator
*LR2=Rectifier only for battery charging

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Evolved Sprockets I Chain .... 20-40, 66 P 314 HYVO
Front Suspension .. XTRA-10 Reverse ............ Standard
Maximum Width ... . 42.50"(107.95cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0-8 mm) Chaincase Center Dist. 6 518"(16.83cm)
Toe Out .......... . 1l8-114"(3-6.35mm) Driveshaft Sprockets . 2 Drivers
Front Shocks ..... . Nit rex Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 80#Iin.
Front Spring Preload 0.13" Thread Adjust
Front Vertical Travel 10.0 in.(25.4cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 11.5 in.(29.21 em)
Front Track Shock .. Nit rex
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Indy Select
Rear Springs ..... . .437" I 7JO
Track Type ....... . 15"x133.5"x.82" (38.1 x339.09x2.08cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM FIRM(STD)

.406" diameternr .421" diametern7o .437" diametern7o
L.H 7041463-067 L.H. 7041461-067 L.H. 7041465-067
R.H. 7041464-067 R.H 7041462-067 R.H. 7041466-067

Polaris Industries Inc. 1.31 10/98

GENERAL
1999 Model Specifications

MODEL: .......... TRAIL RMK

MODEL NUMBER: . 099SR5BS
ENGINE MODEL: . . EC55PM021

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni (ACCS) AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 270 Altitude Below -20°F -20" to +tO"F +10"to Above
Pilot Jet . . . . . . . . . . . . . 35 Below-29"C -29°to -12°C +40"F
-12" to +5"C
+40°F
Above S"C
Jet Needle . . . . . . . . . . 6DH7 -3
Meters D-900 310 290 270 260
Needle Jet .......... Q-0(480) (Feet) (0-3000)
#4 #4 #4 #4
Cutaway . . . . . . . . . . . . 3.0 900-1800 310 290 270 260
(3000-6000)
Air Screw . . . . . . . . . . . 1.5 Turns #4 #4 #3 #3
Valve Seat . . . . . . . . . . 1.5 1800-2700 310 290 270 260
(6000-9000)
Fuel Octane (R+M/2) 87 Non-Oxygenated or #3 #3 #3 #3
89 Oxygenated 2700-3700 310 290 270 260
(9000-12000) #3
Throttle Gap #3 #3 #3

~
Under Cutaway .218" - (5.54mm)
Idle Sync Gap -#refers to the clip position from top of jet needle .
Under Cutaway .242" -(6.15mm)
c:::J - Production Setting

CLUTCH
Type ................ P-85
Be~ ................. 3211070
Belt Width (Projected) . 1.375" (34.93mm) CLUTCH CHART
Side Angle (Overall) . . 28° DRIVE DRIVEN
Outside Circumference 47.250 Altitude Shift Clutch Clutch Driven Chaincase
Weight Spring Spring Helix
Center Distance . . . . . . 12" (305mm) Gearing
Meters
Shift Weights . . . . . . . . 10-56 Bushed (Feet)
D-900
(0-3000)
10-60
Dark Blue
Silver/ R-32 18-41 68 p
Bushed Blue #-2 3/4 HYVO
Primary Spring . . . . . . . Dark Blue
900-1800 10-58 Silver/ R-32 18-4168P
Secondary Spring . . . . Silver/Blue (3000-6000) Bushed
Dark Blue
Blue #-2 3/4 HYVO
Driven Helix . . . . . . . . . R-32 #2 1800-2700 10-56 Silver/ R-32 18-41 68 p
(6000-9000) Dark Blue
Bushed Blue #-2 3/4 HYVO

2700·3700 10-54 Silver/ R-32 18-41 68 p

Dark Blue
(9000-12000) Bushed Blue #-2 3/4 HYVO

ENGINE
Type ....................... Fan Cooled Reed Assist
Displacement . . . . . . . . . . . . . . . 544 cc
Bore ....................... 2.874" (73mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.559" (65mm)
Piston I Cylinder Clearance . . . 0.0041" - 0.0055"(0.1 04 - 0.139mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 5MB
Piston Ring Marking . . . . . . . . . N
Piston Ring End Gap .........015"-.022"(.40-.55mm)
Head cc's (Uninstalled) . . . . . . 33.8 cc
Head cc's (Installed) ......... 27.7 cc
Operating RPM±200 . . . . . . . . . 6800 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 3600 RPM
Cylinder Head Torque ........ 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 30-34 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.32 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... TRAIL RMK

MODELNUMBER:. 099SR5BS
ENGINE MODEL: . . EC55PM021

ELECTRICAL CAPACITIES
Flywheel I.D. . . . . . . F004T32971 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking . . . . . . . F6291 A Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output ... 240 Watts@4000 RPM Coolant ............. N/A
Ignition Timing ..... 27° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.175" BTDC (0.157 -0.195")
4.45mm BTDC (3.97-4.93mm)
Operating Timing . . . 1r @ 6500 RPM
Spark Plug I Gap . . . NGK BR8ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75/60 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 18-41, 68 P 3/4 HYVO
Front Suspension .. 38RMK Reverse ............ Option
Maximum Width ... . 38.00"(96.52cm) Brake Pads ......... Type 69
Camber .......... . 0"±5/16"(0-8mm) Chaincase Center Dist.7.05"(17.91cm)
Toe Out .......... . 1/8" -1 /4"(3-6.35mm) Driveshaft Sprockets . 2 Drivers
Front Shocks ..... . Nitrex Brake Type ......... Polaris HPB
IFS Spring Rate ... . 80#/in.
Front Spring Preload 0.3" Thread Adjust
Front Vertical Travel 8.18 in.(20.78cm)
Rear Suspension .. . XTRA-Lite 136
Rear Travel ....... . 12.0 in.(30.48cm)
Front Track Shock .. Hydraulic
Spring Rate ...... . 181 #/in.
Rear Track Shock .. Indy Select
Rear Springs ..... . .359"(sq) I 77°
Track Type ....... . 15"x136"x1.25" (38.1 x345.44x3.175cm)
Track Tension ..... . 3/8"- 1/2" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diameter/77° .359"(sq.) diameter/77° .375"(sq.) diameter/77°
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.33 10/98

GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . SUPER SPORT

MODEL NUMBER: . 099SB5BS
ENGINE MODEL: . . EC55PM011

CARBURETION JETTING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 310 Altitude Below -20°F -20° to +10°to Above +40°F
Pilot Jet ............ . 35 Below-29°C +10,F
·29oto -12°C
+40°F
-12° to +5°C
Above soc

Jet Needle ......... . 6DH7-3 Q-900

Meters 320 310 300 300
Needle Jet ......... . Q-2(480) (Feet) (0-3000) #3 #3 #3 #2
Cutaway ........... . 3.0
900-1800 270 260 250 240
Air Screw .......... . 1.5 Turns (3000-6000)
#3 #3 #3 #2
Valve Seat ......... . 1.5 1800-2700 220 210 200 190
Fuel Octane (R+M/2) 87 Non-Oxygenated or (GOOQ-9000) #3 #3 #2 #2
89 Oxygenated 2700-3700 180 170 160 150
(9000-12000) #3 #2 #2 #2
Throttle Gap

~
Under Cutaway .218" - (5.54mm)
Idle Sync Gap • # refers to the clip position from top of jet needle .
Under Cutaway .242" -(6.15mm)
c:::J - Production Setting

CLUTCH
Type ................ P-85
BeH ................. 3211070
Belt Width (Projected) . 1.375" (34.93mm) CLUTCH CHART
Side Angle (Overall) . . 28° DRIVE DRIVEN
Outside Circumference 47.250 Altitude Shift Clutch Clutch Driven Chaincase
Weight Spring Spring Helix
Center Distance . . . . . . 12" (305mm) Gearing
Meters
Shift Weights . . . . . . . . 10-60 Bushed (Feet)
Q-900
(0-3000)
10-60
Dark Blue
Silver/ 36° 19-39 66 p
Bushed Blue #-2 3/4HYVO
Primary Spring . . . . . . . Dark Blue
OOQ-1800 10-58 Silver/ 36° 19-3966 p
Secondary Spring . . . . Silver/Blue (300Q-6000) Bushed
Dark Blue
Blue #-2 3/4 HYVO
Driven Helix . . . . . . . . . 36° #2 180Q-2700 10·56 Silver/ 36° 19-39 66 p
Dark Blue
(GOOQ-9000) Bushed Blue #-2 3/4HYVO

270Q-3700 1Q-54 Silver/ 36° 19·3966 p

Dark Blue
(9000-12000) Bushed Blue #-2 3/4HYVO

ENGINE
Type ....................... Fan Cooled Reed Assist
Displacement . . . . . . . . . . . . . . . 544 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.874" (73mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.559" (65mm)
Piston I Cylinder Clearance . . . 0.0041" - 0.0055"(0.1 04- 0.139mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 5MB
Piston Ring Marking . . . . . . . . . N
Piston Ring End Gap .........015"-.022"(.40-.55mm)
Head cc's (Uninstalled) . . . . . . 33.8 cc
Head cc's (Installed) ......... 27.7 cc
Operating RPM±200 . . . . . . . . . 6500 RPM
Idle RPM±200 . . .. . .. . .. .. .. 1600 RPM
Engagement RPM±300 . . . . . . 3600 RPM
Cylinder Head Torque . . . . . . . . 18-19 ft.lbs(2.5-2.8 kgm)
Cylinder Base Nut Torque . . . . 30-34 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.34 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . SUPER SPORT

MODEL NUMBER: . 09958585
ENGINE MODEL: • . EC55PM011

ELECTRICAL CAPACITIES
Flywheel I.D. . . . . . . F004T32971 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking . . . . . . . F6291 A Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output ... 240 Watts@4000 RPM Coolant ............. NlA
Ignition Timing . . . . . 2JO BTDC@ 3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.175" BTDC (0.157"-0.195")
4.45mm BTDC (3.97-4.93mm)
Operating Timing . . . 1yo @ 6500 RPM
Spark Plug I Gap . . . NGK BR8ES I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 19-39, 66 P 314 HYVO
Front Suspension .. XTRA-10 Reverse ............ Option
Maximum Width ... . 42.50"(1 07 .95cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0±8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out .......... . 118"-114"(3-6.35mm) Driveshaft Sprockets . 2 Drivers
Front Shocks ..... . Nitrex Brake Type ......... Polaris HPB
IFS Spring Rate ... . 80#Iin.
Front Spring Preload 0.5'' Thread Adjust
Front Vertical Travel 10.0 in.(25.4cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 10.0 in.(25.4cm)
Front Track Shock .. Nitrex
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Indy Select
Rear Springs ..... . .406" I 77°
Track Type ....... . 15"x121 "x.82"(38.1 x307 .34x2.08cm)
Track Tension ..... . 318" -112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

50FT(5TD) MEDIUM FIRM

.406" diameternr .421" diametern7o .437" diametern7o
L.H 7041463-067 L.H. 7041461-067 L.H. 7041465-067
R.H. 7041464-067 R.H 7041462-067 R.H. 7041466-067

Polaris Industries Inc. 1.35 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY 500

MODEL NUMBER: . 099EB4BS(A)
ENGINE MODEL: . . ECSOPL172

CARBURETION JETTING CHART

Type ............... . VM38SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 350 Altitude Below -20°F
Below-29°C
-20° to
+10oF
+10°tO
+40°F
Above +40"F
Above soc
Pilot Jet ............ . 45 -29°tO -12oC -12° to +Soc

Jet Needle ......... . 6F9-3 Meters 0-900 370

Needle Jet ......... .
Cutaway ........... .
P-6(247)
2.5CH
(Feet) (0-3000)

900-1800
#3
I 350
#3
310
I 330
#3
290
310
#3
270
330
(3000-6000)
Air Screw .......... . 3/4 Turn #3 #3 #3 #2
Valve Seat ......... . 1.5 Viton 1800-2700
(6000-9000)
290 270 250 230
#3 #3 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or
2700-3700 250 240 220 210
89 Oxygenated (9000-12000) #3 #2 #2 #2
Throttle Gap
Under Cutaway
Idle Sync Gap
.219" - (5.55mm)
~ - # refers to the clip position from top of jet needle.

Under Cutaway .240" -(6.1 mm)

c:::J - Production Setting

CLUTCH
Type ................ P-85
Belt . . . . . . . . . . . . . . . . . 3211 070 CLUTCH CHART
Belt Width (Projected) . 1.375" (34.93mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chaincase
Spring
Outside Circumference 47.250 Weight Spring Helix Gearing

Center Distance . . . . . . 12" (305mm) Meters

(Feet)
0-900 10M
Gold Gold 36° 22-41 68 p
(0-3000) Bushed #-2 3/4 HYVO
Shift Weights . . . . . . . . 1OM Bushed
10M
Primary Spring . . . . . . . Gold 900-1800
Blue Gold Gold
36° 22-41 68 p
(3000-6000) #-2 3/4 HYVO
Secondary Spring . . . . Gold Bushed

Driven Helix . . . . . . . . . 36° #2 1800-2700

10M
White Dark Blue Gold
36° 22-41 68 p
(6000-9000) #-2 3/4 HYVO
Bushed
10M 22-41 68 p
2700-3700 36°
Red Dark Blue Gold
(9000-12000) #-2 3/4 HYVO
Bushed

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 488 cc
Bore ....................... 2.8346" (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance ... 0.0035"- 0.0049"(0.09- 0.125mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 58
Piston Ring Marking . . . . . . . . . 58
Piston Ring End Gap .........008"-.016"(.20-.40mm)
Head cc's (Uninstalled) . . . . . . 28cc
Head cc's (Installed) . . . . . . . . . 23.6cc
Operating RPM±200 . . . . . . . . . 7800 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 4000 RPM
Cylinder Head Torque . . . . . . . . 8mm 17-20 ft.lbs, 1Omm 24-26 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.36 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: . . . . .. . . . . INDY 500

MODEL NUMBER: . 099EB4BS(A)
ENGINE MODEL: .. EC50PL172

ELECTRICAL CAPACITIES
Flywheel J.D ....... FP5445 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking ....... CU6417 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 200 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 28° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.173" BTDC (±0.0175")
4.40mm BTDC (±0.48mm)
Operating Timing . . . 16° @ 7500 RPM
Spark Plug I Gap ... Champion RN-3C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@2 watts
Brake . . . . . . 1 @17 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Evolved Sprockets I Chain .... 22-41, 68 P 314 HYVO
Front Suspension .. XTRA-10 Reverse ............ Option
Maximum Width ... . 42.50"(1 07 .95cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0-8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out .......... . 1l8-114"(3-6.35mm) Driveshaft Sprockets . 2 Drivers
Front Shocks ..... . Nit rex Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 80#Iin.
Front Spring Preload 0.5'' Thread Adjust
Front Vertical Travel 10.0 in.(25.4cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 10.0 in.(25.4cm)
Front Track Shock .. Nit rex
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Indy Select
Rear Springs ..... . .406" 11r
Track Type ....... . 15"x121"x.82" (38.1x307.34x2.08cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR TORSION SPRINGS

SOFT(STD) MEDIUM FIRM

.406" diametern7o .421" diametern7o .437" diametern7o
L.H 7041463-067 L.H. 7041461-067 L.H. 7041465-067
R.H. 7041464-067 R.H 7041462-067 R.H. 7041466-067

Polaris Industries Inc. 1.37 10/98

GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . 500 CLASSIC

MODEL NUMBER: . 099ED4BS
ENGINE MODEL: .. EC50PL172

CARBURETION JETTING CHART

Type ............... . VM38SS Mikuni AMBIENT TEMPERATURE
Below -20°F -20° to Above +40°F
Main Jet ........... . 350 Altitude
Below -29°C +10°F
+10°!0
+40°F Above soc
Pilot Jet ............ . 45 -29°to -12°C -12° to +SoC

Jet Needle ......... . 6F9-3 Meters 0-900 370 350 330 310
(Feet) (0-3000) #3
Needle Jet ......... . P-6(247) #3 #3 #3
Cutaway ........... . 2.5 CH 900-1800 330 310 290 270
(3000-6000) #3 #3 #3 #2
Air Screw .......... . 3/4 Turn
Valve Seat ......... . 1.5 Viton 1800-2700
(6000-9000)
290 270 250 230
#3 #3 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or
2700-3700 250 240 220 210
89 Oxygenated (9000-12000) #3 #2 #2 #2
Throttle Gap
Under Cutaway
Idle Sync Gap
.219" 7/32"- (5.55mm)
~ - # refers to the clip position from top of jet needle.

Under Cutaway .240" -15/64"(6.1mm) c:::J - Production Setting

CLUTCH
Type ................ P-85
CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . 3211070
Belt Width (Projected) . 1.375" (34.93mm) DRIVE DRIVEN
Side Angle (Overall) .. 28° Altitude Shift Clutch Clutch Driven Chain case
Weight Spring Spring Helix Gearing
Outside Circumference 47.250
Meters 0-900 22-4168P
Center Distance . . . . . . 12" (305mm) (Feet) (0-3000)
10M
Bushed
Gold Gold
34°
#-2 3/4 HYVO
Shift Weights . . . . . . . . 1OM Bushed 10M
900-1800 34° 22-41 68 p
Primary Spring . . . . . . . Gold (3000-6000) Blue Gold Gold
#-2 3/4 HYVO
Bushed
Secondary Spring .... Gold
10M
Driven Helix ......... 34° #2 1800-2700
White Dark Blue Gold
34° 22-41 68 p
(6000-9000) #-2 3/4 HYVO
Bushed

10M 22-41 68 p
2700-3700 34°
Red Dark Blue Gold
(9000-12000) #-2 3/4 HYVO
Bushed

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 488 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346" (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0035" - 0.0049"(0.09 - 0.125mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 58
Piston Ring Marking . . . . . . . . . 58
Piston Ring End Gap .........008"-.016"(.20-.40mm)
Head cc's (Uninstalled) . . . . . . 28cc
Head cc's (Installed) . . . . . . . . . 23.6cc
Operating RPM±200 . . . . . . . . . 7800 RPM
Idle RPM±200 .............. 1600 RPM
Engagement RPM±300 . . . . . . 4000 RPM
Cylinder Head Torque ........ 8mm 17-20 ft.lbs, 10mm 24-26 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) . . . . 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.38 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . 500 CLASSIC

MODEL NUMBER: . 099ED4BS
ENGINE MODEL: .. EC50PL172

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP5445 Fuel Tank ........... 11.8 gallons (44.71iters)
COl Marking . . . . . . . CU6417 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 200 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 28° BTDC@3000RPM±1.5° Chaincase Oil ....... 9 fl.oz(265cc)
0.173" BTDC (±0.0175")
4.40mm BTDC (±0.48mm)
Operating Timing . . . 16° @ 7500 RPM
Spark Plug I Gap ... Champion RN-3C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@2 watts
Brake . . . . . . 1@ 17 watts
Voltage Regulator . . LR9, LR2
Electric Start . . . . . . . Standard
*LR9= Half wave voltage regulator
*LR2=Rectifier only for battery charging

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Evolved Sprockets I Chain .... 22-41, 68 P 314 HYVO
Front Suspension .. XTRA-12 Reverse ............ Standard
Maximum Width ... . 42.50"(1 07 .95cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0±8mm) Chaincase Center Dist. 6 518"(16.83cm)
Toe Out .......... . 118" -1 l4"(3-6.35mm) Driveshaft Sprockets . 2 Drivers
Front Shocks ..... . Nit rex Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 65#lin.
Front Spring Preload 0.5" Thread Adjust
Front Vertical Travel 10 in.(25.4cm)
Rear Suspension .. . XTRA-12
Rear Travel ....... . 12.0 in.(30.48cm)
Front Track Shock .. Indy Select
Spring Rate ...... . 751125#1in.
Rear Track Shock .. Nitrex with 85# Spring
Rear Springs ..... . .406" I 55°
Track Type ....... . 15"x121"x.82" (38.1x307.34x2.08cm)
Track Tension ..... . 112" (12.7mm) free hang 2" (5.08cm) behind rail bumper with no weight attached

OPTIONAL REAR TORSION SPRINGS

SOFT(STD) FIRM
.406" diameter/55° .421" diameter/55°
L.H 7041394-067 L.H. 7041406-067
R.H. 7041395-067 R.H 7041407-067

Polaris Industries Inc. 1.39 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY 500 RMK

MODEL NUMBER: . 099ER4BS
ENGINE MODEL: .. EC50PL162

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . . VM34SS Mikuni (ACCS) AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 260 Altitude Below ·20°F -20o to +tOoF +10°tO Above
Pilot Jet ............. 55 Below -29°C -29°to -12°C +40°F
-12° to +5°C
+40°F
Above soc
Jet Needle . . . . . . . . . . 6FJ43-3
Meters 0-900 290 270 260 240
Needle Jet . . . . . . . . . . P-0(480) (Feet) (0-3000) #4 #4 #4 #4
Cutaway . . . . . . . . . . . . 2.5 CH 900-1800 290 270 260 240
(3000-6000)
Air Screw . . . . . . . . . . . 1.25 Turns $4 #4 #3 #3
Valve Seat . . . . . . . . . . 1.5 1800-2700
(6000-9000)
290 270 260 240
Fuel Octane (R+M/2) 87 Non-Oxygenated or #3 #3 #3 I #3
89 Oxygenated 2700-3700 290 270 260 240
(9000-12000) #3 #3 #3 #3
Throttle Gap

~
Under Cutaway .0.203" - (5.16mm)
Idle Sync Gap - # refers to the clip position from top of jet needle.
Under Cutaway 0.228" -(5.8mm)
c::J - Production Setting

CLUTCH
Type ................ P-85
Belt ................. 3211070
Belt Width (Projected) . 1.375" (34.93mm) CLUTCH CHART
Side Angle (Overall) . . 28° DRIVE DRIVEN
Outside Circumference 47.250 Altitude Shift Clutch Clutch Driven Chaincase
Weight Spring Spring Helix Gearing
Center Distance . . . . . . 12" (305mm)
Meters 17-41 66 p
Shift Weights . . . . . . . . 1OMR Bushed (Feet)
0-900
(0-3000)
10M
Gold Red
34°
Bushed #-2 3/4 HYVO
Primary Spring . . . . . . . Gold
900-1800 10MB 34° 17-41 66 p
Secondary Spring . . . . Red (3000-6000) Bushed
Gold Red
#-2 3/4 HYVO
Driven Helix ......... 34° #2 1800-2700 10MR 34° 17-41 66 p
Dark Blue Red
(6000-9000) Bushed #-2 3/4HYVO

2700-3700 10-40 34° 17-41 66 p

Dark Blue Red
(9000-12000) Bushed #·2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 488 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346" (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0024" - 0.0037"(0.06 - 0.095mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 5W
Piston Ring Marking . . . . . . . . . 51 A
Piston Ring End Gap .........008"-.016"(.20-AOmm)
Head cc's (Uninstalled) . . . . . . 28cc
Head cc's (Installed) . . . . . . . . . 22cc
Operating RPM±200 . . . . . . . . . 7800 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 3800 RPM
Cylinder Head Torque ........ 8mm 17-20 ft.lbs, 10mm 24-26 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) . . . . 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.40 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY 500 RMK

MODEL NUMBER: . 099ER4BS
ENGINE MODEL: . . ECSOPL162

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP5445 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking ....... CU6417 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 200 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 28° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.173" BTDC (±0.0175")
4.40mm BTDC (±0.48mm)
Operating Timing . . . 16° @ 7500 RPM
Spark Plug I Gap ... Champion RN-3C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR9
Electric Start . . . . . . . Option
*LR9= Half wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Evolved Sprockets I Chain .... 17-41, 66 P 314 HYVO
Front Suspension .. 38RMK Reverse ............ Option
Maximum Width ... . 38.00"(96.52cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0-8mm) Chaincase Center Dist. 6 518"(16.83cm)
Toe Out .......... . 318"-112"(9.65-12.7mm) Driveshaft Sprockets . 2 Drivers
Front Shocks ..... . Nit rex Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 80#Iin.
Front Spring Preload 0.6" Thread Adjust
Front Vertical Travel 8.18 in.(20.78cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 11.5 in.(29.21 em)
Front Track Shock .. Nit rex
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Indy Select
Rear Springs ..... . .359"(sq.) I 7JD
Track Type ....... . 15"x133.5"x1.25" (38.1 x339.09x3.175cm)
Track Tension ..... . 318" -112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diametern7o .359"(sq.) diametern7o .375"(sq.) diameternr
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.41 10/98

GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . CLASSIC TOURING

MODEL NUMBER: . 099ET4BS
ENGINE MODEL: .. EC50PL192

CARBURETION JETTING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Main Jet ........... . 250 Below -20°F -20° to +10°tO Above +40°F
Altitude
Pilot Jet ............ . 40 Below-29°C +10°F
-29oto -12oC
+40°F
-12o to +5oC
Above soc

Jet Needle ......... . 6EJ26-3 0-900

Meters 260
Needle Jet ......... .
Cutaway ........... .
P-2(480)
3.0CH
(Feet) (0-3000)

900-1800
#3

240
I 250
#3
230
I 240
#3
220
230
#3
210
Air Screw .......... . 3/4 Turn (3000-6000)
#3 #3 #3 #2
Valve Seat ......... . 1.5 1800-2700 220 210 195 185
Fuel Octane (R+M/2) 87 Non-Oxygenated or (6000-9000)
#3 #3 #2 #2
89 Oxygenated 2700-3700 200 190 180 175
(9000-12000) #2
Throttle Gap #3 #2 #2

~
Under Cutaway .218" - (5.54mm)
Idle Sync Gap ~ -it refers to the clip position from top of jet needle .
Under Cutaway .240" -(6.1 mm)
~ - Production Setting

CLUTCH
Type ................ P-85
Belt . . . . . . . . . . . . . . . . . 3211 070
Belt Width (Projected) . 1.375" (34.93mm) CLUTCH CHART
Side Angle (Overall) . . 28° DRIVE DRIVEN
Outside Circumference 47.250 Altitude Shift Clutch Clutch Driven Chaincase
Weight Spring Spring Helix
Center Distance . . . . . . 12" (305mm) Gearing
Meters
Shift Weights . . . . . . . . 1OMB Bushed (Feet)
0-900
(0-3000)
10MB Gold Silver 34° 19-40 66 p
Bushed it-2 3/4 HYVO
Primary Spring . . . . . . . Gold
900-1800 10MB 34° 19-40 66 p
Secondary Spring . . . . Silver (3000-6000) Bushed
Blue Silver
it-2 3/4 HYVO
Driven Helix ......... 34° #2 1800-2700 34° 19-40 66 p
10MW Blue Silver
(6000-9000) #-2 3/4 HYVO

2700-3700 10MR 34° 19-40 66 p

Blue Silver
(9000-12000) Bushed #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Piston Port
Displacement . . . . . . . . . . . . . . . 488 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346" (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0024" - 0.0037"(0.06 - 0.095mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 5W
Piston Ring Marking . . . . . . . . . 51 A
Piston Ring End Gap ......... 008"-.016"(.20-.40mm)
Head cc's (Uninstalled) . . . . . . 28cc
Head cc's (Installed) . . . . . . . . . 23.6cc
Operating RPM±200 . . . . . . . . . 7800 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1600 RPM
Engagement RPM±300 . . . . . . 4000 RPM
Cylinder Head Torque . . . . . . . . 8mm 17-20 ft.lbs, 1Omm 24-26 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) . . . . 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.42 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... CLASSIC TOURING

MODEL NUMBER: . 099ET4BS
ENGINE MODEL: . . ECSOPL192

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP5445 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking ....... CU6417 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 200 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 28° BTDC@3000RPM±1.5° Chaincase Oil ....... 9 fl.oz(265cc)
0.173" BTDC (±0.0175")
4.40mm BTDC (±0.48mm)
Operating Timing . . . 16° @ 7500 RPM
Spark Plug I Gap ... Champion RN-3C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@9 watts
Brake . . . . . . 2@ 18 watts
Voltage Regulator . . LR9, LR2
Electric Start . . . . . . . Standard
*LR9= Half wave voltage regulator
*LR2=Rectifier only for battery charging

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Evolved Sprockets I Chain .... 19-40, 66 P 314 HYVO
Front Suspension .. XTRA-12 Reverse ............ Standard
Maximum Width ... . 42.50"(1 07.95cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0±8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out .......... . 118" -1 14"(3-6.35mm) Driveshaft Sprockets . 2 Drivers
Front Shocks ..... . Indy Select Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 100#Iin.
Front Spring Preload 0.43" Thread Adjust
Front Vertical Travel 10.0 in.(25.4cm)
Rear Suspension .. . XTRA-12
Rear Travel ....... . 12.0 in.(30.48cm)
Front Track Shock .. Indy Select
Spring Rate ...... . 901150#Iin.
Rear Track Shock .. Indy Select with 275# Spring
Rear Springs ..... . .437" I 7JO
Track Type ....... . 15"x133.5"x.82" (38.1 x339.09x2.08cm)
Track Tension ..... . 1-1 118" (2.54-2.86cm) free hand 16" (40.64cm) ahead of rear idler shaft with no weight

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM FIRM(STD)

.406" diameter/77° .421" diametern7o .437" diametern7o
L.H 7041394-067 L.H. 7041406-067 L.H. 7041487-067
R.H. 7041395-067 R.H 7041407-067 R.H. 7041488-067

Polaris Industries Inc. 1.43 10/98

GENERAL
1999 Model Specifications

MODEL: .......... XLT SPECIAL

MODEL NUMBER: . 099AB6AS
ENGINE MODEL: .. EC58PL160

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . .
3 TM38 Mikuni
AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 360
Below -20°F -20° to +10°tO Above +40°F
Pilot Jet ............. 35 Altitude Above soc
Below-29°C +10°F +40°F
-29oto -12°C -12° to +5"C
Jet Needle . . . . . . . . . . 9DH3-54-4
Meters 0-900 380
Needle Jet . . . . . . . . . . 0-6
Cutaway . . . . . . . . . . . . 3.0
(Feet) (0-3000)

900-1800
#4
I 360
$4
330
340
$4
320
330
$4
300
Idle Mixture Screw . . . . 1.5 Turns (3000-6000)
350
#4 $4 $4 $3
Valve Seat . . . . . . . . . . 1.5 Viton
1800-2700 320 300 290 270
Fuel Octane (R+M/2) . 87 Non-Oxygenated or (6000-9000)
$4 $4 $3 $3
89 Oxygenated 2700-3700 290 280 270 250
Starter Jet . . . . . . . . . . . 155 (9000-12000)
$4 #3 $3 $3
Pilot Air Jet . . . . . . . . . . 1.0
CD - # refers to the clip position from top of jet needle.

c::J - Production Setting

CLUTCH
Type ................ P-85
BeH ................. 3211070
Belt Width (Projected) . 1.375" (34.93mm) CLUTCH CHART
Side Angle (Overall) . . 28°
DRIVE DRIVEN
Outside Circumference 47.250
Altitude Shift Clutch Clutch Driven Chaincase
Center Distance ...... 12" (305mm) Weight Spring Spring Helix Gearing
Shift Weights . . . . . . . . 1OM Bushed Meters 0-900 10M R-32 22-41 68 p
Dark Blue Silver
Primary Spring . . . . . . . Dark Blue (Feet) (0-3000) Bushed #-2 3/4HYVO
Secondary Spring . . . . Silver 900-1800 10MB
Dark Blue Silver
34° 22-41 68 p
(3000-6000)
Driven Helix . . . . . . . . . R-32 #2 Bushed #-2 3/4 HYVO

1800-2700 10MR R-32 21-4168P

Dark Blue Silver
(6000-9000) Bushed #-2 3/4 HYVO

2700-3700 10MR R-32 21-41 68 p

Dark Blue Silver
(9000-12000) Bushed #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Piston Port Triple
Displacement . . . . . . . . . . . . . . . 598cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.5600" (65.025mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0035" - 0.0049"(0.09 - 0.125mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 58F
Piston Ring Marking . . . . . . . . . 3N
Piston ring end gap ...........012"-.020"(.30-.50mm)
Head cc's (Uninstalled) . . . . . . 20.5cc
Head cc's (Installed) . . . . . . . . . 17.1 cc
Operating RPM±200 . . . . . . . . . 8300 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1900 RPM
Engagement RPM±300 . . . . . . 4200 RPM
Cylinder Head Torque . . . . . . . . 8mm 17-20 ft.lbs, 1Omm 24-26 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.44 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... XLT SPECIAL

MODEL NUMBER: . 099AB6AS
ENGINE MODEL: . . EC58PL160

ELECTRICAL CAPACITIES
Flywheel I. D. . . . . . . FP91 02 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking ....... CU2552 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 28° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.173" BTDC (±0.0175")
4.40mm BTDC (±0.48mm)
Operating Timing . . . 20° @ 7500 RPM
Spark Plug I Gap . . . Champion RN-2C I 0.028" (0. 7mm)
Lights: Head . . . . . . Halogen 1301110 watts
Tail ........ 2@9 watts
Brake ...... 2@18 watts
Voltage Regulator . . LR7
Electric Start . . . . . . . Option
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Aggressive Sprockets I Chain .... 22-41, 68 P 314 HYVO
Front Suspension .. XTRA-10, CRC Reverse ............ Option
Maximum Width ... . 41.00"(104.14cm) Brake Pads ......... Type 69
Camber .......... . 314"±5116"(19.05±8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out .......... . 318"-112"(9.65-12.7mm) Driveshaft Sprockets . 2 Drivers wide
Front Shocks ..... . Indy Select Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 100#Iin.
Front Spring Preload 0.13" Thread Adjust
Front Vertical Travel 9.30 in.(23.62cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 8.25 in.(25.4cm)
Front Track Shock .. Ryde FX
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Polaris Position Sensitive Shock
Rear Springs ..... . .359"(sq.) I 7JO
Track Type ....... . 15"x121"x.82" (38.1x307.34x2.08cm)
Track Tension ..... . 318" - 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diametern7o .359"(sq.) diametern7o .375"(sq.) diameternr
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.45 10/98

GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . XLT CLASSIC

MODEL NUMBER: . 099ED6AS
ENGINE MODEL: .. EC58PL131

CARBURETION JETTING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Below ·20°F -20° to +tO'to
Main Jet ........... . 250 Altitude
Below -29'C +10'F +40'F
Above +40°F
Above soc
Pilot Jet ............ . 40 -29'to -t2'C -t2' to +5'C

Jet Needle ......... . 6DP17-2 Meters 0-900 250 250 230 210
(Feet) (0-3000)
Needle Jet ......... . Q-4(480) #2 #2 #2 #2
Cutaway ........... . 2.5CH 900-t800 230 220 210 195
(3000-6000)
Air Screw .......... . 1 Turn #2 #2 #1 #1
Valve Seat ......... . 1.5 Viton t800-2700
(6000-9000)
210 200 190 180
#2 #1 #1 #1
Fuel Octane (R+M/2) 87 Non-Oxygenated or
2700-3700 190 180 175 165
89 Oxygenated (9000-t2000)
#2 #1 #1 #1
Throttle Gap
Under Cutaway
Idle Sync Gap
.21 0" - (5.53mm)
~ - # refers to the clip position from top of jet needle .

Under Cutaway .234" (5.94mm) c::J - Production Setting

CLUTCH
Type ................ P-85
CLUTCH CHART
Belt . . . . . . . . . . . . . . . . . 3211 070
Belt Width (Projected) . 1.375" (34.93mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chaincase
Weight Spring Spring Helix Gearing
Outside Circumference 47.250
Meters 0-900 22-4t 68 p
Center Distance . . . . . . 12" (305mm) (Feet) (0-3000)
tOM
Bushed
Silver/Gold Silver 34'
#-2 3/4 HYVO
Shift Weights . . . . . . . . 1OM Bushed tOM
900-tBOO 22-4t 68 p
Primary Spring . . . . . . . Silver/Gold (3000-6000) Blue Silver/Gold Silver
34'
#-2 3/4 HYVO
Bushed
Secondary Spring . . . . Silver
tOM
Driven Helix ......... 34° #2 t800-2700
White Dark Blue Silver
34' 2t-41 68 p
(6000-9000) #-2 3/4 HYVO
Bushed
tOM 2t-4t 68 p
2700-3700 34'
Red Dark Blue Silver
(9000-12000) #·2 3/4 HYVO
Bushed

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Piston Port Triple
Displacement . . . . . . . . . . . . . . . 598cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.5600" (65.025mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0035" - 0.0049"(0.09 - 0.125mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 58F
Piston Ring Marking . . . . . . . . . 3N
Piston Ring End Gap .........012"-.020"(.30-.50mm)
Head cc's (Uninstalled) . . . . . . 19.9cc
Head cc's (Installed) . . . . . . . . . 19.5cc
Operating RPM±200 . . . . . . . . . 8000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1900 RPM
Engagement RPM±300 . . . . . . 4000 RPM
Cylinder Head Torque . . . . . . . . 8mm 17-20 ft.lbs, 1Omm 24-26 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.46 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . XLT CLASSIC

MODEL NUMBER: . 099ED6AS
ENGINE MODEL: . . EC58PL131

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP9102 Fuel Tank ........... 11.8 gallons (44.7 liters)
COl Marking . . . . . . . CU2552 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 28° BTDC@3000RPM±1.5° Chaincase Oil ....... 9 fl.oz(265cc)
0.173" BTDC (±0.0175")
4.40mm BTDC (±0.48mm)
Operating Timing . . . 20° @ 7500 RPM
Spark Plug I Gap ... Champion RN-3C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@2 watts
Brake . . . . . . 1 @17 watts
Voltage Regulator .. LR7, LR2
Electric Start . . . . . . . Standard
*LR7= Full wave voltage regulator
*LR2=Rectifier only for battery charging

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Evolved Sprockets I Chain .... 22-41, 68 P 314 HYVO
Front Suspension .. XTRA-12 Reverse ............ Standard
Maximum Width ... . 42.50"(1 07.95cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0±8mm) Chaincase Center Dist. 6 518"(16.83cm)
Toe Out .......... . 118-114"(3-6.35mm) Driveshaft Sprockets . 2 Drivers Wide
Front Shocks ..... . Indy Select Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 75#1in.
Front Spring Preload 0.25" Thread Adjust
Front Vertical Travel 10.0 in.(25.4cm)
Rear Suspension .. . XTRA-12
Rear Travel ....... . 12.0 in.(30.48cm)
Front Track Shock .. Ryde AFX
Spring Rate ...... . 751125#1in.
Rear Track Shock .. Ryde AFX with 85# Spring
Rear Springs ..... . .406" I 55°
Track Type ....... . 15"x121 "x.82" (38.1 x307.34x2.08cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT(STD) FIRM
.406" diameter/55° .421" diameter/55°
L.H 7041394-067 L.H. 7041406-067
R.H. 7041395-067 R.H 7041407-067

Polaris Industries Inc. 1.47 10/98

GENERAL
1999 Model Specifications

MODEL: .......... XLT TOURING

MODEL NUMBER: . 099ET6AS(A)
ENGINE MODEL: .. EC58PL131

CARBURETION JETTING CHART

Type ............... . VM34SS Mikuni AMBIENT TEMPERATURE
Below -20"F -20" to +10"to Above +40"F
Main Jet ........... . 250 Altitude Below-29"C +10"F +40"F AboveS"C
Pilot Jet ............ . 40 -29"to -12"C -12" to +5"C

Jet Needle ......... . 6DP17-2 Meters 0-900 250 250 230 210
(Feet) (0-3000) #2
Needle Jet ......... . Q-4(480) #2 #2 #2
Cutaway ........... . 2.5CH 900-1800 230 220 210 195
(3000-6000) #2 #2 #1 #1
Air Screw .......... . 1 Turn
Valve Seat ......... . 1.5 Viton 1800-2700 210 200 190 180
(6000-9000) #2 #1 #1 #1
Fuel Octane (R+M/2) 87 Non-Oxygenated or
2700-3700 190 180 175 165
89 Oxygenated (9000-12000) #2 #1 #1 #1
Throttle Gap
Under Cutaway
Idle Sync Gap
.21 0" - (5.53mm) Dr] - # refers to the clip position from top of jet needle.

Under Cutaway .234" (5.94mm) c:::::J - Production Setting

CLUTCH
Type ................ P-85
CLUTCH CHART
BeH ................. 3211070
Belt Width (Projected) . 1.375" (34.93mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chain case
Weight Spring Spring Helix Gearing
Outside Circumference 47.250
Meters Q-900 34° 20-40 66 p
Center Distance . . . . . . 12" (305mm) (Feet) (0-3000)
10MB
Bushed
Silver/Gold Silver
#-2 3/4 HYVO
Shift Weights . . . . . . . . 1OM Bushed 10M
900-1800 34° 20-40 66 p
Primary Spring . . . . . . . Silver/Gold (3000-6000) Blue Silver/Gold Silver
#-2 3/4 HYVO
Bushed
Secondary Spring . . . . Silver
10M
Driven Helix ......... 34° #2 1600-2700
White Dark Blue Silver
34° 20-40 66 p
(6000-9000) #-2 3/4 HYVO
Bushed

10M 20-40 66 p
2700-3700 34°
Red Dark Blue Silver
(9000-12000) #-2 3/4 HYVO
Bushed

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Piston Port Triple
Displacement . . . . . . . . . . . . . . . 598cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.5600" (65.025mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.3622" (60mm)
Piston I Cylinder Clearance . . . 0.0035" - 0.0049"(0.09 - 0.125mm)
Service Limit . . . . . . . . . . . . . . . . 0.0078" (0.20mm)
Piston Marking . . . . . . . . . . . . . . 58F
Piston Ring Marking . . . . . . . . . 3N
Piston Ring End Gap .........012"-.020"(.30-.50mm)
Head cc's (Uninstalled) . . . . . . 19.9cc
Head cc's (Installed) ......... 19.5cc
Operating RPM±200 . . . . . . . . . 8000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1900 RPM
Engagement RPM±300 . . . . . . 3800 RPM
Cylinder Head Torque ........ 8mm 17-20 ft.lbs, 10mm 24-26 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) . . . . 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) . . . 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.48 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... XLT TOURING

MODEL NUMBER: . 099ET6AS(A)
ENGINE MODEL: . . EC58PL131

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP9102 Fuel Tank ........... 11.8 gallons (44.7 liters)
CDI Marking . . . . . . . CU2552 Oil Tank ............ 2 quarts (1.9 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 28° BTDC@3000RPM±1.5° Chaincase Oil ....... 9 fl.oz(265cc)
0.173" BTDC (±0.0175")
4.40mm BTDC (±0.48mm)
Operating Timing . . . 20° @ 7500 RPM
Spark Plug I Gap ... Champion RN-3C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator .. LR7, LR2
Electric Start . . . . . . . Standard
*LR7= Full wave voltage regulator
*LR2=Rectifier only for battery charging

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Evolved Sprockets I Chain .... 20-40, 66 P 314 HYVO
Front Suspension .. XTRA-12 Reverse ............ Standard
Maximum Width ... . 42.50"(1 07 .95cm) Brake Pads ......... Type 69
Camber .......... . 0"±5116"(0±8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out .......... . 118" -1 14"(3-6.35mm) Driveshaft Sprockets . 4 Drivers
Front Shocks ..... . Indy Select Brake Type ......... Hydraulic Disc
IFS Spring Rate ... . 120#Iin.
Front Spring Preload 0.13" Thread Adjust
Front Vertical Travel 10.0 in.(25.4cm)
Rear Suspension .. . XTRA-12
Rear Travel ....... . 12.0in.(30.48cm)
Front Track Shock .. Ryde AFX
Spring Rate ...... . 901150#Iin.
Rear Track Shock .. Indy Select with 275# Spring
Rear Springs ..... . .437" I 7JO
Track Type ....... . 15"x133.5"x.82" (38.1 x339.09x2.08cm)
Track Tension ..... . 1-1 118" (2.54-2.86cm) free hand 16" (40.64cm) ahead of rear idler shaft with no weight

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM FIRM(STD)

.406" diameternr .421" diametern7o .437" diametern7o
L.H 7041394-067 L.H. 7041406-067 L.H. 7041487-067
R.H. 7041395-067 R.H 7041407-067 R.H. 7041488-067

Polaris Industries Inc. 1.49 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY 500 XC I 500 XC SP

MODEL NUMBER: . 099SB5AS I 099SP5AS
ENGINE MODEL: . . S50-44-99A2

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . .
TM38 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 370 Altitude Below-20°F -20° to+10°F +10°tO +40°F Above +40°F
Below-29°C -29°to -12°C -12° to +5"C Above soc
Pilot Jet ............. 45
Meters 0-900 380 370 350 330
Jet Needle . . . . . . . . . . 9FH4-57 -3 (Feet) (0-3000) #3 #3 #3 #3
Needle Jet . . . . . . . . . . P-6
900-1800 340 320 300 290
Cutaway . . . . . . . . . . . . 1.5 (3000-6000) #3 #3 #3 #2
Air Screw . . . . . . . . . . . 2 Turns 1800-2700 300 290 '270 250
Valve Seat . . . . . . . . . . 1.5 Viton (6000-9000) #3 #3 #3 #2
Fuel Octane (R+M/2) . 87 Non-Oxygenated or 2700-3700 270 260 240 220
(9000-12000) #3 #3 #2
89 Oxygenated #3

~
Starter Jet . . . . . . . . . . . 155
Pilot Air Jet . . . . . . . . . . 1.0 - # refers to the clip position from top of jet needle.

c:::::J - Production Setting

c:::::J - Line zone should remove washer from underneath needle and place on top

CLUTCHES
Type ................ P-85
Belt ................. 3211074
Belt Width (Projected) . 1.438" (36.52mm) CLUTCH CHART
Side Angle (Overall) . . 28° DRIVE DRIVEN
Outside Circumference 47.625 Altitude Chain case
Shift Clutch Clutch Driven
Center Distance . . . . . . 12" (305mm) Weight Spring Spring Helix Gearing
Shift Weights . . . . . . . . 10-56 Meters 0-900 R-32 22-41 70 p
(Feet) 10-56 Dark Blue Silver
Primary Spring . . . . . . . Dark Blue (0-3000) #-2 3/4 HYVO

Secondary Spring . . . . Silver 900-1800

10-54
Almond Silver
R-32 22-41-70 p
(3000-6000) Gold #-2 3/4 HYVO
Driven Helix . . . . . . . . . R-32 #-2
1800-2700 10Alor Almond R-32 22-41 70 p
Silver
(6000-9000) 10 Gold #-3 3/4 HYVO

2700-3700 Almond R-32 22-41 70 p

10 Silver
(9000-12000) Gold #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed
Displacement . . . . . . . . . . . . . . . 500 cc
Bore ....................... 2.776" (70.5mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.520" (64mm)
Piston I Cylinder Clearance . . . 0.0023" - 0.0037''(0.06 -0.095mm)
Service Limit . . . . . . . . . . . . . . . . 0.0059" (0.15mm)
Piston Marking . . . . . . . . . . . . . . 70.38, ELCO 2205
Piston Ring Marking . . . . . . . . . "o" faces upward
Piston Ring End Gap . . . . . . . . .012"-.018"(.30-.46mm)
Head cc's (Uninstalled) . . . . . . 28.6cc
Head cc's (Installed) . . . . . . . . . 25.4cc
Operating RPM±200 . . . . . . . . . 8000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1500 RPM
Engagement RPM±300 . . . . . . 4200 RPM
Cylinder Head Torque . . . . . . . . 20-24 ft.lbs(2.8-3.3 kgm)
Cylinder Base Nut Torque . . . . 30-34 ft.lbs(4.15-4.7 kgm)
Crankcase Torque (8mm) . . . . 20-24 ft.lbs(2.8-3.3 kgm)
Crankcase Torque (10mm) ... N/A
Flywheel Torque . . . . . . . . . . . . 90 ft.lbs(12.4 kgm)

10/98 1.50 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY 500 XC /500 XC SP

MODEL NUMBER: . 099SB5AS I 099SP5AS
ENGINE MODEL: . . S50-44-99A2

ELECTRICAL CAPACITIES
Flywheeii.D ...... . 4060141 Fuel Tank ........... 11.8 gai.(44.7L)I1 0.5(39.7)
CDI Marking ...... . 4060198 Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output .. . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing .... . 12° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.034" BTDC (±0.008")
0.872mm BTDC (±0.208mm)
Operating Timing .. . 15°@ 7500 RPM
Spark Plug I Gap .. . Champion RN-2C I 0.028" (0.7mm)
Lights: Head ..... . Halogen 75160 watts
Tail ....... . 2@8 watts-XC (2@2 watts SP)
Brake ..... . 2@8 watts-XC (1 @17 wattsSP)
Voltage Regulator .. LR7
Electric Start ...... . NIA
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 22-41, 70 P 314 HYVO
Front Suspension .. XC-10, CRC Reverse ............ Option
Maximum Width ... . 41.00"(1 04.14cm) Brake Pads ......... Type 69
Camber .......... . 1.05"±5116"(26.67±8mm) Chaincase Center Dist. 7.05"(17.91 em)
Toe Out .......... . 0-118"(0-3mm) Driveshaft Sprockets . 2 Drivers Wide
Front Shocks ..... . Indy Select(XC) I Fox™ IFP(SP) Brake Type ......... Polaris HPB
IFS Spring Rate ... . 1OO#Iin.(XC) I 741120#in.(SP)
Front Spring Preload 0.20" Thread Adjust(XC) I 1.13" Thread Adjust(SP)
Front Vertical Travel 9.0 in.(22.86cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 8.25 in.(21 em)
Front Track Shock .. Ryde FX(XC) I Fox™ IFP(SP)
Spring Rate ...... . 200#Iin. variable(XC) I 190#Iin.(SP)
Rear Track Shock .. Polaris Position Sensitive Shock
Rear Springs ..... . .359" (sq.) I no
Track Type ....... . 15"x121"x.82" (38.1x307.34x2.08cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diameter/77° .359"(sq.) diametern7o .375"(sq.) diameternr
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.51 10/98

GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . INDY 600 XC /600 XC SP

MODEL NUMBER: . 099SB6DS I 099SP6DS
ENGINE MODEL: .. SN60-70-99A2

CARBURETION JETTING CHART

Type ............... . 2-Keihin PWK 39 AMBIENT TEMPERATURE
Main Jet ........... . 185 Altitude Below ·20°F -20° to +10°F +10oto +40°F Above +40°F
Pilot Jet ............ . #38 Below-29°C -29°to ·12°C ·12° to +SoC Above soc

Jet Needle ......... . R1368G-3 Meters

(Feet)
0-900
(0-3000)
190 185 178 172
#3 #3 #3 #3
Needle Jet ......... . 2.9mm fixed
Cutaway ........... . 5.5 900-1800
(3000-6000)
178 175 168 162
#3 #3 #3 #3
Air Screw .......... . 1.0 Turn
1800·2700 170 165 158 155
Valve Seat ......... . 1.8 (6000-9000) #3 #3 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or 2700-3700 158 155 150 145
89 Oxygenated (9000-12000)
#3 #2 #2 #2
Throttle Gap
Under Cutaway
Idle Sync Gap
.028"- (.7mm)
~ - # refers to the clip position !rom top ot jet needle.

Under Cutaway .059" - (1.5mm) c::J - Production Setting

CLUTCH
Type ................ P-85
BeH ................. 3211065 CLUTCH CHART
Belt Width (Projected) . 1.438" (36.53mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chaincase
Outside Circumference 48.375 Weight Spring Spring Helix Gearing
Center Distance ...... 12.5" (317.5mm) Meters 0-900 10·S8 Silver
R-32 22·40 70 p
(Feet) Dark Blue
(0-3000)
Shift Weights . . . . . . . . 10-58 Bushed Bushed #-2 3/4 HYVO

Primary Spring . . . . . . . Dark Blue 900-1800

(3000·6000)
10-56 Almond Silver/ R-3 22-40-70 p
Bushed Gold Blue #-2 3/4HYVO
Secondary Spring . . . . Silver
1800-2700 10-S4 Almond Silver/ R-3 21-41 70 p
Driven Helix . . . . . . . . . R-32 #-2 (6000-9000) Bushed Gold Blue #-3 3/4 HYVO

2700-3700 10AL Almond Silver/ R-3 21-41 70 p

(9000-12000) Bushed Gold Blue #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed
Displacement . . . . . . . . . . . . . . . 593 cc
Bore ....................... 2.9930" (74.5mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.6772" (68.0mm)
Piston I Cylinder Clearance . . . .0043" - .0059"(.11 -.15mm)
Service Limit . . . . . . . . . . . . . . . . .0078" (.2mm)
Piston Marking . . . . . . . . . . . . . . EK2202
Piston Ring Marking . . . . . . . . . "o" faces upward
Piston Ring End Gap .........012"-.018"(.30-.46mm)
Head cc's (Uninstalled) . . . . . . 34.0cc
Head cc's (Installed) . . . . . . . . . 26.0cc
Operating RPM±200 . . . . . . . . . 8000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1500 RPM
Engagement RPM±300 ...... 4200 RPM
Cylinder Head Torque . . . . . . . . 20ft.lbs(2.8kgm)
Cylinder Base Nut Torque .... 35-40 ft.lbs(4.8-5.5 kgm)
Crankcase Torque (8mm) . . . . N/A
Crankcase Torque (10mm) ... 35-40 ft.lbs(4.8-5.5 kgm)
Flywheel Torque ............ 55 ft.lbs(7.4 kgm)

10/98 1.52 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY 600 XC /600 XC SP

MODEL NUMBER: . 099SB6DS I 099SP6DS
ENGINE MODEL: . . SN60-70-99A2

ELECTRICAL CAPACITIES
Flywheeii.D ....... 4010130 Fuel Tank ........... 11.8 ga1.(44.7L)I10.5(39.7)
CDI Marking . . . . . . . 4060209 Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing . . . . . 6° BTDC@ 1750RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.009" BTDC (±0.005")
0.22mm BTDC (±0.1 05mm)
Operating Timing . . . 13° @ 7500 RPM
Spark Plug I Gap ... Champion RN-2C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@8 watts-XC (2@2watts SP)
Brake ...... 2@8 watts-XC (1 @17 watts SP)
Voltage Regulator . . LR7
Electric Start . . . . . . . Optional
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 22-40, 70 P 314 HYVO
Front Suspension .. XC-10, CRC Reverse ............ Option
Maximum Width ... . 41.00"(1 04.14cm) Brake Pads ......... Type 69
Camber .......... . 1.05"±5116"(26.67±8mm) Chaincase Center Dist. 7.05"(17.91 em)
Toe Out .......... . 0-118"(0-3mm) Driveshaft Sprockets . 2 Drivers Wide
Front Shocks ..... . Indy Select(XC) I Fox™ IFP(SP) Brake Type ......... Polaris HPB Liquid Cooled
IFS Spring Rate ... . 1OO#Iin.(XC) I 7 41120#in.(SP)
Front Spring Preload 0.20" Thread Adjust(XC) I 1.13" Thread Adjust(SP)
Front Vertical Travel 9.0 in.(22.86cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 8.25 in.(21cm)
Front Track Shock .. Ryde FX(XC) I Fox™ IFP(SP)
Spring Rate ...... . 200#Iin. variable(XC) I 190#Iin.(SP)
Rear Track Shock .. Polaris Position Sensitive Shock
Rear Springs ..... . .359" (sq.) I 77°
Track Type ....... . 15"x121 "x.91" (38.1x307.34x2.31cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diameter/77° .359"(sq.) diametern7o .375"(sq.) diametern7o
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.53 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY 700 XC /700 XC SP

MODEL NUMBER: . 099SB7AS I 099SP7AS
ENGINE MODEL: .. SN70-70-99A2

CARBURETION JETTING CHART

Type ............... . 2-Keihin PWK 39 AMBIENT TEMPERATURE
Altitude Below -20°F
Main Jet ........... . PTO 185/MAG 190 Below -29°C
-20° to+10°F
-29"to -12°C
+1ooto +40° F
-12° to +5°C
Above +40°F
Above soc
Pilot Jet ............ . #38 Meters 0-900 MAG195 MAG 190 MAG 182 MAG 178
Jet Needle ......... . R1368G-3 (Feet) (0-3000)
PTO 190 PTO 185 PTO 178 PTO 172
Needle Jet ......... . 2.9mm fixed #3 #3 #3 #3
Cutaway ........... . 5.5 900-1800 MAG 182 MAG 180 MAG 172 MAG 168
(3000-6000)
Air Screw .......... . 1.0 Turn PTO 178 PTO 175 PTO 168 PTO 162
#3 #3 #3 #3
Valve Seat ......... . 1.8 1800-2700 MAG 175 MAG 170 MAG 162 MAG 160
Fuel Octane (R+M/2) 87 Non-Oxygenated or (6000-9000)
PTO 170 PTO 165 PTO 158 PTO 155
89 Oxygenated #3 #3 #2 #2
Throttle Gap 2700-3700
(9000-12000)
MAG 162 MAG 160 MAG 155 MAG 150
PTO 158 PTO 155 PTO 150 PTO 145
Under Cutaway .059" - (1.5mm)
#3 #2 #2 #2
Idle Sync Gap
Under Cutaway .063" - (1.6mm)
~ - # refers to the clip position from top of jet needle.

~ - Production Setting
CLUTCH
Type ................ P-85
Belt ................. 3211065
Belt Width (Projected) . 1.438" (36.53mm)
Side Angle (Overall) . . 28° CLUTCH CHART
Outside Circumference 48.375 DRIVE DRIVEN
Center Distance ...... 12.5" (317.5mm) Altitude Shit! Clutch Clutch Driven Chaincase
Weight Spring Spring He!ix
Shift Weights . . . . . . . . 10-60 Bushed Gearing
Meters
Primary Spring . . . . . . . Dark Blue (Feet)
0-900 1060
Dark Blue Silver
36°
Mod
24-40 70 p
(0-3000) Bushed 3/4 HYVO
Secondary Spring . . . . Silver #-2

Driven Helix . . . . . . . . . 36° Mod #-2 900-1800 10-58 Almond Silver/ R-11 24-40-70 p
(3000-6000) Bushed Gold Blue #-2 3/4 HYVO

1800-2700 10-56 Almond Silver/ R-11 23-41 70 p

(6000-9000) Bushed Gold Blue #-2 3/4 HYVO

2700-3700 10-54 Almond Silver/ R-11 23-40 70 p

(9000-12000) Bushed Gold Blue #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed Twin
Displ . . . . . . . . . . . . . . . . . . . . . . . 700 cc
Bore ....................... 3.1889" (81mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.6772" (68mm)
Piston I Cylinder Clearance .... 0043"- .0053"(.11 -.135mm)
Service Limit . . . . . . . . . . . . . . . . .0078" (.2mm)
Piston Marking . . . . . . . . . . . . . . EK21 08
Piston Ring Marking . . . . . . . . . "o" faces upward
Piston Ring End Gap . . . . . . . . .014"-.020"(.36-.51 mm)
Head cc's (Uninstalled) . . . . . . 40.2cc
Head cc's (Installed) . . . . . . . . . 32.5cc
Operating RPM±200 . . . . . . . . . 8000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1500 RPM
Engagement RPM±300 . . . . . . 4200 RPM
Cylinder Head Torque . . . . . . . . 20ft.lbs(2.8kgm)
Cylinder Base Nut Torque . . . . 35-40 ft.lbs(4.8-5.5 kgm)
Crankcase Torque (8mm) . . . . N I A
Crankcase Torque (1 Omm) . . . 35-40 ft.lbs(4.8-5.5 kgm)
Flywheel Torque . . . . . . . . . . . . 55 ft.lbs(7.4 kgm)

10/98 1.54 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY 700 XC /700 XC SP

MODEL NUMBER: . 099SB7 AS I 099SP7 AS
ENGINE MODEL: . . SN70-70-99A2

ELECTRICAL CAPACITIES
Flywheel I. D. . . . . . . 4010139 Fuel Tank ........... 11.8 ga1.(44.7L)I10.5(39.7)
CDI Marking . . . . . . . 4060212 Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing . . . . . 6° BTDC@ 1750RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.009" BTDC (±0.005")
0.22mm BTDC (±0.1 05mm)
Operating Timing . . . 17° @ 7500 RPM
Spark Plug I Gap ... Champion RN-2C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@8 watts-XC (2@2 watts SP)
Brake ...... 2@8 watts-XC (1 @17 watts SP)
Voltage Regulator . . LR7
Electric Start . . . . . . . Optional
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 24-40, 70 P 314 HYVO
Front Suspension .. XC-10, CRC Reverse ............ Option
Maximum Width ... . 41.00"(1 04.14cm) Brake Pads ......... Type 69
Camber .......... . 1.05"±5116"(26.67±8mm) Chaincase Center Dist. 7.05(17.91 em)
Toe Out .......... . 0-118"(0-3mm) Driveshaft Sprockets . 2 Drivers Wide
Front Shocks ..... . Indy Select(XC) I Fox™ IFP(SP) Brake Type ......... Polaris HPB Liquid Cooled
IFS Spring Rate ... . 1OO#Iin.(XC) I 741120#in.(SP)
Front Spring Preload 0.20" Thread Adjust(XC) I 1.13" Thread Adjust(SP)
Front Vertical Travel 9.0 in.(22.86cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 8.25 in.(21cm)
Front Track Shock .. Ryde FX(XC) I Fox™ IFP(SP)
Spring Rate ...... . 200#Iin. variable(XC) I 190#Iin.(SP)
Rear Track Shock .. Polaris Position Sensitive Shock
Rear Springs ..... . .359" (sq.) I no
Track Type ....... . 15"x121 "x.91" (38.1x307.34x2.31cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diametern7o .359"(sq.) diametern7o .375"(sq.) diametern7o
L. H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.55 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY 600 RMK

MODEL NUMBER: . 099SR6DS(A)
ENGINE MODEL: .. SN60-70-99A1

CARBURETION JETTING CHART

Type ............... . 2-Keihin PWK 39 AMBIENT TEMPERATURE
Altitude Below-20"F -20" to +10"F + 10"to +40"F Above +40"F
(ACCS) Below -29"C -29"to -12"C -12" to +S"C Above S"C
Main Jet ........... . 185 Meters 0-900 195 190 185 180
Pilot Jet ............ . 50 (Feet) (0-3000) #2 #2 #2 #2
Air Screw 2 turns Air Screw 2 turns Air Screw 2 turns Air Screw 2 turns
Jet Needle ......... . R1367G-2
Needle Jet ......... . 2.9x4.6x1.5mm fixed 900-1800 195 190 185 180
(3000-6000) #2 #2 #2 #2
Cutaway ........... . 6.0 Notched Air Screw 1.5 turns Air Screw 1.5 turns Air Screw 1.5 turns Air Screw 1.5 turns
Air Screw .......... . 1.0 Turn 1800-2700 195 190 185 180
(6000-9000)
Valve Seat ......... . 1.8 #2 #2 #2 #2
Air Screw 1 tum Air Screw 1 tum Air Screw 1 tum Air Screw 1 tum
Fuel Octane (R+M/2) 87 Non-Oxygenated or
89 Oxygenated 2700-3700 195 190 185 180
(9000-12000) #2 #2 #2 #2
Throttle Gap Air Screw 1/2 turn Air Screw 1/2 tum Air Sere 112 turn Air Screw 1/2 tum
Under Cutaway 0.102"- (2.6mm)
Idle Sync Gap
Under Cutaway 0.118"- (3.0mm)
DE] - # refers to the clip position from top of jet needle.

CJ - Production Setting
CLUTCH
Type ................ P-85
Belt. ................ 3211065
Belt Width (Projected) . 1.438" (36.53mm)
CLUTCH CHART
Side Angle (Overall) . . 28°
Outside Circumference 48.375 DRIVE DRIVEN
Center Distance ...... 12.5" (317.5mm) Altitude Shift Clutch Clutch Driven Chain case
Weight Sprtng Sprtng Helix Gearing
Shift Weights . . . . . . . . 10-54 Bushed
Meters 0-900 10-58 Silver/ R-8 19-40 68 p
Primary Spring . . . . . . . Dark Blue (Feet) (0-3000) Bushed
Dark Blue
Blue #-2 3/4 HYVO
Secondary Spring . . . . Silver/Blue 900-1800 10-56 Silver/ R-8 19-40-68 p
Dark Blue
Driven Helix . . . . . . . . . R-8 #-2 (3000-6000) Bushed Blue #-2 3/4HYVO

1800-2700 10-54 Silver/ R-8 19-40 68 p

Dark Blue
(6000-9000) Bushed Blue #-2 3/4 HYVO

2700-3700 10 Silver/ R-8 19-40 68 p

Dark Blue
(9000-12000) Bushed Blue #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed Twin
Displacement . . . . . . . . . . . . . . . 593 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.9930" (7 4.5mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.6772" (68mm)
Piston I Cylinder Clearance . . . .0043" - .0059"(.11 -.15mm)
Service Limit . . . . . . . . . . . . . . . . .0078" (.2mm)
Piston Marking . . . . . . . . . . . . . . EK2202
Piston Ring Marking . . . . . . . . . "o" faces upward
Piston Ring End Gap ......... 012"-.018"(.30-.46mm)
Head cc's (Uninstalled) . . . . . . 34.0cc
Head cc's (Installed) . . . . . . . . . 26.0cc
Operating RPM±200 . . . . . . . . . 8000 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1500 RPM
Engagement RPM±300 . . . . . . 4200 RPM
Cylinder Head Torque . . . . . . . . 20ft.lbs(2.8kgm)
Cylinder Base Nut Torque .... 35-40 ft.lbs(4.8-5.5 kgm)
Crankcase Torque (8mm) . . . . N/A
Crankcase Torque (10mm) ... 35-40 ft.lbs(4.8-5.5 kgm)
Flywheel Torque ............ 55 ft.lbs(7.4 kgm)

10/98 1.56 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY 600 RMK

MODEL NUMBER: . 099SR6DS(A)
ENGINE MODEL: .. SN60-70-99A1

ELECTRICAL CAPACITIES
Flywheeii.D. . . . . . . 4010139 Fuel Tank ........... 11.8 gai.(44.7L)
CDI Marking ....... 4060209 Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing . . . . . 6° BTDC@ 1750RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.0086" BTDC (±0.0045")
0.22mm BTDC (±0.1 05mm)
Operating Timing . . . 13° @ 7500 RPM
Spark Plug I Gap ... Champion RN-2C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR7
Electric Start . . . . . . . Optional
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 19-40, 68 P 314 HYVO
Front Suspension .. RMKCRC Reverse ............ Option
Maximum Width ... . 38.00"(96.52cm) Brake Pads ......... Type 69
Camber .......... . 11132"±5116"(9±8mm) Chaincase Center Dist. 7.05"(17.91cm)
Toe Out .......... . 318-112"(9.65-12.7mm) Driveshaft Sprockets . 2 Drivers Wide
Front Shocks ..... . Nit rex Brake Type ......... Polaris HPB Liquid Cooled
IFS Spring Rate ... . 100#Iin.
Front Spring Preload 0.13" Thread Adjust
Front Vertical Travel 8.05in.(20.54cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 11.5 in.(29.21 em)
Front Track Shock .. Nit rex
Spring Rate ...... . 200#1in. variable
Rear Track Shock .. Indy Select
Rear Springs ..... . .359" (sq.) I 77°
Track Type ....... . 15"x136"x1.7512.0" (38.1 x345.44x4.4415.08cm)
Track Tension ..... . 318" -112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diametern7o .359"(sq.) diametern7o .375"(sq.) diametern7o
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.57 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY 700 RMK

MODEL NUMBER: . 099SR7 AS( A)
ENGINE MODEL: . . S70-70-99A3

CARBURETION JETTING CHART

Type ............... . 2-Keihin PWK 39 AMBIENT TEMPERATURE
(ACCS) Altitude Below-20°F ·20" to +10"F +10"to +40"F Above +40°F
Below -29"C -29"to ·12oC -12" to +5"C Above soc
Main Jet ........... . 190
Meters 0-900 200 195 190 185
Pilot Jet ............ . 48 (Feet) (0-3000) #2 #2 #2 #2
Jet Needle ......... . R1368G-2 Air Screw 2 turns Air Screw 2 turns Air Screw 2 turns Air Screw 2 turns

Needle Jet ......... . 2.9x4.6x1.5mm fixed 900-1800 200 195 190 185
(3000-6000) #2 #2
Cutaway ........... . 6.0 Notched #2 #2
Air Screw 1.5 turns Air Screw 1.5 turns Air Screw 1.5 turns Air Screw 1.5 turns
Air Screw .......... . 1.0 Turn 1800-2700 200 195 190 185
Valve Seat ......... . 1.8 (6000-9000) #2 #2 #2 #2
Fuel Octane (R+M/2) 87 Non-Oxygenated or Air Screw 1 tum Air Screw 1 tum Air Screw 1 tum Air Screw 1 tum

89 Oxygenated 2700-3700 200 195 190 185

(9000-12000) #2 #2
Throttle Gap #2 #2
Air Screw 112 turn Air Screw 1/2 tum Air Sere 1/2 turn Air Screw 1/2 turn
Under Cutaway 0.102"- (2.6mm)

~
Idle Sync Gap
Under Cutaway 0.118"- (3.0mm) • # refers to the clip position from top of jet needle.

CLUTCH c=J - Production Setting

Type ................ P-85

Belt. . . . . . . . . . . . . . . . . 3211 065
Belt Width (Projected) . 1.438" (36.53mm)
Side Angle (Overall) . . 28° CLUTCH CHART
Outside Circumference 48.375
DRIVE DRIVEN
Center Distance ...... 12.5" (317.5mm) Altitude Shift Clutch Clutch Driven Chaincase
Shift Weights . . . . . . . . 10-58 Bushed Weight Spring Spring Helix Gearing
Primary Spring . . . . . . . Dark Blue Meters Q-900 10-60 Silver/ R-11 21-41 70 p
Dark Blue
Secondary Spring . . . . Silver/Blue (Feet) (0-3000) Bushed Blue #-2 3/4 HYVO

Driven Helix . . . . . . . . . R-11 #-2 900-1800 10-58

Dark Blue
Silver/ R-11 21-41-70 p
(3000-6000) Bushed Blue #-2 3/4 HYVO

1800-2700 10-58 Silver/ R-11 21-41 70 p

Dark Blue
(6000-9000) Bushed Blue #-2 3/4 HYVO

2700-3700 10-56 Silver/ R-11 21-41 70 p

(9000-12000) Dark Blue
Bushed Blue #-2 3/4 HYVO

ENGINE
Type ................... . Liquid Cooled Case Reed Twin
Displacement ............ . 700cc
Bore .................... . 3.1889" (81mm)
Stroke .................. . 2.6772" (68mm)
Piston I Cylinder Clearance .0043"- .0053"(.11 -.135mm)
Service Limit ............ . .0078" (.20mm)
Piston Marking ........... . EK2108
Piston Ring Marking ...... . "o" faces upward
Piston Ring End Gap ..... . .014"-.020"(.36-.51 mm)
Head cc's (Uninstalled) ... . 40.2cc
Head cc's (Installed) ...... . 32.5cc
Operating RPM±200 ...... . 8000 RPM
Idle RPM±200 ........... . 1500 RPM
Engagement RPM±300 ... . 4200 RPM
Cylinder Head Torque .... . 20ft.lbs(2.8kgm)
Cylinder Base Nut Torque .. 35-40 ft.lbs(4.8-5.5 kgm)
Crankcase Torque (8mm) .. N/A
Crankcase Torque (1 Omm) . 35-40 ft.lbs(4.8-5.5 kgm)
Flywheel Torque ......... . 55 ft.lbs(7.4 kgm)

10/98 1.58 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY 700 RMK

MODEL NUMBER: . 099SR7 AS( A)
ENGINE MODEL: .. S70-70-99A3

ELECTRICAL CAPACITIES
Flywheeii.D ....... Ducati 4010139 Fuel Tank ........... 11.8 ga1.(44.7L)
CDI Marking ....... 4060211 Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 12° BTDC@3000RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.037" BTDC (±0.004")
0.93mm BTDC (±0.22mm)
Operating Timing . . . 16° @ 8250 RPM
Spark Plug I Gap ... Champion RN-2C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR7
Electric Start . . . . . . . Optional
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 21-41, 70 P 314 HYVO
Front Suspension .. RMKCRC Reverse ............ Option
Maximum Width ... . 38.00"(96.52cm) Brake Pads ......... Type 69
Camber .......... . 11 132"±5116"(9±8mm) Chaincase Center Dist. 7.05"(17.91cm)
Toe Out .......... . 318"-112"(9.65mm-12.7mm) Driveshaft Sprockets . 2 Drivers Wide
Front Shocks ..... . Nitrex Brake Type ......... Polaris HPB Liquid Cooled
IFS Spring Rate ... . 100#Iin.
Front Spring Preload 0.13" Thread Adjust
Front Vertical Travel 8.05in.(20.45cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 11.5 in.(29.21cm)
Front Track Shock .. Nitrex
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Indy Select
Rear Springs ..... . .359" (sq.) I 77°
Track Type ....... . 15"x136"x1.7512.0" (38.1 x345.44x4.4415.08cm)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diametern7o .359"(sq.) diameternT .375"(sq.) diametern7o
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.59 10/98

GENERAL
1999 Model Specifications

MODEL: .......... INDY 700 SKS

MODEL NUMBER: . 099SS7 AS
ENGINE MODEL: .. SN70-70-99A1

JETTING CHART
CARBURETION
AMBIENT TEMPERATURE
Type ............... . 2-Keihin PWK 39 Altitude Below -20°F -20° to +10°F +10°tO +40°F Above +40°F
Main Jet ........... . PTO 185/MAG 190 Below-29°C -29"to -12"C -12° to +Soc Above soc
Pilot Jet ............ . #38 Meters 0-900 MAG195 MAG 190 MAG 182 MAG 178
(Feet) (0-3000)
Jet Needle ......... . R1368G-3 PTO 190 PTO 185 PTO 178 PTO 172
#3 #3 #3 #3
Needle Jet ......... . 2.9mm fixed
900-1800 MAG 182 MAG 180 MAG 172 MAG 168
Cutaway ........... . 5.5 (3000-6000) PTO 178 PTO 175 PTO 168 PTO 162
Air Screw .......... . 1.0 Turn #3 #3 #3 #3
Valve Seat ......... . 1.8 1800-2700 MAG 175 MAG 170 MAG 162 MAG 160
Fuel Octane (R+M/2) 87 Non-Oxygenated or (6000-9000) PTO 170 PTO 165 PTO 158 PTO 155
89 Oxygenated #3 #3 #2 #2
2700-3700 MAG 162 MAG 160 MAG 155 MAG 150
Throttle Gap (9000-12000) PTO 158 PTO 155 PTO 150 PTO 145
Under Cutaway .051"- (1.3mm) #3 #2 #2 #2
Idle Sync Gap
Under Cutaway .063" - (1.6mm)
~ - # refers to the clip position from top of jet needle.

c::::J - Production Setting

CLUTCH
Type ................ P-85
BeH ................. 3211065
Belt Width (Projected) . 1.438" (36.53mm) CLUTCH CHART
Side Angle (Overall) . . 28° DRIVE DRIVEN
Outside Circumference 48.375 Altitude Shift Clutch Clutch Driven Chaincase
Center Distance . . . . . . 12.5" (317 .5mm) Weight Spring Spring Helix Gearing
Shift Weights . . . . . . . . 10-60 Bushed Meters 0-900 1060 Silver/ R-11 23-40 70 p
Dark Blue
Primary Spring . . . . . . . Dark Blue (Feet) (0-3000) Bushed Blue #-2 3/4 HYVO

Secondary Spring . . . . Silver/Blue 900-1800 10-58

Dark Blue
Silver/ R-11 23-40-70 p
(3000-6000) Bushed Blue #-2 3/4HYVO
Driven Helix ......... R-11 #-2
1800-2700 10-56 Silver/ R-11 21-41 70 p
Dark Blue
(6000-9000) Bushed Blue #-2 3/4 HYVO

2700-3700 10-54 Silver/ R-11 21-41 70 p

Dark Blue
(9000-12000) Bushed Blue #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed Twin
Displacement . . . . . . . . . . . . . . . 700 cc
Bore ....................... 3.1889" (81mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.6772" (68mm)
Piston I Cylinder Clearance .... 0043"- .0053"(.11 -.135mm)
Service Limit .................0078" (.2mm)
Piston Marking . . . . . . . . . . . . . . EK21 08
Piston Ring Marking . . . . . . . . . "o" faces upward
Piston Ring End Gap .........014"-.020"(.36-.51 mm)
Head cc's (Uninstalled) . . . . . . 40.2cc
Head cc's (Installed) . . . . . . . . . 32.5cc
Operating RPM±200 . . . . . . . . . 8000 RPM
Idle RPM±200 .............. 1500 RPM
Engagement RPM±300 . . . . . . 4200 RPM
Cylinder Head Torque . . . . . . . . 20ft.lbs(2.8kgm)
Cylinder Base Nut Torque .... 35-40 ft.lbs(4.8-5.5 kgm)
Crankcase Torque (8mm) .... N/A
Crankcase Torque (10mm) ... 35-40 ft.lbs(4.8-5.5 kgm)
Flywheel Torque ............ 55 ft.lbs(7.4 kgm)

10/98 1.60 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY 700 SKS

MODEL NUMBER: . 099SS7 AS
ENGINE MODEL: .. SN70-70-99A1

ELECTRICAL CAPACITIES
Flywheel J.D. . . . . . . 4010139 Fuel Tank ........... 11.8 ga1.(44.7L)I10.5(39.7)
CDI Marking . . . . . . . 4060212 Oil Tank ............ 3 quarts (2.8 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing . . . . . 6° BTDC@ 1750RPM±1.5° Chaincase Oil ....... 7 fl.oz(21 Occ)
0.009" BTDC (±0.005")
0.22mm BTDC (±0.1 05mm)
Operating Timing . . . 17° @ 7500 RPM
Spark Plug I Gap ... Champion RN-2C I 0.028" (0.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail ........ 2@3 watts
Brake . . . . . . 18 watts
Voltage Regulator . . LR7
Electric Start . . . . . . . Optional
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAINCASE

Body Style ....... . GenII Sprockets I Chain .... 23-40, 70 P 314 HYVO
Front Suspension .. XTRA-10 CRC Reverse ............ Option
Maximum Width ... . 41.00"(1 04.14cm) Brake Pads ......... Type 69
Camber .......... . 314"±5116"(19.05±8mm) Chaincase Center Dist.7.05"(17.91cm)
Toe Out .......... . 318"-112"(9.65-12.7mm) Driveshaft Sprockets . 2 Drivers Wide
Front Shocks ..... . Nitrex Brake Type ......... Polaris HPB Liquid Cooled
IFS Spring Rate ... . 100#Iin.
Front Spring Preload 0.38" Thread Adjust
Front Vertical Travel 9.30 in.(23.62cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 9.5 in.(24.13cm)
Front Track Shock .. Nit rex
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Indy Select
Rear Springs ..... . .359" (sq.) I 7r
Track Type ....... . 15"x136"x1.25" (38.1 x345.44x3.175cm)
Track Tension ..... . 318" - 112" (9.65-12. 7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diametern7o .359"(sq.) diametern7o .375"(sq.) diametern7o
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.61 10/98

GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . INDY 700 XCR

MODEL NUMBER: . 099AB7BS
ENGINE MODEL: .. EC70PL011

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . .
TM38 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 430 Altitude Below-20°F ·20° to +10°F +10"to +40°F Above +40cF
Pilot Jet . . . . . . . . . . . . .
50 Below-29"C -29oto ·12"C -12° to+5°C Above soc
0-900
Jet Needle .......... 9CG1-54-3 Meters
(Feet) (0-3000)
460 430 400 380
#3 #3 #3 #3
Needle Jet . . . . . . . . . . P-4(825)
900-1800 410
Cutaway . . . . . . . . . . . . 2.0 (3000-6000)
390 370 340
#3 #3 #3 #2
Idle Mixture Screw . . . . 1.5 Turn
1800-2700 370 350 330 310
Valve Seat . . . . . . . . . . 1.5 (6000-9000) #3 #3 #2 #2
Fuel Octane (R+M/2) . Adjustable with 2700-3700 330 310 300 280
key switch (9000-12000) #3 #2 #2 #2
Starter Jet . . . . . . . . . . . 145
Pilot Air Jet . . . . . . . . . . 1.0 ~ - # refers to the clip position from top of jet needle.

c::::J - Production Setting

CLUTCH
Type ................ P-85
Belt ................. 3211075 CLUTCH CHART
Belt Width (Projected) . 1.438" (36.52mm) DRIVE DRIVEN
Side Angle (Overall) . . 28° Altitude Shift Clutch Clutch Driven Chaincase
Outside Circumference 47.625" Weight Sprtng Sprtng Helix Gearing
Center Distance . . . . . . 12" (305mm) Meters 0-900 1058 Silver/ R-12 24-40 68 p
(Feet) Almond
(0-3000)
Shift Weights . . . . . . . . 10-58 Bushed Bushed Blue #-2 3/4HYVO

Primary Spring . . . . . . . Almond 900-1800

(3000-6000)
10-56
Almond
Silver/ R-12 24-40-68 p
Bushed Blue #-2 3/4HYVO
Secondary Spring . . . . Silver/Blue
1800-2700 10-56 Silver/ R-12 22-4068 p
Driven Helix . . . . . . . . . R-12 #-2 (6000-9000) Bushed
Almond
Blue #-2 3/4HYVO

2700-3700 10-54 Silver/ R-12 22-40 68 p

Almond
(9000-12000) Bushed Blue #-2 3/4HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed Triple with VES
Displacement . . . . . . . . . . . . . . . 700 cc
Bore ....................... 2.6614" (67.6mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.5591" (65mm)
Piston I Cylinder Clearance . . . .0027" - .0041 "(.070 -.1 05mm)
Service Limit . . . . . . . . . . . . . . . . .0059" (.15mm)
Piston Marking . . . . . . . . . . . . . . 70A
Piston Ring Marking . . . . . . . . . 70A
Piston Ring End Gap .........012"-.018"(.30-.45mm)
Head cc's (Uninstalled) . . . . . . 25.3cc
Head cc's (Installed) . . . . . . . . . 21.2cc
Operating RPM±200 . . . . . . . . . 8500 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1500 RPM
Engagement RPM±300 . . . . . . 4000 RPM
Cylinder Head Torque ........ 8mm-17-20 ft.lbs, 10mm-24-26 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.62 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: .......... INDY 700 XCR

MODEL NUMBER: . 099AB7BS
ENGINE MODEL: .. EC70PL011

ELECTRICAL CAPACITIES
Flywheel J.D ....... FP9104 Fuel Tank ........... 11.8 ga1.(44.7L)I10.5(39.7)
CDI Marking ....... K7A08 Oil Tank ............ 2.4 quarts (2.3 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 20° BTDC@1750RPM±1.5° Chaincase Oil ....... 7 fl.oz(210cc)
0.098" BTDC (±0.007")
2.476mm BTDC (±0.018mm)
Operating Timing . . . 18° @ 8100 RPM
Spark Plug I Gap ... Champion RN-2CI.028" (.7mm)
Lights: Head . . . . . . Halogen 130111 0 watts
Tail ........ 2@9 watts
Brake ...... 2@18 watts
Voltage Regulator . . LR7
Electric Start . . . . . . . NIA
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Aggressive Sprockets I Chain .... 24-40, 68 P 314 HYVO
Front Suspension .. XTRA-10 CRC Reverse ............ Option
Maximum Width ... . 41.00"(104.14cm) Brake Pads ......... Type 69
Camber .......... . 314"±5116"(19.05±8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out .......... . 318"-112"(9.65-12.7mm) Driveshaft Sprockets . 4 Drivers
Front Shocks ..... . FoxTM IFP Brake Type ......... Liquid Cooled Hydraulic Disc
IFS Spring Rate ... . 120#Iin.
Front Spring Preload 1.063" Thread Adjust
Front Vertical Travel 9.30 in.(23.62cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 10.2 in.(25.91cm)
Front Track Shock .. FoxTM IFP
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. FoxTM IFP
Rear Springs ..... . .359" (sq.) I 77o
Track Type ....... . 15"x121 "x.91" (38.1 x307.34x2.31 em)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diameter/77° .359"(sq.) diametern7o .375"(sq.) diametern7o
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.63 10/98

GENERAL
1999 Model Specifications

MODEL: • . . . . . . . . . INDY 800 XCR

MODEL NUMBER: . 099AB8AS
ENGINE MODEL: .. EC79PL011

CARBURETION JETTING CHART

Type . . . . . . . . . . . . . . . .
TM38 Mikuni AMBIENT TEMPERATURE
Main Jet . . . . . . . . . . . . 450 Altitude Below·20"F ·20" to +10"F +10"to +40"F Above +40"F
Below-29"C -29"to -12"C Above s·c
Pilot Jet ............. 50 -12" to+S"C
Q-900 480
Jet Needle . . . . . . . . . . 9DH6-54-3 Meters
(Feet) (0-3000)
450 420 400
#3 #3 #3 #3
Needle Jet . . . . . . . . . . P-4 Fixed
90Q-1800 440 410 390 370
Cutaway . . . . . . . . . . . . 2.0 (300Q-6000) #3 #3 #3 #2
Idle Mixture Screw . . . . 1.25 Turn
1800-2700 380 360 330 310
Valve Seat . . . . . . . . . . 1.5 (600Q-9000) #3 #3 #2 #2
Fuel Octane (R+M/2) . Adjustable with 2700-3700 350 320 300 280
key switch (900Q-12000)
#3 #2 #2 #2
Starter Jet . . . . . . . . . . . 145
Pilot Air Jet . . . . . . . . . . 1.0 ~ - # refers to the clip position from top of jet needle.

c::J - Production Setting

CLUTCH
Type ................ P-85
Belt . . . . . . . . . . . . . . . . . 3211 075 CLUTCH CHART
Belt Width (Projected} . 1.438" (36.52mm) DRIVE DRIVEN
Side Angle (Overall} . . 28° Altitude Shift Clutch Clutch Driven Chaincase
Outside Circumference 47.625" Weight Spring Spring Helix Gearing
Center Distance . . . . . . 12" (305mm) Meters Q-900 1060
Almond
Silver/ R-12 24-39 68 p
(Feet) (0-3000) #-2 3/4HYVO
Shift Weights . . . . . . . . 10-60 Bushed Bushed Blue

Primary Spring . . . . . . . Almond 90Q-1800

(300Q-6000)
10-58
Almond
Silver/ R-12 24-39-68 p
Bushed Blue #-2 3/4 HYVO
Secondary Spring . . . . Silver/Blue
1800-2700 10-58 Silver/ R-12 23-41 68 p
Driven Helix . . . . . . . . . R-12 #-2 (600Q-9000) Bushed
Almond
Blue #-2 3/4HYVO

2700-3700 10-56 Silver/ R-12 23-41 68 p

Almond
(900Q-12000) Bushed Blue #-2 3/4 HYVO

ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Case Reed Triple with VES
Displacement . . . . . . . . . . . . . . . 794 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 2.8346" (72mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.5591" (65mm)
Piston I Cylinder Clearance .... 0027"- .0041"(.07 -.105mm)
Service Limit .................0078" (.20mm)
Piston Marking . . . . . . . . . . . . . . 79B
Piston Ring Marking . . . . . . . . . 79B
Piston Ring End Gap .........012"-.018"(.30-.45mm)
Head cc's (Uninstalled) ...... 28.7
Head cc's (Installed} . . . . . . . . . 23.9
Operating RPM±200 . . . . . . . . . 8500 RPM
Idle RPM±200 . . . . . . . . . . . . . . 1500 RPM
Engagement RPM±300 . . . . . . 4000 RPM
Cylinder Head Torque ........ 17-20 ft.lbs
Cylinder Base Nut Torque . . . . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) .... 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (10mm) ... 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque . . . . . . . . . . . . 60-65 ft.lbs(8.3-9 kgm)

10/98 1.64 Polaris Industries Inc.

 GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . INDY 800 XCR

MODEL NUMBER: • 099AB8AS
ENGINE MODEL: . . EC79PL011

ELECTRICAL CAPACITIES
Flywheel I. D. . . . . . . FP91 03 Fuel Tank ........... 11.8 ga1.(44.7L)I10.5(39.7)
CDI Marking ....... CU7311 Oil Tank ............ 2.4 quarts (2.3 liters)
Alternator Output . . . 280 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 26° BTDC@3250RPM±1.5° Chaincase Oil ....... 7 fl.oz(210cc)
0.163" BTDC (±0.008")
4.138mm BTDC (±0.021 mm)
Operating Timing . . . 15° @ 8300 RPM
Spark Plug I Gap . . . Champion RN-2CI.028" (.7mm)
Lights: Head . . . . . . Halogen 1301110 watts
Tail ........ 2@9 watts
Brake . . . . . . 2@ 18 watts
Voltage Regulator . . LR7
Electric Start . . . . . . . NIA
*LR7= Full wave voltage regulator

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . Aggressive Sprockets I Chain .... 24-39, 68 P 314 HYVO
Front Suspension .. XTRA-10 CRC Reverse ............ Option
Maximum Width ... . 41.00"(104.14cm) Brake Pads ......... Type 69
Camber .......... . 314"±5116"(19.05±8mm) Chaincase Center Dist.6 518"(16.83cm)
Toe Out .......... . 318"-112"(9.65-12.7mm) Driveshaft Sprockets . 4 Drivers
Front Shocks ..... . Fox""' IFP Brake Type ......... Liquid Cooled Hydraulic Disc
IFS Spring Rate ... . 120#Iin.
Front Spring Preload 1.063" Thread Adjust
Front Vertical Travel 9.30 in.(23.62cm)
Rear Suspension .. . XTRA-10
Rear Travel ....... . 10.2 in.(25.91 em)
Front Track Shock .. Fox""' IFP
Spring Rate ...... . 200#Iin. variable
Rear Track Shock .. Fox""' IFP
Rear Springs ..... . .359" (sq.) I 7?D
Track Type ....... . 15"x121 "x.91" (38.1 x307 .34x2.31 em)
Track Tension ..... . 318"- 112" (9.65-12.7mm) slack with 10# (4.54kg) weight 16" (40.64cm) ahead of rear idler shaft

OPTIONAL REAR SUSPENSION SPRINGS

SOFT MEDIUM(STD) FIRM

.347"(sq.) diametern7o .359"(sq.) diameternr .375"(sq.) diametern7o
L.H 7041627-067 L.H. 7041629-067 L.H. 7041631-067
R.H. 7041628-067 R.H 7041630-067 R.H. 7041632-067

Polaris Industries Inc. 1.65 10/98

GENERAL
1999 Model Specifications

MODEL: .......... WIDETRAK LX

MODEL NUMBER: . 099SU4BS
ENGINE MODEL: . . EC50PL202

CARBURETION
Type ............... . VM34SS JETTING CHART
Main Jet ........... . 195 AMBIENT TEMPERATURE
Pilot Jet ............ . 35 Altitude Below -20°F ·20° to +10°F +10°10 +40°F Above +40°F
Below-29°C -29°tO -12oC -12° to +5°C Above soc
Jet Needle ......... . 6EJ26-2
P-6(166) Meters 0-900 205 195 185 175
Needle Jet ......... . (Feet) (0-3000) #2 #2 #2 #2
Cutaway ........... . 3.0CH
900-1800 190 180 170 170
Air Screw .......... . 0.5 Turn (3000-6000)
#2 #2 #2 #1
Valve Seat ......... . 1.5 1800-2700 175 165 155 145
Fuel Octane (R+M/2) 87 Non-Oxygenated or (6000-9000) #2 #2 #1 #1
89 Oxygenated 2700-3700 155 150 140 135
(9000-12000)
Throttle Gap #2 #1 #1 #1
Under Cutaway .219" - (5.55mm) f""XXxl
Idle Sync Gap ~ - # refers to the clip position from top of jet needle .
Under Cutaway .240" - (6.1 mm)
c=J -Production Setting

CLUTCH
Type ................ P-85
Belt . . . . . . . . . . . . . . . . . 3211070
Belt Width (Projected) . 1.375" (34.93mm)
Side Angle (Overall) . . 28° CLUTCH CHART
Outside Circumference 47.250" DRIVE DRIVEN
Center Distance . . . . . . 12" (305mm) Altitude Shift Clutch Clutch Driven Chaincase
Shift Weights . . . . . . . . 10 Bushed Weight Spring Spring Helix Gearing
Primary Spring . . . . . . . Brown Meters 0-900 10 Brown Silver
36° 19-41 66 p
(Feet) (0-3000)
Secondary Spring . . . . Silver Bushed #-2 3/4 HYVO

Driven Helix . . . . . . . . . 36° #-2 900-1800

(3000-6000)
10
Red/White Silver 36° 19-41-66 p
Bushed #-2 3/4 HYVO

10M 19-41 66 p
1800-2700 36°
Blue Red/White Silver
(6000-9000) #-2 3/4 HYVO
Bushed

10M 19-4166P
2700-3700 36°
White Red/White Silver
(9000-12000) #-2 3/4 HYVO
Bushed

ENGINE

Type ...................... . Liquid Cooled Piston Port Twin

Displacement .............. . 488cc
Bore ...................... . 2.8346" (72mm)
Stroke .................... . 2.3622" (60mm)
Piston I Cylinder Clearance .. . .0023"- .0037"(.06 -.095mm)
Service Limit ............... . .0078" (.20mm)
Piston Marking ............. . 5W
Piston Ring Marking ........ . 51 A
Piston Ring End Gap ....... . .008"-.016"(.20-.40mm)
Head cc's (Uninstalled) ..... . 28.8cc
Head cc's (Installed) ........ . 23.6cc
Operating RPM±200 ........ . 7000 RPM
Idle RPM±200 ............. . 1600 RPM
Engagement RPM±300 ..... . 3800 RPM
Cylinder Head Torque ....... . 8mm-17 -20 ft.lbs, 1Omm-24-26 ft.lbs
Cylinder Base Nut Torque ... . 24-28 ft.lbs(3.3-3.9 kgm)
Crankcase Torque (8mm) ... . 17-18 ft.lbs(2.2-2.3 kgm)
Crankcase Torque (1 Omm) .. . 23-25 ft.lbs(3.2-3.5 kgm)
Flywheel Torque ........... . 60-65 ft.lbs(8.3-9 kgm)
10/98 1.66 Polaris Industries Inc.
 GENERAL
1999 Model Specifications

MODEL: . . . . . . . . . . WIDETRAK LX
MODEL NUMBER: . 099SU4BS
ENGINE MODEL: . . EC50PL202

ELECTRICAL CAPACITIES
Flywheeii.D ....... FP5445 Fuel Tank ........... 11.8 ga1.(44.7L)I10.5(39.7)
COl Marking . . . . . . . CU6417 Oil Tank ............ 2.4 quarts (2.3 liters)
Alternator Output ... 200 Watts Coolant ............. 3 quarts (2.8 liters)
Ignition Timing ..... 28° BTDC@3000RPM±1.5° Chaincase Oil ....... 20 fl.oz(590cc)
0.173" BTDC (±0.0175")
4.40mm BTDC (±0.48mm)
Operating Timing . . . 16° @ 7500 RPM
Spark Plug I Gap ... Champion RN-3CI.028" (.7mm)
Lights: Head . . . . . . Halogen 75160 watts
Tail . . . . . . . . 8 watts
Brake . . . . . . 29 watts
Voltage Regulator . . LR9, LR2
Electric Start . . . . . . . Standard
*LR9= Half wave voltage regulator
*LR2= Rectifier only for battery charging

SUSPENSION I CHASSIS CHAIN CASE

Body Style ....... . GenII Sprockets I Chain .... 19-41, 66 P 314 HYVO
Front Suspension .. 38IFS Reverse ............ Standard Hi/Low
Maximum Width ... . 38.00"(96.52cm) Brake Pads ......... Type 69 Widetrak
Camber .......... . 25132"±5116"(20±8mm) Chaincase Center Dist.NIA
Toe Out .......... . 0-118"(0-3mm) Driveshaft Sprockets . 4 Drivers Widetrak
Front Shocks ..... . Nitrex Brake Type ......... Mechanical Disc
IFS Spring Rate ... . 105#lin.
Front Spring Preload 3 Shims
Front Vertical Travel 7.25 in.(18.42cm)
Rear Suspension .. . Slide Rail
Rear Travel ....... . 9 in.(22.86cm)
Front Track Shock .. Nit rex
Spring Rate ...... . 181#lin.
Rear Track Shock .. Nit rex
Rear Springs ..... . .468" (sq.) /74°
Track Type ....... . 20"x156"x1.0" (50.8x396.24x2.54cm)
Track Tension ..... . 314" - 1" (1.90-2.54cm) slack with 10# (4.54kg)weight 16" 40.64cm) ahead of rear idler shaft

Polaris Industries Inc. 1.67 10/98

CHAPTER 2
MAINTENANCE I TUNE UP

Maintenance Schedule, 500 Mile ............... 2.1

Maintenance Schedule, 1500 Mile .............. 2.2
Recommended Maintenance Products .......... 2.3
Intake Filter .................................. 2.4
Lubrication ................................... 2.5
Water Pump Belt - Domestic ................... 2.6
Water Pump Belt- Fuji ........................ 2.7
Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8-2.9
Suspension Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 2.1 0-2.11
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Track Maintenance/Alignment . . . . . . . . . . . . . . . . . . 2.13-2.17
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Drive Belt Removal/Installation ................. 2.19
Backrest Adjustment .......................... 2.20
Headlight Adjustment ......................... 2.21-2.22
Bulb Replacement ............................ 2.22
Handlebar Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24-2.26
Reverse Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 2.27-2.28
Off Season Storage ........................... 2.29-2.31
Variable Exhaust Systems . . . . . . . . . . . . . . . . . . . . . 2.32-2.34
Routing Diagrams ............................ 2.35-2.71
 MAINTENANCE/TUNE UP
Maintenance Schedule
500 Mile (805 km) Initial Maintenance Inspection

_17a.Brakes-Hydraulic
1. Check cylinder head and base area for signs of exhaust A. Check brake fluid level.
or coolant leaks. B. Check for proper hose routing; tighness of banjo bolts
_2. Re-torque cylinder heads (cold) & cylinder base nuts and line fasteners.
_3. Check ignition timing C. Check for system fluid leaks.
observed BTDC D. Visually inspect pads for wear damage or looseness.
corrected BTDC E. Check security and surface condition of brake disc.
_4. Check clutch offset (belt removed) 17b.Brake-Mechanical
_5. Check belt condition A. Check cable condition I routing.
_6. Check and adjust belt tension B. Check brake pad and brake disc condition and mounting.
_7. Inspect rubber engine mounts C. Adjust brake to proper specifications.
_8. Torque engine mounting plate to chassis fasteners 18. Check auxiliary shut-off switch.
9. Adjust engine torque stop (if equipped) 19. Perform throttle safety switch tests.
10. Carburetor Inspections 20. Check brake light for proper operation.
A. Adjust choke plungers _21. Check tail lights.
B. Adjust pilot air screw _22. Check headlamp fasteners and high-low beam operation.
c. Synchronize carburetor slide valves at idle 23. Liquid cooled models:
and off idle A. Check coolant level and specific gravity.
D. Adjust engine idle RPM B. Check water pump drive belt condition & deflection
E. Adjust throttle lever free play (where applicable).
F. Synchronize oil pump lever C. Check coolant hose, routing and clamps.
G. Inspect choke/throttle cables D. Inspect heat exchangers condition and fasteners.
H. lnpect vent lines for wear or kinking E. Check cooling system for proper coolant circulation.
11. Check ski toe alignment _24. V.E.S. (Variable Exhaust System) - if applicable.
12. Torque and inspect all steering fasteners A. Disassemble and clean components.
13. Torque suspension-to-tunnel mounting bolts ACCS
14. Check rear suspension fasteners for tightness A. Inspect vent lines, clamps.
15. Adjust track tension and align track
16. Remove chaincase cover, flush chaincase, inspect Recommendations
and adjust chain, refill with new chaincase oil.

Polaris Service Technician _ _ _ _ _ _ _ _ _ _ _ _ __ Base Inspection Price _ _ _ _ _ __

Authorized Dealer _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ Parts _ _ _ _ _ _ _ _ _ _ _ __

Date _ _ _ _ _ _ _ _ _ _ __ Labor _ _ _ _ _ _ _ _ _ _ _ _ __

Polaris Industries Inc. 2.1 10/98

MAINTENANCE/TUNE UP
Maintenance Schedule

1500 Mile (2400 km) Maintenance Inspection

1. Check cylinder head and base area for signs of exhaust or _21a. Brakes-Hydraulic
coolant leaks. A. Check brake fluid level.
_2. Re-torque cylinder heads & cylinder base nuts (cold). B. Check for proper hose routing; tighness of banjo bolts and line
_3. Check compression and record readings. fasteners.
_4. Check ignition timing. C. Check for system fluid leaks.
observed BTDC D. Visually inspect pads for wear damage or looseness.
corrected BTDC E. Check security and surface condition of brake disc.
_5. Inspect recoil starter rope .. F. Flush brake fluid and change every two years.
_6. Check drive to driven clutch offset (belt removed). _21b. Brake-Mechanical
_7. Remove clutches, disassemble & inspect all wear A. Check cable conditions I routing.
surfaces. Clean sheaves, repair clutch as necessary, B. Check brake pad and brake disc condition and mounting.
reassemble clutches and torque to specifications.
C. Adjust brake to proper specifications.
_8. Check belt condition.
_22. Check auxiliary shut-off switch & perform throttle safety
_9. Check and adjust belt deflection. switch tests.
_10. Inspect rubber engine mounts. _23. Inspect brake light, taillight, oil light and all electrical accessories.
11. Torque engine mounting plate to chassis fasteners. _24. Inspect Hi!Lo beam operation and aim headlight; check fasteners.
_12. Adjust engine torque stop (if equipped) (0.10"-0.30"). _25. Liquid cooled models:
13 Carburetor Inspections. A. Check coolant level and specific gravity.
A. Adjust choke plungers. B. Check water pump drive belt condition & deflection
B. Adjust pilot air screw. (where applicable).
C. Synchronize carburetor slide valves at idle. C. Check coolant hose, routing and clamps.
and off idle. D. Inspect heat exchangers condition and fasteners.
D. Adjust engine idle RPM. E. Check cooling system for proper coolant circulation.
E. Adjust throttle lever free play. F. Replace recovery line filter: NOTE: Must use correct filter.
F. Synchronize oil pump lever. G. Check coolant recovery line one way check valve (must hold
G. Inspect Choke/Throttle Cables. pressure) where applicable.
H. Inspect vent lines for wear or kinking. H. Pressure test cooling system.
_14. Remove chaincase cover, flush chaincase, inspect. _26. Fan Cooled: Inspect cooling fins and shrouds.
and adjust chain, refill with new chaincase oil. _27. Remove chaincase cover, flush chaincase, inspect chain & sprock-
ets and adjust chain. Inspect chaincase seals.
15. Change primary fuel filter and oil filter.
_28. Check condition of drive shaft and jackshaft bearings. Lubricate
16. Check fuel and oil line condition and routing.
greaseable bearings with Premium All Season grease.
17 Inspect fuel and oil tank vent lines/routing.
_29. Inspect and adjust reverse cable (if applicable).
_18. Inspect airbox fitiair filter. Clean or replace.
_30. Remove ski pivot bushings and lubricate.
19. Change shock oil (Fox) annually before storage.
_31. Inspect ski wear bars.
_20. V.E.S (Variable Exhaust System) - if applicable.
_32. Check camber alignment and lubricate spindles.
A. Disassemble and clean components.
_33. Remove radius rod end bushings, lubricate and reinstall, inspect all
_21. ACCS radius rod ends.
A. Inspect vent lines. _34. Reinstall skis and inspectiadjust toe alignment.
_35. Check handlebar centering and lubricate all steering pivots.
Polaris Service Technician: _ _ _ _ _ _ _ _ _ __ _36. Torque tie rod end bolts and jam nuts.
Authorized Dealer: _ _ _ _ _ _ _ _ _ _ _ _ __ _37. Inspect steering arms and torque bolts. Inspect handlebar bolt
Base Inspection Price: _ _ _ _ _ _ _ _ _ _ __ torque.
Date: Parts: _ _ _ _ Labor: _ _ _ __ _38. Lubricate rear suspension pivot shafts.
_39. Torque suspension mounting bolts and check all rear suspension
fasteners and components.
_ 40. Inspect rear suspension wheels, bearings and hi-fax.
_ 41. Inspect track for damage. Adjust tension and alignment.
For optimum performance and reliability, repeat the above mainte-
nance and inspections annually (preferably before off-season stor-
age) or every 1000 miles, except where noted.

RECOMMENDATION:---------------

10/98 2.2 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Recommended Maintenance Products

Recommended Maintenance Products

ENGINE OIL RETAINING/SEALING PRODUCTS
Part# Description Packaging Part# Description Packaging
{size I quantity) (size/quantity)

2871721 Synthetic 2-Cycle Premium Gold Quarts/ 6 2870652 Fuel Stabilzer 16 oz/ 12
2871722 Synthetic 2-Cycle Premium Gold Gallon I 4 2872280 Fuel Stabilizer 2.5 Gallon I 2
2871723 Synthetic 2-Cycle Premium Gold 16 Gallon Drum 2871027 Corrosion Resistant DiElectric 2 oz
Grease
2871884 Synthetic 2 Cycle Premium Gold 55 Gallon Drum 2871064 T-9 Metal Protectant each
2871098 Premium 2-Cycle Oil (TC-W3) Quart Cans I 12 2870632 Metal Polish 10 oz I each
2871097 Premium 2-Cycle Oil (TC-W3) Gallon I 6 2871076 Battery Tender'" 8 oz
2871240 Premium 2-Cycle Oil (TC-W3) 2.5 Gallon I 2 2870585 Primer N, Aerosol 25 gr I 1
2871566 Premium 2-Cycle Oil (TC-W3) 16 Gallon Drum 2870584 680 Retaining Compound 10cc I each
2871385 Premium 2-Cycle Oil (TC-W3) 30 Gallon Drum 2871949 Threadlock 242 50cc I 10
2871096 Premium 2-Cycle Oil (TC-W3) 55 Gallon Drum 2871950 Threadlock 242 6cc I 12
2871281 Premium-4 Synth. 4 Cycle Oil (OW-40) Quarts/ 12 2871951 Threadlock 262 50cc I 10
2871567 Premium-4 Synth. 4 Cycle Oil (OW-40) 16 Gallon Drum 2871952 Threadlock 262 6cc I 12
2871844 Premium-4 Synth. 4 Cycle Oil (OW-40) Gallon/ 4 2871953 Threadlock 271 6cc I 12
2871818 Premium-4 Synth. 4 Cycle Oil (OW-40) 55 Gallon Drum 2871954 Threadlock 271 36cc I 6
MAINTENANCE PRODUCTS 2871955 Instant Adhesive: Prism 401 3cc I 30
2871326 Carbon Clean Plus 12 oz I 12 2871956 Pipe Sealant 565 50cc I 6
2871478 Premium Synthetic Gearcase Lube 12oz/12 2871957 Silicone, Black RTV 3 oz tube I 12
2871477 Premium Synthetic Gearcase Lube Gallon I 4 2871958 Silicone, Black RTV 11 oz Cartridge/12
2872275 Premium Synthetic Gearcase Lube 2.5 Gallon I 2 2871959 Ultra Blue RTV 3.35 oz I 12
2871280 Chain Case Lubricant Quart/ 12 2871960 Ultra Blue RTV 13 oz Cartridge/12
2870464 Chain Case Lubricant Gallon I 6 2871961 518 Flange Sealant 50cc I 10
2871323 Premium Antifreeze 60/40 Premix Gallon/ 6 CRANKCASE SEALANTS
2871534 Premium Antifreeze 60/40 Premix Quart I 12 2870587 518 Gasket Eliminator 50cc
2870995 Premium Gas Shock Oil Quart I 6 2871557 3 Bond 1215 5oz
2872279 Premium Gas Shock Oil 2.5 Gallon I 2 VALUE PACKS
2870990 Premium Brake Fluid DOT-3 12oz/ 12 2871967 Synthetic Lube Value Pack 4 I Value pack
2870791 Premium Fogging Oil (spray) 12oz/12 2871593 TC-W3 Lube Value Pack 4 I Value pack
2871517 Premium Fogging Oil (liquid with spout) Quart I 12 WAX AND POLISH
2871518 Premium Fogging Oil (liquid) Gallon I 6 2871589 Revival/Detailing Kit 6 I Kit
2871312 Grease Gun Kit (All Season) 3 oz I 4 2871966 Restore polish/scuff remover 12 I 12 oz.
2871322 Premium All Season Grease 3 oz I 24 2871965 Reflect Wax Final Finish 12/12oz.
2871423 Premium All Season Grease 14 oz I 10 2871964 Renew vinyl rubber protector 12/12oz.
2871460 Premium Starter Grease 2 oz I 12
2871592 Barrel Pump (for 16/30/55 gal. drums) Each
2871285 Flex Spout (fits gal. and 2.5 gal. jugs) 25
2870505 Isopropyl 10 oz I 24

Polaris Industries Inc. 2.3 10/98

MAINTENANCE/TUNE UP
Intake Filter
The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check
top of foam filter periodically to remove any accumulation of snow.

Do not operate machine with the intake filters removed. This can cause carburetor icing resulting in poor fuel
economy or carburetor malfunction.

~
' ~
' ~
~~~~ 2
2 ~~

1 3

··~
------
~
'
-:-~/
;
~ - ~/-----
/

~~/
,~J~ 2
\
-----._\
-,,
4

1. Intake Foam Filter 3. Air Plenum

2. Air Intake Box 4. Dash Cowl

Under Hood Air Intake System

The Indy 340, Indy 340 Deluxe, and Indy 340 Tour-
ing are equipped with an under hood air intake sys-
tem which should normally be left open. The door
should be closed and latched above 35° F (2° C) for
maximum performance during warm weather op-
eration. Simply pull the strap out and up to latch the
door. Reverse the procedure to open it.

10/98 2.4 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Lubrication

Lubricate the following fittings with Polaris Premium All Season

grease annually or approximately every 1000 miles (1600 km).
Remove weight from the component being greased to permit
better penetration and flushing of the joint. Ski Spindles and Bushings
• Spindles, left and right.
~
• Rear suspension pivot shafts.
• Lubricate both front ski pivots at fitting as shown using low
temperature grease.
Trailing '97+
• Grease jackshaft and driveshaft (clutch side) bearings.
• Grease steering post support bracket bushings.
@J
Leading Type
Typical Spindle

• Grease center steering arm (bell crank), pitman arm, and idler
arm (where applicable).
Pitman Arm Idler Arm
NOTE: A grease gun kit complete with grease and adaptors is
available to lubricate all fittings on Polaris snowmobiles.

Polaris Premium All Season Grease

14 oz. PN 2871423
Center Steering Arm Bushings
Grease Gun Kit PN 2871312 (Bell Crank)

Jackshaft Bearing Greasing

Loosen driven clutch retaining bolt and pull clutch outward to ex-
pose bearing. Use a point type grease gun fitting to inject grease Grease
through hole in flangette into bearing until grease purges out in-
side or outside bearing seal. Push clutch back onto shaft and re-
place clutch retaining bolt.

Grease Gun Adapter: 2871174

PointType '

Jackshaft Bearing
Driveshaft Bearing Greasing
Inject grease into fitting on speedometer drive adaptor until
grease purges out inside or outside bearing seal.

Driveshaft Bearing Greasing - WideTrak

Jackshaft coupler

··~
,/ _______ Drive shaft~
Ct.- _____
WideTrak

Polaris Industries Inc. 2.5 10/98

MAINTENANCE/TUNE UP
Water Pump

Water Pump Belt Tension - Replace if width is less than .25"

600/700 Domestic Twins (6.35mm). Nominal new width is
.345" (8.75mm).
The water pump belt on all 600 & 700 domestic twins
snowmobile engines should be inspected every 1500
miles. Belts should be inspected by measuring the width
at several locations around the belt. Belt width at any
location should not be thinner than .250" (6.35mm). Re-
place 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 re-
sult. Nominal thickness of a new belt should be approxi-
mately .345" (8.75mm).
Check belt tension by rotating crankshaft 1/8 turn at a
time. The tension should be equal at all points of rota-
tion.

1. A weight is needed to test belt deflection. Construct a

weight out of wire and weights such as thick washers.
Use the illustration to assist you . The finished weight
should weigh 2 lbs. Weight Construction

2. Measure the belt deflection using the following

procedure:
I
a. Hang weight midway between pulleys. Weight I ~
I .062" to .090"
must hang free and not rest on any part of ma- Wire Suggested
chine.
Wide Enough
b. Lay a straight edge or straight piece of stiff materi- to Span Belt
al (steel is suggested) across the top of both pul-
leys. The straight edge should measure approxi-

c.
mately 1/8" x 8" x 1".

Measure the gap between the belt and the

3J
Weight should equal 2 lbs.
straight edge at the point where the weight is
hanging.
Hang Weight Here
d. Measured distance must be between .1" and
.25". If the measured distance is more than the
specification, try another waterpump belt.
NOTE: Do not use tools to assemble belt on pulleys.
Damage can occur which could shorten belt life. Before
installing new belt, check pulley teeth, remove all foreign
material, dirt, and oil. Never install a used belt on a differ-
ent engine. Install belt so writing on the belt can be read
from the right side of the machine.

10/98 2.6 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Water Pump

Water Pump Belt Tension- Fuji

Loosen pump mounting bolts.Push on pump housing to
apply tension to belt and hold in this position. Tighten
pump mounting bolts.Apply light pressure at center of
belt span. Check total deflection of belt span and
compare to specifications. Re-adjust if necessary.

Water Pump, Belt .Tension

1/8"- 3/16"

Oil Pump Adjustment

Refer to Page 3.83 for oil pump adjustment procedure.

Polaris Industries Inc. 2.7 10/98

MAINTENANCE!TUNE UP
Chaincase
Chaincase Oil Level (All Except WideTrak Models)
The Indy models have a silent chain design. The drive chain is contin-
uously immersed in oil. Proper 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 to maintain proper level. Use Polaris syn-
thetic chaincase oil. Do not overfill.

Polaris Synthetic Chaincase Lubricant

Gallon PN 2871477
12 oz. PN 2871478

E---~
Magnetic Plug
Ill. 1
Polaris Synthetic Chaincase Lubricant is compatible with our petro-
leum 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 - Chaincase cover on

To obtain correct chain tension:
1. Elevate rear of machine so track is off floor.

2. Loosen locknut and chain adjuster.

3. Back off adjuster bolt 1/2 turn. (For models with reverse, back off adjuster bolt 1 1/4 to 1 1/2 turns)

4. Hold adjuster bolt in position and tighten locknut.

Drive Chain Tension - Chaincase cover removed

To obtain correct chain tension:
1 . Remove drain plug (F) and drain oil into a suitable container.
Dispose of properly.
2. Remove the chaincase cover.
3. 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 em) deflection on the chain at point (B). Refer to illlustration 1.
4. The chain is adjusted by loosening the adjusting bolt locknut (C) and turning adjusting bolt (D) until correct
chain deflection is obtained.
5. Lock the adjusting bolt locknut (C) while holding a wrench on the adjusting bolt (D) to prevent it from turning.
6. Reinstall the chaincase cover and drain plug. Add Polaris synthetic chaincase lubricant (PN 2871478)
through the dipstick opening to the level described above.
NOTE: Clean the magnetic plug (E) every 500 miles (800 km) and whenever checking or changing lubricant.

10/98 2.8 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Chain case

Chaincase Oil Level (WideTrak Models)

Using Polaris Synthetic Chaincase Lubricant, maintain the proper oil
level. Proper oil level is determined by checking the level on the dip-
stick (A) with the machine placed on a level surface. The oil level
should be between the "safe" marks on the dipstick. Add oil through
the dipstick opening to maintain proper oil level. Do not overfill.
NOTE: Clean the magnetic plug (B) every 500 miles (800 km) and
whenever checking or changing lubricant.

Polaris Synthetic Chaincase Lubricant

Gallon PN 2871477
12 oz. PN 2S71478

~
B

Polaris Synthetic Chaincase Lubricant is compatible with our petro-

leum 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.

Polaris Industries Inc. 2.9 10/98

MAINTENANCE!fUNE 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
before summer storage each year. The riding characteristics of the snowmobile will be affected by lack of lubrica-
tion of these shafts. NOTE: A grease gun kit complete with grease and adaptors is available to lubricate all fittings
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.

* LUBRICATION POINTS - WideTrak

Grease all fittings

* *

-
Forward

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

*(Both Sides)
*
~rward

10/98 2.10 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Suspension Lubrication
Suspension Lubrication

XTRA 10 Style

Grease at fittings

* LUBRICATION POINTS
*
*

* *
*
-
Forward

*
XTRA 12 Style

Grease at fittings

* LUBRICATION POINTS

*
-
Forward *
(Both sides)

*
Polaris Industries Inc. 2.11 10/98
MAINTENANCE/TUNE UP
Cooling System
A 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 between the minimum and maximum levels to
prevent overheating and serious engine damage.
Recommended Coolant
Use a 50/50 or 60/40 mixture of antifreeze and distilled water depending on the freeze protection required for your
area. Do not use tap water in the system or reduced cooling or filter contamination may result. Replace coolant
every 2 years or if contaminated. Inspect coolant filter annually for contamination and replace if necessary.
COOLANT
0 Check Valves - tapered
somE side points in flow direction

' ' __.- Check Valve

\ Flow
Filter
Filter - Filter is located before the check valve

Bleeding the Cooling System - Pressure Caps

If the cooling system should become low in the tank and/or
filler neck, the system should be bled of any trapped air us- Lift Lock Lever To Bleed

~
ing the following procedure: Remote Filler Neck
1. Allow the system to cool completely. Fill the reseNoir Bleed at 600 RPM
with coolant to the maximum indicated mark. Filler Neck On
2. With pressure cap removed, add coolant and fill to the I Cylinder Head
top of the filler neck. Bleed at fast idle
3. Install the pressure cap with the lever lock up in its f1 Caution:
~
release position and run the engine at fast idle for two
Increase RPM
to three minutes. This will purge the system of trapped
slowly when lever

J
air. Close the lever lock and check recovery tank fluid
lock is up to avoid
level. CAUTION: On models equipped with remote .. loss of coolant.
filler neck, low idle RPM must be used for bleeding
(600 RPM ± 100) to allow all air to purge and prevent Remote Filler Neck Shown
trapped air which can lead to overheating. Reset idle
to specified RPM after bleeding.
Bleeding the Cooling System - Surge Tanks
If the cooling system should become low in the surge tank, Manifold Bleed Screw
the system must be bled of any trapped air using the fol-
lowing procedure:
1. Allow the system to cool completely. Fill the surge tank
with coolant to the maximum indicated mark.
I
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.
3. Loosen the bleed screw at the end and top of the water
outlet manifold until trapped air has been purged.
Tighten the bleed screw.
4. Recheck the surge tank coolant level and add coolant Fill Surge Tank
again if necessary.

10/98 2.12 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Track Maintenance/Alignment
A WARNING

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

Never make this maintenance check with the engine running as se-
rious personal injury can result. 2 1 3 1 2
Using a hoist, safely lift and support the rear of the snowmobile off
the ground. Rotate the track by hand to check for any possible dam-
age.
To inspect track rods, carefully examine the track along the entire
length of each rod, bending the track and inspecting for breakage.
The three most common places where breakage occurs are shown
in the illustration.
If any rod damage is found, the track should be replaced.
A WARNING

Broken track rods are a serious hazard, since they can cause a ro- Lug Track window
tating track to come off the machine. Never operate or rotate a torn
or damaged track under power. Serious personal injury or death
may occur.

Track Alignment
Track alignment affects track tension. Misalignment will cause ex-
cessive wear to the track and slide rail.
A periodic check should be made to see that the track is centered
and running evenly on the slide rails. Misalignment will cause ex-
cessive wear to the track and slide rail. NOTE: If excessive hi-fax
wear occurs due to poor snow conditions, additional wheel kits are
available.
1. Safely support the rear of the machine with the track off the
ground.
2. Start the engine and apply a small amount of throttle until the
track turns slowly at least five complete revolutions. Stop the
engine.
3. Inspect track alignment by looking through the track window to Looking through
track window,
make sure the rails are evenly spaced on each side. If the track
make sure the
runs to the left, loosen left locknut and tighten the left adjusting rails are evenly
bolt. If the track runs to the right, loosen right locknut and Hi-fax
spaced on each
tighten the right adjusting bolt. side.
4. After adjustments are complete, be sure to tighten locknuts and
idler shaft bolts. Torque to specification.

Idler Shaft Bolt Torque -

35-40 ft.lbs. (4.8 • 5.5 kgm)

Idler
Shaft Bolt

Polaris Industries Inc. 2.13 10/98

MAINTENANCE/TUNE UP
Track Maintenance/Adjustment
Track Tension Data

Suspension Weight Measurement Location Measurement

XTRA 12 121" none 2" behind rail bumper 1/2" (1.3 em)
free hanging
XTRA 12 133" none 16" ahead of rear idler shaft 1-1 1/8" (2.5- 2.9 em)
free hanging
XTRA 10 121", 133", 136" 10 lbs. (4.54 kg) 16" ahead of rear idler shaft 3/8- 1/2" (1 - 1.3 em)
WideTrak 10 lbs. (4.54 kg) 16" ahead of rear idler shaft 3/4- 1" (1.9- 2.5 em)
XTRA Lite 121" and 133" 10 lbs. (4.54 kg) 16" ahead of rear idler shaft 3/8 -1/2" (1 - 1.3 em)
XTRA Lite 136" 10 lbs. (4.54 kg) 16" ahead of rear idler shaft 3/8- 1" (1 -2.5 em)

A WARNING

When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal
injury.

Track Tension - XTRA Lite Style

1. Turn the machine off.
2. Lift the rear of the machine and safely support it off the
ground.
3. Place a 10 lb. (4.5 kg) weight on the track at a point
approximately 16" (40.6 em) ahead of the center of the
rear idler wheel.
4. Check for proper slack between the inside of the track clip
wear surface and the hi-fax (C). NOTE: Measure at the
point where the weight is hanging.

XTRA Lite 121" and 133"-

Track
3/8- 1/2" slack (1 - 1.3 em) w/10
lb. (4.54 kg) weight 1 0 lb. Weight
(4.5 kg)
XTRA Lite 136"- 3/8-1"(1-2.5 em)
w/10 lb. (4.54 ka) weiaht

If the track needs adjustment:

5. Loosen rear idler shaft bolts (D) on both sides of the machine.
6. Loosen track adjusting bolt locknuts (A).
7. Tighten or loosen the track adjusting bolts (B) evenly as necessary to obtain proper track tension.
8. Tighten idler shaft bolts and adjuster 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.

10/98 2.14 Polaris Industries Inc.

 MAINTENANCEfTUNE UP
Track Maintenance/Adjustment

A WARNING

When performing the following checks and adjustments, stay clear

of all moving parts to avoid serious personal injury.

Track Tension - WideTrak LX

Tension adjustments should be made only after the track is
warmed up and limber.
1. Turn the machine off.
2. Lift the rear of the machine and safely support it off the
ground.
3. Place a 10 lb. (4.5 kg) weight on the track at a point
approximately 16" (40.6 em) ahead of the center of the
rear idler wheel.
4. Check for 3/4-1" (1.9-2.5 em) slack between the inside of
the track clip and the plastic hi-fax (C). 10 lb. Weight
(4.5 kg)
NOTE: Measure at the point where the weight is hanging .

.
WideTrak LX Track Tension -
314 -1" slack (1.9 • 2.5 em)
w/1 0 lb. (4.54 kg) weight

If the track needs adjustment:

5. Loosen rear idler shaft bolt (D).
6. Loosen locknuts (A).
7. Tighten or loosen the track adjusting screws (B) 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.

Polaris Industries Inc. 2.15 10/98

MAINTENANCE/TUNE UP
Track Maintenance/Adjustment

,A WARNING

When performing the following checks and adjustments, stay clear

of all moving parts to avoid serious personal injury.

Track Tension - XTRA 10 Style

1. Turn the machine off.
2. Lift the rear of the machine and safely support it off the
ground.
3. Place a 10 lb. (4.5 kg) weight on the track at a point
approximately 16" (40.6 em) ahead of the center of the
rear idler wheel (D).
4. Check for 3/8-1/2" (1-1.3 em) slack between the inside of
the track clip and the hi-fax (C). NOTE: Measure at the
point where the weight is hanging.

XTRA 10 121",133n, & 136"StyleTrack

Tension -318- 1/2" slack (1 - 1.3 em)
Track
w/10 lb. (4.54 kg) weight
10 lb. Weight
(4.5 kg)

If the track needs adjustment:

5. Loosen rear idler shaft bolts (D) on both sides of the
machine.
6. Loosen track adjusting bolt locknuts (A).
7. Tighten or loosen the track adjusting bolts (B) evenly as
necessary to obtain proper track tension.
8. Tighten idler shaft bolts and adjuster bolt locknuts.

Always inspect track alignment after track tension adjustment.

NOTE: Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail.
Excessive Hi Fax wear will appear on units with track tension set too tight.

10/98 2.16 Polaris Industries Inc.

 MAINTENANCE!TUNE UP
Track Maintenance/Adjustment

A WARNING

When performing the following checks and adjustments, stay clear

of all moving parts to avoid serious personal injury.

Track Tension - XTRA 12 Style

1. Turn the machine off.
2. Lift 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.
Rear
idler
shaft
bolt
XTRA 12 Style Track Tension -
121" 1/2" (1.3 em) free hanging Rail bumper
133" 1 - 1 1/8" (2.54 - 2.86 em) free
hanging

If the track needs adjustment:

4. Loosen rear idler shaft bolts on both sides of the machine.
5. Loosen track adjusting bolt locknuts.
Track
6. Tighten or loosen the track adjusting bolts evenly as measured 16"ahead
necessary to obtain proper track tension. Hi-fax of rear idler center
7. Tighten idler shaft bolts and adjuster bolt locknuts.

Always inspect track alignment after track tension adjustment.

NOTE: Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail.
Excessive Hi Fax wear will appear on units with track tension set too tight.

Polaris Industries Inc. 2.17 10/98

MAINTENANCE!TUNE UP
Spark Plugs
Spark Plug Selection
Original equipment parts or their equivalent should always be used. However, the heat range of spark plugs is
of utmost importance. A spark plug with a heat range which is too high will cause engine damage. A spark plug
with a heat range which is too low will cause excessive fouling and malfunction.

In selecting a spark plug heat range for production, a manufacturer is forced to assume that the engine is going
to be operated under extreme heavy duty conditions. This protects the engine from internal damage in the event
that the purchaser actually does operate the engine in this manner. This selection however, could cause the cus-
tomer who normally operates the engine under medium or light duty to have spark plug failure.

A plug with a heat range which is too high will always cause engine damage if the engine is operated in conditions
more severe than that for which the spark plug was intended.

A new engine can cause temporary spark plug fouling even though the heat range is correct, due to the preserva-
tive which has been added 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 spark plugs.

NOTE: Incorrect fuel mixture can often cause a spark plug to appear to be too dark or too light in color. Before
changing spark plug heat ranges, be sure the correct main jet is installed in the carburetor(s).

The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be
read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color.

Normal
The insulator tip is gray, tan, or light brown. There will be a few combustion deposits. The electrodes are not
burned or eroded. This indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper
spark plug or incorrect carburetion adjustments.

Wet Fouled
The insulator tip is black. A damp oily film covers the firing end. There may be a carbon layer over the entire
nose. Generally, the electrodes are not worn. General causes are excessive oil, use of non-recommended injec-
tion oil, excessive idling, idle too low or too rich, or weak ignition output.
1. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the
electrodes.
2. Clean with electrical contact cleaner or a glass bead spark plug cleaner only.

A wire brush or coated abrasive should not be used.

3. Measure gap with a wire gauge and adjust to specifications by bending side electrode carefully.
4. Coat spark plug threads with a small amount of anti-seize compound.
5. Install spark plug and torque to specification.

Spark Plug Torque:

11 Ft. Lbs (1.52 kg-m)

10/98 2.18 Polaris Industries Inc.

 MAINTENANCE!TUNE UP
Drive Belt Removal/Installation

Drive Belt

A WARNING

Inspect the condition of the drive belt. Inspect clutch sheaves for damage, wear, or belt residue. Clean with non-oil
base cleaner such as isopropyl alcohol.
To ensure satisfactory belt life, install belts so they operate in the same direction of rotation. Position the identifica-
tion 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
Removal
stop. Remove the retaining knob or pin and open the clutch
guard.
2. Apply brake (or lock parking brake if so equipped).
3. 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.
Belt Installation
1. Drop the drive belt over the drive clutch and pull back the slack.
2. Turn the driven clutch moveable sheave clockwise while at the
Installation
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 retaining knob or pin. 1.

Belt Inspection

5. Refer to PVT Section for belt inspection and width

measurement.
6. 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.

7. Replace belt if worn past the service limit. Belts with thin
spots, burn marks, etc., should be replaced to eliminate
noise, vibration, or erratic operation. See
Troubleshooting Chart at the back of this chapter for
possible causes. NOTE: If a new belt is installed, check
belt deflection. Install so part numbers are easily read.
Refer to the specification charts for belt specifications and
measurement procedures.

Polaris Industries Inc. 2.19 10/98

MAINTENANCE/TUNE UP
Backrest Adjustment

Backrest Adjustment
The passenger backrest on the
Classic Touring and XLT Touring
Backrest Cushion
Models is adjustable. To move the
Adjuster
backrest forward or backward, lift
the adjustment lever on the left
side. Backrest Cable
Wind Deflector Adjuster
To lengthen or shorten the back-
rest cable, lift the cable until spring
tension is felt and lock the jamb
nut. Backrest -------+;.+="'--6f;
When adjusting the backrest from Adjustment
a passenger position to a single Lever
rider position, rotate the backrest
cushion adjustment knobs until
the proper angle is reached.
The grab bars have five height ad-
justments. To raise or lower the Grab Bar Adjustment
Knob
grab bar, remove the grab bar ad-
juster knob, position the grab bar
at the desired height, and reinstall
the knob.
The Classic Touring and XLT Tour-
ing models are also equipped with
passenger handwarmers. The
handwarmer switch, located un-
der the left hand wind deflector,
has three settings: high, off, and
low.

10/98 2.20 Polaris Industries Inc.

 MAINTENANCEfrUNE UP
Headlight Adjustment - Gen II, Indy 340, and Evolved Style Models

Headlight Adjustment
The headlight can be adjusted for vertical aim using the following pro-
cedure:
1. Place the snowmobile on a level surface with the headlight
25' (7.6 m)
approximately 25' (7.6 m) from a wall.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall.
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

adjustment knob located inside the hood just below the headlamp
opening. Turn knob in or out as needed for proper aim.

Removing the Center Bulb ~bdU

~-
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 Headlight Adjustment Knob
harness.

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
Wire a1
lamp. H~ss ~/~~
1.
2.
Hold bulb by metal base only and install into wire harness.
Insert bulb into housing.
~r ""'b
Spring
3. Push spring down until it is secured by spring retainer.
4. Verify headlight aim.
Removing the Side Bulbs
1. Disconnect terminal from back of bulb.
2. 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 headlight operation.

Polaris Industries Inc. 2.21 10/98

MAINTENANCE!TUNE UP
Headlight Adjustment - Aggressive Style Models

Headlight Adjustment
The headlight can be adjusted for vertical aim using the following proce-
dure:
25' (7.62 m)
1. Place snowmobile on a level surface with headlight approximately 25'
(7.6m) from a wall.
2. Measure distance from floor to center of headlight and make a mark
on the wall.
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 em) below the mark placed on the wall in Step
2. NOTE: Rider weight must be included on the seat.

5. If necessary, headlight aim can be adjusted by inserting a Phillips

screwdriver into the boss in the top of the console and turning the
screw until correct adjustment is achieved.

Removing the Bulb

1. 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 Insert screwdriver into access
housing. hole and turn screw to adjust
4. Grasp bulb by metal base and carefully separate bulb from harness.

~~
Installing the Bulb
1. Hold bulb by metal base and install into wire harness.

I ~--: I
B"lb
2. Insert bulb into housing.
3.
4.
Carefully flip spring back into housing placing it around wire harness.
Push spring down until it is secured by spring retainer.
W Spring
Wire
Harness

5. Verify headlight aim.

Taillight Bulb Replacement
1. Remove (5) Phillips screws from taillight lens. Lens

2. Working from front to back, carefully pry lens away from seal and
remove lens.
3. Pull bulb straight out from socket and insert new bulb.
4. Reinstall lens.

10/98 2.22 Polaris Industries Inc.

 MAINTENANCE!TUNE UP
Handlebar Adjustment
Handlebar Adjustment - Evolved and Aggressive Style 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 mm) wrench, 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 fully to the left or right.
4. Torque the handlebar adjuster block bolts to specification.
Maintain an equal gap on front and back of block.
5. Replace console cover.
Bottom of Adjuster Block

Handlebar Adjustment - All Other Models

1 . Remove handlebar cover.
Socket Screws
2. 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
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 to specification.
Maintain an equal gap on front and back of block.
5. Replace handlebar cover.

Handlebar Adjuster Block Bolt ,Torque-

i .
i'

11 ·13 ft.lbs~ (1.5 -1.8 kgm)

A WARNING

Improper adjustment of the handlebars, or incorrect torquing of the

adjuster block tightening bolts can cause limited steering or loosen-
ing of the handlebars, resulting in loss of control.

Polaris Industries Inc. 2.23 10/98

MAINTENANCE/TUNE UP
Brakes

Replenishing Brake Fluid

Remove brake fluid master cylinder reservoir cover. Add Polaris
brake fluid as required to bring the level up to the top of the fluid
level mark on the inside of the reservoir (B). The proper fluid level 1/4-5/16"
(.6-.8 em) B
is 1/4-5/16" (.6-.8 em) below the lip of the reservoir opening.
NOTE: On some models, the brake fluid level can be seen
through the plastic reservoir. The fluid should be maintained be-
tween the minimum and maximum marks on the reservoir for
those models.

Inspect the reservoir to be sure it contains the correct amount of

fluid. Use only Polaris DOT 3 high temperature brake fluid.
Change fluid every 2 years or whenever the fluid is dark or con-
tamination is suspected.

Master Cylinder Fluid level Polaris DOT 3 High Temp Brake Fluid

1/4- 5/16" (.6- .8 em) below lip of PN 2870990

reservoir opening

A 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 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.

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to re-
move air from the system.
1. Remove brake fluid master cylinder reservoir cover and gasket.
CAUTION: Brake fluid is a hazardous material. Contact with decals, paint, and many plastics will cause damage.
Use proper precautions when handling brake fluid.
2. Fill the master cylinder reservoir (B) and replace gasket and cover. Keep the fluid level 1/4-5/16" (.6-.8 em)
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 container.

A 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 bleeder valve
(A) 3/4 of a turn to release air.
5. Close bleeder valve first and then release brake lever.
Repeat steps 4 and 5 until fluid 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 reservoii as lev-
el as possible to minimize the possibility of air entering the system.

10/98 2.24 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Brakes

Brake Adjustment - Mechanical Disc Brakes

If excessive brake lever to brake block clearance is evident, the caliper adjuster should be adjusted using the
following method.

A 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 could result in severe injury or death.

Caliper Adjustment
1. Bend locking tab (A) away from lock nut (B) and loosen
lock nut.
2. Push down on actuating lever (C) and insert a .015" feeler
gauge between the brake disc and outer brake pad.
3. Turn adjusting bolt (D) in until a slight pressure is felt
against the feeler gauge.
4. While holding adjusting bolt (D), tighten locknut (B).
5. Bend locking tab (A) against locknut.

A WARNING

Be certain locking tab is correctly positioned in actuating lever.

After locknut is tightened, check pad to disc clearance to be
certain there is .015" clearance.
Be certain brake pads are not dragging on disc and brake lever
travel is not excessive.
Improper brake adjustment could result in brake failure which
could result in severe injury or death.

Brake Pad to Disc Clearance -

.015" (.38 mm)

.015" Feeler Gauge

NOTE: Replace pads when worn beyond service limit.

Minimum Pad
Thickness
Brake Pad Thickness - Type M3 .250"
shown. (6.35mm)
Service Limit .250" (6.35mm)
(All brake pads)

Polaris Industries Inc. 2.25 10/98

MAINTENANCEffUNE UP
Brakes

WT-2 Brake Adjustment

1. Check to ensure floating parts move freely and that Lock
all other parts are mounted securely. Tighten Nuts
hardware as required.
2. Check actuator linkage to ensure there is adequate
freedom of movement for positive brake operation.
Periodic adjustment of pad gap can be performed
using actuating cable.
3. Loosen lock nuts.

Move cable up or
down in bracket
to adjust freeplay

4. To increase brake lever free play turn nuts

counterclockwise to move cable down in bracket.
To decrease lever free play move cable up in
bracket. Tighten lock nuts.

Brake Lever Free Play

1/4-318 in. (6-10mm)

5. If cable adjuster has reached maximum (used up),

the lever arm can be re-indexed. Loosen lock nuts 1/4-3/8" (6-10 mm)
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.

C~;m~p
M~hing
6. Slip long leg of lever spring off caliper and rotate to
the side.
Spring
7. Rotate the lever one tooth in the direction opposite

~)J ; ~
the actuation direction, and tighten bolt making
sure spline teeth are properly engaged.
Lever S pnng
.
8. Bend up a tab aligning with one of the bolt head flats 00

9.
to prevent bolt rotation.
Return the spring to its original position on the
caliper. Both lever and linkage must be free to
o~'\Lifter Balls

return to original position. ....-; ~ ~ Separator

10. Perform steps 3. and 4. to adjust lever freeplay. ~ \ ~ Plate
11. Verify proper brake operation. Disc should rotate ~-~ <::J.
freely without drag. Tab Washer ~
12. Check disc surface condition. Refer to Brake/Final
Drive section to inspect disc and pad condition and
thickness.

10/98 2.26 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Reverse Kit Maintenance
Adjustment
Due to break-in or replacement of components, the re-
verse shift mechanism may require adjustment.
Shift Lever
GenII Style

1. Loosen jam nuts on linkage rod (A).

Clevis Pin
2. Turn the threaded linkage rod (B) to lengthen or

3.
shorten the throw until reverse engages fully.
Tighten jam nuts and re-check adjustment.
J
+--- Shift Lever
Actuator

Evolved and Aggressive Style

1. Lift shift lever slowly while observing shift arm on

transmission.
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.
3. Loosen jam nuts on lower end of cable.
Chaincase Cover Assembly
4. Adjust cable end at transmission until the end of the
Gen II Models
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.
5. Tighten jam nuts and re-check adjustment.

Reverse Cable End Play -

1-1 1/2" (2.5-3.8
1/32" (.08 em) em)
free play

Reverse Shift Lever Freeplay-

1 - 1 1/2" (2.5 - 3.8 em) measured at

end of shift lever

Evolved/Aggressive

Polaris Industries Inc. 2.27 10/98

MAINTENANCE/TUNE UP
Reverse Kit Maintenance
Adjustment
Due to break-in or replacement of components, the re-
verse shift mechanism may require adjustment. Adjust
with the shifter in the forward position.
Indy 340 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.

Reverse Cable End Play -

1/32" (.08 em)

1/32" Adjustment
(.08 em)
Reverse Shift Lever Freeplay-

1 - 1 1/2" (2.5 - 3.8 em) measured at

end of shift lever

10/98 2.28 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Off Season Storage

Cleaning And Preservation Of Hood, Chassis And Trim

Proper storage starts by cleaning, washing and waxing the hood, chassis, upholstery and plastic parts. Clean and
touch up with paint any rusted or bare metal surfaces. Ensure that all corrosive salt and acids are removed from
surfaces before beginning preservation with waxes and rust inhibitors (grease, 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 full capacity. Remove and store the battery in a cool dry
place.
The machine should be stored in a dry garage or shed out of the sunlight and covered with a fabric snowmobile
cover. Do not use plastic to cover the machine; moisture will be trapped inside causing rust and corrosion
problems.

Controls And Linkage

All bushings, spindle shafts and tie rod ends should be coated with a light coat of oil or grease. Throttle controls
and cables should be lubricated with Polaris Cable Lubricant. Force a small amount of lubricant down cables.

Polaris Cable Lubricant

PN 2870510

Electrical Connections

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 electrical wire and connectors.

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
applied onto the rollers and weight pins. All lubrication applied as a rust preventative measure must be cleaned off
before installing belt for service and operating machine.

Chaincase Lubricant

Change chaincase lubricant as outlined in this section. Remove the outer cover and clean the chaincase
thoroughly.

Polaris Industries Inc. 2.29 10/98

MAINTENANCE/TUNE UP
Off Season Storage

Lubrication

Refer to page 2.6-2.11 for complete lubrication information.

To prevent corrosion, always grease jackshaft and drive

shaft (clutch side) bearings with premium all season Grease
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 Jacks haft
Ill. 1
speedometer drive adaptor until grease purges out Bearing
inside or outside bearing seal. Lubricate both front ski
pivots at bushings and spindles. See 111.1 and 2. Grease

Polaris Premium All Season Grease

PN 287142314 1/2 oz.

111. 2
Driveshaft
Bearing
®
Located on left side
of machine (clutch side)

Grease Gun Adapter: 2871174

Point Type

Use T-9 Metal Protectant (or equivalent) on shock

absorber shafts to help prevent corrosion.

T-9 Metal Protectant

PN2871064

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 off the ground to allow
free hanging of track.

10/98 2.30 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Off Season Storage

Engine and Carburetor

Fog engine with Polaris Fogging Oil (aerosol type)
according to directions on can. On models with carburetor
vacuum fittings the fogging oil can be sprayed through the
fitting.

If you choose not to use Polaris Fogging Oil perform the

following procedure: Support front of snowmobile so
engine is level or tilted slightly rearward. Remove spark
plug(s). Rotate piston to BDC and pour approximately two
ounces (16 ml) Polaris 2-Cycle Injector oil into the cylinder.
NOTE: Allow ample time for oil to flow from top of piston
down transfer ports and onto crankshaft bearings before
proceeding to next cylinder. Turn engine over several
times to insure coverage of piston rings, cylinder walls and
crankshaft bearings. See photo at right.

I. Polaris Fogging Oil PN 2870791

1

I· Carbon Clean PN 2871326

Treat the fuel system with Polaris Carbon Clean.

If Polaris fuel system additive is not used, fuel tank, fuel

lines, and carburetor should be completely drained of gas-
oline. To eliminate any fuel remaining in the carburetor,
run the engine until it stops.

Battery

Disconnect and remove battery. Fill with distilled water. Clean terminals and cables. Apply dielectric grease.
Charge until specific gravity is t least 1.270 (each cell). If machine is to be stored for one month or longer, fill and
charge battery monthly using Polaris Battery Tender, or a 1 amp trickle charger to maintain at 1.270 specific gravity.

··Polaris Battery Tender

PN 2871076

Exhaust System
At approximately 2000 miles, or in preparation of off season storage, it is a good idea to check the exhaust system
for wear or damage. To inspect, allow the 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 or damper/sup-
port grommets.

A WARNING

Exhaust system temperatures can exceed 900° F (500° C). Serious burns may occur if this inspection is per-
formed without allowing adequate time for the exhaust system to cool. Never perform this procedure with the
engine running.

Polaris Industries Inc. 2.31 10/98

MAINTENANCEfTUNE UP
Variable Exhaust System

Variable Exhaust System (V.E.S.)

Some snowmobiles are equipped with the Polaris (patent pending) Variable Exhaust System (V.E.S.)

This unique exhaust valve management system changes the effective exhaust port height in the cylinder to pro-
vide maximum horsepower at high RPM without sacrificing fuel economy and engine torque at low to midrange
throttle settings .
.-----------------------------------------------------,

LOW RPM POSIT!ON7

Piston

Housing
Exhaust Valve
EXHAUST
PORT

CYLINDER
Fig. 1

*This is a representation only. Your model may differ.

In order to understand the operation and function of the V.E.S. we must first consider the characteristics of a two
stroke engine. The height of the exhaust port in a two stroke engine cylinder has an affect on the total power output
of an engine, as well as the RPM at which the power occurs.

Exhaust systems are ''tuned" by design to match engine exhaust port configuration and desired power delivery charac-
teristics. Engines with relatively "high" exhaust ports (and exhaust pipe to match) produce more horsepower at high
RPM, but only at the expense of low to midrange fuel economy and torque. On the other hand, "low" port engines
provide good fuel economy in the midrange and make their power at relatively lower RPM, but will not produce as
much peak horsepower for a given displacement range. In general, an engine designed for a racing or high perfor-
mance snowmobile will have a relatively high exhaust port compared to an engine of the same displacement range
designed for touring.

Although the V.E.S. does not in ttself increase horsepower, tt does allow an engine to be designed for maximum horsepower
without the inherent disadvantages of a high exhaust port.

The main components of the V.E.S. are the exhaust valve, valve housing, bellows, piston, return spring, and cov-
er.

A guillotine style exhaust valve is connected to a moveable piston. This piston is attached to a flexible bellows, forming
two chambers. The lower chamber is connected to the cylinder by a drilled passageway located just above the exhaust
port. The upper chamber is vented to atmospheric pressure. A valve return spring is located in the upper chamber
between the piston and cover.

At idle and low speeds, the exhaust valve is held in the "low port" position by the return spring. When throttle is applied
(and RPM begins to increase) rising cylinder pressure is applied to the under side of the bellows via the actuation port.
This forces the exhaust valve upward against spring pressure. The valve continues to move upward toward the "High
Port" position as cylinder pressure, horsepower, and RPM increase.

10/98 2.32 Polaris Industries Inc.

 MAINTENANCE!TUNE UP
Variable Exhaust System

440 XCR

V.E.S. Maintenance
Due to the simplicity of V.E.S. design, maintenance is limited to a periodic inspection and cleaning of system compo-
nents. The V.E.S. should be disassembled, inspected, and cleaned (remove carbon deposits) every 1000 to 2000
miles, depending on operating conditions. To ensure maximum performance and minimize required maintenance,
Polaris recommends the use of Premium Gold Synthetic 2 Cycle lubricant (PN 2871721) only. The use of other lubri-
cants may cause improper function of the valve mechanism, and increase the frequency of required cleaning due to
excessive buildup of carbon deposits.

NOTE: To ensure maximum performance and minimize required maintenance, break in the engine using Polaris
TC-W3 oil (premix and injection tank) and then switch to Polaris Premium Gold Synthetic 2 cycle lubricant.

V.E.S. Removal and Cleaning

For VES removal and cleaning, refer to 440/500 Domestic Case Reed Twin and 700/800 XCR section in chapter
3, Engines.
Adjuster nut ~
0-ring •
cover-~~
Valve
Spring ~
Valve cap ~;. 7" \

Bellows~~/' Bolt

Washer~~/

. "'-~,Valve
~
housing
Dowel pin

4
.&

\il Gasket
Valve

700/800 XCR

Polaris Industries Inc. 2.33 10/98

MAINTENANCE!TUNE UP
Variable Exhaust System

V.E.S. Troubleshooting
Symptom Possible Cause Remedy
Engine will not reach Valve not opening or not opening completely:
designed operating RPM 1. Exhaust valve sticking
1. Remove carbon deposits,
2. Cylinder pressure feed port burrs etc.
restricted 2. Clean port
3. Bellows damaged or not sealing 3. Inspect bellows, fastener
correctly straps, and gasket and
repair as required
4. Incorrect spring 4. Inspect
5. Problem in clutch setup, drive 5. Inspect
line, engine, etc.
Poor acceleration; Valve opening too early:
hesitation; High RPM
performance is normal or 1. Valve sticking open or partially 1. Clean, Inspect
near normal open
2. Broken, damaged, or incorrect, 2. Inspect, Replace
spring

10/98 2.34 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Hood - Alignment - Evolved

Up to .10" gap
allowable

.25" ± .06"

Avoid pucker in this area.

"Cheek Area"

1. Ensure front of hood and side bumper

are flush. Maintain .25" ± .06" gap.
2. Center rear of hood to console.
3. After steps 1 & 2 are complete, adjust
hood overhang (if needed) by pushing or
pulling side panel at bracket in "Cheek
Area" to achieve required gap.

Polaris Industries Inc. 2.35 10/98

MAINTENANCE!TUNE UP
Side Bumper, Panel and Console Mounting - Evolved

·r(~ --------

~~
11 /"
~ Torque
~
4-6 in. lbs.

Torque
4-6 in. lbs.

Torque
4-6 in. lbs.

Torque 6 ft. lbs.

Torque 4-6 in. lbs.

10/98 2.36 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Handlebar Assembly - Evolved, Aggressive

Handlebar cable
tie location

When adjusting the handlebars, tighten all

screws evenly until bars are held in the desired
position. Torque the front handlebar screws first
and then the rear screws (11-13 ft. lbs.).
NOTE: The slightly wider gap at the rear of the
block is normal.

4' a;=- :o-::=- ~~~

~I
r
~~
Self tapping screws-
do not overtighten 0
With throttle and brake blocks
~

aligned in riding position, position

' heater grip flush with end. Align
wires with channel in throttle and
brake, respectively.

Polaris Industries Inc. 2.37 10/98

MAINTENANCE/TUNE UP
Routing Diagram - 340, 340 Deluxe, 340 Touring

Oil line
Push excess
vent line into
steering post

To fuel tank

To oil tank

10/98 2.38 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Oil Line Routing, 340 - 340 Touring

Recoil Rope Over the Top

of Wire Harness and Oil
Line

Oil Tank
Convoluted
Tubing

Oil Line
Toward
Outside

Polaris Industries Inc. 2.39 10/98

MAINTENANCEffUNE UP
Oil Line Routing - 340 Deluxe

--
Oil Tank

Wire Harness and Oil Line

Cable Tied to Bracket
Stand

Wire Harness

Oil Line Routed Convoluted

Under Recoil Tubing
Ring

NOTE: Be sure not to kink or pinch oil line.

10/98 2.40 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Fuel Tank I Oil Tank Vent Line Routing - Sport, Sport Touring, TranSport

Vent Line Routing

Steering Hoop

Polaris Industries Inc. 2.41 10/98

MAINTENANCE/TUNE UP
Fuel Pump and Fuel Line Routing - Sport, Sport Touring, TranSport

To Fuel
Shut-Off
Valve
---

Impulse Line

10/98 2.42 Polaris Industries Inc.

 MAINTENANCE!TUNE UP
Fuel Tank/Oil Tank Vent Line Routing - XCF, Super Sport

Cable Tie

Vent Spring (3)

'\
Steering Hoop

Cable Tie (Panduit)

Polaris Industries Inc. 2.43 10/98

MAINTENANCEITUNE UP
Carburetor Vent Line Routing - Super Sport

Carburetor

t
i
Air Box

10/98 2.44 Polaris Industries Inc.

 MAINTENANCE!TUNE UP
Fuel Tank/Oil Tank Vent Line Routing - Trail, Trail Touring

Cable Tie

Polaris Industries Inc. 2.45 10/98

MAINTENANCE/TUNE UP
Wire Harness And Speedometer Cable Routing - Trail, Trail Touring

Speedometer
Cable
Panduit

Wire Harness -

Panduit In nosepan area,

speedometer cable is
routed as shown with
no other panduits in
this area.

10/98 2.46 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Fuel Pump and Fuel Line Routing - Trail, Trail Touring

To Fuel
Shut-Off
Valve-------

Impulse Line

Polaris Industries Inc. 2.47 10/98

MAINTENANCE/TUNE UP
Carburetor Vent Line Routing - Trail, Trail Touring

Carburetor

i
Air Box

10/98 2.48 Polaris Industries Inc.

 MAINTENANCEn"UNE UP
Fuel Tank/Oil Tank Vent Line Routing - 500, 500 Classic, Classic Touring

To Fuel Tank Cable Tie

Vent Line Routing
Cable Tie
\

To Oil Tank Vent

Steering Hoop

Torque
4-6ft. lbs.
1
() I I
t;jl
~~~~~
J/l

8 em j\)J Coolant Bottle & Hose

® ~P
8\m~~iJl'
·~~
V~/~
~ 8cm
Oil Tank

Polaris Industries Inc. 2.49 10/98

MAINTENANCE!TUNE UP
Wire Harness and Speedometer Cable Routing - 500, 500 Classic, Classic Touring

Speedometer
Cable
Panduit

Wire Harness -

In nosepan area,
speedometer cable is
routed as shown with
no other panduits in
this area.

10/98 2.50 Polaris Industries Inc.

 MAINTENANCEfTUNE UP
Fuel Pump and Fuel Line Routing - 500, 500 Classic, Classic Touring

To Fuel
Shut-Off
Valve-----

Torque
4-6 in. lbs. Ii
\ )@/ I
; l
\~
~j))Y

Impulse Line

Polaris Industries Inc. 2.51 10/98

MAINTENANCEfTUNE UP
Carburetor Vent Line Routing - 500, 500 Classic, Classic Touring

~ Air Box

+ ..'
.

10/98 2.52 Polaris Industries Inc.

 MAINTENANCE!TUNE UP
Cooling System - 500, 500 Classic, Classic Touring

Keep Away From Exhaust

Hats

Keep Hose From Looping Way

Out Into Nosepan

Polaris Industries Inc. 2.53 10/98

MAINTENANCE/TUNE UP
Fuel Pump and Fuel Line Routing - Widetrak LX

To Fuel
Shut-Off
Valve-----

Impulse Line

10/98 2.54 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Cooling System- Widetrak LX

\
Secure to clamp
with tie strap
Maintain approx. 1/4"
gap between hose
and sway bar

Keep Hose From Looping Way

Out Into Nosepan

Polaris Industries Inc. 2.55 10/98

MAINTENANCE/TUNE UP
Fue Tank/Oil Tank Routing - Widetrak LX

ToFu I Tank

Vent Line Routing

Cable Tie

Steering Hoop To Oil Tank Vent

Torque nut
4-6ft. lbs.

I
®--®---_

((
1
\
I

10/98 2.56 Polaris Industries Inc.

 MAINTENANCEITUNE UP
Fuel Tank I Oil Tank Vent Line Routing- XLT Classic, XLT Touring, XLT Special

To Fuel Tank Cable Tie

Vent Line Routing

Cable Tie
\

To Oil Tank Vent

Steering Hoop
Torque
4-6ft. lbs.

Oil Tank
26cm

Polaris Industries Inc. 2.57 10/98

MAINTENANCE/TUNE UP
Wire Harness and Speedometer Cable Routing- XLT Classic, XLT Touring

Rosebud Clip

Panduit

Panduit

Wire Harness -

Panduit In nosepan area,

speedometer cable is
routed as shown with
no other panduits in
this area.

10/98 2.58 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Fuel Pump and Fuel Line Routing- XLT Classic, XLT Touring

Oil Line

Polaris Industries Inc. 2.59 10/98

MAINTENANCE/TUNE UP
Backrest- Classic Touring, XLT Touring

Leave cable on rear outside

portion of backrest adjuster
so it doesn't get pinched / 7 - 9 ft. lbs.
when backrest is put down fr
on seat for shipping u

/
// /'@r(J·@),:,
I /'.l:
/ . (./ !?>
/ \ 1:0
/ I
37ft. lbs.

16 - 18 ft. lbs.
fl ...... /

16 - 18 ft. lbs.

10/98 2.60 Polaris Industries Inc.

 MAINTENANCE!TUNE UP
Handle Grip Heater Wire Routing- Classic Touring, XLT Touring

Zipper Position

0 Seat
Cushion
0
\...__)
LH Grip L.....------~ RH Grip

Locate center of grip heater.

Position 1" forward from
center of handgrip with
zipper toward seat cushion.
Cut and remove zipper tab.

Switch

Switch on Connect wiring and tuck in behind

Right Hand taillight housing so not visible from
Side side

Wiring to be separated at bottom one wire per slot

Polaris Industries Inc. 2.61 10/98

MAINTENANCEffUNE UP
Fuel Tank and Coolant Bottle Vent Line Routing, 440 XCR, 500 XC/SP, 600 XC/SP, 700
XC/SP

Cable Tie

Vent Line Routing

Steering Hoop

Torque 50 ~--®/
in. lbs.

10/98 2.62 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Fuel Tank and Coolant Bottle Vent Line Routing - 700 XCR, 800 XCR

Steering Hoop

·- -

',1~<5, --~
Torque nut
4-6ft. lbs. ·; fi A I
_I I \~ ~%
/~ ~~
Torque nut ~f!J
4-6ft. lbs.

Polaris Industries Inc. 2.63 10/98

MAINTENANCE/TUNE UP
Fuel Tank/Oil Tank Vent Line Routing -Trail RMK

Cable Tie

Torque 50 ~--®
in. lbs.

Torque 40
in.lbs. ~-%
~~

10/98 2.64 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
ACCS System -Trail RMK

/To handlebars

Polaris Industries Inc. 2.65 10/98

 MAINTENANCE!TUNE UP
Fuel Tank I Oil Tank Vent Line Routing - 500 RMK

To Fuel Tank Cable Tie

Vent Line Routing

Cable Tie
\

Steering Hoop
/~-@._ -_- /
Torque I
4-6 ft. lbs. el
(()I I

~~ ~~: J../l

a em ~J Coolant Bottle & Hose

® ~P
p~lj

v~
~ 8cm
Oil Tank

10/98 2.66 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Wire Harness and Speedometer Cable Routing - 500 RMK

Panduit

Wire Harness -

In nosepan area,
speedometer cable is
routed as shown with
no other panduits in
this area.

Polaris Industries Inc. 2.67 10/98

MAINTENANCE/TUNE UP
Cooling System - 500 RMK

Keep Away From Exhaust

Hats

Maintin Approx 1/4" Gap

Between Hose & Sway
Bar

Keep Hose From Looping Way

Out Into Nosepan

10/98 2.68 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Fuel Pump and Fuel Line Routing- 500 RMK

To Fuel
Shut-Off
Valve-----

Torque
4-6 in. lbs.
~\~~r
~j)V

Impulse Line

Polaris Industries Inc. 2.69 10/98

MAINTENANCEfTUNE UP
ACCS System- 500 RMK

/To handlebars

/
/

Torquato~
4 to 6 in. lbs.

10/98 2.70 Polaris Industries Inc.

 MAINTENANCE/TUNE UP
Fuel Tank and Coolant Bottle Vent Line Routing - 600 RMK, 700 RMK, 700 SKS

Vent Line Routing

Cable Tie

Steering Hoop

Torque 50 --~J~"~~
in. lbs.

Polaris Industries Inc. 2.71 10/98

CHAPTER 3
ENGINES
Torque Specifications ......................... 3.1
Torque Patterns - Cylinder Heads, Cylinder Base . 3.2
Torque Patterns - Crankcase ................... 3.3
Piston/Cylinder Clearance Specifications ........ 3.4
Engine Removal and Installation, Typical ........ 3.5-3.12
Disassembly, Fan Cooled Twin Cylinder Series ... 3.13-3.17
Assembly, Fan Cooled Twin Cylinder Series ...... 3.18-3.21
Disassembly, Liquid Twin Cylinder- Fuji ......... 3.22-3.25
Assembly, Liquid Twin Cylinder- Fuji ............ 3.26-3.28
Disassembly, Three Cylinder Monoblock ........ 3.29-3.33
Assembly, Three Cylinder Monoblock ........... 3.24-3.37
Disassembly, 440/500 Domestic Case Reed Twins 3.38-3.44
Assembly, 440/500 Domestic Case Reed Twins .. 3.44-3.49
Disassembly, 600/700 Domestic Case Reed Twins 3.50-3.56
Assembly, 600/700 Domestic Case Reed Twins .. 3.57-3.61
Disassembly, 700/800 Case Reed - Fuji ......... 3.62-3.64
Assembly, 700/800 Case Reed - Fuji ............ 3.65-3.68
700/800 Fuji VES System ...................... 3.69-3.72
General Inspection Procedures ................. 3.73-3.84
Cooling System Bleeding Procedures ........... 3.85
Cooling System, 500, 500 RMK Classic,Ciassic
Touring, Widetrak LX, XLT Classic, XLT Touring .. 3.86
Cooling System, 600 XC/SP, 700 XC/SP ......... 3.87
Cooling System, 600 RMK, 700 RMK, 700 SKS .. 3.88
Cooling System, 440 XCR ..................... 3.89
Cooling System, 500 XC/SP ................... 3.90
Cooling System, XLT Special ................... 3.91
Cooling System, 700/800 XCR ................. 3.92
Recoil Starter Spring Replacement .............. 3.93
Troubleshooting .............................. 3.94-3.95
 ENGINES
Torque Specifications

When tightening bolts, nuts, or screws, a torque pattern should 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.

The most common units of torque in the English system are ft. lb. and in. lb. In the Metric system, torque is
commonly expressed in units of kg-m or Nm (Newton Meters). Multiply foot pounds by .1383 to obtain kg-m.
Move decimal point one place to the right to obtain Nm from kg-m.

Engine Cylinder Head* Cylinder Crankcase Crankcase Flywheel

Base Nuts 8mm 10mm
Fan Cooled 18-19 ft. lbs. 24-28 ft. lbs. 17-18ft.lbs. 23-25 ft. lbs. 60-65 ft. lbs.
Twin (2.5-2.65 kgm) (3.3-3.9 kgm) (2.2-2.3 kgm) (3.2-3.5 kgm) (8.3-9.0 kgm)
Cylinder
EC50PL 8mm 10 mm 24-28 ft. lbs. 17-18 ft. lbs. 23-25 ft. lbs. 60-65 ft. lbs.
EC58PL* 17-20 ft. lbs. 24-26 ft. lbs. (3.3-3.9 kgm) (2.2-2.3 kgm) (3.2-3.5 kgm) (8.3-9.0 kgm)
EC70PL (2.4-2.8 kgm) (3.3-3.6 kgm)
EC79PL
SN44** 20-24 ft.lbs. 30-34 ft.lbs 20-24 ft.lbs. 90ft. lbs.
SN50** (2.9- 3.3 kgm) (4.1-4.7 kg-m) (2.8 - 3.3 kgm) (12.4 kgm)
SN60** 20-24 ft. lbs. 30-34 ft.lbs 20-24 ft.lbs. 26-30 Ft lbs 55 ft. lbs.
SN70** (2.8 - 3.3 kgm) (4.2-4.7 kg-m) (2.8 - 3.3 kgm) (3.6-4.15 kgm) (7.4 kgm)

* Use high end of torque range on EC58PL

**Torque head bolts prior to torquing cylinder base nuts .. Apply loctite""" 242.
All 6mm Crankcase Bolts . . . . . 108 in. lbs. (1.24 kg-m)
All7/16-14 Engine Mount Strap Bolts ..... 44-48 ft. lbs. (6.0-6.63 kg-m)

Polaris Industries Inc. 3.1 10/98

ENGINES
Torque Patterns - Cylinder Heads, Cylinder Base

0 0
G) CYLINDER HEAD
CYLINDER HEAD- 5 STUD CYLINDER HEAD- 6 STUD Domestic Twins 500 I 600 I 700

@ 000 ®
® ®cvGfDcvG:{iV@
@) 80 0
@@0000@®@ @ 000 ®
CYLINDER HEAD - EC58PL CYLINDER HEAD- EC45150PL

G)@ 00 0PTO G) 0 0
MAG
@ G) G) @ SIDE SIDE

0G) G) @) 0 0 0
CYL. BASE- 5001600/700 Twins Fuji Liquid Twins
Cylinder Head - domestic 440
Cylinder Base

10/98 3.2 Polaris Industries Inc.

 ENGINES
Torque Patterns - Crankcase

0 (j)
0 00 ® @
@
00G)G)(j)~@
f11\ @

@ 0 0 @ ®®CV%0®8 ®®
0 ®
CRANKCASE- TWIN CYLINDER - Fuji CRANKCASE-3CYLINDER

0 0
0 CD 0 @@
@ G) ® @@
CRANKCASE- @ 0 ®
GOO /700 DOMESTIC TWINS CRANKCASE - 440 I 500 Domestic Twins

Polaris Industries Inc. 3.3 10/98

ENGINES
Piston/Cylinder Clearance 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

0
clearance specifications.

Cylinder bore must be straight and concentric. Refer to

honing information outlined in this chapter for specific
procedures. Refer to the specifications section in chapter
1 for Target Clearance when re-boring cylinder, or Service
Limit specifications (to determine if piston requires
replacement.

FUJI ENGINES- Measure 1/2" (12.7mm) up

from bottom of skirt
DOMESTIC ENGINES - Measure 3/8"
(1 O.Omm) up from bottom of skirt

Piston to Cylinder Clearance

Refer to specifications in chapter 1 for specific models.

Piston Ring Installed Gap

Refer to specifications in chapter 1 for specific models.

Important! Always verify piston to cylinder clearance and piston ring installed gap prior to
assembling an engine.

10/98 3.4 Polaris Industries Inc.

 ENGINES
Engine Removal

Engine Removal, Typical

1. On some models, it may be necessary to remove the
hood for earier access to engine components or to
prevent damage.

2. Disconnect battery ground H from battery (if

applicable). Shut off fuel. Ground Cable

3. Remove fuel pump or COl from airbox if applicable.

4. Remove airbox.

Polaris Industries Inc. 3.5 10/98

ENGINES
Engine Removal

Engine Removal, Typical-Cont.

5. Free recoil rope from chassis.

NOTE: Be sure to tie a knot in recoil rope upon removal
so rope doesn't wind up into recoil housing.

6. Loosen clamps at carburetor mounting flange. Pull

carbs from adaptors and secure out of the way. Note
routing of all cables and hoses for reassembly.

7. Disconnect oil pump control cable.

8. Disconnect and plug oil supply line.

TIP: A bolt or spare water trap plug can be used to plug
the oil line from the oil reservoir.

10/98 3.6 Polaris Industries Inc.

 ENGINES
Engine Removal

Engine Removal, Typical-Cont.

9. Remove drive belt.

NOTE: If drive clutch removal is necessary, it may be
done at this time. Refer to Chapter 5, clutches.

10. Remove exhaust system.

NOTE: On triple pipe models, mark pipe location to sim-
plify reassembly.

11. Disconnect coolant supply hoses as necessary at the

most convenient location on liquid cooled models.
Drain coolant into suitable container.

Polaris Industries Inc. 3.7 10/98

ENGINES
Engine Removal

Engine Removal, Typical-Cont.

12. Disconnect electrical connections from stator and

starter motor (where applicable).

13. Remove two front and two rear engine mount bolts
(nuts) that secure engine mount plate (straps) to
chassis.

14. Remove engine from chassis.

10/98 3.8 Polaris Industries Inc.

 ENGINES
Engine Installation

Engine Installation, Typical

1. Prepare chassis for engine installation by moving

hoses and wiring out of the way.
2. If model is equipped with a torque stop, loosen
locking screw and turn torque stop in to gain
clearance when installing engine.
NOTE: Torque stop must be adjusted properly after
clutch alignment (see chapter 5, clutches)

3. Check condition of bonded rubber engine mounts.

Be sure mounts are tight before installing engine.
With engine mounting plate or mount straps installed
on engine, set engine on rubber mounts and loosely
install mounting bolts and nuts.

4. Install drive belt (and clutch if removed) and check

clutch offset/alignment. Adjust torque stop (where
applicable). Refer to chapter 5, clutches, for torque
stop adjustment procedure.

5. Tighten engine mounting bolts to specification.

Engine Mounting Bolt Torque-

Front- 28 Ft lbs (6.67 kgm)

Rear- 28 Ft lbs (6.67 kgm)

Polaris Industries Inc. 3.9 10/98

ENGINES
Engine Installation

Engine Installation, Typical-Cont.

6. Apply a light film of Polaris dielectric grease to all

connections. Connect all stator connections and
temperature switch.

Dielectric grease-

PN 2871329- 1/4 oz.

7. Connect oil supply line to oil pump. Bleed oil pump by

opening bleed screw until oil flows steadily. Tighten
bleed screw securely. Install throttle cable to oil
pump and check adjustment. Refer to General
Inspection Procedures in this chapter for oil pump
adjustment procedure.

8. Install carburetors and tighten clamps. Make sure

hoses and cables are routed correctly.

9. Connect oil lines to carburetors

10/98 3.10 Polaris Industries Inc.

 ENGINES
Engine Installation

Engine Installation, Typical-Cont.

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 star

models).

13. Install exhaust system in reverse order o

disassembly.

Polaris Industries Inc. 3.11 10/98

ENGINES
Engine Installation
Engine Installation, Typical-Cont.
14. Install hood if previously removed.

15. Install airbox.

16. Secure fuel pump and CDI box.

17. Fill cooling system (liquid models) with Polaris

Premium Antifreeze 60/40 premix.

Polaris Premium Antifreeze

60/40 premix
Quart PN 2871534
Gallon PN 2871323

18. Add a full tank of premix fuel (40:1) to fuel tank.

19. Start engine and check operation. Bleed cooling
system on liquid models. See Cooling System
Bleeding Procedures in this chapter.

10/98 3.12 Polaris Industries Inc.

 ENGINES
Fan Cooled Twin Cylinder
NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, 0-rings,
and gaskets during disassembly. Refer to pages 3.73-3.84 for general inspection proce-
dures.
Engine Disassembly

The photo at right shows a complete fan cooled twin cyl-

inder engine.

1. Remove carburetors.

2. Disconnect oil pump feed lines and remove oil

pump.

3. Remove carburetor adaptors.

4. Remove air shrouds. NOTE: There may be

gaskets between shroud and cylinder.

Polaris Industries Inc. 3.13 10/98

ENGINES
Fan Cooled Twin Cylinder

Engine Disassembly, Cont.

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. Hold flywheel with tool PN 8700229. Remove

flywheel retaining nut.

Flywheel Holding Tool

PN 8700229

10/98 3.14 Polaris Industries Inc.

 ENGINES
Fan Cooled Twin Cylinder
Engine Disassembly, Cont.

9. Using flywheel puller, remove flywheel. Use all

available puller bolt holes on flywheel. Do not install
puller bolts more than 5/16" (7mm) into flywheel
threads or stator damage may result.

Flywheel Puller

PN 2871043

10. Mark stator plate and crankcase for reference upon

reassembly. Remove stator plate.

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.

Polaris Industries Inc. 3.15 10/98

ENGINES
Fan Cooled Twin Cylinder

Engine Disassembly, Cont.

13. Remove cylinder base nuts and cylinders. NOTE:

Refer to General Inspection Procedures for cylinder
inspection.

14. Support piston to prevent damage. Remove piston

c-clip.

15. Remove piston pin and remove pistons. Refer to

General Inspection Procedures in this chapter.

Piston Pin Puller

PN 2870386

16. Remove engine mount plate or straps and remove

all crankcase bolts.

10/98 3.16 Polaris Industries Inc.

 ENGINES
Fan Cooled Twin Cylinder

Engine Disassembly, Cont.

17. Separate crankcase halves.

18. Measure connecting rod side clearance. Refer to

General Inspection section for measurement
procedure.

Connecting Rod Side Clearance

.012"- .016 (.30- .40 mm)

19. Refer to General Inspection section for crankshaft

inspection procedure.

Polaris Industries Inc. 3.17 10/98

ENGINES
Fan Cooled Twin Cylinder
Engine Assembly
1. Clean all engine components thoroughly in a
solvent tank. Blow dry with compressed air.
2. Apply 3-Bond™ sealer to top half of crankcase.
Lubricate oil pump drive gear.

3-Bond TM 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 retainer fit
properly into grooves.

4. Install bottom crankcase half and insert crankcase

bolts. Torque to specification in proper sequence
shown in beginning of this chapter. Lubricate
crankshaft bearings though oil holes in upper
crankcase.

5. Install pistons with arrow (.....) on piston facing

flywheel. Install C-clips securely in piston groove.
6. Lubricate rings and pistons with two stroke oil.
Install rings with letter, mark, or beveled side facing
upward.
7. Install base gasket with adhesive sealant strip
facing up (if applicable).

10/98 3.18 Polaris Industries Inc.

 ENGINES
Fan Cooled Twin Cylinder
Engine Assembly, Cont.
8. Lubricate cylinder with two stroke oil and install onto
piston while compressing piston rings by hand. Be
sure ring end gap is centered over locating pin or
ring damage may occur. NOTE: Use a piston
support block to help hold piston and prevent piston
damage during assembly.

Piston Support Block

PN 2870390

9. Torque cylinder base bolts to specification found in

the beginning of this chapter.

1 0. Install head gasket with wide side of fire ring facing

down (narrow side up).

11. Install cylinder heads and torque head bolts to

specification found in the beginning of this chapter.
NOTE: Make sure threaded head nuts are in the
proper position for shroud mounting. See "x" in
photo at right.

Polaris Industries Inc. 3.19 10/98

ENGINES
Fan Cooled Twin Cylinder
Engine Assembly, Cont.
12. Install inner fan shroud.

Do not tighten bolts until outer shroud is bolted in place.

Outer shroud must determine placement of inner shroud,
or damage may result.

13. Install stator plate aligning ignition timing marks

made during disassembly. Tighten stator mounting
bolts securely.

14. Make sure key is on crankshaft and install flywheel

aligning keyway.

15. Install flywheel nut and torque to specification found

in the beginning of this chapter.

Flywheel Holding Wrench-

PN 8700229

10/98 3.20 Polaris Industries Inc.

 ENGINES
Fan Cooled Twin Cylinder
Engine Assembly, Cont.
16. Install recoil starter hub and recoil housing.
NOTE: Tighten two inner shroud bolts.

17. Reassemble cooling shroud.

18. Install oil pump. If crankcase, oil pump, or pump

drive components were replaced, refer to General
Inspection Procedures in this chapter to inspect
drive gear end play.

Oil Pump Mounting Screw Torque:

48-72 in.lbs. (.55- .83 kg-m)

Polaris Industries Inc. 3.21 10/98

ENGINES
Liquid Twin Cylinder - Fuji
NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, 0-rings,
and gaskets during disassembly. Refer to pages 3.73-3.84 for general inspection proce-
dures.
Disassembly
The photo at right shows a complete liquid cooled twin
cylinder engine.

1. Remove carburetors.

2. Remove recoil housing and exhaust manifold.

3. Remove water pump, and 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. Use all flywheel bolt holes.

Do no install puller bolts more that 5/16" (7mm) into
flywheel or stator damage may result.

Flywheel Puller

PN 2871043

10/98 3.22 Polaris Industries Inc.

 ENGINES
Liquid Twin Cylinder - Fuji
Disassembly, Cont.

5. Mark stator plate and crankcase for reference when

reassembling the engine.

6. Using an impact screwdriver, remove stator screws.

7. Remove oil pump, oil pump feed lines, and banjo

bolts from cylinder. Clean and inspect all
components.

8. Remove cylinder head.

Polaris Industries Inc. 3.23 10/98

ENGINES
Liquid Twin Cylinder - Fuji
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 retainers from piston as shown.

12. Using piston pin puller, remove piston pin from

piston as shown.

Piston Pin Puller

PN 2870386

10/98 3.24 Polaris Industries Inc.

 ENGINES
Liquid Twin Cylinder - Fuji
Disassembly, Cont.

13. Remove crankcase bolts.

NOTE: Refer to General Inspection Procedures on

pages 3.73-3.84 for engine component inspection (i.e.
crankshaft and crankcase inspection, piston clearance,
oil pump drive gear end play etc.).

Polaris Industries Inc. 3.25 10/98

ENGINES
Liquid Twin Cylinder- Fuji
Assembly
Prior to assembly, refer to page 3.81 and check ring end gap and piston to cylinder clearance.

1. Grease crankshaft end seals and oil pump drive

gear area as shown. Seals should be installed with
spring and lip facing inward toward crankshaft.

2. Turn bearing until anti-rotation pins are positioned in

the proper location.

3. Apply 3-Bond™ sealant to crankcase halves.

3-Bond TM 1215

PN 2871557 120 Gram Tube

4. Torque crankcase bolts following sequence

outlined in beginning of this chapter. Lubricate
crankshaft main bearings through access holes.

5. Install pistons with "F" mark or arrow (.....) toward

flywheel.

6. Install C-clip using installation tool PN 2870773.

7. Install new base gasket.

8. Lubricate rings and pistons with two stroke oil.

Install rings with letter, mark, or beveled side facing
upward.

10/98 3.26 Polaris Industries Inc.

 ENGINES
Liquid Twin Cylinder- Fuji
Assembly, Cont.

9. Lubricate rings and cylinder with Premium 2 Cycle

Lubricant and compress rings with fingers, 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 correct specifications found in the
beginning of this chapter

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 in the
beginning of this chapter.

12. Before installing oil pump drive gear, refer to end

play adjustment in General Inspection Procedures.

13. Install oil pump in the sequence shown in photo at

right.

Polaris Industries Inc. 3.27 10/98

ENGINES
Liquid Twin Cylinder- Fuji
Assembly, Cont.

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 nut to

specification found in beginning of this chapter.

Flywheel Holding Tool -

PN 8700229

17. Install water pump and recoil starter cup.

18. Adjust tension on water pump belt by loosening

mounting bolts, applying tension, and re-tightening
bolts.

Water Pump Belt Deflection -

1/8- 3/16"(.3- .4 em)

19. Install recoil housing, carburetors, and oil pump

cable. Refer to oil pump bleeding in General
Inspection Procedures.

20. Connect COl to stator plug connector.

10/98 3.28 Polaris Industries Inc.

 ENGINES
Three Cylinder Monoblock
NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, 0-rings,
and gaskets during disassembly. Refer to pages 3.73-3.84 for general inspection proce-
dures.
Disassembly
1. Remove carburetors and secondary coils.

2. Remove oil pump.

3. Remove recoil housing.

4. Remove recoil hub.

Polaris Industries Inc. 3.29 10/98

ENGINES
Three Cylinder Monoblock
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.

10/98 3.30 Polaris Industries Inc.

 ENGINES
Three Cylinder Monoblock

Disassembly, Cont.
8. Mark or note location of stator plate on plate and
crankcase.

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

0-rings in head cover. Also note the quantity and
location of shim washers located beneath the
0-rings.

Polaris Industries Inc. 3.31 10/98

ENGINES
Three Cylinder Monoblock
Disassembly, Cont.

12. Remove cylinder heads. Mark PTO, Center, and

Mag head to ensure correct reassembly.

0-Ri
Ring

Cylinder Heads Gasket

(Mark For
Reassembly)

13. Remove cylinder and base gasket.

14. Refer to cylinder inspection procedure on page 3.86

to inspect cylinder.

Use care to ensure pistons are not damaged as cylinder

is removed.

15. Support pistons with piston support block and

remove C-clips.

10/98 3.32 Polaris Industries Inc.

 ENGINES
Three Cylinder Monoblock
Disassembly, Cont.
16. Remove piston pins using piston pin puller and
adaptor as shown. Refer to General Inspection
Procedures in this section.

Piston Pin Puller PN 2870386

Adapter PN 5130971

17. Remove all crankcase bolts.

18. Separate crankcase halves and remove crankshaft.

19. Follow procedure in General Inspection Procedures

for crankshaft inspection.
20. Clean all components in a solvent tank to remove
any dust, dirt, debris, and excess sealant. Inspect
mating surface of upper and lower crankcase for
damage.

Polaris Industries Inc. 3.33 10/98

ENGINES
Three Cylinder Monoblock
Assembly
1. Apply 3-Bond™ to upper crankcase half. Lubricate
oil pump drive gear. Lightly grease seals and install
on crankshaft with seal lip (spring) facing inward.

3-Bond TM 1215

PN 2871557 120 Gram Tube

2. Install crankshaft in upper crankcase.

NOTE: Make sure seals and all locating (anti-rotation)
pins fit correctly in grooves and detent notches.

3. Install bottom crankcase half. Make sure

anti-rotation pins are aligned properly and torque
bolts to specification found in beginning of this
chapter.

4. Lubricate crankshaft main bearings through oil

holes in upper crankcase. Lubricate connecting rod
big end bearing.
5. Lubricate pistons, rings, connecting rod small end
bearing and cylinder before assembly. Install
pistons, piston pins, and C-clips with end gap up or
down. NOTE: Marking on piston faces flywheel.
Be sure "C" clips are fully seated in groove.

6. 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.

10/98 3.34 Polaris Industries Inc.

 ENGINES
Three Cylinder Monoblock
Assembly, Cont.
7. Before installing cylinder, refer to honing procedure
on pages 3.73-3.74 of this section. Inspect piston to
cylinder clearance and piston ring installed gap as
shown on page 3.81. 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

8. Torque base bolts, starting in the middle, alternate

intake to exhaust side, moving toward PTO end and
mag end. Refer to torque patterns in beginning of
this chapter.

9. Install new head gasket. Be sure cylinder and

cylinder head sealing surfaces are clean.
NOTE: EX stamping should be readable and facing ex-
haust side.

10. Install heads in the correct position and location as

marked during disassembly. Torque head bolts to
specification found in the beginning of this chapter.

Polaris Industries Inc. 3.35 10/98

ENGINES
Three Cylinder Monoblock
Assembly, Cont.
11. Replace outer 0-ring on cover.

12. Apply Loctite 515 to cover as shown. Cover

13. Position shim and 0-Ring as shown.

Apply Sealant
To Top Of Shim ~ Shim

0-Ring 0

14. Install head cover.

15. Install and torque head cover mounting bolts to

specification.

Head Cover Mounting Bolt Torque

17-20 Ft lbs (2.4-2.8 kgm)

16. Install stator in the previously marked position and

tighten screws securely.

17. Install and torque flywheel nut to specification found

in beginning of this chapter.

Flywheel Holder Wrench:

PN 8700229

18. Install water pump and belt. Apply proper tension to

belt and tighten pump mounting bolts.

Water Pump Belt Tension

1/8" - 3116" (3-4mm)

10/98 3.36 Polaris Industries Inc.

 ENGINES
Three Cylinder Monoblock
Assembly, Cont.

19. Install oil pump and connect feed lines. If

crankcase, oil pump, or drive components were
replaced, refer to oil pump drive gear end play
adjustment in General Inspection Procedures.

20. Install recoil housing.

21. Install secondary coils and secure carburetors to

rubber mounts.

Polaris Industries Inc. 3.37 10/98

ENGINES
440/500 Domestic Case Reed Twin
NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, 0-rings,
and gaskets during disassembly. Refer to pages 3.73-3.84 for general inspection proce-
dures.
Disassembly

1. Remove carburetor mount adaptors, reed cages,

Reed Pedal
stuffers, and oil pump. Note position of stator wire guide. Exaggerated
Clearance .015"
for illustration
(.38 mm) max.
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.

V.E.S. Removal - 440

2. Pull back cover retainer clip while holding the

cover in place.
1. Hold Cover
3. Remove cover and return spring. 2. Slide Clip
Down

4. If the spring stays in the cover, hold the cover

with spring facing toward you. Rotate spring in
a counterclockwise direction while pulling
outward on the spring. Do not distort the spring Cover >...,
Retainer C~ ~

remove~
upon removal.
CAUTION: Do not attempt to remove the plastic Rotate to
valve piston at this time. The bellows must first be
removed from the piston or damage may occur to fromcover ~~
the bellows or piston.

5. Remove two (5mm) hex screws from valve

6.
housing.

Note location of "TOP" marks on housing and Align TOP marks ~

\UP
exhaust valve. Lift entire valve assembly from
cylinder along with gasket.

j§) Housing Bolts: Appl

Loctite ™ 242(blue)
Torque: 108 in. lbs.
(1.24 kg-m)

10/98 3.38 Polaris Industries Inc.

 ENGINES
440/500 Domestic Case Reed Twin

Disassembly, Cleaning, Inspection- VES- 440 XCR

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 low-
er edge of piston.

Lower Clamp

3. Hold exhaust valve securely and remove piston

by turning the 1Omm hex counterclockwise. ·~·
Housing / ·~·
4. Slide exhaust valve out of housing.
5. Remove 0-ring from exhaust valve shaft.
6. Compress lower spring clamp and remove bel-
Gasket ~ 10mm
Hex
lows and clamp. 0-ring \.,
7. Clean 0-ring and bellows in warm water and ~/)C?
mild detergent. Inspect bellows for holes, dis- ~

~Hold exhaust valve

tortion or damage. Replace if necessary. In-
spect 0-ring for damage.
8. Clean all other parts with solvent. Be sure all then remove pisto
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.
1 O.Carbon deposits can be removed from valve
with a Scotch Brite'" pad or similar soft abra-
sive 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 bind-
ing. If the valve sticks anywhere in the travel
range, check the valve and valve bore in the cyl-
inder for carbon deposits and clean if neces-
sary.

Polaris Industries Inc. 3.39 10/98

ENGINES
440/500 Domestic Case Reed Twin

V.E.S. Assembly - 440 XCR

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".
Align TOP marks $1 \UP
5. Apply Loctite"' 242 to threads of exhaust valve ;:§} Housing Bolts: Appl
and install the piston. Hold exhaust valve and Loctite"' 242(blue)
torque piston to 25 in. lbs. (.28 kg-m). Torque: 108 in. lbs.
6. Install valve assembly in cylinder with TOP (1.24 kg-m)
marks on valve and housing facing up. Apply
Loctite 242 (blue) to housing bolt threads. Install
and torque bolts to 1 08 in. lbs. (1.24. kg-m).
7. Fit upper sealing edge of bellows into groove on
piston.
8. Secure the bellows by installing the fastener 1. Compress
strap. NOTE: Move the valve up and down in and Hold
the full travel range and check for smooth op- Cover
2. Slide Clip
eration. If the valve binds in any spot, check the
Up
bellows to be sure it is not twisted on the piston.
9. Install spring and cover. Be sure spring is prop-
erly positioned on the piston and in the cover.

10/98 3.40 Polaris Industries Inc.

 ENGINES
440/500 Domestic Case Reed Twin
Disassembly, Cont.

7. Remove cylinder head cover and inspect 0-rings

and sealing surfaces for damage or debris. Use
new 0-rings upon assembly.

8. Remove cylinder base nuts. Note location of acorn

nuts on exhaust side (where applicable).
9. Carefully remove cylinders while supporting pistons
and connecting rods to prevent piston damage.
Refer to General Inspection Procedures in this
chapter.
10. Remove outer piston pin C-clips using a scribe
through access slot in piston.

11. Place support block under piston and remove piston

pins using pin puller.

Piston Pin Puller PN 2870386

Support Block PN 2870390

12. Remove water pump cover from front of engine.

Polaris Industries Inc. 3.41 10/98

ENGINES
440/500 Domestic Case Reed Twin
Disassembly, Cont.

13. Remove recoil housing and drive hub.

14. Remove flywheel using heavy-duty flywheel puller.

Use drive clutch puller T-handle or a wrench to hold
puller.

Flywheel Puller PN 2871043

T-Handle PN 5020326

15. Before removing stator plate, note where ignition

timing marks are located, or scribe additional marks
for reference upon reassembly.

16. Mark or note location of engine mount straps and

remove.

10/98 3.42 Polaris Industries Inc.

 ENGINES
440/500 Domestic Case Reed Twin
Disassembly, Cont.

17. Remove bolts and separate case halves. Keep

bolts in order for assembly.

18. To prevent damage to snap-ring grooves, lift

crankshaft straight upward and out of lower case.

19. If pump shaft removal is necessary, remove

retaining pin from crankcase using a diagonal cutter
or similar tool.

20. 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.

Polaris Industries Inc. 3.43 10/98

ENGINES
440/500 Domestic Case Reed Twin
Disassembly, Cont.

21. Press front bushing, oil seal and mechanical seal

out of lower crankcase using a suitable (soft) drift
from the oil pump (rear) side. Be careful not to
damage bushing.
Remove bushings, seals

Assembly

1. 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.

2. Install oil seal with spring facing outside of

crankcase (toward you) until seated against
bushing.
3. Lubricate and install washer on pump shaft
(water pump end). Install shaft with washer
through bushing and oil seal from the oil pump
side of case. Be sure spring stays in position on
seal lip.
4. Install remaining washer on shaft.
5. Lubricate and install rear bushing with new
0-ring until seated against shaft.
6. Install oil pump, being careful to engage pump
shaft in drive shaft.

Oil Pump Mounting Screw Torque:

60 in. lbs. (.70 kg-m)

10/98 3.44 Polaris Industries Inc.

 ENGINES
440/500 Domestic Case Reed Twin
Assembly, Cont.

7. Install mechanical seal guide (special tool) on

end of pump shaft. Washer
10.3x14x1 mm
Mechanical Seal Guide
Tool1999 440/500
domestic engines
8.4mm: PN 2872010
@-iltbB
I
10 ft.lbs.

kg-m)

8. Lubricate seal guide and drive or press a new

mechanical seal into case until fully seated using Mechanical Washer
Seal .325x.75x.063"
the seal press tool.

9. Lubricate all crankshaft bearings with Premium

2-Cycle or Premium Gold Engine Lubricant.
10. Lightly grease pump shaft drive gear and sealing lip
of crankshaft seals.
11. Install seals on crankshaft with spring facing inward
(toward crankshaft).
12. Clean and de-grease lower crankcase and install
crankshaft assembly, aligning seals and snap ring
with grooves in case.
13. Apply a thin coating of 3-Bond 1215 sealant to lower
crankcase mating surface.
14. Install upper crankcase on lower crankcase.
15. Apply Loctite 242 to threads of bolts and install.
Torque bolts in three steps to specification outlined
in beginning of this chapter following the sequence
shown at right

MAG End PTO End

® ®
® G) G) @®
@ @ ® @@
GJ @
@

Polaris Industries Inc. 3.45 10/98

ENGINES
440/500 Domestic Case Reed Twin
Assembly, Cont.

16. Assemble engine mount straps to crankcase.

Engine Mount Strap Torque:

44-48 ft. lbs. (6.0-6.6 kg-m)

17. Lubricate main bearing oil holes with Polaris

Premium 2 Cycle or Premium Gold engine oil and
rotate crankshaft to distribute oil evenly.

18. Install a new C-clip in both pistons (inside) with gap

facing down. Be sure clip is fully seated in groove.

19. Lubricate and install new connecting rod small end

bearing in rod.

20. Install piston with arrow facing exhaust (ring

locating pins should be facing intake). Warming the
piston may help to ease installation of pin.

21. Install remaining C-clip with gap down. Be sure both

clips are fully seated on the groove.

22. Install new base gasket. Be sure gasket surface is

clean and free of nicks, burrs, or scratches.

23. Lubricate and install piston rings on piston with mark

on end of ring facing upward.

24. Place piston support under skirt and lubricate

pistons and cylinders thoroughly. Straight Edge

25. Align ring end gaps with locating pins and compress
ez:--4'
rings. Install cylinder carefully with a gentle front to Piston Ring Cutaway
rear rocking motion. Install cylinder base nuts
loosely. Do not tighten them at this time. Repeat
Steps 22-25 for other cylinder. Keystone Piston Ring

Do not twist or force cylinder during installation.

26. Install new cylinder head 0-rings and install cylinder

head. Make sure 0-rings are properly seated in
grooves. Apply a light film of grease to hold 0-rings
in place if necessary.

10/98 3.46 Polaris Industries Inc.

 ENGINES
440/500 Domestic Case Reed Twin
Assembly, Cont.

27. Install new cylinder head cover 0-rings and install

cylinder head cover. Make sure 0-rings are
properly seated in grooves. Apply a light film of
grease to hold 0-rings in place if necessary.

28. Loctite 242 to threads of head bolts and install.

29. Torque head bolts to specification outlined in

beginning of this chapter in proper sequence.

00 G®
@ (00 @
00 0 ®
Cylinder Head

30. Torque cylinder base nuts outlined in beginning of

this chapter in proper sequence.

Cylinder Base

31. Install washers and water pump impeller as

shown and torque nut to 10ft. lbs. (1.38 kg-m). Washer
10.3x14x1mm
1o ft.lbs.
Impeller Nut Torque: I
@-,,_~Bkgm)
10Ft lbs (1.38 kgm)

Mechanical Washer
Seal .325x.75x.063"

Polaris Industries Inc. 3.47 10/98

ENGINES
440/500 Domestic Case Reed Twin
Assembly, Cont.

32. Install water pump cover with new gasket.

Water Pump Cover Bolt Torque:

9 Ft lbs (1.25 kgm)

33. Install new exhaust manifold gaskets and

manifold.

Exhaust Manifold Bolt Torque:

16Ft lbs (2.21 kgm)

34. Assemble V.E.S. valve. Refer to V.E.S.

procedures in beginning of this section.

35. Install reed valves, stutters, and carburetor

adaptors. Place stator wire guide on Mag side
carburetor adaptor bolt.

36. Install stator assembly, aligning timing marks or

marks made upon disassembly. Seal stator wires
with high temperature silicone sealant. Install and
tighten stator screws to specification.

37. Measure trigger (pulse) coil gap and compare to

specification.

Stator Screw Torque

60 in. lbs. (.69 kg-m)

Trigger (Pulse) Coil Gap

Minimum: .020" (.5mm )

Maximum: .040" (1.0mm )

10/98 3.48 Polaris Industries Inc.

 ENGINES
440/500 Domestic Case Reed Twin
Assembly, Cont.

38. Apply Loctite"' 262 evenly to the flywheel mounting

taper on crankshaft. Install woodruff key.

39. Install flywheel. Apply Loctite '" 242 to crankshaft

threads. Install washer and nut.

40. Use flywheel holder to hold flywheel and torque nut

to specification found in beginning of this chapter.

Flywheel Holder:

PN 8700229

41. Install recoil hub and recoil housing. Torque bolts to

specification.

Recoil Hub and Housing Bolt

Torque:

108 in. lbs. (1.25 kg-m)

42. Install engine in chassis and align clutches.

43. Refer to General Inspection Procedures in this

chapter to fill and bleed cooling system and oil
pump.

Polaris Industries Inc. 3.49 10/98

ENGINES
600noo Domestic Case Reed Twin
NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, 0-rings,
and gaskets during disassembly. Refer to pages 3.73-3.84 for general inspection proce-
dures.
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. Re- Replace if width is

place if width is less than .25, (6.35mm). Nominal new less than .25" (6.35mm)
width is .345, (8.75mm). Refer to Maintenance chapter
for water pump belt installation.

10/98 3.50 Polaris Industries Inc.

 ENGINES
600/700 Domestic Case Reed Twin
Disassembly, Cont.

4. Remove drive gears and belt.

5. Remove flywheel nut using flywheel holder.

Flywheel Holder

PN 8700229

6. Remove flywheel using flywheel puller.

Flywheel Puller

PN 2871043

7. Note the ignition timing strip on the flywheel.

8. Before removing stator plate, mark the plate and

crankcase for reference upon assembly.

Polaris Industries Inc. 3.51 10/98

ENGINES
600nOO Domestic Case Reed Twin
Disassembly, Cont.

9. Remove 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. Remove crankshaft seal from housing by driving

seal to inside of housing. Replace seal if removed.

12. Remove water pump cover bolts.

10/98 3.52 Polaris Industries Inc.

 ENGINES
60onoo Domestic Case Reed Twin
Disassembly, Cont.

13. Remove impeller nut.

14. Slide shaft out back side.

15. Inspect bearings. Replace if necessary. Replace

mechanical seal using the special tools listed below.
Use the seal press to install a new mechanical seal
in cover with spring sleeve toward impeller housing.
Install seal guide over end of shaft and apply a light
film of grease to seal guide. Carefully install shaft
and bearings in cover. Assemble 1Ox14mm
washer, impeller, washer, and nut. Torque impeller
nut to specification.

Water Pump Mechanical Seal

Installation Tool -
1999 soonoo domestic engines:
8.9mm. PN 2872389

Impeller Nut Torque

10ft. lbs. (1.38 kg-m)

Polaris Industries Inc. 3.53 10/98

ENGINES
60onoo Domestic Case Reed Twin
Disassembly, Cont.

16. Remove reed cover, reed stutters, and reeds.

Reed Valve Inspection

17. Measure air gap between fiber reed and reed

Reed Pedal
block as shown. The air gap should not exceed Exaggerated
Clearance .015" for illustration
.015" (.4 mm). If clearance is excessive DO NOT
(.38 mm) max.
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.

18. Remove cylinder head. Note condition and

placement of both cylinder head 0-rings.

19. Loosen cylinder base nuts and remove cylinders.

10/98 3.54 Polaris Industries Inc.

 ENGINES
6oonoo Domestic Case Reed Twin
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 5130971

22. Remove water manifold by removing both retainer

brackets.

23. Remove bottom crankcase bolts and separate

crankcase halves.

Polaris Industries Inc. 3.55 10/98

ENGINES
600/700 Domestic Case Reed Twin
Disassembly, Cont.

24. Remove snap rings and crankshaft seals.

25. Clean thoroughly to remove all grease, oil, dirt, and

old sealant.

10/98 3.56 Polaris Industries Inc.

 ENGINES
60onoo Domestic Case Reed Twin
Assembly

1. Clean all parts with solvent and dry with

compressed air.

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 clear-
ance.

3-Bond TM 1215

PN 2871557 120 Gram Tube

3. 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.

Polaris Industries Inc. 3.57 10/98

ENGINES
600/700 Domestic Case Reed Twin
Assembly, Cont.
4. If studs were removed or new crankcase installed,
apply Loctite™ 242 to threads of studs and screw in
until bottomed. Tighten securely.

5. 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. Install crankcase halves together. Torque bottom

crankcase bolt to specification in the proper
sequence found in the beginning of this chapter.

7. Install new 0-rings on water manifold. Grease

0-rings and install manifold.

8. Install pistons and rings. Make sure C-clips are

firmly seated in grooves. NOTE: Keystone ring
bevel must be up. Marking near ring end gap faces
upward.
Straight Edge j
ez_..~ ~
Piston Ring Cutaway

Keystone Piston Ring

10/98 3.58 Polaris Industries Inc.

 ENGINES
600nOO Domestic Case Reed Twin
Assembly, Cont.

9. Lubricate pistons, rings, upper rod bearing, and

cylinders with two stroke oil and install cylinders.
Align ring end gaps with locating pins and compress
rings. Install cylinder carefully with a gentle front to
rear rocking motion. Loosely install cylinder nuts.

1 0. Install new cylinder head 0-ring and install cylinder

head. Make sure 0-ring is properly seated in
groove.

11. Torque cylinder base bolts in proper sequence.

Refer to specifications in the beginning of this
chapter.

700 Cylinder Base

12. Torque head bolts in proper sequence. Refer to

specifications in the beginning of this chapter.

700 Cylinder Head

Polaris Industries Inc. 3.59 10/98

ENGINES
600/700 Domestic Case Reed Twin
Assembly, Cont.

13. Reassemble water pump carefully installing seal.

14. Install crankcase seal to ignition/water pump

housing from inside toward outside until bottomed
on housing. Spring and seal lip must face inward
toward crankshaft.

15. Apply 3 Bond™ sealant to pump housing crankcase

mating surface and carefully install onto crankcase.
Tighten water pump to engine hose clamp and
torque bolts to specification.

Ignition/Water Pump Housing Torque

22 Ft. lbs (3.04kgm)

16. Align timing marks and install stator.

10/98 3.60 Polaris Industries Inc.

 ENGINES
60onoo Domestic Case Reed Twin
Assembly, Cont.

17. Install flywheel and torque flywheel nut to

specification found in the beginning of this chapter.

Flywheel Holder

PN 8700229

18. Install water pump belt and recoil hub.

NOTE: See 600/700 domestic twin water pump belt
installation in chapter 2, Maintenance, for correct belt
installation

Recoil Hub Bolt Torque -

96-108 in. lbs. (1.11 -1.25 kg-m)

19. Install recoil cover and oil pump. Make sure oil
pump drive slot mates properly with water pump
shaft.

20. Install reed valve, reed stuffer, and reed cover.

Polaris Industries Inc. 3.61 10/98

ENGINES
700/800 Case Reed - Fuji
NOTE: Inspect all parts for wear or damage during disassembly. Replace all seals, 0-rings,
and gaskets during disassembly. Refer to pages 3.73-3.84 for general inspection proce-
dures.
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 exhaust valve assembly from each

cylinder.

3. Remove recoil housing, water pump belt guard,

water pump and flywheel nut.

Flywheel Holder PN 8700229

4. Install flywheel puller and remove flywheel.

Flywheel Puller

PN 2871043

.·.CAUTION:'

Do not thread puller bolts more than 3/8" (0.5 mm) into
flywheel or stator coil damage may occur.

10/98 3.62 Polaris Industries Inc.

 ENGINES
700/800 Case Reed - Fuji
Disassembly, Cont.

5. Mark stator plate at case parting line and remove

plate.

6. Remove head covers, heads and cylinder base

nuts.

7. Carefully remove cylinders.

8. Remove C-clip retainers.

9. Use piston pin puller to remove piston pins.

Piston Pin Puller

PN 2870386

Polaris Industries Inc. 3.63 10/98

ENGINES
700/800 Case Reed - Fuji
Disassembly, Cont.

10. Remove crankcase bolts and separate crankcase

halves.

11. Inspect crankcase and crankshaft as outlined in

general inspection procedures.

12. Clea11 crankcase thoroughly to remove all grease,

oil, dirt, and old sealant.

10/98 3.64 Polaris Industries Inc.

 ENGINES
700/800 Case Reed- Fuji
Assembly

1. Grease oil pump drive gear and end seals.

2. Position anti-rotation pins with relief in case.

3. Apply a light film of 3 Bond™ 1215 to crankcase and

reassemble halves.

3-Bond ™ 1215

PN 2871557 120 Gram Tube

Polaris Industries Inc. 3.65 10/98

ENGINES
700/800 Case Reed- Fuji
Assembly, Cont.

4. Install bolts and torque to specifications and pattern

found in beginning of this chapter.

5. Install piston pin bearings.

6. Install piston with arrow(~) toward flywheel.

7. Install C-clip retainers using tool. NOTE: The C-clip

opening should be in the up or down position. Be
sure C-clips are properly seated in groove.

C-Ciip Retainer Installation Tool

PN 2870773

8. Lightly oil rings and cylinder. NOTE: Keystone ring

bevel must be up. Marking near ring end gap faces
upward.

Straight Edge
ez_.
Piston Ring Cutaway
9. Install new base gaskets with sealant facing (where
applicable.
Keystone Piston Ring

10. Carefully compress rings and install cylinder over

piston. Torque cylinder base nuts to specification
found in the beginning of this chapter.

10/98 3.66 Polaris Industries Inc.

 ENGINES
700/800 Case Reed- Fuji
Assembly, Cont.

11. Install new head and head cover 0-rings.

0-rings

12. Install heads and torque to specification found in

beginning of this chapter.

Reed Pedal
Reed Valve Inspection Clearance .015"
(.38 mm) max.
13. Measure air gap between fiber reed and reed
block as shown. The air gap should not exceed
.015" (.4 mm). If clearance is excessive DO NOT
attempt to reverse the reeds to reduce the air
gap. Always replace them if damaged. Check
each fiber reed for white stress marks or missing
material. Replace if necessary.

Reed Air Gap - Maximum

.015" (.4 mm)

14. Install reed cages and carburetor mounting flanges.

Polaris Industries Inc. 3.67 10/98

ENGINES
700/800 Case Reed - Fuji
Assembly, Cont.

15. Install oil pump drive gear in correct sequence.

16. Check oil pump drive gear end play. See

adjustment in General Inspection Procedures.

17. Install oil pump.

18. Position stator plate at previously marked position

and secure in place.

19. Torque flywheel nut to specification found in

beginning of this chapter. Install new 0-ring on
water pump and grease lightly. Install pump, recoil
cup, and belt.

Flywheel Holder:

PN 8700229

20. 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 -

1/8- 3/16"(.3- .4 em)

10/98 3.68 Polaris Industries Inc.

 ENGINES
700/800 Case Reed - Fuji

V.E.S. Adjustment- 700/800 XCR

The RPM at which the exhaust valves open and
close can be tuned by turning the spring adjuster in
or out for the desired valve characteristics.

1. Turning spring adjuster in:

• Creates more spring pressure
• Allows exhaust valve to open at slower rate
• For applications such as drag racing
2. Turning spring adjuster out:
• Creates less spring pressure
• Allows exhaust valve to open at faster rate
• For applications such as trail riding

Riders can fine tune the VES to suit their riding con-
ditions and power delivery characteristics. Base
setting is with adjuster screw flush with housing.

CAUTION: Do not turn spring adjuster too far. The

spring adjuster is turned out to its maximum when
the adjuster is flush with top of housing.

Polaris Industries Inc. 3.69 10/98

ENGINES
700/800 Case Reed - Fuji

V.E.S. Removal - 700/800 XCR

1. Remove two mounting bolts. Remove exhaust

valve assembly from cylinder.

2. Remove four cover bolts, cover, and return

spring.
CAUTION: Valve is spring loaded. Hold cover in
position until all bolts are removed.

3. If the spring stays in the cover, hold the cover

with spring facing toward you. Rotate spring in
a counterclockwise direction while pulling
outward on the spring. Do not distort the spring
upon removal.

4. With a 10 mm wrench, loosen exhaust valve

cap and remove.
NOTE: Top nut is secured to valve with adhesive.
Removing top nut may damage threads on valve.

5. Remove exhaust valve remaining

components. NOTE: 700 XCR valves are
marked "70 UP" and 800 XCR valves are
marked "79 UP". Upon installation be sure this
marking faces upward.

10/98 3.70 Polaris Industries Inc.

 ENGINES
700/800 Case Reed - Fuji

Disassembly, Cleaning, Inspection - VES - 700/800 XCR

1. Clean 0-ring and bellows in warm water and
mild detergent. Inspect bellows for holes, dis- 0-ring~·

~?
tortion or damage. Replace if necessary. In-
spect 0-ring for damage.
Bellow~.t;t
2. Clean all other parts with solvent. Be sure all

~·.j'
parts are thoroughly clean.

ll!J~
3. Inspect the actuator port in cylinder and valve
housing. Be sure it is clear and not obstructed
by debris or carbon.

4. Carbon deposits can be removed from valve

with a Scotch Brite"' pad or similar soft abra-
sive brush.

5. 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 bind-
ing. If the valve sticks anywhere in the travel
range, check the valve and valve bore in the cyl- ~
inder for carbon deposits and clean if neces-
sary.

Polaris Industries Inc. 3.71 10/98

ENGINES
700/800 Case Reed - Fuji

V.E.S. Assembly - 700/800 XCR

1. Replace gasket and insert exhaust valve into
valve housing.

2. Install washer, beveled side out. Bevel side out

3. Install bellows and valve cap.

4. Install spring, valve cover, and adjuster nut.

5. Set adjuster nut according to rider preference.

Refer to page 3.69.

10/98 3.72 Polaris Industries Inc.

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

Cylinder Hone Selection

Selecting a hone which will straighten as well as re-
move material from the cylinder is very important.
Honing a cylinder with a spring loaded glaze breaker
is never advised. Polaris recommends using a rigid
type hone which also has the capability of oversizing.
These hones are manufactured by such companies as
Sunnen Products Company of St. Louis, Missouri; and
Ammco Tools, Inc., of North Chicago, Illinois.
Shown at right is the Ammco No. 3950 hone. This
hone has roughing and finishing stone sets available
to service engines with cylinder bores up to 75mm in
diameter.

De-glazing
If cylinder wear or damage is minimal, hone the cylin-
der lightly with finish stones following the procedure
outlined on page 3.74

Honing To Oversize
If cylinder wear or damage is excessive, it will be nec-
essary to oversize the cylinder using a new oversize
piston and rings. This may be accomplished by either
boring the cylinder and then finish honing to the final
bore size, or by rough honing followed by finish honing.
NOTE: Portable rigid hones are not recommended for
oversizing cylinders, cylinder boring, and finish hon-
ing. The use of an arbor type honing machine is rec-
ommended.
For oversize honing always wet hone using honing oil EXAMPLE OF CROSS HATCH PATTERN
and a coarse roughing stone. Measure the new piston
at room temperature (see piston measurement) and
rough hone to the size of the piston or slightly larger.
Always leave .002 - .003'' (.05 - .07 mm) for finish hon-
ing. Complete the sizing with fine grit stones to provide
the proper cross-hatch finish and required piston
clearance.
Inspect cylinder for taper and out-of-round. Taper or
out-of-round on the finished bore should not exceed
.0004" (.002mm).
NOTE: Always check piston to cylinder clearance and piston ring installed gap after boring/honing is complete!

Polaris Industries Inc. 3.73 10/98

ENGINES
General Inspection Procedures
Honing Procedure
1. Wash cylinder with solvent. Clamp cylinder in a soft
jawed vise by the exhaust port studs.

2. Place hone in cylinder and tighten stone adjusting

knob until stone contacts the cylinder walls (DO
NOT OVERTIGHTEN). Cylinders may be wet or
dry honed depending on the hone manufacturer's
recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in
the bore. Using a 1/2" (13 mm) drill motor rotating
at a speed of 300-500 RPM, run the hone in and out
of the cylinder rapidly until cutting tension
decreases. Remember to keep the hone drive
shaft centered to prevent edge loading and always
bring the stone approximately 1/2" (1.3 em)
beyond the bore at the end of each stroke. Release
the hone at regular intervals to inspect bore size
and finish.

Ni-Ca-Sil Honing

Ni-Ca-Sil cylinders can be lightly honed

if the proper stone is used. Ammco
#3955 honing stones (for use with the
Ammco 3950 cylinder hone) are suit-
able and can be ordered through most
automotive supply stores or VST. See
General Information chapter for tool
ordering information.

Port Chamfering
Remove the sharp edges at the bottom and top of each
port whenever boring or honing is performed. Make
sure there are no sharp edges.

IMPORTANT:

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly
cleaned after honing to remove all grit material. Wash
the cylinder in a solvent, then in hot soapy water. Pay
close attention to areas where the cylinder sleeve
meets the aluminum casting (transfer port area). Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air, and
oil the bore immediately with Polaris Premium 2 Cycle
Lubricant.
NOTE: Always check piston to cylinder clearance and piston ring installed gap after boring/honing is complete!

10/98 3.74 Polaris Industries Inc.

 ENGINES
General Inspection Procedures

Crankcase Inspection I Bearing Fit

Any time crankshaft bearing failure occurs and the case

is to be reused, Polaris recommends checking the bear-
ing 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, or if the
crankcase bearing surface is severly galled or
damaged, the case should be replaced.

Crankcase Bearing Interference Fit:

C-3- .0006" (.015mm)

C-4- .001" (.025mm)

Crankshaft Main 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 bear-
ings.

Polaris Industries Inc. 3.75 10/98

ENGINES
General Inspection Procedures
Connecting Rod (Big End) Bearing Inspection
1. Measure connecting rod big end side clearance with
a feeler gauge. Clearance should be equal on all
rods (within .002"). Rotate rod on crankshaft and
check for rough spots. Check radial end play in rod
by supporting rod against one thrust washer and
alternately applying up and down pressure.
Replace bearing, pin, and thrust washers if side
clearance is excessive or if there is any up and down
movement detectable in the big end bearing.

NOTE: Specialized equipment and a sound knowledge

of crankshaft repair and straightening is required to per-
form crankshaft work safely and correctly. Crankshaft
repair should be performed by trained Polaris seNice
technicians in a properly equipped shop.

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 fingernail along the length of the
pin and replace it if any rough spots, galling or wear is
detected.

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 your 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 centered 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 evident with
a new pin and bearing, replace the connecting rod.

10/98 3.76 Polaris Industries Inc.

 ENGINES
General Inspection Procedures
Crankshaft Truing
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 ham-
mer, always be sure to re-check previously straightened areas to verify truing. Refer to the illustrations below.

Crankshaft Alignment Fixture

PN 2870569

NOTE: The rod pin position in relation to the dial indi-

cator position tells you what action is required to
straighten the shaft.

5. To correct a situation like the one shown in the

illustration at right, strike the shaft at point A with a
brass hammer.

NOTE: The rod pin position in relation to the dial indi- SUPPORT CRANKSHAFT
cator position tells you what action is required to AT THESE TWO BEARINGS
straighten the shaft.

6. To correct a situation like the one shown in the

illustration at right, squeeze the crankshaft at HIGH .002 (.05mm)
point A. (Use tool from alignment kit).
.HIGH .005 (.13mm)

•
7. If the crank rod pin location is 180° from the dial
indicator (opposite that shown above), it will be HIGH .002 (.05mm)
necessary to spread the crankshaft at the A
position as shown in the illustration at right. When 14-~A • HIGH .005 (.13mm)
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).
•

Polaris Industries Inc. 3.77 10/98

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° (triples) apart from each other.
It is sometimes necessary to check multi-cylinder crank-
shafts 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 acci-
dent;
Abrupt piston or other mechanical failure;
Engine lock-up due to drive belt failure;

Following is a method of checking:

Disconnect battery ground cable and all spark plug high

tension leads; ground high tension leads to engine. Dis-
connect lanyard from engine stop switch before proceed-
ing 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. .100 ATDC
Dial Indicator
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.
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 Degree
center (TDC) on the cylinder with the indicator Wheel
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 .1 00"
(2.54mm) after top dead center (ATDC).

IMPORTANT: Do not allow the crankshaft to move

from this position.

10/98 3.78 Polaris Industries Inc.

 ENGINES
General Inspection Procedures
Crankshaft Indexing (Continued)
6. Bend the pointer or move the degree wheel until the
pointer aligns with the 180 or 120° mark on the
degree wheel.
7. With the pointer aligned, make sure the degree wheel
and pointer are secured and will not move out of
position. Re-check accuracy of this location by
repeating steps 4. and 5 .. The pointer should align
with the 180 or 120° mark when the dial indicator
reads .1 00" (2.54mm) ATDC.
IMPORTANT: Do not move the degree wheel or pointer
after the initial setting on the mag end cylinder - simply
read the wheel and dial indicator.

8. Remove the dial indicator and install in cylinder #2 or

center cylinder. Repeat steps 4. and 5. Note the
degree wheel indication when the dial indicator reads
.1 00" ATDC. It should be 180 or 120° (± 2°) from
cylinder #1. Repeat procedure on PTO cylinder (#3)
where applicable. Cylinder #3 should also be 120°(±
2°) from cylinder #1.
Symptoms of an out of index crankshaft can include:
Difficulty calibrating carburetor (repetitive plug
fouling on one cylinder with no other cause);
• Unexplained piston failure on one cylinder (i.e.
severe detonation, broken ring lands, piston hol-
ing);
• Excessive vibration of engine, backfiring, etc.;
• Rough idle, poor top speed.

Polaris Industries Inc. 3.79 10/98

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" (.08mm)

Cylinder Measurement
1. Inspect each cylinder for wear, scratches, or
damage. If no damage is evident, measure the
cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure
the bore 1/2" from the top of the cylinder; in line with
the piston pin and 90° to the pin to determine if the
bore is out of round. Repeat the measurements at
the middle of the cylinder and 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.

10/98 3.80 Polaris Industries Inc.

 ENGINES
General Inspection Procedures
Piston Inspection/Measurement
1. Check piston for scoring or cracks in piston crown or
pin area. Excessive carbon buildup below the ring
lands is an indication of piston, ring or cylinder wear.
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-cylinder clearance measure-
ment.

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.

Piston Ring Installed 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 cylinder.
NOTE: A difference in end gap indicates cylinder taper.
The cylinder should be measured for excessive taper
and out of round. Replace rings if the installed end gap
exceeds the service limit.

NOTE: Always check piston ring installed gap after re-

boring a cylinder or when installing new rings. Refer to
specifications in chapter 1 for piston ring installed gap.

Straight Edge
12Z-i
Piston Ring Cutaway

Keystone Piston Ring

Polaris Industries Inc. 3.81 10/98

ENGINES
General Inspection Procedures

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 71bs. of pressure. Perform this test with 40:1 premix
in fuel tank.

1. With engine in chassis, oil reservoir full, and pump

bled, remove two oil feed line banjo bolts (A) from Pressed
their location on the manifold or carburetors. NOTE:
Install new sealing washers upon installation on
either side of the banjo check valve. Apply Pressure Here
To Test
2. Loosely thread only the banjo bolts back into the
manifold or carburetors.
3. Place oil feed lines with their check valves away
from the clutch area. Start the engine and let it idle
at normal idle RPM.
Banjo

4. Lift oil pump control lever up to its maximum flow

position.

5. 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.

6. If oil does not flow from one of the check valves,

remove oil line from check valve and again idle
engine. If oil then flows, the check valve is defective
and must be replaced.

7. If oil does not flow with check valves removed from

their feed lines, the malfunction is one of the
following:
• lnline filter blocked
• Air not bled from oil pump
• Feed lines leaking
• Oil tank vent restricted or kinked
• Defective pump.

10/98 3.82 Polaris Industries Inc.

 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 bleed screw (A). After a short time oil should

flow from beneath the screw head to indicate the
pump is free of air.

3. Tighten bleed bleed screw securely.

Oil Pump Adjustment- All Models

NOTE: Adjust carburetor synchronization, idle speed,
and throttle cable free play before adjusting oil pump.

1. Stop engine.

2. With throttle in its idle position, the pump lever index

mark (A) must align with the pump housing boss
index mark (B). On domestic 500 cc engines, align
the dot on the pump arm to the mark on pump.

3. Loosen lock nuts on cable housing sleeve and vary

cable housing length as required until proper marks
are aligned. NOTE: Verify pump lever moves upon
initial throttle opening.

Oil Pump Bushing End Play Adjustment- Fuji

If the oil pump, crankcase, or any pump drive component
is replaced, inspect the drive gear bushing end play us-
ing the following procedure:

1. Assemble oil pump drive gear assembly. Be sure the

bushing is fully seated in the crankcase.
2. Measure distance from oil pump mounting surface to
bushing. Call this measurement "A".

Polaris Industries Inc. 3.83 10/98

ENGINES
General Inspection Procedures

Oil Pump Bushing End Play Adjustment- Fuji, continued

3. Measure distance from oil pump mounting flange

surface to end of seal flange as shown. Call this
measurement "B".

4. Subtract measurement "B" from "A" to determine

total bushing end play.

5. Measure thickness of existing shims and subtract

from total bushing end play determined in step 3.
6. Add or subtract shims as required to provide
specified end play.

7. Lightly grease a new 0-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. lbs. (.9 kg-m).

End Play

.008- .016" (.203- .406 mm)

Optional Shims:

PN 3083671 = .006"(.15mm)
=
PN 3083672 .012" (.3mm)
=
PN 3083673 .024" (.6mm)

Oil Pump Mounting Bolt Torque

(242 Blue)

78 in. lbs (.9 kg-m)

10/98 3.84 Polaris Industries Inc.

 ENGINES
Cooling System Bleeding Procedures
A 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.
NOTE: Always use Polaris premium antifreeze 60/40 premix. Bleed system at specified RPM or air will remain
trapped in system, which may result in overheating.

Filling and Bleeding Procedure

Lift Lock L~leed
If the cooling system should become low in the reservoir-
tank and/or filler neck, the system should be bled of any
trapped air using one of the following procedures, depend-
r---------,
ing on model.
Fuji {except 700/800 XCR)
I Remote Filler Neck
Bleed at 600 RPM
1. Elevate front end of machine approximately 10" (25
em). Caution:
2. Fill coolant reservoir to indicated maximum level line. ;, · . Increase RPM

~
slowly when lever
3. Remove pressure cap and slowly add coolant until
lock is up to avoid
coolant level iseven with top of filler neck. Install
, loss of coolant.
pressure cap and lift lever.
4. Install the pressure cap with the lever lock up in its Remote Filler Neck Shown
release position and run the engine at low idle RPM (600
RPM± 100) to allow all air to purge and prevent trapped
air which can lead to overheating and engine damage.
Reset idle to specs after bleeding. System is properly Bleed Screw
bled when no air bubbles are visible in overflow line
when RPM is increased slightly. Lock pressure cap and
fill the coolant reservoir to proper level.
700 and 800 XCR Bleeding Procedure
1. Fill cooling system. Leave pressure cap off.
2. With engine running at specified idle speed, loosen
bleed screw on water outlet manifold.
3. Continue adding antifreeze mixture to reservoir bottle
until system is purged of air.
700/800 XCR
4. Close bleed screw and tighten securely.
5. Fill reservoir bottle until it is between the minimum and
maximum fill marks. Bleed Screw
6. Replace pressure cap.
7. Start engine and check for leaks.
500/GOOnoo Domestic Twins Bleeding Procedure
1. Fill cooling system . Leave pressure cap off.
2. With engine running at specified idle speed, loosen
bleed screw on thermostat housing.
3. Continue adding antifreeze mixture to reservoir until
system is purged of air.
4. Close bleed screw and tighten securely.
5. Fill reservoir bottle until coolant level is between the 500/600/700 Domestic Twins
minimum and maximum fill marks.
6. Replace pressure cap.
7. Start engine and test for leaks.

Polaris Industries Inc. 3.85 10/98

ENGINES
Cooling System -Indy 500/500 RMK, Classic, Classic Touring
Widetrak LX, XLT Classic, XLT Touring

Note: Filter is located before

the check valve. Coolant flows
from tank, through filter, then
check valve, to water pump.

RH c oler

Crossover hose

Hose, filler/RH
cooler

LH cooler

Hose, side to center cooler

Hose, center cooler to pump

ENGINE

NOTE: When leak testing cooling system, system

pressure should not exceed 2 lbs. less than cap pres-
sure. Refer to filling and bleeding procedure on page
3.85.

LH COOLER RH COOLER

10/98 3.86 Polaris Industries Inc.

 ENGINES
Cooling System - 600 XC/SP, 700 XC/SP

Bypass Hose Not Shown

wear strip
coolers

Hose, close-off to wear strip cooler

Protective conduit

Hose, engine out to bottom close-off (center cooler)

ENGINE
BRAKE
COOLER

NOTE: When leak testing cooling system, system

pressure should not exceed 2 lbs. less than cap pres-
sure. Refer to filling and bleeding procedure on page
3.85.

CENTER
COOLER
• t

TUNNEL STRIP
COOLERS

Polaris Industries Inc. 3.87 10/98

ENGINES
Cooling System- 600 RMK, 700 RMK, 700 SKS
Bypass Hose Not Shown

Hose, tee to
brake cooler

Protective conduit

Hose, engine out to bottom close-off

Hose, tee to pump in

ENGINE

\
BRAKE
NOTE: When leak testing cooling system, system COOLER
pressure should not exceed 2 lbs. less than cap pres-
sure. Refer to filling and bleeding procedure on page
3.85.

COOLANT
BOTTLE

TUNNEL COOLERS

10/98 3.88 Polaris Industries Inc.

 ENGINES
Cooling System - 440 XCR

Hose, tee to center

cooler Hose, close-off to wear strip coolers

ENGINE

~~ COOLANT
NOTE: When leak testing cooling system, system
pressure should not exceed 2 lbs. less than cap pres-
'=:=:::::::!~CJ1t--~~ BOTTLE
sure. Refer to filling and bleeding procedure on page BRAKE
3.85. COOLER

t
~ TUNNEL STRIP
COOLERS

Polaris Industries Inc. 3.89 10/98

ENGINES
Cooling System - 500 XC/SP

Hose, rear wear strip coolers

Hose, tee to bottle

Hose, engine out to brake cooler

Hose, tee
to center
Hose, close-off to wear
cooler
strip cooler

Hose, tee out

to pump in
Hose, bypass out to tee in

ENGINE

NOTE: When leak testing cooling system, system

pressure should not exceed 2 lbs. less than cap pres-
sure. Refer to filling and bleeding procedure on page BRAKE
3.85. COOLER

• TUNNEL STRIP
COOLERS

10/98 3.90 Polaris Industries Inc.

 ENGINES
Cooling System - XLT Special

RH cooler
Center cooler

Hose, filler out

Hose, engine out

to filler

LH cooler

Hose, side to center

__},

ll
ENGINE i+1
I
II
.. FILLE R
0
NOTE: When leak testing cooling system, system
pressure should not exceed 2 lbs. less than cap pres-
sure. Refer to filling and bleeding procedure on page
• ~
3.85.

/:

l(( \\
..
' .
I
CENTER
COOLER
I
' .
LH COOLER RH COOLE

Polaris Industries Inc. 3.91 10/98

ENGINES
Cooling System - 700/800 XCR

Hose, pump to surge tank, lower

Ho e, tee to rear cooler

Hose, crossover, short

Crossover hose
Hose, center cooler to top surge tank fitting

NOTE: When leak testing cooling system, system BRAKE COOLER

pressure should not exceed 2 lbs. less than cap pres- SURGE
sure. Refer to filling and bleeding procedure on page
TANK
3.85.

t+

LH COOLE
u
RH COOLER

TUNNEL COOLERS

10/98 3.92 Polaris Industries Inc.

 ENGINES
Recoil Starter Spring Replacement
Disassembly

Wear eye protection when servicing recoil. Spring can unwind suddenly and unexpectedly if dislodged.

1. Remove recoil handle and allow rope to retract and

spring to unwind completely.

2. Remove retaining nut, friction plate, and ratchet pawl

from reel face.

3. Lift reel assembly straight up, out of housing. NOTE:

If spring tension is relieved and the reel is lifted
straight out, the spring will most likely remain in the
housing; however-be sure to heed caution above.
Assembly

1. If the spring was removed, reinstall it by spiraling

counterclockwise toward the center.

2. Lubricate center shaft and spring with grease.

Premium All Season Grease

PN 2871423 (14 oz.)

3. Wind rope in a counterclockwise direction around

outside of reel, as viewed from ratchet side of reel.

4. 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.

5. Reinstall ratchet pawl onto reel face. NOTE:

Ratchet spring must hold ratchet in retracted
position.

6. Reinstall friction plate with one end of friction spring

in hole on end of ratchet pawl.

7. Reinstall flange nut and torque to 5 ft. lbs. (.69 kg/m).

8. Pull recoil rope to full extension and align notch on

outside edge of reel with housing rope guide hole.

9. Using a needle nose pliers or hooked wire, pull a loop

of rope through the notch into center of housing.

10. Holding side of rope loop attached to reel, wind reel

counterclockwise until coil bind is felt. Then unwind
reel between one and two turns.

11. Pull loop to outside of housing by pulling on rope

handle.

12. Allow rope to fully retract and check for normal recoil
and ratchet operation.

Polaris Industries Inc. 3.93 10/98

ENGINES
Troubleshooting
PROBLEM PROBABLE CAUSE
Will not start! -Check ignition switch for run position, moisture contamination
hard starting -Check auxiliary shut-off switch operation
-Check fuel supply
-Check wiring from engine to coil(s) or spark plug(s)
-Check spark plug(s)
-Disconnect engine connector to eliminate any shorts that might be in the system
-If starter won't work (electric models), check wires from starter solenoid and battery or check battery
and battery cables
-Open or broken reed valves
Low compres- -Crankcase plug is out
sion -Head gasket faulty
-Poor ring sealing, piston damage
No spark -Spark plug fouled
-Secondary coil faulty or wires disconnected; poor ground on secondary coil mount
-Primary coil shorted or open
-Ignition switch shorted, contaminated with moisture
-Auxiliary switch shorted or contaminated with moisture
Engine idles but -Restricted fuel flow/air flow
no acceleration -Clogged main jet
-Timing
-Clutching
-Engine not running on all cylinders
Engine runs but -Clogged fuel filter
fails to reach -Incorrect track tension
maximum RPM -Incorrect main jet
-Throttle slides not fully open
-Chain too tight
-Clutching
-Excessive driveline friction (Hi Fax overheating)
-Engine not running on all cylinders
Engine runs but -Incorrect air mixture setting
fails to idle -Throttle stop screw incorrectly adjusted
-Restricted pilot jet
-Low compression
-Tight belt
-Piston damage
-Enricher plunger not seating properly
Engine runs, -Enricher plunger are not seating properly
but overloads -Fuel pump diaphragm is ruptured (caused by engine backfiring)
with fuel -Carburetor slides are not synchronized
-Main jet too large
-Needle and seat not seating properly
-Incorrect float level
-Check reed valve condition
Carburetion and -Verify all tune up adjustments: carb sync, oil pump adjustment, pilot screw setting, spark plug type
plug fouling and gap, venting for carbs, proper jetting for altitude and temperature, belt tension, clutch operation. If
tune up items are correct, check: float level, jet needle position, jet needle wear, inlet needle and seat
wear, spark quality, etc.
Engine runs but -Coolant level low or air in cooling system
overheats -Incorrect main jet
-Incorrect timing
-Incorrect spark plug
-Water pump belt loose or broken
-Cooling restriction
-Inadequate snow for cooling (ice and/or marginal conditions)
Battery will not -Check for faulty connections
charge (battery -Check alternator output
equipped mod- -Check diodes (rectifier)
els only) -Sulphated battery
-Battery electrolyte overfilled or low
-Refer to alternator testing in chapter 9, electrical

10/98 3.94 Polaris Industries Inc.

 ENGINES
Troubleshooting
PROBLEM PROBABLE CAUSE
Lights don't -Engine must be running
work -Check wiring harness connector
-Check for burned out bulbs
-Check wiring for shorts or loose connections
-Disconnect taillight if headlight works, short is in taillight wiring or taillight
Unit fails to pro- -Check belt (center distance)
pel itself -Check clutch
-Check chain
-Check drive sprocket assembly
-Track frozen or stuck
Track wears un- -Check tension
evenly -Check for proper alignment
-Check for loose, bent, or broken suspension parts
Chain case -Check oil level
overheating -Check chain tension
-Check track assembly

Polaris Industries Inc. 3.95 10/98

CHAPTER 4
FUEL SYSTEM I CARBURETION

Jet Part Numbers ............................. 4.1-4.3

1999 Condensed Data ........................ 4.4
Exploded View - TM-38 ........................ 4.5
Exploded View - Keihin ........................ 4.6
Exploded View - VM30SS . . . . . . . . . . . . . . . . . . . . . 4. 7
Exploded View - VM34SS . . . . . . . . . . . . . . . . . . . . . 4.8
Exploded View - VM38SS ..................... 4.9
Exploded View - VM34SS with ACCS . . . . . . . . . . . 4.1 0
Exploded View - Keihin with ACCS .............. 4.11
ACCS System ................................ 4.12
Gasoline Volatility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Systems ..................................... 4.14-4.15
Component Functions ......................... 4.16-4.21
Component Effect vs Throttle Opening .......... 4.22
Keihin Needle Explanation ..................... 4.23
Mikuni VM Carburetor Service .................. 4.24-4.27
Keihin Carburetor Service ..................... 4.28-4.33
Mikuni TM-38 Carburetor Service ............... 4.34-4.38
Mikuni TM-38 Synchronization Procedure ........ 4.39-4.40
Carburetor Adjustments ....................... 4.41
Primer Systems .............................. 4.42
Fuel Pump Operation ......................... 4.43
Exploded View- Fuel Pumps ................... 4.44-4.47
Water Trap Service ........................... 4.48
Troubleshooting .............................. 4.49-4.50
 FUEL SYSTEM/CARBURETION
Jet Part Numbers
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 you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change cloth-
ing.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poi-
sonous and can cause loss of consciousness and death in a short time.
Jet Part Numbers
The following chart lists main and pilot jets and the part number of each that are presently available.
Mikuni Mikuni Keihin Keihin
PILOT JET NO. PART NO. PILOT JET NO. PART t:cJO. PILOT JET PART NO. PILOT JET PART NO.
25 ............. 3130064 50 3130069 35 . . . . . 3050219·35 50 ..... 3050219·50
30 ............. 3130065 55 3130070 38 ..... 3050219·38 52 ..... 3050219·52
35 ............. 3130066 60 3130071 40 ..... 3050219·40 55 ..... 3050219·55
40 ............. 3130067 65 3130072 42 ..... 3050219·42 58 ..... 3050219·58
45 ............. 3130068 45 . . . . . 3050219·45 60 ..... 3050219·60
50 ............. 3130629 48 . . . . . 3050219·48 62 ..... 3050219·62
55 ............. 3130070 65 3050219·65
Mikuni Mikuni Keihin
HEX HEAD HEX HEAD Long Hex Head
MAIN JET NO. PART NO. MAIN JET NO. PART NO. MAIN JET NO PART NO.
80 ............. 3130099 250 ............ 3130128 140 ......... 3050235·140
85 ............. 3130100 260 ............ 3130129 142 ......... 3050235·142
90 ............. 3130101 270 ............ 3130130 145 ......... 3050235·145
95 ............. 3130102 280 ............ 3130131 148 . . . . . . . . . 3050235·148
100 ............ 3130103 290 ............ 3130132 150 ......... 3050235·150
105 ............ 3130104 300 ............ 3130133 152 ......... 3050235·152
110 ............ 3130105 310 ............ 3130134 155 ......... 3050235·155
115 ............ 3130106 320 ............ 3130135 158 •• 0 •••• 0. 3050235·158
120 ............ 3130107 330 ............ 3130136 160 ••••• 0. 0. 3050235·160
125 ............ 3130108 340 ............ 3130137 162 ......... 3050235·162
130 ............ 3130109 350 ............ 3130138 165 • 0 ••••••• 3050235·165
135 ............ 3130110 360 ............ 3130139 168 • 0 •••• 0 •• 3050235·168
140 ............ 3130111 370 ............ 3130290 170 ......... 3050235·170
145 ............ 3130112 380 ............ 3130140 172 ......... 3050235·172
150 ............ 3130113 390 ............ 3130480 176 ......... 3050235·176
155 ............ 3130114 400 ............ 3130141 178 ......... 3050235·178
160 ............ 3130115 410 ............ 3130599 180 ......... 3050235·180
165 ............ 3130116 420 ............ 3130142 182 . . . . . . . . . 3050235·182
170 ............ 3130117 430 ............ 3130143 185 ......... 3050235·185
175 ............ 3130118 440 ............ 3130144 188 ......... 3050235·188
180 ............ 3130119 450 ............ 3130145 190 .. .. .. .. . 3050235·190
185 ............ 3130120 460 ............ 3130146 192 ......... 3050235·192
190 ............ 3130121 470 ............ 3130147 195 ......... 3050235·195
195 ............ 3130122 490 ............ 3130148 198 ......... 3050235·198
200 ............ 3130123 500 ............ 3130149 200 . . . . . . . . . 3050235·200
210 ............ 3130124 530 ............ 3130150 205 . . . . . . . . . 3050235·205
220 ............ 3130125 560 ............ 3130151 210 . . . . . . . . . 3050235·21 0
230 ............ 3130126 590 ............ 3130152 215 . . . . . . . . . 3050235·215
240 ............ 3130127 620 ............ 3130153 220 . . . . . . . . . 3050235·220

Polaris Industries Inc. 4.1 10/98

FUEL SYSTEM/CARBURETION
Jet Part Numbers

Jet Needle Part Numbers (Mikuni}

JET NEEDLE NO. PART NO. JET NEEDLE NO. PART NO.
5DP7 ........... 3130155 6DH4 ................ 3130402
5DT49 .......... 3130154 6DH5 ................ 3130391
5DP10 .......... 3130333 6DH7 ................ 3130329
5DP10 .......... 3130310 6DH8 ................ 3130645
5DT2 ........... 3130473 6DH29 ............... 3130462
5D78 ........... 3130667 6DP1 ................ 3130156
5F81 ............ 3130528 6DP17 ............... 3130374
6CEY6 .......... 3130476 6EJ26 ............... 3130423
6CF1 ........... 3130725 6EJ3 ................ 3130680
6CGY3. . . . . . . . . . 3130484 6F4 ................. 3130319
6CGY6 . . . . . . . . . . 3130652 6F9 ................. 3130378
6DH3 ........... 3130470

Jet Needle Part Numbers (Keihin}

JET NEEDLE NO. PART NO. JET NEEDLE NO. PART NO.
R-1368G . . . . . . . . 3050244 R-1369G . . . . . . . . . . . . . 3050245
R-1370G . . . . . . . . 3050220 R-1370J ............. 3050221
R-1371 G . . . . . . . . 3050256 R-1371J ............. 3050246
R-1372J ......... 3050247

Needle Jet Part Numbers (Mikuni}

NEEDLE JET NO PART NO. NEEDLE JET NO PART NO.

P-4 (159} ........ 3130162 P-6 (247) ............. 3130655
P-2 (166) ........ 3130460 P-8 (247) ............. 3130382
P-4(166) ........ 3130348 Q-0 (247) ............ 3130414
P-4 (166) . . . . . . . . 3130499 Q-2(247) ............ 3130165
P-6 (166) ........ 3130160 Q-4(247) ············ 3130603
P-8 (166) ........ 3130421 Q-8 (247) ............ 3130485
Q-2(166} ........ 3130376 R-0 (247) ............ 3130477
0-4 (169} ........ 3130166 P-0 (286} ............. 3130607
0-4(169) ........ 3130409 P-2 (286) ............. 3130608
0-6 (169) ........ 3130358 0-4 (286} ............ 3130635
0-6 (169} . . . . . . . . 3130469 0-6 (480) ............ 3130429
0-8 (169} ........ 3130453 0-8 (480} ............ 3130683
0-8 (171} ........ 3130035 P-2 (480} ............. 3130675
P-0 (225} . . . . . . . . 3130579 P-4(480) ............. 3130639
P-2 (255) . . . . . . . . 3130608 Q-6 (480} ............ 3130618
P-2 (259) . . . . . . . . 3130161 P-8 (513) ............ 3130510
P-0 (247) ........ 3130671
P-2 (247) ........ 3130672
P-4 (247) ........ 3130641

Throttle Valve Part Numbers (Keihin}

Throttle Valve No. PART NO.
3.0 ............ . 3050234-802
4.0 ............ . 3050234-C02
5.0 3050234-D02
5.5 ............ . 3050234-J02
6.0 ............ . 3050234-E02
6.5 3050234-K02
7.0 ............ . 3050234-F02
7.5 ............ . 3050234-L02
8.0 ............ . 3050234-G02
9.0 ............ . 3050234-H02

10/98 4.2 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Mikuni TM-38 Jet Part Numbers
DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER
Jet Needles Pilot Air Jets Cont.
Jet Needle J8-9FH04-57 3130794 Pilot Air Jet 1.3 3130781
Jet Needle J8-9EH01-57 3130795 Pilot Air Jet 1.4 3130782
Jet Needle J8-9DH01-54 3130796 Pilot Air Jet 1.5 3130783
Jet Needle J8-9CJB01-50 3130797 Pilot Air Jet 1.6 3130784
Needle Jets Pilot Air Jet 1.7 3130785
Needle Jet 0-8 3130798 Pilot Air Jet 1.8 3130786
Needle Jet P-0 3130799 Pilot Air Jet 1.9 3130787
Needle Jet P-2 3130800 Pilot Air Jet 2.0 3130788
Needle Jet P-4 3130801 Piston Valves (Slides)
Needle Jet P-6 3130802 Piston Valve 1.5 3130940
Needle Jet P-8 3130803 Piston Valve 2.0 3130789
Needle Jet Q-0 3130804 Piston Valve 2.5 3130790
Starter Jets Piston Valve 3.0 3130791
Starter Jet 130 3130805 Piston Valve 3.5 3130792
Starter Jet 135 3130767 Piston Valve 4.0 3130793
Starter Jet 140 3130768
Starter Jet 145 3130769
Starter Jet 150 3130770
Starter Jet 155 3130771
Starter Jet 160 3130772
Pilot Air Jets
Pilot Air Jet 0.5 3130773
Pilot Air Jet 0.6 3130774
Pilot Air Jet 0.7 3130775
Pilot Air Jet 0.8 3130776
Pilot Air Jet 0.9 3130777
Pilot Air Jet 1.0 3130778
Pilot Air Jet 1.1 3130779
Pilot Air Jet 1.2 3130780

The part numbers for main jets and pilot jets are the same as Mikuni VM round slide carburetors.

Polaris Industries Inc. 4.3 10/98

FUEL SYSTEM/CARBURETION
1999 Condensed Data -
Machine Engine Carburetor Std. Std. Air Jet Needle Needle Throt. Float
Model Model Model, Mount Type Main Jet Pi- Screw & Jet# Valve Level
&No. lot (Turns ECiip Cutaway
Jet Out) (see
note be-
low)

Indy 340/ EC34-2PM051 VM30SS (2)Zinc 150 35 1 1/2 5DP7 0-6 2.5AL 1
340 Deluxe/ #2 (169)
340Touring

Indy Sport/ EC44-3PM025 VM34SS (2)Zinc 185 35 1 6FJ6 P-8 2.0AL 1

Sport Touring/ #3 (166)
TranSport
Indy XCF EC45PM011 VM34SS (2)Zinc 270 40 1 6DP1 P-8 3.0 1
#3 (480)

Indy 440 XCR SN44-44-98A 1 VM34SS 360 45 1 1/4 6DH7 P-4 2.0 1
#3 (286)
Indy Trail/Touring EC50PM044 VM34SS (2)Zinc 230 40 1 6DH7 P-8 3.0 1
#3 (166)
Indy Trail RMK EC55PM021 VM34 (2)Zinc 270 35 1 1/2 6DH7 Q-0 3.0 1
(ACCS) #3 (480)
Indy Super Sport EC55PM011 VM34SS (2)Zinc 310 35 1 1/2 6DH7 Q-2 3.0 1
#3 (480)

Indy 500/ EC50PL172 VM38SS (2) AL 350 45 3/4 6F9 P-6 2.5 1
500 Classic #3 (247)
Indy 500 RMK EC50PL162 VM34SS (2)Zinc 260 55 1 1/4 6FJ43 P-0 2.5 1
(ACCS) #3 (480)
Indy Classic Trng EC50PL192 VM34SS (2)Zinc 250 35 3/4 6EJ26 P-2 3.0 1
#3 (480)
Indy XLT SP EC58PL160 TM-38 {3) 360 35 1 1/2 9DH3-54 0-6 3.0 3
#3
Indy XLT Classic EC58PL131 VM34SS (3)AL 250 40 1 6DP17 Q-4 2.5 1
#2 (480)
XLT Touring EC58PL131 VM34SS (3)Zinc 250 40 1 6DP17 Q-4 2.5 1
#2 (480)
Indy 500 XC I SP S50-44-99A2 TM-38 (3) 370 45 2 6FH4-57 P-6 1.5 3
#3
Indy 600 XC I SP SN60-70-99A2 Keihin PWK 39 (2) 185 38 1 R1368G 5.5 2
AL #3 FIXED
Indy 700 XC I SP SN70-70-99A2 Keihin PWK 39 (2) PT0-185 38 1 R1368G 5.5 2
AL MAG-190 #3 FIXED
Indy 600 RMK S N60-70-99A 1 Keihin PWK 39 (2) 185 50 1 R1367G 6.0 2
(ACCS) #2 FIXED
Indy 700 RMK SN70-70-99A3 Keihin PWK 39 (2) 190 48 1 R1368G 6.0 2
(ACCS) #2 FIXED
lndy700 SKS SN70-70-99A1 Keihin PWK 39 (2) PT0-185 38 1 R1368G 5.5 2
(ACCS) MAG-190 #3 FIXED
Indy WideTrak LX EC50PL202 VM34SS (2)Zinc 195 35 1/2 6EJ26 P-6 3.0 1
#2 (166)
Indy 700 XCR EC70PL011 TM-38 (3) 430 50 1.5 9CG1-54 P-4 2.0 3
#3 (825)

Indy 800XCR EC79PL011 TM-38 (3) 450 50 1.25 9DH6-54 P-4 2.0 3
#3 (825)

Fuel Requirements: All 1999 models 87 non-oxygenated or 89 oxygenated.

Float Levels: 1. With carburetor inverted and float bowl removed, float arm must be parallel with float bowl
gasket mating surface.
2. Use Keihin float level gauge tool PN 2872126 to achieve 16mm float height
3. Floats are not adjustable on Mikuni TM-38 carburetors.

10/98 4.4 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Exploded View -Mikuni TM - 38

Top Cap

~---Adjustment Screw

1 4 ~ ~,- R'lng CheGk Valve

~
riil" ......__,Lever
~ Plate
/
~Cap
~Adjuster
o@ ., Plate /
d ~ ~= d
•
CD
CD ~
//Packing
/ /F,
t unne 1 8 @@mr. /
Cap \ ~@ ,y- E-Ring , ~@~
~ . Ring Spring ,/ Spring
®--Guide ~ / / . rr----Pilot Jet
Holder Piston Valve , / Main Jet-~ Starter Jet
~- Spring ~
®!JD~r /
Jet Needle, /

\ _/ Float/Needle &
d
Plunger I' / -.........._ Pilot Air Jet
o / Seat Asm.

v ~
'

Float Body

Drain Plug ----Q I

&

Polaris Industries Inc. 4.5 10/98

FUEL SYSTEM/CARBURETION
Exploded View - Keihin

Adjuster
ft~ if3/ L o c k Nut
Gasket~ -~~
Spring ~
~1:Sl
~ /Spring Seat
~ /Retainer

Jet Needle V'-~~ "E" Clip

/Vent

1 /"1 ~, /e
~/-- ,~./

Idle Adjustment /,
1~ " '
serene
~
~~~~
I •
~-1 Main Jet
~ ·. ~ ft~ Fuel Inlet Needle
Air Screw ~ a Float
Pilot Jet

0-Ring

10/98 4.6 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Exploded View - VM30SS

Mixing Chamber Top

(Including Gasket)

Throttle Spring

Polaris Industries Inc. 4.7 10/98

FUEL SYSTEM/CARBURETION
Exploded View - VM34SS

Mixing Chamber Top

(Including Gasket)

---Throttle Spring

Plunger Cap

V Plunger Spring
J tNeedle V
Th rattle Valve VPiunger
I

)
(/

Drain Plug

10/98 4.8 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Exploded View - VM38SS

~ Mixing Chamber Top

~Y (Including Gasket)

Throttle Spring

Plunger Cap
Plat
(Plunger Spring

rPiunger

(/)

Drain Plug -~ •

Polaris Industries Inc. 4.9 10/98

FUEL SYSTEM/CARBURETION
Exploded View- VM34SS with ACCS- Trail RMK/500 RMK

MAG.SIDE PTO.SIDE

Rubber Pipe

ACCS Valve Markings:

Trail RMK:
500 RMK: 50M05

ACCS Valve

Do not change calibration setting

or serious engine damage may result.

ACCS valves cannot be interchanged between models. When replacing a faulty valve, be sure the
identification number stamped on the valve body is correct.

10/98 4.10 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Exploded View- Keihin Carbs with ACCS- 600 RMK/700 RMK

ACCS
Valve

ACCS Valve

ACCS Valve Markings:

600 RMK: 1253232
700 RMK: 1251086

Do not change calibration setting

or serious engine damage may result.

ACCS valves cannot be interchanged between models. When replacing a faulty valve, be sure the
identification number stamped on the valve body is correct.

Polaris Industries Inc. 4.11 10/98

FUEL SYSTEM/CARBURETION
ACCS System

Altitude Compensating Carburetor System (ACCS)

The Altitude Compensating Carburetor System (ACCS) is designed to automatically compensate for changes
in altitude. This allows the snowmobile to operate in changing elevations without having to change jets, although
extreme temperatures may require re-jetting for optimum performance. Refer to the jetting compensation chart
in the specifications sections.
A vacuum line is connected to the float bowl.
The ACCS valve is connected to this line via High Atmospheric Pressure-
the 4-way manifold. At low altitude the ACCS • Bellows compress
valve supplies atmospheric pressure to the • Fuel flow increases
vacuum line and the float bowl (see Ill. 1). Vacuum from
Venturi To Float Bowls

This
end
fixed

Low Altitude I High

Atmospheric Pressure
ACCS System Ill. 1

At high altitudes the bellows expand, moving

the plunger to the left and closing off some of Low Atmospheric Pressure-
• Bellows expand
the passageways through the ACCS valve
• Fuel flow decreases
(see Ill. 2}. This prevents atmospheric pres-
sure from reaching the float bowl, allowing the
vacuum line to reduce the pressure in the float To Float Bowls
bowl. This reduces the amount of fuel sup-
plied through the carburetor, preventing the
mixture from becoming too rich.
NOTE: The ACCS valve is calibrated specifi-
cally for the model it was intended. There are
no adjustments for the valve, and it should not This
be tampered with in any way. end
fixed

Ill. 2

10/98 4.12 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Gasoline Volatility
Explanation of Gasoline Volatility
One of the sometimes misunderstood properties of gasoline is its volatility, or ability to vaporize at different ambi-
ent temperatures and altitudes during the year.
When gasoline is blended, it is given a Reid Vapor Pressure (RVP) number which reflects its ability to vaporize
or mix with air at a given temperature range. Gasoline vapor pressure is measured by putting a sample of fuel
inside a closed container and applying a specified amount of heat to the container for a certain amount of time.
RVP will vary from about 7.0 PSI during the summer to approximately 13.5 PSI during the colder months. Service
stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the
year in their local area.

When the weather is very cold, gasoline must be able to vaporize very quickly in order for an engine to start and
warm up properly. If summer blend fuel is being used in the winter, little or no vaporization will occur. Droplets
will form causing flooding and very hard starting.
If winter blend fuel is being used during the summer months, it may cause vapor lock (boiling fuel) inside the fuel
lines, fuel pump, or carburetor. This will cause warm engine driveability problems and hard starting when warm.
Some states are limiting the Reid Vapor number to 9.0 PSI year around to help meet evaporative emissions stan-
dards.

Warm Weather Low Vaporization Rate

Maximum Reid Vapor Ambient Air Temp. Range
Class Pressure Low High
A 7.0 PSI 60° F 11 oo F +
B 9.0 PSI 50° F 110° F
c 10.5 PSI 40° F 9JC F
D 12.0 PSI 30° F 85° F
E 13.5 PSI 20° F 69° F

Cold Weather High Vaporization Rate

Add 2.4° F for each 1000 feet above seal level.

Polaris Industries Inc. 4.13 10/98

FUEL SYSTEM/CARBURETION
Systems
Float Chamber Venting
Fuel flows through a carburetor by creating a pressure difference between the venturi and the float bowl. The
greater the pressure difference, the greater the fuel flow. On some models the float bowl is vented to the handle-
bars. This provides consistent atmospheric pressure for a consistent fuel flow. If the vent lines become kinked,
plugged, or exposed to fluctuating pressures (under hood) the pressure difference will change, causing erratic
fuel flow.
Polaris has airbox venting on some models. The vent lines are connected to a baffle inside the airbox. This pro-
vides a more consistent pressure difference between the carburetor venturi and the float bowl as the vacuum
inside the airbox changes. For example, if the airbox foam filter becomes restricted with snow when riding in pow-
der, the airbox vacuum increases. Without airbox venting, the pressure difference would increase substantially,
choking or flooding the engine. With airbox venting, the pressure difference remains the same, creating a slightly-
leaner mixture to compensate for reduced air flow.

Vent Line Routing

(Opposite Carb to Handlebar)

Tee Fitting

One Way
Check Valve _____., j \:---'r-tt--- Atmospheric
Pressure
Drain Hose _ __,, 61i~:Ction
Through
Valve Some Models Have
Interconnecting Lines Between each Carb

-V Tee Fittings Are

Orientated Vertically
I_
I
~
$
~
Air Box

Some models have airbox venting

10/98 4.14 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Fuel Delivery System - Typical

The fuel system contains many components which directly affect fuel mixture and driveability. When performing
diagnosis or carburetor maintenance, the entire fuel delivery system should be inspected. The illustration below
shows parts of the system requiring periodic maintenance to ensure there is no fuel or air leaks present.
Fuel filters should be replaced at least once per season or more often if any contamination is suspected.
Fuel lines should be replaced every other season or more often if they become brittle or swollen. Fittings should
be inspected at that time for cracks or leaks.
Test run and check the fuel system for leaks any time parts are replaced. Verify that all lines are routed correctly
away from any moving parts.

I
Vent Lines
Carb Mounts

Weighted Pickup
and Line

NOTE: 1999 500 XC and 500 XC SP fuel filters are inside the fuel tank. To inspect/replace filter:
• Remove fuel from tank
• Remove air box
• Remove fuel line fitting from fuel tank
• Pull fuel line, pickup, and filter from tank

Polaris Industries Inc. 4.15 10/98

FUEL SYSTEM/CARBURETION
Typical Mikuni Starter System - Closed Throttle
Mikuni carburetors use a starter enricher system rather than a choke. In this type of carburetor, fuel and air for
starting the engine are metered with entirely independent jets. The fuel metered in the starter jet is mixed with
air and is broken into tiny particles in the emulsion tube. The mixture then flows into the plunger area, mixes again
with air coming from the air intake port for starting and is delivered to the engine through the fuel discharge nozzle
in the optimum air/fuel ratio. The starter is opened and closed by means of the starter plunger. The starter type
carburetor is constructed to utilize the negative pressure of the inlet pipe, so it is important that the throttle valve
is closed when starting the engine.

,- ;:=--=---=------=---=---.. : : - ~ --=---=---=---=---=--=--=--=--=---=-.. ::::-- ,-,

II II
,, ~~
II Cable Adjuster I 1
II II
II I I
l: Cable Adjuster Lock Nut II
II
~~
Plunger Spring l~~~o~
I1 Plunger Cap Throttle Valve
II Starter Plunger

llI ,_ -=-=~-__J

Inlet Bleed Air

Starter Jet

10/98 4.16 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Pilot System (0-3/8 Throttle)
The pilot system's main function is to meter fuel at idle and low speed driving. Though its main function is to supply
fuel at low speed, it does feed fuel continuously throughout the entire operating range.
Fuel for the pilot jet is drawn from the float bowl, mixed with air regulated by the air screw, and delivered to the
engine through the pilot outlet.
The mixture is regulated to some degree by adjusting the air screw. When the air screw is closed, the 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.

Throttle Valve

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

Pilot Air Screw

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

Polaris Industries Inc. 4.17 10/98

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

Cutaway Angle
Throttle Valve
Jet Needle
By-pass
Pilot Outlet

Pilot Jet

Main Jet

3.

Leaner Richer

Throttle Valve

The throttle valve controls the rate of engine air intake

by moving up and down inside the main bore. At small I
throttle openings, air flow control is performed chiefly
by the cutaway. By controlling air flow the negative
pressure over the needle valve is regulated, in turn
varying the fuel flow.
I
The throttle valves are numbered 1.0, 1.5, 2.0, etc., ~__i Cutaway
according to the size of the cutaway. The higher the - ~
number, the leaner the gasoline/air mixture.

10/98 4.18 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Jet Needle/Needle Jet (3/8-3/4 Throttle)

The jet needle and needle jet have the most effect be-
tween 3/8 and 3/4 throttle opening. Some mixture adjust-
ment can be accomplished by changing the location of the
"E" clip on the needle. Moving the clip down raises the
needle in the jet passage and richens the mixture. Moving
the clip up lowers the needle in the jet passage and leans Throttle Valve
the mixture. Letter and number codes are stamped into Jet Needle
the needle and the jet indicating sizes and tapers (needles By-pass
only) of each.
Pilot Outlet

Jet Needle I Needle Jet - Fig. 1

The jet needle tapers off at one end and the clearance be-
tween the jet needle and the needle jet increases as the
throttle valve opening gets wider. The air/fuel mixture ratio Pilot Jet
is controlled by the height of the "E" ring inserted into one Needle Jet
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.

Needle Jet - Fig. 2

The needle jet works in conjunction with the jet needle to

~
regulate fuel flow rate. An air bleed opening in the side of .r-2
the needle jet brings in air measured by the air jet. This air -3
~4
initiates the mixing and atomizing process inside the needle
jet. Mixing is augmented by a projection at the needle jet
4
outlet, called the primary choke. The letter number code
stamped on the jet indicates jet inside diameter.

Throttle Opening vs. Fuel Flow - Fig. 3

In a full throttle condition the cross sectioned area be-
tween the jet needle and the needle jet is larger than
the cross sectioned area of the main jet. The main jet
therefore has greater control over fuel flow.

Large
Clearance

15 50 75 100%
Fig. 1 Throttle Valve Opening

Air Bleed
Opening

Closed
Throttle
One-half
Throttle
Full
Throttle Fig. 3
Fig. 2
i
Polaris Industries Inc. 4.19 10/98
FUEL SYSTEM/CARBURETION
Main System (3/4 to Full Throttle)
The main system is designed to deliver 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 Throttle Valve
system works in conjunction with the needle jet sys- et Needle
tem.
By-pass
During low speed driving, there is very little clearance Pilot Outle
between the jet needle and the needle jet; therefore,
very little fuel from the main jet can pass between the
jet needle and the needle jet. As the throttle valve
opening is increased, the tapered jet needle is raised
farther out of the needle jet, allowing greater fuel flow.
Under full throttle opening, the cross sectioned area of
clearance between the jet needle and the needle jet
becomes greater than the cross sectioned area of the
main jet. Thus the main jet is now controlling the
amount of fuel flow.

Main Jet

When the throttle opening becomes greater and the

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

Keihin Main Jet

The number on the Keihin main jet corresponds to the
diameter of the metering orifice.

Jetting Guidelines
Changes in altitude and temperature affect air density, which is essentially the amount of oxygen available for
combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher
temperatures, the air is less dense.
Carburetors on most Polaris models are calibrated for an altitude of 0-3000 ft (0-900 meters) and ambient temper-
atures between -20° to+ 1oo F (-29° to -12° C). All carburetors must be re-calibrated if operated outside the pro-
duction temperature and/or altitude range. The main jet installed in production is not correct for all altitudes and/or
temperatures.

A main jet that is too small will cause a lean operating condition and may cause serious engine damage.
Jet the carburetors carefully for elevation and temperature according to the jetting charts in this manual,
or the jetting charts in the Owner's Safety and Maintenance Manual for each particular model.
NOTE: It is the owner's responsibility to ensure that the correct jets are installed in the machine for a geographical
area. Be very careful when jetting down in warm weather. As the weather turns colder it will be necessary to re-jet
upward to prevent engine damage. When selecting the proper main jet always use the lowest elevation and tem-
perature that is likely to be encountered.

10/98 4.20 Polaris Industries Inc.

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

Polaris Industries Inc. 4.21 10/98

 FUEL SYSTEM/CARBURETION
Component Effect vs Throttle Opening

z
en
<t
w
a:
0
z I
I
EFFECT I
G
z I
UJ I
<t I
w
a: I
0
w I
c
I

0 1/8 1/4 3/8 1/2 5/8 3/4 7/8 FULL

THROTTLE OPENING- TYPICAL MIKUNI VM

- - - - - - - - Throttle Valve Cut-Away

- - - Jet Needle/Needle Jet
Polaris TM-38 Mikuni component effect versus throttle opening chart.

needle valve

Main jet needle

needle jet

throttle valve
bypass
Slow ot outlet
air jet
hoke plunger 100%
Start starter jet 100%
(
fuel screw

0 start idle 1/4 1/2 3/4 Full

Throttle Position

10/98 4.22 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Keihin Needle Explanation
Polaris currently uses Keihin PWK 39 carburetors on some of the domestic engines. What follows is an explanation of Keihin
jet needle nomenclature.

NOTE: Polaris carburetors are calibrated correctly for their intended use. It is not necessary to change needles for normal
applications. The following is intended to be used as information to better understand the operation of Keihin carburetors and
does not suggest that a technician should be changing jet needles for any reason. The only change for the needle that Polaris
normally recommends is to the "clip" position.

Use illustrations below and the explanation to determine the affect and characteristics of different jet needles.
Keihin needles generally affect fuel delivery in three areas:
1. The diameter (D) of the needle primarily controls fuel delivery from 1/8 to 1/4 throttle openings. A needle with a smaller diameter at
"D" would be richer than a needle with a larger diameter at "D" in the 1/8 to 1/4 throttle range.

2. The length (L 1) of the needle mainly affects fuel delivery from 1/4 to 1/2 throttle openings. A shorter needle will be richer and a longer
needle will be leaner. This produces same effect as raising or lowering the needle clip, but to a larger degree.

3. The taper (A) primordially controls fuel delivery from 1/2 to 3/4 throttle openings. A steeper taper will deliver more fuel in this throttle
position range.

EXAMPLE: R-1370G
Taper "A"
R-1370G

L 1 and Clip Position

R-1370~

Diameter @ "D"
R-1370G

0 1/8 1/4 1/2 3/4 Full 2.515mm

Ill. 1 Throttle Opening

R = Aluminum Construction
13 =Taper Angle of the needle (depicted at point "A")
13= 1°34' a 14 would be 1°45'
The larger the number= the steeper the taper.
A steeper taper is richer than a shallow taper.
An R-1470G needle would be richer in the 1/2 to 3/4
throttle range than a R-1370G needle.
70 = Diameter of the straight portion of the needle (see
point "D").
A larger diameter needle at point "D" would be
leaner in the 1/8 to 1/4 throttle range than a needle
with a smaller diameter at point "D".
A R-1368G has a diameter of 2.685mm at point "D"
A R-1370G has a diameter of 2.705mm at point "D"
G = The length from the top of the needle to a point on the
taper that is 2.515mm in diameter.
A "G" is shorter than a "J".
This length mainly affects mixture in the 1/4 to 1/2
throttle range.
A R-1370G is shorter at "L 1" than a R-1370J and
a R-1370G is richer in the 1/4 to 1/2 throttle range
than a R-1370J.

Polaris Industries Inc. 4.23 10/98

FUEL SYSTEM/CARBURETION
Mikuni VM Carburetor Service

Wear eye protection when using compressed air or cleaning

solvents. Review all fuel system warnings found on page
4.1 before proceeding.

Carburetor Removal, Disassembly, and Inspection (Typical VM Mikuni)

1. Remove carburetor from engine. Before

disassembling, clean outside of carburetor thoroughly
with solvent.

I·. CAUTION: I
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. Remove slide valve. Inspect for nicks or burrs which

may cause sticking. Cap---C)
-::?J
Gas ket___<i;:'-
3. 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
Spring

"E" Clip
1
------ , /
Q)
Retainer Plate
Jet Needle
somewhere along the taper.

Slide Valve ---e1

--~- /

4. Remove enricher (choke) plunger. Check condition of

seal on tip of plunger. Any nicks or cuts will cause

Spring~i
leakage and a rich fuel condition, usually most evident
at idle and low speeds. Inspect the plunger seat for
damage or foreign material.
I

~-----
5. Check choke cable movement. Plungers and springs
should move back and forth freely, without binding.

Plunger Seat

10/98 4.24 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Mikuni VM Carburetor Service

Carburetor Disassembly and Inspection

6. Remove water trap assembly from float bowl and inspect

0-ring, hose and clamp condition. Refer to exploded LHJ....---- Trap Nut
view corresponding with carburetor being serviced.
I
~

Hose_ fi Clamp

~ DrainPiug

f/
7. Inspect enricher (choke) fuel supply passage in bowl for
obstruction.

8. Use an automatic center punch to remove float arm pin.

Remove inlet needle and seat assembly.

9. Inspect needle for wear and replace sealing washers

upon reassembly.

Do not bend float arm during disassembly. Do not use exces-

sive force to remove float arm pin. The float pin tower cast-
ings are very easily damaged and are not repairable.

Polaris Industries Inc. 4.25 10/98

FUEL SYSTEM/CARBURETION
Mikuni VM Carburetor Service

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.

Wear eye protection when using compressed air or cleaning

solvents. Review all fuel system warnings found on page
4.1 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.
13. Reassemble carburetor, adjusting float level before
installing float bowl.
Refer to page 4.27 for float level adjustment and leak testing
procedures.

10/98 4.26 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Mikuni VM Carburetor Adjustments

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: 'I
Never bend the float arm itself.

Leak Testing Needle and Seat

1. Be sure float level is adjusted properly.
2. Invert carburetor.
3. Install float chamber and connect pressure tester PN
2870975 to fuel inlet fitting.

Pressure Tester PN 2870975

4. 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.

Polaris Industries Inc. 4.27 10/98

FUEL SYSTEM/CARBURETION
Keihin Carburetor Service

Wear eye protection when using compressed air or cleaning

solvents. Review all fuel system warnings found on page
4.1 before proceeding.

Carburetor Removal, Disassembly, and Inspection

1. Remove carburetor from engine. Before

disassembling, clean outside of carburetor thoroughly
with solvent.

Do not use compressed air to dry at this time. The float

chamber could become pressurized resulting in damage to
the floats or inlet needle and seat. Do not soak Keihin car-
buretors in carb cleaner. Clean only with aerosol cleaner.

2. Remove slide valve. Inspect for nicks or burrs which

may cause sticking.

3. Remove jet needle by compressing return spring

toward top cap and removing throttle cable.
Disconnect cable holder and remove jet needle. Note
"E" clip position and inspect needle taper for wear. An
indication of wear would be an hourglass shape or
polished spots somewhere along the taper.

4. Remove enricher (choke) plunger. Check condition of

seal on tip of plunger. Any nicks or cuts will cause

Spring~~
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 enricher (choke) cable movement. Plungers
and springs should move back and forth freely, without
~~
binding.
Plunger Seat

10/98 4.28 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Keihin Carburetor Service

Disassembly Cont.

6. Remove water trap assembly from float bowl and inspect

0-ring, hose and clamp condition. Refer to exploded
view corresponding with carburetor being seNiced.
r{P--- Trap Nut

I
g

Hose , (j Clamp

~
X/
DrainPiug

7. Inspect choke fuel supply passage as shown for

obstruction.

8. Remove float arm pin. Remove inlet needle. NOTE:

Seat assembly is not replaceable. DO NOT remove.

9. Inspect needle for wear.

I: CAUlJO~; ' I
Do not bend float arm during disassembly. Do not use exces-
sive force to remove float arm pin. The float pin tower cast-
ings are very easily damaged and are not repairable.

Polaris Industries Inc. 4.29 10/98

FUEL SYSTEM/CARBURETION
Keihin Carburetor Service

Carburetor Disassembly Cont.

10. Remove main jet.

11. Remove pilot jet.

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.

10/98 4.30 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Keihin Carburetor Service

Carburetor Assembly
1. Install pilot jet and main jet.

2. Install inlet needle and float assembly.

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.

Float Height- Keihin:16mm ± 2 mm

Float Level Guage: PN 2872126

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.

Polaris Industries Inc. 4.31 10/98

FUEL SYSTEM/CARBURETION
Keihin Carburetor Service

Leak Testing Needle and Seat

1. After adjusting float level, place carburetor in an

inverted position.
2. 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

3. Carefully inspect float bowl gasket and replace if

necessary. Install float bowl on carburetor.
4. Install idle screw and air adjusting screw.
5. Install jet needle E-clip into correct groove on needle
jet.

6. Install jet needle into throttle valve.

7. Screw cable holder into throttle valve to secure jet

needle and throttle valve.

8. Inspect gasket under throttle cap. Install throttle cable,

spring, and collar. Connect cable to slide valve.
9. Install carburetor top cap until seated on carburetor
body.

10/98 4.32 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Adjustments
Throttle Synchronization Procedure-Mikuni and Keihin
1. Remove air box, noting position of throttle cable .....-------------------,
junction block. Reposition throttle cable and junction Drill gauges with 8mm ap
block in same position when air box is reinstalled.
Throttle Cable Synchronization (Throttle Gap) l_c::t:=;;t;:L-------~*==
2. Referring to specification section in chapter 1, select
correct diameter Throttle Gap synchronization drill
gauge for your engine. KEIHIN
NOTE: Keihin carburetors, require a special tool with two Carburetor Synchronization Tool
drill gauges separated by an 8mm gap. See illustrations
Refer to Specification Section for
at right. Tool Part Number
Ill. 1
3. Back out idle screws about three turns.
4. Slightly lift throttle slides with throttle lever and insert KEIHIN
tool or drill gauge under throttle slide. Allow throttle Insert tool under
slides to return. NOTE: Be sure tool is positioned slide; push in until
properly on Keihin carburetors - see Ill. 2 and Ill. 3. edge of tool body is
Mikuni see Ill. 4. even with air bleed
5. Loosen lock nut and turn throttle cable adjuster (on orifice in carb body.
top of carburetor) in (clockwise) or out
(counterclockwise) as required until a slight drag can "~
~~/
be felt on the gauge or tool.
6. Securely tighten throttle cable synchronization lock Forward Edge of tool to even '
nut. Ill. 2
7. Repeat steps 3 through 5 on remaining carburetor.
KEIHIN
Idle Gap Synchronization
8. Referring to chart in the Specifications section, ~orward
chapter 1, select correct diameter Idle Gap drill
gauge for the engine.
9. Slightly lift throttle slides with throttle lever and insert
idle gap drill gauge under throttle slide. Allow throttle
slides to return.
10. Turn idle adjustment screw in as required until only a
slight drag can be felt on the gauge. ~Tool must extend to front
11. Repeat steps 8 through 10 for remaining cylinders. Ill. 3 edge of slide
12. Verify proper throttle lever free play and adjust if
necessary, by loosening cable adjuster locknuts and
turning adjusters out equally until throttle lever MIKUNI
freeplay is correct. Center of slide
under cutaway 0
Throttle Free Play - See chart
(Std.) 0.010- 0.030" (.25-,.76mm) for size --~~

EZ Throttle 0.050- 0.060" (1.25-1.50mm)

111.4 Forward

Polaris Industries Inc. 4.33 10/98

FUEL SYSTEM/CARBURETION
Mikuni TM-38 Carburetor Service

Wear eye protection when using compressed air or cleaning

solvents. Review all fuel system warnings found on page
4.1 before proceeding.

Carburetor Removal, Disassembly, and Inspection

1. Remove carburetor rack from engine. Before

disassembling, clean outside of carburetor thoroughly
with solvent.

Do not use compressed air to dry at this time. The float

chamber could become pressurized resulting in damage to
the floats or inlet needle and seat. Do not soak carburetors
in carb cleaner. Clean only with aerosol cleaner.

2. Remove top caps.

3. Remove four screws on funnel.

4. Turn throttle shaft so slide opens all the way.

NOTE: You may have to turn out slide stop screw for slide
to move farther up body.

5. With slide fully open, pull funnel out bottom first.

10/98 4.34 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Mikuni TM-38 Carburetor Service

Disassembly Cont.

6. From top of carb, loosen allen head screw holding

needle in position. Slide holding plate to side.

7. Reach into top of carb with a long nose pliers and pull out
needle.

8. Inspect needle for wear.

9. Remove E-rings, packing, plate, spring, and rings

connecting slide to lever.

Polaris Industries Inc. 4.35 10/98

FUEL SYSTEM/CARBURETION
Mikuni TM-38 Carburetor Service

Carburetor Disassembly Cont.

10. Remove water trap/drain plug (17 mm) and single screw
on bottom of carb.

11 . Remove float body

NOTE: Float body will not come off unless water trap/drain
plug is removed, which is threaded and screws into main jet
housing.

12. Remove 2 screws holding float/needle & seat assembly

in position. Remove float/needle & seat assembly.

13. Inspect needle for wear.

NOTE: Needles are not available separately. If needle is
bad, you must replace float/needle & seat assembly.

10/98 4.36 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Mikuni TM-38 Carburetor Service

Carburetor Disassembly
1. Remove main jet, starter jet, pilot jet, and idle
screw.

2. Clean all passages in carburetor body with

carburetor cleaner. Dry all passages and jets
with compressed air. Replace gaskets and
any parts which show wear or damage.

Carburetor Assembly

1. Install pilot jet, main jet, starter jet, and idle screw.

2. Install float/needle & seat assembly.

Polaris Industries Inc. 4.37 10/98

FUEL SYSTEM/CARBURETION
Mikuni TM-38 Carburetor Service

3. Place carburetor in an inverted position.

4. 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 (needle comes with
float). The seat cannot be replaced. If the seat surface
is damaged replace the carburetor.

Pressure Tester PN 2870975

5. Carefully inspect float bowl gasket and replace if

necessary. Install float bowl on carburetor.
6. Install float body.
7. Install air adjusting screw.

8. Install throttle slide.

9. Install jet needle.

10. Install funnel.

11. Install carburetors on snowmobile.
12. Synchronize carbs as outlined on pages 4.39 - 4.40.
13. Replace top caps.

10/98 4.38 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Adjustments
Throttle Synchronization Procedure-
Mikuni TM-38 Flatslide Carburetors

Mikuni TM-38 carburetors are synchronized at wide open

throttle without the engine running. The middle carburetor
on triples, and the PTO side carburetor on twins have a
non-adjustable set screw on the throttle shaft. This carbu-
retor is what the other carb(s) is synchronized to.

1. Remove airbox

2. Remove top caps on all carburetors

3. Hold throttle wide open and view position of

carburetor slide on set carburetor. (Middle carb on
triples, PTO carb on twins.)

4. With throttle held wide open, turn the slide stop screw
with screwdriver until slide is flush with top of carb
opening.

Polaris Industries Inc. 4.39 10/98

FUEL SYSTEM/CARBURETION
Adjustments
Throttle Synchronization Procedure-
Mikuni TM-38 Flatslide Carburetors

5. On remaining carb(s), loosen phillips head screw

inside the offset nut.

6. When screw is loose, hold throttle to wide open. Turn

offset nut until throttle slide is in same position as set
carburetor.

7. Tighten phillips head screw.

8. Replace top caps.

10/98 4.40 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Adjustments - Choke
Choke Adjustments

With the dash mounted choke control toggle flipped to the

full off position, the choke plunger must be seated on the Choke Toggle Position
fuel passage way in the carburetor. If the plunger is not
seated on the passage way, the engine will flood or run too
rich, causing plug fouling and very poor engine perfor-
mance.
If cable slack is too great there will be excessive toggle free
play resulting in hard starting. Also, the half on position
used for intermittent applications will not function.

If the choke lever assembly becomes damaged, a lever kit

is available. This allows replacement of the lever assembly
rather than the entire cable assembly. Installation instruc-
tions are included with the kit.
Full On

Choke Lever Kits -

2 Cylinder PN 2200188
3 Cylinder PN 2200189
Contents of Lever Kit

Adjustment Procedure
1. Flip choke toggle to full off position.
2. Loosen adjustment locknut (A) on carburetor(s).
3. Turn cable sleeve adjusting nut (B) clockwise on
carburetor(s) until 1/4" (.6 em) or more choke toggle
free play is evident.
4. Turn cable sleeve adjusting nut counterclockwise on
one carburetor until toggle has zero free play, then
rotate it clockwise until1/8"-1/4" (.3-.6 em) toggle free
play is evident.
5. Tighten adjustment locknut (A).
6. Repeat steps 4 and 5 for remaining carburetor(s).

Choke Lever Freeplay -

1/8- 1/4" (.3- .6 em)

1/8-1/4" (.3-.6 em)

Freeplay

Polaris Industries Inc. 4.41 10/98

FUEL SYSTEM/CARBURETION
Primer Systems
Domestic 600 & 700 Primer Systems

Primer Kit Schematic

Tee Fitting Primer kit part #2871889

1998 Domestic 600/700s, 1997 700 SKS and RMK

Fuel Inlet Line to Primer

/ r·~
l \-·, r··-.. -CJ-·!
r~
___L_n_l I
~===============~ ~ CJ cl]ttl ~-··-··-·-··-··-·.i
Fuel Out to Carburetors/

Standard primer routing diagram for 1999 600/700 twins

10/98 4.42 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Fuel Pump - Operation

The fuel pumps on all Polaris engines are basically the same.
The differences are in the size and location of the pumps.
Pumps may be mounted to the engine or to the chassis.

In the two cycle engine, the pressure in the crankcase changes

with the up and down stroke of the piston. The amplitudes of
pressure vary according to the RPM and degree of throttle
opening. Whether idling or at full throttle, the pressure built up
in the crankcase has enough amplitude to operate the pump.

When the piston is on the upstroke, crankcase pressure in that

cylinder becomes less positive. The diaphragm in the fuel pump
moves toward the engine, causing a negative pressure or suc-
tion in the pump chamber. This causes the inlet valve from the
fuel supply to open and permits fuel to enter the chamber. This
same suction causes the outlet valve (to the carburetor) to close
so that fuel cannot return form the carburetor.

When the piston begins its downward stroke, the pressure from
the crankcase becomes positive, causing the fuel pump dia-
phragm to move in the opposite direction and reversing the
pressure in the fuel pump chamber. This causes the inlet valve
in the pump to close and the outlet valve to open, filling the float
bowl in the carburetor. When the float level in the carburetor
reaches its standard level, the needle valve will close, prevent-
ing more fuel from entering the carburetor, even though the fuel
pump continues to try to provide the carburetor with fuel.

Maintenance

The impulse operated diaphragm fuel pump does not require any specific scheduled maintenance. However, the
following procedures should be observed.
Operation:

• The pump may be checked for operation by re-

moving the fuel supply line from the carburetor
and placing it into a container. With the engine
idling at approximately 2000 RPM, a steady flow
of fuel should be visible.

Cleaning:

The pump and impulse line must be disas-

sembled and cleaned of foreign material in the
event of piston or other internal engine part fail-
ures which produce fragments.

Inspection:

• Disconnect impulse line from pump. Connect

Mity Vac™ to impulse fitting (or line) and apply
4-6 PSI pressure. Diaphragm should hold pres-
sure indefinitely.

• The diaphragms and check valves must be care-

fully examined for cracks, holes, or other dam-
age. If in doubt as to the condition of any internal
parts, replace all diaphragms, check valves, and
gaskets.

Polaris Industries Inc. 4.43 10/98

FUEL SYSTEM/CARBURETION
Exploded View Fuel Pump

Taio Giken

Description of Parts

~
1. Vacuum (from crankcase)
2. Diaphragm 3 2
.
3. Gaskets
4. Check Valves
5. Fuel Outlets (to carbs)
6. Fuel Inlet (from tank)

10/98 4.44 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Exploded View -Twin Cylinder (Typical) Fuel Pump

Parts Description

1. Pump Body Assembly

2. Lower Gasket
3. Diaphragm
4. Upper Gasket
5. Screw (6 used)
6. Check Valve

Polaris Industries Inc. 4.45 10/98

FUEL SYSTEM/CARBURETION
Exploded View - 3 Cylinder Fuel Pump

Parts Description

1. Pump Valve Body

6
2. Diaphragms and Gaskets
3. Screw (6 used)
4. Check Valves
NOTE: Be sure of proper order and
2 position of gaskets and diaphragms
upon reassembly.
5. Fuel Outlet (3 to carbs)
6. Fuel Inlet (from tank)
7. Vacuum/Pressure (from crank-
case)

0
__.,-

7--- <::-:

10/98 4.46 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Exploded View- Twin Cylinder Domestic Fuel Pump

Walbro Fuel Pump

NOTE: Individual parts

are not available for do-
mestic engine fuel
pumps. If any internal
parts are faulty, the
pump must be replaced.

Polaris Industries Inc. 4.47 10/98

FUEL SYSTEM/CARBURETION
Water Trap Service

A WARNING

Fuel spillage will occur during this installation. Gasoline is extremely flammable and explosive under certain
conditions.
A Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where
gasoline is stored.
'} Do not weld or operate a torch near the fuel system. Remove fuel tank before any chassis welding is per-
~ formed.
A If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.

A 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 poison-
~ ous and can cause loss of consciousness and death in a short time.
1. Turn fuel valve off.
2. Remove air silencer.
3. Position a shop cloth or container below drain
plug and water trap plug. Float
Bowl
4. Remove drain plug and sealing 0-Ring, or slide
clamp upward and remove water trap plug.
5. Drain water/fuel. Clean trap with electrical
contact cleaner and dry with compressed air. ----0-Ring

6. Lightly grease 0-ring and install water trap Drain P l u g - i

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. Hose
Clamp
The water traps should be periodically inspected and
drained. Draining frequency will depend upon fuel
supply, riding conditions, and fuel handling precau-
tions.
I
8-------water Trap
Plug

10/98 4.48 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Troubleshooting
Fuel system diagnosis should follow a specific path, first examining the fuel tank, then the filters, fuel lines, vent
lines, fuel pump, impulse hose, air box, exhaust system and finally the carburetors.
The following troubleshooting information assumes that the general mechanical condition of the engine (pistons,
rings, bearings, etc.) is good.
When the fuel/air mixture is diagnosed as improper due to spark plug readings, clean the carburetor and blow
its passages clear with compressed air. Use the spark plug firing end condition as a guide for further determination
of whether the mixture is too rich or too lean.
Use the throttle lever to determine at what degree of throttle valve opening the problem exists.

CONDITION SYMPTOMS
Mixture Too Rich -Black spark plug tip; plug fouling
-Heavy exhaust smoke
-Engine runs worse after warm up
-Engine "loads up"
Mixture Too Lean -Spark plug electrodes white
-Fluctuation in engine speed
-Power loss
-Engine overheats
-Cylinder scoring I Holing pistons
-Backfiring - detonation
-Throttle diagnostic opening check points
Poor Fuel Mileage -Incorrect ignition timing
-Improper track tension (too tight)
-Incorrect carburetor jetting
-Fuel leaks (lines, fittings, fuel pump)
-Needle and seat leaks
-Plugged exhaust
-Carburetor vent line problems
-Clutching incorrect for conditions I worn belt

Troubleshooting Tips, 0-1/4 Throttle:

Pilot air screw misadjusted
• Pilot jet of wrong size, loose, or obstructed
• Obstruction of pilot jet
Pilot jet loose
• 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

Polaris Industries Inc. 4.49 10/98

FUEL SYSTEM/CARBURETION
Troubleshooting

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

Troubleshooting Tips, 3/8-3/4 Throttle:

• Main jet incorrect size or clogged (lean)
• Needle jet damaged or loose
• Needle jet/jet needle worn (rich)
• E-clip position incorrect for altitude and temperature

Troubleshooting Tips, Full Throttle:

Main jet size (rich or lean)
Fuel filter blocked (lean)
Fuel vent lines or check valves plugged
Exhaust system plugged
Air box restricted
Fuel pump weak
Exhaust leaking into engine compartment (rich)
• Water in float bowl (lean)

10/98 4.50 Polaris Industries Inc.

CHAPTER 5
CLUTCHES

Clutch Service Tools .......................... 5.1

Drive Clutch Weight Identification ............... 5.2-5.4
Drive Clutch Spring Rates ..................... 5.5
Drive Clutch Spring Data ...................... 5.6
Driven Clutch Spring Data I Rates .............. 5.7
P-85 Drive Clutch Exploded View ............... 5.8
P-85 Driven Clutch Exploded View .............. 5.9
P-90 Drive Clutch Exploded View ............... 5.10
P-90 Driven Clutch Exploded View .............. 5.11
Drive Clutch Operation ........................ 5.12-5.13
Driven Clutch Operation ....................... 5.14
Drive Clutch Identification andRemoval .......... 5.15
Drive Clutch Disassembly and Inspection ........ 5.16-5.17
Spider Roller Removal ........................ 5.18
Roller Installation ............................. 5.18-5.19
Spider Assembly ............................. 5.19-5.20
Drive Clutch Assembly ........................ 5.21-5.22
Drive Clutch Installation ....................... 5.22-5.23
Spider Indexing .............................. 5.24
Driven Clutch Removal ........................ 5.25
Driven Clutch Disassembly .................... 5.26-5.27
Driven Clutch Assembly ....................... 5.28-5.30
Helix Angles and Effects ....................... 5.29
Driven Clutch Installation ...................... 5.31
Drive Belt Information ......................... 5.32
Drive Belt Inspection I Troubleshooting .......... 5.33
Drive Belt Deflection .......................... 5.34-5.35
Clutch Offset/Alignment ....................... 5.36-5.37
Torque Stop Adjustment ....................... 5.37
Belt to Sheave Clearance ...................... 5.38
Clutch Bushing Replacement - P-85 ............. 5.39-5.44
Clutch Bushing Replacement - P-90 ............. 5.45-5.52
Troubleshooting .............................. 5.53-5.55
 CLUTCHES
Service Tools

A WARNING

All drive clutch maintenance, disassembly and assembly must be performed only by an authorized Polaris dealer
who has attended current model Dealer Service Seminars, has received a certificate of completion, and displays
the Polaris Servicing Dealer decal.
Because of the 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. A tool catalog update
is available through the Polaris parts department. The part number is 9915235.
Description Part Number
Offset Alignment Tool- 21/32" (1.7 em) P-90 Clutches ....... . 2870914
Offset Alignment Tool - 5/8" (1.6 em) P-85 Clutches .......... . 2870426
T-Handle Drive Clutch Puller (Large Shaft ID) ............... . 2870506
Drive Clutch Puller 14mm (Small Shaft ID) .................. . 2871855
Drive Clutch Puller- '99 550 Fuji Engines . . . . . . . . . . . . . . . . . . . 2872084
Drive Clutch Puller- '99 700/800 XCR . . . . . . . . . . . . . . . . . . . . . . 2872085
Strap Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870336
Replacement Strap for 2870336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870389
Spider Spanner Nut Driver (Jam Nut) . . . . . . . . . . . . . . . . . . . . . . . 2870338
Spider Removal I Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 2870341
Holding Fixture ........................................... 2871358
Holding Fixture Tab ....................................... 5130518
Tapered Reamer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870576
Spider Button Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870985
Clutch Bushing Rebuild Tool Kit (P-85/P90) ................. 2871025
P-85 Drive Clutch Compression Tool . . . . . . . . . . . . . . . . . . . . . . . . 2870984
Driven Clutch Puller (P-90) ................................ 2871056
Torque Wrench, 250 ft. lb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially Available
Torque Wrench, 0-200 in. lb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercially Available
Clutch Compression Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8700220
Clutch Holding Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9314177
SLP Button Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 871601 0
SLP Clutch Sheave Clamp Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8716020

Polaris Industries Inc. 5.1 10/98

CLUTCHES
Drive Clutch Weight Identification - Actual Size

u w G - (B Modified)
Gram Weight: 34± 1 Gram Weight: 37.5 ± 1 A
PN 5630107 PN 5630109 Gram Weight: 41.5 ± 1 Gram Weight: 47.5± 1
PN 5630063 PN 5630080

02 03
02 0 03
0
Gram Weight: 49 ± 1 Gram Weight: 51 Gram Weight: 32.5 ± 1
Gram Weight: 53± 1
PN 5630225 PN 5610088 PN 5630174 PN 5630227

04 M1 (Modified) K1 P1
Gram Weight: 57.5 ± 1 Gram Weight: 46.0 ± 1 Gram Weight: 39 ± 1 Gram Weight: 42 ± 1
PN 5630229 PN 5630301 PN 5630144 PN 5630089

10/98 5.2 Polaris Industries Inc.

 CLUTCHES
Drive Clutch Weight Identification - Actual Size

07
J1 05 06 07
Gram Weight: 44± 1 Gram Weight: 53.5 ± 1 Gram Weight: 52± 1
Gram Weight: 50± 1
PN 5630065 PN 5630234 PN 5630243 PN 5630244

08 15 10 Bushed 1OM-W Bushed

Gram Weight: 47.5 ± 1 Gram Weight: 55.5 ± 1 Gram Weight: 51.5 ± 1 Gram Weight: 46 ± 1
PN 5630245 PN 5630274 PN 1321526 PN 1321527

10M Bushed 1OM Blue Bushed 1OM Red Bushed

Gram Weight: 49.5 ± 1 Gram Weight: 47.5 ± 1 Gram Weight: 44 ± 1
PN 1321528 PN 1321529 PN 1321530

Polaris Industries Inc. 5.3 10/98

CLUTCHES
Drive Clutch Weight Identification - Actual Size

10-AL Bushed 10-66 Bushed 10-64 Bushed 10-62 Bushed

Gram Weight: 53± 1 Gram Weight: 66 Gram Weight: 64 Gram Weight: 62
PN 1321531 PN 1321584 PN 1321585 PN 1321586

10-60 Bushed 10-58 Bushed 10A Bushed 10-56 Bushed

Gram Weight: 60 Gram Weight: 58 Gram Weight: 55 Gram Weight: 56±1
PN 1321587 PN 1321588 PN 1321589 PN 1321684

s s s
55R

10-54 Bushed S53B S53R S55R

Gram Weight: 54±1 Gram Weight:49 ±1 Gram Weight:51 ±1 Gram Weight:53 ±1
PN 1321685 PN 1321730 PN 1321731 PN 1321759

10/98 5.4 Polaris Industries Inc.

 CLUTCHES
Drive Clutch Spring Rates
The following chart will aid in the setup and balance of engine RPM power curves for special converter tuning
requirements such as high operating altitude, heavy loads, mountainous terrain, etc.

Drive Clutch Spring Compression Rate Chart

Drive Clutch Spring Compression Rate Chart

320

P-90 TRAVEL---+---~
P-85 TRAVEL ---+---+--+------::r-tiM
_ _ _ Gold
7041148
_ _ _ Silver
7041062
Red
- - - - 7041083
-Red/White
7041150
----Brown
7041061
Orange
7041060
~---+--J...- ••••••• Pink
7041065
__,___,_ _ --Yellow
7041102
~~------Green
7041168
----Purple

120

_ _ _ _ Blue/Green
7041157
ATVonly

2.50 2.25 2.00 1.75 1.50 1.25 1.19

COMPRESSED SPRING LENGTH (INCHES)

Polaris Industries Inc. 5.5 10/98

CLUTCHES
Drive Clutch Spring Data
PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH+/- .125"
7041021 Clear .157" 4.38"
7041022 Black .140" 4.25"
7041063 Purple .168" 4.37"
7041062 Silver .208" 3.12"
7041065 Pink .177" 4.69"
7041060 Orange .196" 3.37"
7041080 Blue/Gold .207" 3.50"
7041083 Red .192" 3.77"
7041102 Yellow .192" 2.92"
7041061 Brown .200" 3.06"
7041132 White .177" 2.92"
7041168 Green .177" 3.05"
7041148 Gold .207" 3.25"
7041150 Red/White .192" 3.59"
7041286 Silver/Gold .218" 3.05"
7041080 Blue .207" 3.55"
7041526 Dark Blue .218" 3.52"
7041781 Dark Blue/White .225" 3.52"
7041566 Almond .207" (Square) 3.65"
7041645 Almond/Gold .207" 4.0"

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 driv-
en clutch components. One of the most critical and easily serviced parts is the drive clutch spring. Due to the
severe stress the spring is subject to during operation, it should always be inspected and checked for tolerance
limits during any clutch operation diagnosis or repair.
With the spring resting on a flat surface, measure free
length from outer coil surfaces as shown. Refer to the
chart above for specific free length measurements and
tolerances.
In addition to proper free length, the spring coils should
be parallel to one another when placed on a flat sur-
face. Distortion of the spring indicates stress fatigue.
Replacement is required.

10/98 5.6 Polaris Industries Inc.

 CLUTCHES
Driven Clutch Spring Rates
Driven Clutch Spring Data
Part Number Description
7041198 Red
7041782 Black-5 Coil
7041501 Gold-6 Coil
7041499 Silver
7041296 Blue
7041646 Silver I Blue

Driven Spring Charts

140 Blue
Silver or Silver/Blue
120

100

80
lil
..0
..c 60
C)
c::
:.::;..
(])
::::J 40
o-
....
0
1- 20

0
6]0 Degrees of Rotation 150°

80
__ - Silver/Blue
70

60

50

-2c:: 40
::::J
0
~ 30
"0
ell
0
_J 20

10

0
Compression Distance (in) 1.375"
2.5"

Polaris Industries Inc. 5.7 10/98

CLUTCHES
P-85 Drive Clutch Exploded View- Typical

Do not lubricate drive clutch components

Cover

Retaining Ring
. VVasher
Spnng ( \ /Roller
Jam Nut~~ VVeight w/Bushing

L-· ·" r;\_ 1 Weight Pin

'-(!_) /
L.-r ~
Sleeve Bushing

Spider
Spacer

Clutch Assembly
(Less weights, spring) Moveable Sheave

Fixed Sheave

Replacement clutches come complete and balanced without clutch weights and clutch spring.
The clutch cover, spider, and sheaves cannot be purchased separately as replacement parts.

10/98 5.8 Polaris Industries Inc.

 CLUTCHES
P-85 Driven Clutch Exploded View- Typical

Do not lubricate driven clutch components

except inside of ramp helix hub to reduce
fretting and corrosion.

Stationary Sheave
Driven Plate Driven Bushing ~-
Retaining Ring ~ Adjustment Cam

I
Moveable Sheave
Screw

Clutch Assembly

Replacement driven clutches come complete with ramp and spring. The moveable and station-
ary sheaves cannot be ordered as separate service parts.

Polaris Industries Inc. 5.9 10/98

CLUTCHES
P-90 Drive Clutch Exploded View - Typical

Do not lubricate drive clutch components

Cover
Cover Bushing
Retaining Ring
Spring

/
RollerPin~Y

\))~

Spider
Moveable Bushing

Movea le Sheave

Fixed Sheave
Clutch Assembly
(Less weights, spring)

Replacement clutches come complete and balanced without clutch weights and clutch spring. The
clutch cover, spider, and sheaves cannot be purchased separately as replacement parts. Ring
gears are not included with replacement P-90 clutches and must be purchased separately.

10/98 5.10 Polaris Industries Inc.

 CLUTCHES
P-90 Driven Clutch Exploded View

Do not lubricate driven clutch components

except inside of ramp (helix) hub to reduce
fretting and corrosion.

Retaining Ring
lZtton
Bolt

Moveable Bushing 1"

Ramp

Moveable Bushing 1/2"

Spring
Stationary Sheave

Moveable Sheave

Driven Clutch Asm

A - Snap Ring Retainer

(Used on some models)

Can be retro-fit to all P-90

models used in heavy load
conditions. Install Extreme
Duty P-90 Mounting Kit
PN 2200752.

Replacement driven clutches come complete with ramp and spring. The moveable and station-
ary sheaves cannot be ordered as separate service parts.

Polaris Industries Inc. 5.11 10/98

CLUTCHES
Operation
The Polaris drive system is a centrifugally actuated variable speed belt drive unit. The drive clutch, driven clutch,
and belt make up the torque converter system. Each clutch comes from the factory with the proper internal
components installed for its specific engine model. Therefore, modifications or variations of components at
random are never recommended. Proper converter setup and adjustments of existing components must be the
primary objective in converter operation diagnosis.

All converter maintenance repairs must be performed only by an authorized Polaris service technician who has
attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this
manual. Because of the critical nature and precision balance incorporated into the drive clutch, it is absolutely
essential that no attempt at clutch disassembly and/or repair be made without factory authorized special tools and
service procedures. Any unauthorized modifications to clutches, such as adding or removing weights, will void the
warranty.

Relationship Between Drive Clutch Weights And Spring In Maintaining Operating RPM
The drive clutch is an RPM and torque sensing unit designed to transfer the maximum amount of horsepower from
the engine to the ground. This is accomplished by weights and a spring inside the unit which react to the
centrifugal force from the engine RPM.
The spring and weights work in combination. In a properly set up clutch, the maximum desired operating RPM will
be reached immediately after clutch engagement, under full throttle conditions. To gain optimum power this RPM
should be maintained. As centrifugal force pushes the weights against the rollers, the moveable sheave will force
the belt to climb up the drive clutch sheave and increase vehicle speed.

9000--------------------------

8000
,.-------
- - - - - - ENGIN~OPERATING RANGE ±250 RPI\L __
7000------------;jr-----------
~ 6000 ,
~ I
5000-----------r'--------------
ENGAGEMENT~-------~~=~~---------------
3000--------------------------

If the weights are too light, or the spring rate too high, the maximum RPM will be too great and the drive belt will not
move into high gear at the top of the clutch.

10/98 5.12 Polaris Industries Inc.

 CLUTCHES
Operation

9000--------------------------
BOOO--------------------------
- - - - - - ENGINE OPERATING RANGE ±250 RPM
7000--------------------------
~ 6000 .r'"_______ _

a: 5000 ,,7
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
fast, keeping the engine out of its power band.

9000--------------------------
8000--------------------------
7000--------------------------
~ 6ooo-:;z""!:!---- - - -- -ENGINE OPERATING RANGE ±250 RPM

5000~,~----------------------­

ENGAGEMENT~------------------------
3000--------------------------

If the weights and spring are matched properly, the engine RPM will go to the desired range and remain there
on both upshift and backshift.

Polaris Industries Inc. 5.13 10/98

CLUTCHES
Driven Clutch Operation
The driven clutch operates in conjunction with the drive clutch. Its function is to maintain drive belt tension pre-
venting slippage, and sense variations in load requirements necessary to maintain optimum engine torque output
and load requirements from the track. Output torque is transmitted through the chaincase jackshaft and chain-
case to the front drive shaft and track.
When the load on the driven clutch is increased and becomes greater than the torque delivered from the engine,
the driven clutch becomes dominant and overrides the drive clutch. The driven clutch downshifts into a ratio which
will match the increased load.
Because the driven clutch can sense and shift into the proper ratio, engine RPM will remain within the specified
range.

Driven Clutch Adjustments

The driven clutch has a provision for varying the torque required to change its ratio. It can be readjusted by relocat-
ing 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)

10/98 5.14 Polaris Industries Inc.

 CLUTCHES
Drive Clutch

Removal

1. Hold clutch with strap wrench. Remove drive clutch

retaining bolt, grease puller thread and tip lightly and
install puller into clutch. Tighten puller with a
wrench, or strike t-bar with a hammer until clutch is
removed.

NOTE: 440, 500, 600, &700 domestic twins use puller

PN 2871855. The 1999 Trail RMK and Supersport use
puller PN 2872084, and the 700/800 XCR use puller PN
2872085.

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 manually rotating clutch clockwise. Do not
ream taper more than required to remove galling or
scoring. Never use power tools to ream taper of
drive clutch.

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 varia-

tion for individual engines. For easy identification, refer
to the three numbers behind date code on clutch cover
plate. These numbers are the last three digits of the
clutch part number. Last 3 digits of
part number

Polaris Industries Inc. 5.15 10/98

CLUTCHES
Drive Clutch

Disassembly and Inspection

1. Install drive clutch in clutch compression tool

(8700220). Mark both moveable and fixed sheave,
cover, and spider with a permanent marker.

Sheaves must be marked to provide a reference point for

clutch balance and spider indexing. If the sheaves are
not marked, and spider shim washers are changed or
misplaced, the will clutch will be out of balance and must
be replaced. See page 5.24 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 5.39 for inspection and repair procedure.

Drive Clutch Compression Tool

PN 8700220
Drive Clutch Holding Fixture
PN 2871358

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

PN2870338

4. Install spider removal tool and remove spider in a

counterclockwise direction (standard thread).

Spider Removal Tool

PN 2870341

10/98 5.16 Polaris Industries Inc.

 CLUTCHES
Drive Clutch

Disassembly, Cont.
5. Measure the total thickness of the spacer washers
installed beneath spider and record.

NOTE: In order to maintain proper belt-to-sheave clear-

ance and clutch balance, the same washers (or equiva-
lent 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 5.24 if belt-
to-sheave clearance is being adjusted.

6. Inspect both sheave surfaces for wear or damage.

Inspect movable sheave bushing. See page 5.41 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.

8. Inspect all rollers, bushings and roller pins by pulling

a flat metal rod across the roller. Roller can also be
inspected by rolling with finger to feel for flat spots,
roughness, or loose bushing. Also inspect to see if
roller and bushing are separating. Bushing must fit
tightly in roller. Replace roller and pin if roller fails to
roll smoothly (flat spots) or if bushing is loose.

Polaris Industries Inc. 5.17 10/98

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

PN2870985

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
.1 00"-.125" (.25-.32 em) beyond the first land of the
spider leg (A). Remove any aluminum burrs from pin
protruding from spider.

2. Install one washer onto pin.

10/98 5.18 Polaris Industries Inc.

 CLUTCHES
Drive Clutch

Roller Installation, 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.

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 fail-
ure.

Spider Button Shimming

1. Determine how many shims are to be used.
NOTE: A shim kit is available which contains an assort-
ment of shims, including .002", .005", and .01 0".

Shim Kit PN 2200387

Polaris Industries Inc. 5.19 10/98

CLUTCHES
Drive Clutch

Spider Button Shimming, Cont.

2. Measure the dimension between towers at the lower
half of the towers as shown.

3. Install spider buttons using a soft face hammer.

4. Record width of spider buttons on each leg.

5. Add shims beneath trailing side spider button to

obtain specified button-to-tower clearance when
assembled.

Button to Tower Clearance -

P-85/ P-90 =.002" (.05 mm)

10/98 5.20 Polaris Industries Inc.

 CLUTCHES
Drive Clutch

Drive Clutch Assembly

1. Place the correct number of spacer washers
beneath the spider.

2. Assemble clutch making sure "X" marks on movable

sheave and spider, or reference marks made before
disassembly are aligned to achieve proper balance.
NOTE: If belt to sheave clearance is being changed by
adding or removing washers from under the spider, and
the sheaves were marked before disassembly, follow in-
dexing procedure on page 5.24.

3. Torque spider to specification.

Spider Torque- P85 and P90

200 ft.lbs. (27.6 kgm)

Spider Removal Tool

PN 2870341

4. Torque jam nut to specification (P-85 Clutches).

Install weights with weight pin nut on trailing side.
Use new nuts to ensure proper retention. Torque nut
to 30 in. lbs.

Jam Nut Torque • P85 models only

235ft. lbs. (32.43 kgm)

Jam Nut Tool

PN2870338
Weight Pin Nut Torque
30 ln. Lbs. (.34 kgm)

Polaris Industries Inc. 5.21 10/98

CLUTCHES
Drive Clutch

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 .. lbs.. (1.03 kgm)

Installation
1. Slight galling or scoring of the bore taper can usually
be corrected using a tapered reamer. Place reamer in
a vise and lubricate with cutting oil. Clean taper by
manually rotating clutch clockwise.

Tapered.Reamer PN 2870576

2. Check crankshaft taper for galling or scoring. If

necessary clean taper evenly with 200 grit emery
cloth.

3. Both clutch taper and crankshaft taper should be

clean and dry.
NOTE: Do not use harsh cleaners which may cause
clutch taper to corrode during use. This will cause diffi-
culty when removing clutch in future. Clean clutch taper
with lacquer thinner or isopropyl alcohol.

10/98 5.22 Polaris Industries Inc.

 CLUTCHES
Drive Clutch

Installation, Cont.
4. Slide clutch fully onto crankshaft taper.

5. Install retaining bolt with any spacers, washers or

0-rings. See appropriate parts manual for type and
placement of retaining bolt components.

6. Torque retaining bolt to specifications. Hold clutch

with st•p wrench.

Drive Clutch Bolt Torque (Large ID Shaft)-

(3/4") 40 • 45 ft. lbs (5.52 ., 6.21 kgm)

Drive Clutch Bolt Torque (SmaiiiD Shaft)-

(14mm /7116") 50ft lbs. (6~9 kgm) ·

NOTE: Re-torque clutch to specification after first peri-

od of operation (such as a test ride).

Polaris Industries Inc. 5.23 10/98

CLUTCHES
Drive Clutch

Spider Indexing

NOTE: Spider indexing affects clutch balance and belt

to sheave clearance. Read procedures carefully before
proceeding.
1. Before disassembling drive clutch, mark spider,
cover, moveable sheave, and stationary sheave in
line with a permanent marker as shown.
2. Disassemble drive clutch as described on page
5.16. Take care to note the amount and thickness of
the shim washers under the spider.

3. Add or remove spider washers 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:

Washers:
PN 5210754 .050"
PN 5210753 .032"
PN 5210752 .020"

4. Install spider washer(s) and spider aligning Xs.

Notice as the spider seat location is changed, the
sheave marks made before disassembly no longer
align. There are two ways to bring the sheave marks
into alignment.
• Vary the amount and thickness of spacer washers
(Washer thickness may vary slightly).
• Re-index marked spider leg to another tower.
This can be done because 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 - re-index

spider clockwise 1/3 turn

• Two .050" or .064" washers removed -

re-index clockwise 2/3 turn

NOTE: Alignment marks should be within 1" (25 mm) af-

ter final assembly and torquing.

10/98 5.24 Polaris Industries Inc.

 CLUTCHES
Driven Clutch

Driven Clutch Removal

1. Remove driven clutch retaining bolt.

2. Slide driven clutch off jackshaft. It may be

necessary to use a puller on some driven clutches.
P-85 clutches (externally adjustable) can be
removed using a 3-point flywheel or steering wheel
puller and the 1/4-20 adjustment bolt holes. Use a
suitable spacer on the end of the jacks haft.

P-90 Driven Clutch Puller

PN 2871056

3. Inspect jackshaft keyway (splines I P-90s) for wear or

damage.
NOTE: Notice the number and thickness of shim washers
between driven clutch and jackshaft bearing. These must
be replaced to maintain proper offset/alignment.

Polaris Industries Inc. 5.25 10/98

CLUTCHES
Driven Clutch

Disassembly

1. Place clutch on bench.

CAUTION: Wear eye protection during disassembly and

assembly of driven clutch.

2. Hold fixed sheave and turn movable sheave 1/4 turn.

Hold movable in place tap helix down with a soft faced
hammer. Remove snap ring and washer. NOTE: On
models equipped with snap ring retainers as shown
below, retainer may stay on back of snap ring when
clutch is removed. Pry lightly to remove retainer and
gain access to snap ring. (Refer to illustration below.)

If retainer stays with clutch,

p evenly to remove (P-90)

Snap
Ring

Retainer

3. Allow sheaves to return and force the helix out.

Before removing helix, note driven clutch spring
position. Remove helix.

4. Inspect helix ramps and movable buttons and for

wear or damage. P-90 driven clutch ramp buttons are
secured by 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 inteNals.

10/98 5.26 Polaris Industries Inc.

 CLUTCHES
Driven Clutch

Disassembly, Cont.
5. Remove driven clutch spring. Both spring tabs should
line up. If not spring is fatigued and should be
replaced.

Tabs Aligned

6. Slide moveable sheave off and inspect sheave

surfaces for wear or grooving. Note size and number
of shim washers between sheaves.

7. Note condition of moveable sheave bushing. Install

helix into bushing. It should slide freely without
binding. See page 5.43 for bushing replacement.

8. Polish helix with a fine emery cloth to remove any

sharp edges or build up which may cause sticking.

Polaris Industries Inc. 5.27 10/98

CLUTCHES
Driven Clutch

Assembly

1. Install appropriate washer(s) on fixed shaft.

Optional Thin Adjustment Washer (P-85)

.048" - PN 7555899

2. Slide moveable sheave on fixed shaft.

3. Install driven clutch spring. Be sure spring tab is

seated in hole in moveable sheave. Refer to
specifications in front of this section for driven spring
setting.
• P-85 driven clutches have 1 spring locat-
ing hole in the movable sheave and 4
holes in the helix.
• P-90 driven clutches have 2 spring locat-
ing holes in the movable sheave, and 3
in the helix
NOTE: The driven clutch helix/moveable assembly has
several different spring locations which affect clutch shift-
ing and RPMs. Tighter spring tension will raise engine
RPMs during clutch upshift and allow quicker downshift
when pulling or negotiating a hill. The lighter tension posi-
tions will tend to have a slower downshift and a harder up-
shift. P-90
Moveable Spring
Example: Helix Sheave Tension

Spring/
Position
B - 1
B - 2
A - 1
Tvy
B - 3
A - 2
A - 3 Soft
P-90 production settings are usually 82
P-85 production settings are usually #2

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).

10/98 5.28 Polaris Industries Inc.

 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*
Description PN Degrees Type The helix spring should always be adjusted within its
34 5130896 34 limits before a helix change is performed. The normal
P85
rate of change between helix angle steps is 250 RPM
34M* 5130751 34 P85 under full throttle. This is approximately the same result
36 5130895 36 P85 as in going from the No. 1 to No. 4 spring position (P-85).
36M* 5130717 36 P85 NOTE: Increasing spring tension increases engine
38 5130723 38 P85 RPM. RPM changes may not be evident if other drive or
40 5130724 40 P85 driven clutch components are substandard.
42 5130725 42 P85 * NOTE: All R-Series, Mod(M), T1, and 40-36 helix
44 5130726 44 P85 ramps are cut 0.060" deeper in the snap ring pocket.
40-36* 5130898 40-36 P85 These are made so the driven clutch can open far
enough for full shift out with wide 1 7/16" belts (standard on
R1* 5131287 40-32 P85
Storm and 600/700 twins).
R2* 5131288 42-32 P85
If these helix ramps are used with narrow belts, 2 (two)
R3* 5131289 45-32 P85
additional (for a total of three) .030" /.8 mm washers (PN
R4* 5131290 50-32 P85 7556804) should be installed under the snap ring to
R5* 5131291 40-34 P85 prevent the belt from touching the inner hub at full shift
R6* 5131292 42-34 P85 which can cause belt failure.
R7* 5131293 45-34 P85 Wide belt models (Storm and 600&700 twins) use only
R8* 5131294 50-34 P85 the existing washer under the snap ring.
R9* 5131295 40-36 P85
R10* 5131296 42-36 P85
R11* 5131297 45-36 P85
R32* 5131623 50-34 P85
R12* 5131298 50-36 P85
T-1* 5131013 42-36-34 P-85
36.5 5130383 36.5 P90
40-38-36 5131161 40-38-36 P90
38-36 5131162 38-36 P90
38-36-34 5131163 38-36-34 P90
34 5131164 34 P90

5. Hold fixed sheave and turn movable sheave 1/4 turn

counterclockwise.

6. Force helix down into place, exposing snap ring

groove.

Polaris Industries Inc. 5.29 10/98

CLUTCHES
Driven Clutch

Assembly, Cont.

7. 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 Preload
on back of snap ring when clutch is removed. Pry 1/4 turn
lightly to remove retainer and gain access to snap
ring. (Refer to illustration below.)

Snap NOTE: Always install snap ring with

Ring Retainer chamfer towards helix (sharp edge out-
ward)

8. 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.

10/98 5.30 Polaris Industries Inc.

 CLUTCHES
Driven 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 movement is detected, disassemble to
determine which parts are worn. Replace the
jackshaft if the new bearing is loose on the shaft. The
bearing should be greased at 1000 mile (1600 km)
intervals and before storage.
NOTE: Spacer washers between driven clutch and jack-
shaft bearing set the offset. Refer to adjustment proce-
dure on page 5.36 to adjust offset between the drive and
driven clutch.
2. Lightly grease jackshaft keyway or spline. With
square key in place (P-85s) slide clutch onto
jacks haft.

3. Install spacer, bolt and washer to hold driven clutch in

place.

Driven Clutch Retaining Bolt Torque-

15 ft. lbs. (2.08 kg-m)

4. P-85 and P-90 driven clutches should float from side

to side (.040-.080" (1-2 mm)). Without a slight free
float, jackshaft bearings could be side loaded,
causing premature bearing failure. NOTE: Some
models with P-90 clutches use a snap ring retainer
cup to captivate the snap ring. On these models end
float should be adjusted between .000 and .01 0"
(.000-.254 mm) Torque bolt to specification.

Driven Clutch Torque/Float

P-85/ P-90- .040-.080" (1-2 mm)

P-90 with retainer .ooo-.010" (.OOG-.254 mm)

Polaris Industries Inc. 5.31 10/98

CLUTCHES
Drive Belt
Drive Belt

Part No. Belt Width* Side Center Outer Notes

(Projected) Angle to Circum-
Overall* Center* terence*
+.100"
-.000"
3211042 1.375" 32° 12.00" 47.250" Common production belt for P-85 systems
(34.93mm)
3211045 1.375" 32° 12.00" 47.125" Close tolerance version of 3211042
(34.93mm)
3211058 1.250" 28° 11.00" 43.313" Indy Lite belt (P-90)
(31.75mm)
3211059 1.250" 28° 12.00" 45.125" Longer Indy Sport Belt (P-90)
(31.75mm)
3211061 1.375" 32° 12.00" 47.188" CVT version of 3211 045
(34.93mm)
3211065 1.438" 28° 12.50" 48.375" CVT Double Cog Storm belt
(36.53mm)
3211066 1.375" 28° 12.00" 47.250" Double cog - CVT- thicker than 3211070. Pro-
(34.93mm) duction on higher horsepower snowmobiles.
3211067 1.375" 28° 12.00" 47.250" Double cog-Good for short runs on higher
(34.93mm) horsepower engines (Drag Racers) - Good for
lower horsepower trail riding
3211070 1.375" 28° 12.00" 47.250" Common production belt for late model P-85
(34.93mm) systems 1997 -current.
3211073 1.438" 28° 12.50" 48.375" Double cog-Good for short runs on higher
(36.52mm) horsepower engines (Drag Racers)- Good for
lower horsepower trail riding
3211074 1.438" 28° 12.00" 47.625" Double cog-Good for short runs on higher
(36.52mm) horsepower engines (Drag Racers) - Good for
lower horsepower trail riding
3211075 1.438" 28° 12.00" 47.625" Double cog - CVT
(36.52mm)

*±Belt dimensions given are nominal dimensions. There is a± variance for all critical dimensions. Clutch
set-up must be inspected when a new belt is installed and, If necessary, clutch set-up must be adjusted.

The drive belt is an important component of the converter system. In order to achieve maximum efficiency from
the converter, drive belt tension (deflection), clutch offset, and alignment must be adjusted properly.
General Belt Selection Guidelines
NOTE: Refer to appropriate parts manual for proper belt. Production belt is recommended unless tuning for a
specific application.
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
• More aggressive at low speeds
• Reduced heat and drive clutch sheave wear
• Used for short, higher horsepower runs (Drag Racing)
• Good trail belt for lower horsepower engines.

10/98 5.32 Polaris Industries Inc.

 CLUTCHES
Drive Belt

Drive Belt Inspection

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.
• The top edges have been trimmed on some L--!rojected Bel~
drive belts. It will be necessary to project the I Width I
side profiles and measure from corner to corner.
• Place a straight edge on each side of the drive
belt.
• Place another straight edge on top of belt.
• Measure the distance where the side straight
edges intersect the top, as shown in the illustra-
tion at right.
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 Solution
Driving at or about engagement RPM for extended periods in all Drive at higher RPM if possible. Gear the machine down. Make
types of conditions sure belt deflection is at 1.25" to achieve optimum starting ratio
Cold weather startups Be patient. Warm up engine at least 5 minutes or until it readily
responds to throttle input. For the quickest most efficient driveaway
in extreme cold weather, take drive belt off machine and bring it in to
a warm environment. Break skis and track loose from the snow.
Engage throttle aggressively for short durations for initial cold drive-
away
Towing another machine at or about engagement RPM When possible, do not go in deep snow when towing another ma-
chine. Use fast, effective throttle to engage the clutch. Not all ma-
chines are intended for pulling heavy loads or other machines.
Spinning track while vehicle is stuck (high RPM, low vehicle speed, Lower the gear ratio. Remove windage plates from driven clutch. If
high ambient temp. Example: 8000 RPM, 10mph vehicle speed, 60 possible, move to better snow conditions and reduce RPM. Avoid
mph indicated on speedometer. riding in very high ambient temperatures.
Ice and snow piled up between track and tunnel overnight or after Break loose snow and ice under tunnel. Allow longer than normal
stopping for a long period of time (enough to re-freeze the snow). warmup. Allow belt to warm sufficiently and increase grip ability on
clutch sheaves. Use fast, effective throttle when engaging clutch.
Poor running engine Maintain good state of tune including throttle and choke synchro-
(Bog, Miss, Backfire, etc.) nization. Check for fouled spark plug(s). Check for foreign material
in carbs. Make sure no water or ice in fuel tank, lines, or carbure-
tors.
Loading machine on trailer Use caution when loading machine. Carbide 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.
Clutch malfunction Check for correct clutch components.
Slow, easy belt engagement- easing on the throttle Use fast, effective throttle to engage the clutch.

Polaris Industries Inc. 5.33 10/98

CLUTCHES
Drive Belt

Belt Deflection

Too much belt deflection - If the belt is too long or the

center distance too short, the initial starting ratio will be Belt too high on initial engagement
too high, resulting in performance loss. This is due to the
belt rising too high in the drive clutch sheaves upon en-
gagement.

Not enough belt deflection (belt too tight) - If the drive

belt is too short or the center distance too long, the ratio
will again be incorrect. In addition, the machine may
creep when the engine idles, causing damage to the in-
ternal face of the drive belt.

10/98 5.34 Polaris Industries Inc.

 CLUTCHES
Drive Belt

Measuring Belt Deflection

IMPORTANT NOTE: Do not apply excessive pressure to force belt into driven sheaves. This will result in an
improper measurement. If belt deflection cannot be adjusted within specification using methods below, inspect
center distance and compare to specifications beginning on page 6.3.
1. Measure belt deflection with both clutches at rest and
in their full neutral position.
2. Place a straight edge on the belt and apply downward
pressure while measuring at the point shown.

Belt Deflection -

1 1/4" (3.2 em)

Adjusting 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 5.26.
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 5.28.

Adjusting Belt Deflection {P-85)

Belt deflection can be adjusted without removing the clutch
from the jackshaft. Used to adjust
belt tension. One must
1. Pull belt into driven clutch to slightly open sheaves. always be installed.

2. Loosen three bolts on adjustment cam.

3. Turn cam counterclockwise to reduce distance Optional Thin Adjustment Washer (P-85)
between sheaves. Do not rotate past #1 position.
;048" • PN 7555899
4. Torque bolts to specification.

Production washer is usually .075" thick with other .020 or .030 washers
as required. May use optional, thinner (.048") washer PN 7555899 if re-
quired to obtain proper sheave width. Either the .075" or .048" washer
must be installed in this location to provide support for the adjustment
pins.

Polaris Industries Inc. 5.35 10/98

CLUTCHES
Drive Belt

Clutch Offset Inspection

NOTE: Proper offset aligns the fixed sheaves of both Offset- Non-Electric Start Models
clutch assemblies. This allows the clutches to be :~:-A 21 /32" Offset
aligned throughout the shift range. ·· · No gap at All models with P90
point "A" driven clutch
1. Remove drive belt. Belt deflection adjustments
affect offset. Set belt deflection first. 5/8" Offset
All models with P85
2. Install proper alignment tool, depending on type of driven clutch
clutch, as shown in Ill. 1. . ~·.
:..,·
3. Rear of driven clutch moveable sheave should just
'..:.·,
contact tool when clutch is pushed inward on
jackshaft. ...
~.:··

"'
NOTE: Up to .060" (1.5mm)
air gap allowed at point "B".
Clutch Alignment (Tools)- Up to .125" is acceptable on
new machines.
P90- 21/32" Offset(PN 2870914)
P85 - 5/8"0ffset (PN 2870426)

P90 Electric Start -

1.28"0ffset (straight edge)
P85 Electric Start -
1" Offset (straight edge)

Clutch Offset Adjustment Offset Alignment Tool

Ill. 1
1. Determine direction driven clutch needs to be
adjusted. (Refer to Clutch Offset Inspection
procedure above).
2. Remove driven clutch retaining bolt, and remove Offset -Electric Start Models
driven clutch. NOTE: Up to .060" (1.5mm)
air gap allowed at point "B".
3. Add or take out washers on jackshaft between the (.125" on new machines)
driven clutch and jackshaft bearing to achieve
proper offset.
4. Most models require the driven clutch to float on the
jackshaft. After adjusting offset, add or remove
shim washers from the retaining bolt to provide a
.030"-.060" (.75-1.5mm) of float on jackshaft. This
will prevent side loads on the jackshaft bearing.
NOTE: On models with driven clutch snap ring 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 Ill. 2. If alignment is off, loosen
the engine mounts and shift engine as required to obtain
the proper offset and alignment.

Driven Clutch Bolt Torque -

12ft. lbs. (1.66 kgm)

Ill. 2

10/98 5.36 Polaris Industries Inc.

 CLUTCHES
Drive Belt

Clutch Alignment Inspection

NOTE: Drive clutches are purposely misaligned slightly forward to compensate for the engine shifting on it's
mounts. Under load, the engine will pull back slightly so both clutches are in alignment.
1. After clutch offset has been verified, inspect
alignment.
2. Install proper alignment tool, depending on type of
clutch, as shown in Ill. 1 page 5.36.
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 Alignment Adjustment

1. Loosen all 4 engine mounting bolts.
2. Adjust engine torque stop until clutches are in
proper alignment.
3. Tighten engine mounts securely.
4. Recheck both clutch offset and alignment.
5. Verify proper 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
loosening lock nut and rotating stop to proper
clearance as shown. Hold torque stop and tighten
jam nut to 15-17 ft. lbs. {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)

'~_.(}
c(',
~ ~··.1'-

// "\ Lock
Nut
\
Adjust gap between stop and engine
crankcase to .1 00" {2.5"mm)
± .01 0" {.25 mm)

Polaris Industries Inc. 5.37 10/98

CLUTCHES
Drive Belt

Belt to Sheave Clearance Inspection

NOTE: The distance between the belt and the moveable

sheave on the drive clutch is very important. This dis-
tance controls the starting ratio (lowest starting ratio is
most preferable) and the position of the clutch weight to
engine RPM. The distance between the belt and move-
able sheave should be as close to .020" (.5 mm) as pos-
sible without creating a drag on the belt, when positioned
around the hub at the bottom of the sheaves.

1. Force belt to one side of drive clutch. NOTE:

Measure total belt to sheave clearance with a new
belt.

2. Install feeler gage between other sheave and belt.

Belt to Sheave Clearance -

.020" ±.015"(.5 mm±.4mm)

Belt to Sheave Clearance Adjustment

Belt to sheave clearance can be adjusted in two ways.
1. Try several new belts to achieve proper clearance.

2. Can add or remove shims from under the spider to

increase or decrease belt to sheave clearance. See
Spider indexing on page 5.24.
NOTE: Spider indexing affects clutch balance and belt
to sheave clearance. Read procedures carefully before
proceeding.

NOTE: Belts with various widths will also affect belt

deflection since they will fit differently in the driven clutch.
Deflection should be checked per procedure on page
5.35.

10/98 5.38 Polaris Industries Inc.

 CLUTCHES
Clutch Bushing Replacement P-85

Kit PN 2871 025

Item Qty. Part Description Part No.
1 P-85 Drive Clutch Moveable Bushing 5020627
Removal and Installation Tool
2 P-90 Drive Clutch and Driven Clutch 5020628
Bushing Installation Tool
3 Drive Clutch Cover Bushing Removal and 5020629
Installation Tool (for all drive clutches)
4 P-85 Driven Clutch DU Split Bushing 5020630
Installation Tool
5 P-90 Driven Clutch Bushing Removal Tool 5020631
6 P-85 Driven Moveable Sheave Removal Tool 5130862
7 P-85 Driven Moveable Sheave 5222768
Removal Bridge
8 1 Main Puller Adapter 5020632
9 Adapter Reducer 5010279
10 Number Two Puller Adapter 5020633
11 Instruction 9912260
You will need to supply:
Piston pin puller (PN 2870386)
Bench vise
Soft face hammer (for P-85 Driven Moveable)
Small scribe or pick (for Cover Bushing Removal)
Hand held propane torch (for P-90 Driven)
Loctite RC 860 Retaining Compound (2870584)

P-85 Drive Clutch Cover Bushing Removal

1. Disassemble clutch as outlined in this section.

2. Inspect or measure bushing and replace if worn beyon1
service limit. Note: Bushing must be installed in covet
There are two types of bushings used. Refer to tht
following specifications.

Cover . Bushing Inspection:

Garmaxn" Style (Installed .Dimension)
Nominal Bearing Bore: 1.125" (28.57mm)
Service Limit: 1.140" (28.95mm)

Cover Bushing Inspection: ·

·Teflon/Bronze Style,
Service Limit: Replace cover bushing if
more bronze than.TeflonTM is visible.
Nominal Bearing Bore: 1.125" (28.57mm)
service Limit: 1.132" (28.75mm)
(Measure When Bushing is Installed)

Polaris Industries Inc. 5.39 10/98

CLUTCHES
Clutch Bushing Replacement P-85

P-85 Drive Clutch Cover Bushing Removal Cont.

3. On models equipped with snap ring, remove round wire

snap ring from inside of clutch cover using a small
scribe or pick and set aside.
4. Install main adapter (Item 8) on puller.
5. From outside of clutch cover, insert removal tool (Item
3) into cover bushing.
6. With inside of cover toward 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 cover counterclockwise on puller rod until

bushing is removed.
9. Remove nut from puller rod and set aside.
10. Remove bushing and bushing removal tool from puller.
Discard bushing.

P-85 Drive Clutch Cover Bushing Installation

1. On Garmax™ style bushings (PN 3576516) apply

Loctite 680 retaining compound (PN 2870584) to the
outer surface of the bushing. Retaining compound is
not required on bronze I Teflon™ type bushings (PN
357651 0). Do not lubricate bushings, or
premature wear will result.
2. Working from inside of cover, insert bushing and
bushing installation tool into center of clutch cover.
3. With main adapter on puller, insert cover onto puller
rod, placing outside of cover toward vise.
4. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed.

5. Turn clutch cover counterclockwise on puller rod until

bushing is seated.
6. Remove nut from puller rod and take installation tool
and clutch cover off rod.
7. Squeezing ends of snap ring, gently fit ring into clutch
cover.

10/98 5.40 Polaris Industries Inc.

 CLUTCHES
Clutch Bushing Replacement 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. Remove nut from puller rod and set aside.
4. Install main adapter (Item 8) onto puller. See Ill. 1.
5. Working from inside of moveable sheave, insert Piston Pin
removal tool (Item 1) into center of sheave. With Puller
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 until it
comes free.
8. Remove nut from puller rod and set aside.
Ill. 1
9. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.
1 0. Remove retaining ring from inside adapter and set
aside.

Polaris Industries Inc. 5.41 10/98

CLUTCHES
Clutch Bushing Replacement P-85

P-85 Drive Clutch Movable Sheave Bushing Installation

1. Place main adapter (Item 8) on puller.

2. Push new bushing into center of sheave by hand.
3. Insert installation tool (Item 1) into center of sheave and
with towers pointing toward vise, slide sheave onto
puller rod.
4. Install nut on puller rod and hand tighten. Turn barrel to
apply additional tension if needed.
5. Turn sheave counterclockwise until bushing is seated.
6. Remove nut from puller rod and set aside.
7. Remove sheave from puller.
8. Remove installation tool.
9. Insert retaining ring removed in step 9 and installation
tool into center of sheave.
10. With towers pointing toward vise, install sheave onto
puller rod.
11. Install nut on puller rod and hand tighten. Turn barrel to
apply additional tension if needed.
12. Turn sheave counterclockwise until ring is seated.
13. Remove nut from puller rod and set aside.
14. Remove sheave from puller.
15. Remove installation tool. Do not lubricate bushings,
or premature wear will result.

10/98 5.42 Polaris Industries Inc.

 CLUTCHES
Clutch Bushings P-85

P-85 Driven Clutch Movable Sheave Large Bushing Removal

NOTE: The P-85 driven moveable has a split bushing.
Note the position of this split during bushing removal.
See Ill. 2.

Note posi-
Moveable Sheave Bushing Inspection: tion
of split
Replace the cover bushing if more
brass. than Teflon™ is visible on. the';
bushing.
.

1. Inspect bushing and replace if excessively worn.

2. Insert bushing removal tool (Item 6) into sheave, Bushing
centering split on tool. NOTE: The split must be removal tool
touching the tool. See Ill. 2.

Ill. 2
3. Install main adapter as illustrated. Install bridge
(Item 7) onto puller with legs pointing toward clutch.
See Ill. 3.
4. From the outside, insert thumb through center of
sheave. Using downward pressure, hold bushing
removal tool tightly in place. 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.
Bridge
8. Remove nut from puller and set aside.
9. Remove tool and bushing from puller. Discard
bushing.
10. Remove bridge and adapter from puller. Ill. 3

Polaris Industries Inc. 5.43 10/98

CLUTCHES
Clutch Bushings P-85

P-85 Driven Clutch Movable Sheave Large Bushing Installation

NOTE: The P-85 driven moveable has a split bushing.
The bushing is held in place after installation by screws.

11. Insert bushing (PN 3569803) into clutch and tap

lightly with a soft face hammer.

Ill. 4
12. Install adapter number two (Item 10) onto puller. See
Ill. 5.
13. Slide clutch sheave onto puller with back side away
from vise.
14. Turn puller barrel until rod extends past back side of
sheave.
15. Insert large installation tool for DU bushing (Item 4)
onto rod.
16. Install nut onto puller rod and hand tighten. Turn
Adapter
puller barrel to increase tension as needed. Number Two
17. Turn clutch sheave counterclockwise until bushing is
seated.
18. Remove nut from puller rod and set aside.
19. Remove installation tool and slide clutch sheave
from puller. Ill. 5
~------------------------------~
NOTE: The screws hold the bushing in place.

10/98 5.44 Polaris Industries Inc.

 CLUTCHES
Clutch Bushing P-90
Polaris Kit PN 2871226

Item Q.t¥,. Part Description Part No.

2 P-90 Drive Clutch and Driven Clutch 5020628
Bushing Installation Tool
3 Drive Clutch Cover Bushing Removal and 5020629
Installation Tool (for all drive clutches)
5 1 P-90 Driven Clutch Bushing Removal Tool 5020631
8 1 Main Puller Adapter 5020632
9 Adapter Reducer 5010279
10 Number Two Puller Adapter 5020633

P-90 Drive Clutch Moveable Sheave - Bushing Removal

Moveable Sheave Bushing Inspection:

Replace the cover bushing if more

brass than Teflon™ is visible on the
bushing.

1. Install handle end of piston pin puller securely into

bench vise and lightly grease puller threads.

2. Remove nut from puller rod and set aside.

3. Install main adapter (Item 8) onto puller.

Piston Pin Puller
PN 2870386

Main Adaptor

4. Insert adaptor #2 into bushing from belt side as

shown. With towers pointing toward vise, slide
sheave and bushing onto puller rod.

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.

Polaris Industries Inc. 5.45 10/98

CLUTCHES
Clutch Bushing P-90
6. Turn sheave and puller barrel together
counterclockwise on puller rod until bushing is
removed.

7. Remove nut from puller rod and set aside.

8. Pull bushing removal tool and adapter from puller rod.

Remove bushing from tool and discard.

Drive Clutch Moveable Sheave- Bushing

Installation
9. Place main adapter (Item 8) on puller.

10. Push bushing into center of sheave on tower side by

hand.

Bushing PN 3576504

11. Insert installation tool (Item 2) into center of sheave and

with towers pointing away from vise, slide sheave onto
puller rod.

12. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed.

13. Turn sheave and barrel together counterclockwise

until bushing is seated.

14. Remove nut from puller rod and set aside.

15. Remove sheave from puller.

16. Remove installation tool.

10/98 5.46 Polaris Industries Inc.

 CLUTCHES
Clutch Bushing P-90
P-90 Drive Clutch Cover - Bushing Removal
1. Install main adapter (Item 8) on puller.

Main Adaptor

2. From outside of clutch cover, insert removal tool

(Item 3) into cover bushing.

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.

Polaris Industries Inc. 5.47 10/98

CLUTCHES
Clutch Bushing P-90
P-90 Drive Clutch Cover - Bushing Installation
8. On Garmax™ style bushings (PN 3576516) apply
Loctite 680 retaining compound (PN 2870584) to
the outer surface of the bushing. Retaining
compound is not required on bronze I Teflon™ type
bushings (PN 357651 0). Do not lubricate
bushings, or premature wear will result.
Working from inside of cover, insert bushing and
bushing installation tool into center of clutch cover.

9. With main adapter on puller, insert cover onto puller

rod, placing outside of cover toward vise.

10. Install nut on rod and hand tighten. Turn puller

barrel to apply more tension if needed.

11. Turn clutch cover and barrel together

counterclockwise on puller rod until bushing is
seated.

12. Remove nut from puller rod and take installation

tool and clutch cover off rod.

10/98 5.48 Polaris Industries Inc.

 CLUTCHES
Clutch Bushing P-90
P-90 Driven Clutch Moveable Sheave -
Bushing Removal
NOTE: Bushings are installed at the factory using Loc-
tite™ 680. In order to remove the bushing it will be nec-
essary 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.. Main Adapter

15. Remove ramp buttons from moveable sheave. \

Adapter
Reducer

16. Using a hand held propane torch, apply heat

directly on bushing until tiny smoke tailings appear.

Clutch components will be hot! In order to avoid serious

burns, wear some type of insulated gloves for the rest of
the removal process.

Polaris Industries Inc. 5.49 10/98

CLUTCHES
Clutch Bushing P-90
17. Working from the top, install bushing removal tool
(Item 5) into center of clutch sheave with smaller
diameter toward bushing to be removed. See
illustration at right.

18. Install sheave onto puller.

19. Install nut onto puller rod and tighten by hand. Turn
puller barrel for further tension if needed.

20. Turn clutch sheave counterclockwise until bushing

is removed. Repeat steps 17. - 20. for other
bushing.

21. Remove nut from puller rod and set aside.

22. Remove adapters from puller.

23. Remove bushing and removal tool from adapters.

Discard bushing.

10/98 5.50 Polaris Industries Inc.

 CLUTCHES
Clutch Bushing P-90
P-90 Driven Clutch Moveable Sheave - Bushing Installation

24. Working from the top, insert adapter number ten

onto puller. See illustration at right.

Adapter
Number Ten

25. Start new bushing evenly in moveable sheave.

26. Install sheave onto puller with new bushing upward

as shown. Install adaptor number two.

Polaris Industries Inc. 5.51 10/98

CLUTCHES
Clutch Bushing P-90

27. Install nut onto puller rod and hand tighten against
installation tool.

28. Turn clutch sheave counterclockwise until bushing

is seated.

29. Remove nut from puller rod and set aside.

30. Remove installation tool and clutch sheave from

puller.

31. Repeat installation procedure for other moveable

bushing.

10/98 5.52 Polaris Industries Inc.

 CLUTCHES
Troubleshooting
SYMPTOMS PROBABLE CAUSE REMEDY
Harsh drive clutch engage- -Drive belt worn too narrow -Replace
ment
-Excessive belt to sheave clearance with -Perform belt to sheave clear-
new belt (high performance version with- ance adjustment with shim
out detent shift weight) washers beneath spider
Drive belt turn over -Wrong belt for application -Replace

-Clutch alignment out of spec -Adjust alignment offset

-Engine mount broken or loose -Inspect, adjust or replace

-Driven clutch sheaves have excessive -Measurement should be tak-

runout, are bent or damaged en .25" in from outer circum-
terence on sheave face. Max-
imum allowable tolerance is
.015" (.6 mm).
Noise in drive system -Broken drive clutch components -Inspect/replace

-Excessive drive clutch button -tower -Install new buttons or shim

clearance out existing buttons

-Inspect/replace
-Bearing failure/ chaincase, jackshaft or
front drive shaft
-Inspect/adjust or replace
-Drive chain loose or worn, sprocket teeth
broken -Inspect/replace

-Driven clutch bushing worn excessively or -Inspect/replace

spring broken

-Drive chain adjustment too tight/too loose Inspect/adjust

-Drive belt surface flat spots Inspect/replace

Over rev during initial accel- -Spider roller position remaining in detent -Add spider shim washers
eration or during heavy pulling
at low ground speeds. -Add driven washers

-Reduce gear ratio (chaincase

Engine bogs after engage- -Improper driven clutch setup models)
ment.
-Worn belt -Replace

-Excessive belt deflection -Subtract driven clutch wash-

ers
-Improper offset/alignment
-Inspect/adjust
-Broken or misadjusted torque stop
-Inspect/adjust/replace
-Broken motor mount
-Inspect/replace
-Jackshaft bearing seizure
-Replace

Polaris Industries Inc. 5.53 10/98

CLUTCHES
Clutch System Troubleshooting
SYMPTOMS PROBABLE CAUSE REMEDY
Engine RPM below specified a) Wrong or broken drive clutch spring a) Replace with recommended spring
operating range, although en- b) Drive clutch shift weight too heavy b) Install correct shift weight kit to
gine is properly tuned c) Driven clutch spring broken or installed match engine application
in wrong helix location c) Replace spring; refer to proper
d) Drive belt too long installation location
e) Improper driven clutch setup d) Install new belt and/or adjust belt
tension
e) Install correct parts and/or adjust to
match engine application and ma
chine use

Erratic engine operating RPM Drive clutch binding or driven clutch -Disassemble drive clutch; inspect shift
during acceleration or load malfunction weights for wear and free operation
variations Clean clutches; install new belt
Converter sheaves greasy; belt slippage -Clean and polish stationary shaft hub;
reassemble clutch without spring to
determine problem area
-Replace ramp buttons
-Inspect moveable sheave for excessive
bushing clearance/replace

Engine RPM above specified a) Incorrect drive clutch spring (too high a) Install proper spring
operating range spring rate) b) Install proper shift weights
b) Drive clutch shift weights incorrect for c) Disassemble and clean clutch,
application (too light) inspecting shift weights and buttons.
c) Drive clutch binding Reassemble without the spring to
d) Driven clutch binding determine probable cause.
e)Converter sheaves greasy; belt slippage d)-Disassemble, clean and inspect
f) Improper driven clutch setup driven clutch, noting worn sheave
bushing and ramp buttons and helix
spring location
e) Clean clutches; install new belt
f) Install correct parts and/or adjust to
match engine application and ma
chine use

Burnt Belts I Premature Wear a) Wrong or broken drive clutch spring a) Replace with recommended spring
Also see Belt Wear I Burning b) Drive clutch shift weight too heavy b) Install correct shift weight kit to match

Diagnosis Chart on page 6.63 c) Driven clutch spring broken or installed engine application
in wrong helix location c) Replace spring; refer to proper
d) Drive belt too long installation location
e) Converter sheaves greasy; belt slip- d) Install new belt and/or adjust belt
page. tension
f) Improper driven clutch setup e) Clean clutches; install new belt
f) Install correct parts and/or adjust to
match engine application and ma
chine use

10/98 5.54 Polaris Industries Inc.

 CLUTCHES
Belt Wear I Burn Diagnosis
Belt Wear I Burn Diagnosis
Possible Cause Of Wear Or Burning Solution
Driving at or about engagement RPM for extended Drive at higher RPM if possible. Gear the machine
periods in all types of conditions down. Make sure belt deflection is at 1.25" to
achieve optimum starting ratio
Cold weather startups Be patient. Warm up engine at least 5 minutes or
until it readily responds to throttle input. For the
quickest most efficient driveaway in extreme cold
weather, take drive belt off machine and bring it in to
a warm environment. Break skis and track loose
from the snow. Engage throttle aggressively for short
durations for initial cold driveaway
Towing another machine at or about engagement When possible, do not go in deep snow when towing
RPM another machine. Use fast, effective throttle to en-
gage the clutch. Not all machines are intended for
pulling heavy loads or other machines.
Spinning track while vehicle is stuck (high RPM, low Lower the gear ratio. Remove windage plates from
vehicle speed, high ambient temp. Example: 8000 driven clutch. If possible, move to better snow condi-
RPM, 1Omph vehicle speed, 60 mph indicated on tions and reduce RPM. Avoid riding in very high am-
speedometer. bient temperatures.
Ice and snow piled up between track and tunnel Break loose snow and ice under tunnel. Allow longer
overnight or after stopping for a long period of time than normal warmup. Allow belt to warm sufficiently
(enough to re-freeze the snow). and increase grip ability on clutch sheaves. Use fast,
effective throttle when engaging clutch.
Poor running engine Maintain good state of tune including throttle and
(Bog, Miss, Backfire, etc.) 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 carbure-
tors.
Loading machine on trailer Use caution when loading machine. Carbide skags
may gouge into trailer and prevent drive train from
spinning freely. Use enough speed to drive com-
pletely onto trailer. If machine cannot be driven com-
pletely onto trailer, it may need to be pulled or
pushed to avoid belt wear I burning.
Clutch malfunction Check for correct clutch components.
Slow, easy belt engagement- easing on the throttle Use fast, effective throttle to engage the clutch.

Polaris Industries Inc. 5.55 10/98

CHAPTER 6
BODY AND STEERING

Torque Spec's Steering Asm, Exploded Views .... 6.1-6.11

Steering Inspection ........................... 6.12
Steering Adjustment Guidelines- AIIIFS ......... 6.13
Steering Adjustment - All IFS ................... 6.14-6.15
Steering Inspection -All IFS .................... 6.16-6.19
High Performance Steering Inspection/Alignment . 6.20-6.25
Ski Spindle Bushing Replacement .............. 6.27-6.28
Steering Arm Installation ....................... 6.29
Ski Skag Removal ............................ 6.30
Ski Skin Installation ........................... 6.31
Ski Installation - Steel Skis/Composite ........... 6.32
Torsion Bar Replacement ...................... 6.33
Handlebar Torque ............................ 6.34
Fuel Tank and Seat Removal ................... 6.35-6.36
Seat Cover Replacement ...................... 6.37-6.39
Hood Repair ................................. 6.39
Taillight Assembly Replacement ................ 6.40
Seat Length Matrix ............................ 6.41
Nosepan Replacement - Evolved Style .......... 6.42
Nosepan Replacement - Gen II XTRA-1 0 Style ... 6.43
Nosepan Replacement - Gen II XC-1 0 Style ...... 6.44
Hood Adjustment- Evolved .................... 6.45-6.46
Decal Removal and Installation ................. 6.47
Troubleshooting .............................. 6.48
 BODY AND STEERING
Torque Specifications- Steering Assembly Exploded View

Torque Application List

Due to the special grade bolts and nuts required for specific applications, observe the following torque values in
the areas specified. Refer to exploded views for torque values and orientation of components and fasteners.

1999 XCF
Illustration depicts proper orientation of rod ends and bolts on steering components.

28-30 ft. lbs.

(3.9-4.1 kg-m)

17-19 ft. lbs.

~
"/
?-> .
,:.._ I
~~
(2.4-2.6 kg-m) /
...
'•<.:.,
' ..
",··~

. . . ·:.l'"..
\. "'+,

17-19ft. lbs.
(2.4-2.6 kg-m)
35-40 ft. lbs. /
(4.8-5.5 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

+ Replace locking fasteners if removed.

Polaris Industries Inc. 6.1 10/98

BODY AND STEERING
Steering Assembly Exploded View

1999 340, 340 Deluxe, 340 Touring

Illustration depicts proper orientation of rod ends and bolts on steering components.

40-45 ft. lbs.

28-30 ft. lbs. (5.5-6.2 kg-m)
(3.9-4.1 kg-m)
28-30 ft. lbs.
(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

+ Replace locking fasteners if removed.

10/98 6.2 Polaris Industries Inc.

 BODY AND STEERING
Steering Assembly Exploded View

1999 Sport, Sport Touring, TranSport

Illustration depicts proper orientation of rod ends and bolts on steering components.

40-45 ft. lbs.

(5.5-6.2 kg-m)

35-40 ft. lbs.

(4.8-5.5 kg-m)

~\ie
~ 28-30 ft. lbs.

/
45-50 ft. lbs.
(3.9-4.1 kg-m)

(6.2-6.9 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

+ Replace locking fasteners if removed.

Polaris Industries Inc. 6.3 10/98

BODY AND STEERING
Steering Assembly Exploded View

1999 WideTrak LX
Illustration depicts proper orientation of rod ends and bolts on steering components.

45-50 ft. lbs.

(6.2-6 9 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

\
28-30 ft. lbs.
(3.9-4.1 kg-m)

+ Replace locking fasteners if removed.

10/98 6.4 Polaris Industries Inc.

 BODY AND STEERING
Steering Assembly Exploded View

1999 Trail RMK, 500 RMK

Illustration depicts proper orientation of rod ends and bolts on steering components.

55-60ft. lbs.
(7.6-8.3 kg-m)

28-30 ft. lbs.

28-30 ft. lbs. (3.9-4.1 kg-m)
(3.9-4.1 kg-m)

35-40 ft. lbs. 28-30 ft. lbs.

(4.8-5.5 kg-m) (3.9-4.1 kg-m)

~-----....::~~- 45-50 ft. lbs.

(6.2-6.9 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

+ Replace locking fasteners if removed.

Polaris Industries Inc. 6.5 10/98

BODY AND STEERING
Steering Assembly Exploded View

1999 Supersport, Trail, Trail Touring 500, 500 Classic, Classic Touring
Illustration depicts proper orientation of rod ends and bolts on steering components.

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)
28-30 ft. lbs.
(3.9-4.1 kg-m)

28-30 ft. lbs.

+ Replace locking fasteners if removed. (3.9-4.1 kg-m)

10/98 6.6 Polaris Industries Inc.

 BODY AND STEERING
Steering Assembly Exploded View

1999 XLT Classic, XLT Touring

28-30 ft. lbs.

(3.9-4.1 k -m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

+ Replace locking fasteners if removed. (3.9-4.1 kg-m)

Polaris Industries Inc. 6.7 10/98

BODY AND STEERING
Steering Assembly Exploded View

1999 440 XCR, 500 XC /SP

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

\
17-19 ft. lbs.
(2.4-2.6 kg-m)
17-19 ft. lbs.
(2.4-2.6 kg-m)
35-40 ft. lbs.
(4.8-5.5 kg-m)
28-30 ft. lbs.
(3.9-4.1 kg-m)

40-45 ft. lbs.

(5.5-6.2 kg-m)

+ Replace locking fasteners if removed.

10/98 6.8 Polaris Industries Inc.

 BODY AND STEERING
XC-10 CRC Steering Assembly Exploded View

1999 600 XC/SP, 700 XC/SP

Illustration depicts proper orientation of rod ends and bolts on steering components for most models.

35-40 ft. lbs.

(4.8-5.5 kg-m)

NOTE: Typical XC-1 0 shown.

Orientation of drag link and
placement of pitman and idler
arms reversed on some models

17-19 ft. lbs.

(2.4-2.6 kg-m)

35-40 ft. lbs.

(4.8-5.5 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)
Jam Nuts
8-14 ft. lbs.
(1.1-1.9 kg-m)

Idler Arm
Pitman Arm
Tie Rod Ends
17-19 ft. lbs (2.4-2.6 kg-m)

.. .... ~ .

Jam Nuts
8-14 ft. lbs.
(1.1-1.9 kg-m)

Polaris Industries Inc. 6.9 10/98

BODY AND STEERING
XC-10 CRC Steering Assembly Exploded View

1999 600 RMK, 700 RMK

Illustration depicts proper orientation of rod ends and bolts on steering components for most models.

35-40 ft. lbs.

(4.8-5.5 kg-m) 28-30 ft. lbs.
(3.9-4.1 kg-m)
40-45 ft. lbs.
(5.5-6.2 kg-m)

~
28-30 ft. lbs.
17-19 ft. lbs. (3.9-4.1 kg-m)
(2.4-2.6 kg-m)

35-40 ft. lbs.

(4.8-5.5 kg-m) 17-19 ft. lbs.
(2.4-2.6 kg-m)

~)
45-50 ft. lbs.
(6.2-6.9 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

28-30 ft. lbs.

(3.9-4.1 kg-m)

+ Replace locking fasteners if removed.

10/98 6.10 Polaris Industries Inc.

 BODY AND STEERING
Steering Assembly Exploded View

Models: 1999 XLT Special, 700 SKS, 700 XCR, 800 XCR
Illustration depicts proper orientation of rod ends and bolts on steering components.

Idler Arm and Pitman Arm Pivot

35-40 ft. lbs. Nut On Top Steering Post
(4.8-5.5 kg-m) 28-30 ft. lbs.
(3.9-4.1 kg-m)
Idler Arm-to-Rack
17-19ft.lbs.
(2.4-2.6 kg-m)

Drag Link

Steering Rod End W/Stud

Rack
17-19 ft. lbs.
(2.4-2.6 kg-m)

Upper
Radius Rod

Trailing Arm

28-30 ft. lbs.

Lower Radius Rod (3.9-4.1 kg-m)

Steering Arm
Weld Positioned Up

Spindle
/ Indicates direction of bolt 28-30 ft. lbs.
(3.9-4.1 kg-m)

Polaris Industries Inc. 6.11 10/98

BODY AND STEERING
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 steering assembly exploded views in this chapter for identification of
components and torque values of fasteners. While disassembling, make notes of what direction a bolt goes
through a part, what type of nut is used in an application, in which direction do the steering arms go on -weld up or
weld down, etc.

Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store. Always use
genuine Polaris parts and hardware when replacing front end components. Review steering adjustment
guidelines on page 6.13 before making adjustments.

The following components must be inspected at this time:

NOTE:Aiways follow rod end engagement guidelines found on page 6.13. Maximum setup width must be
checked whenever front suspension components are adjusted or replaced.
0 Tie rods and tie rod ends
0 Radius rods and radius rod ends
0 Torsion bar and bushings /linkage (where applicable)
0 Handlebars and steering post assembly
0 Spindles and bushings
0 Trailing arms and bushings
0 Skis and skags
0 Bell crank I Pitman arm /Idler arm
0 Steering arms
0 Shock absorbers, shock mounts, springs
0 All related fasteners - check torque. Refer to steering exploded views at the beginning of this section.
0 Grease all fittings.

Alignment Bar Specifications

45" (114.3 em) - - - - - - - - - - . ,

j_
T
0=.623-.625" (5/8)
Alignment Bar PN 8700231 (15.83-15.88 mm)

10/98 6.12 Polaris Industries Inc.

 BODY AND STEERING
Steering Adjustment Guidelines - All IFS

Camber Definition - AIIIFS

The following definitions of camber use automotive Positive, Negative, and Neutral {0°) Camber
terminology to describe positive and negative posi-
tions. Refer to the illustration at right.
+
• 0 (Neutral) Camber- Spindle is goo (perpendicu-
lar) to ground
• + (Positive) Camber- Spindle bottom is canted
inward toward chassis
• - (Negative) Camber- Spindle bottom is canted
outward from chassis

Front View

Radius Rod and Tie Rod End Torque Procedure

Radius rod and tie rod ends must be parallel to their

respective mounting surface after tightening jam nut
as shown at right. Hold tie rod or radius rod and tigh-
ten 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 approxi-
mately 1/8 turn.

Incorrect Correct

Rod End Engagement Guidelines - All IFS

Tie Rod Or Radius Rod End /Jam Nut

Tie Rod Or Radius Rod End Must

,__, I "\.
~
Engage Rod A Minimum Of 2x Thread
Diameter When Adjustment Is Complete ( I mli
-
i''''f,l/1
_/..!..' •J.• L.!._

~/ '\

"""
Tie Rod Or
EXAMPLE
7/16" Rod End x 2 = 7/8"
Minimum Thread Engagement =7/8"
Diameter Of Rod
End x 2 = Minimum - I+-
Thread Engagement Thread Engagement
Radius Rod

11mm x 2 = 22mm
Minimum Thread Engagement =22mm

Polaris Industries Inc. 6.13 10/98

BODY AND STEERING
Steering Adjustment - All IFS

1999 IFS Steering Alignment Specifications

The following information is to be used for 1999 Polaris Snowmobile front suspension setup.
The data in the following table is based on the 1999 Polaris factory settings. Maximum Width
and Camber measurements are to be taken with the front end elevated and shocks at
full extension. Toe alignment is measured at ride height.
Suspension Type Maximum Setup Width Camber Toe
± 1/4" (6mm) ± 5/16" (At Ride Height)

LITE 36 5/16" (92.25 em) 0

340 Indy, 340 Deluxe,
340 Touring

38-RMK 36 3/4" (93.35 em) 0

Trail RMK, 500 RMK

38-RMKCRC 36 15/16" (93.80 em) 3/8"

600 RMK, 700 RMK

38x7 37 9/16" (95.40 em) 3/4"

WIDETRAK ALL MODELS

41x7 40 5/16" (1 02.40 em) 9/16"

Sport, Sport Touring 1/8- 1/4" Toe Out
Transport

XTRA-10 40 7/16" (102.70 em) 0

Trail, Trail Touring, Supersport,
5001ndy At Normal Ride
Height
XTRA-10 CRC 39 1/4" (99.70 em) 3/4"
600 SKS Euro, 700 SKS, 700
SKS Euro, XLT SP, XCF,
700 XCR, 800 XCR

XC-10 CRC 39" (99.00 em) 1 1/16"

440 XCR, 500 XC, 500 XC SP,
600 XC, 600 XC SP, 700 XC,
700 XC SP

XTRA-12 40 7/16" (102.70 em) 0

500 Classic, Classic Touring
XLT Classic, XLT Touring

WIDTH NOTE: Width is measured in inches from the center of the spindles near the grease fitting for the ski
mount bolt located at the base of the spindle. The tolerance on this measurement is± 1/4".
TOE ADJUSTMENT NOTE: Toe is measured in inches with the machine on the ground and resting at normal
ride height- not full rebound. Measure at a point 10" (254mm) forward of the ski mount bolt and 10" behind the
ski mount bolt, preferably on the centerline of carbide skags. Note: Measurements to points on the skis may be
inaccurate.
NOTE:Cambermeasurement is taken in inches from top of alignment bar to the top of ski mount hole in the spindle
(bushing removed). All camber specifications are± 5/16" or 1/2 the diameter of the alignment bar(± 8mm).
• An alternate method of alignment using the Camber and Toe Alignment Travel Bars (Kit PN 2871537)
can be performed on snowmobiles equipped with XTRA-10 CRC or XC-10 CRC front suspension. The
travel bars are not intended for use on 38 RMK CRC or non-CRC models.

10/98 6.14 Polaris Industries Inc.

 BODY AND STEERING
Steering Adjustment - All IFS
Prior to performing steering alignment, the suspension should be inspected for damage or wear and replacement
parts installed as required. See inspection on page 6.12.

A WARNING

A maximum set up width is listed in the chart on page 6.14. 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 are maximum width measurements, and are critical to ensure adequate
torsion bar engagement with the trailing arm. If the suspension is set too wide , 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.
Spindle Centering I 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) oft the floor.
3. Remove skis and ski pivot bushings.
4. Disconnect adjustable torsion bar linkage where applicable.
5. Measure spindle to chassis centering as shown ......-----------------...,
and record measurement. Both spindles should be
an equal distance +1- 1/8" (3 mm) from the center of
the chassis after adjusting camber, width, and toe
alignment. This measurement is controlled by
adjusting radius rod length.

6. Measure set up width and record. This

measurement is controlled by adjusting radius rod
length, and must not exceed the Maximum Setup Spindle To Chassis
Width listed in the appropriate table (at the front of Centering
this section) after all steering adjustments are Left = Right ± 1/8".
complete. See illustration below for procedure.

Measure from center of one spindle to center of the

other spindle with front end elevated and suspension
fully extended to determine set up width.
Measure Set-Up
Width Here*

*Do not exceed maximum

Polaris Industries Inc. 6.15 10/98

BODY AND STEERING
Steering Inspection - All IFS

CAMBER INSPECTION
All Models - Elevate Front End - Shocks Installed

Typical CRC Shown - Style varies by model

Suspension Free Hanging With

IFS Shocks Installed
Upper radius rod

Lower radius rod

Jam Nuts

Measure Here

Refer to specifications for:

•IFS type
•Specified amount of camber

0 To adjust, lengthen or shorten appropriate lower radius rod until top of bar is within specified camber
distance. Measurement should be taken from top of alignment bar to top of ski pivot bushing hole in
spindle {bushing removed). Radius rod must be re-attached to trailing arm before measuring.

CAMBER- ACCEPTABLE RANGE

EXAMPLE:
Specified Camber = 3/4" (19mm)
Specified Tolerance = ± 5/16" (Bmm)
Acceptable Range= 7/16 -1 1/16" (11-27mm)
Refer to specifications on page 6.14

10/98 6.16 Polaris Industries Inc.

 BODY AND STEERING
Steering Adjustment - All IFS

Camber Adjustment

1. Determine which spindle requires the greatest

amount of correction by installing the alignment
bar through one side to the opposite spindle.
Remove the bar and install it through the other
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.
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 6.14 for camber specifications. On
models with neutral camber (O) the bar should
slide freely through both spindles (± 5/16'').

Radius rod ends must remain parallel to the bulkhead Bulkhead

after rod end jam nuts are tightened to specified
torque. See illustration at right. \ Jam Nut

4. Tighten all jam nuts. Torque radius rod attaching

bolts to specification.
Rod end parallel to
mounting surface Rod End
when jam nut is tight.
A WARNING

After camber adjustment is complete, be sure to measure set up width outlined on page 6.15 and compare to specifications
listed on page 6.14. Do not attempt to set suspension wider than the specified maximum set up width. If set up width
exceeds maximum, adjust upper and lower radius rods equally to maintain camber adjustment.

Polaris Industries Inc. 6.17 10/98

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 (Fig 1). On models with negative
camber, the alignment bar cannot be installed
through spindles. On these models, the pitman and
idler arm (Fig II) (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. Torque
ski bolts to specification. Install new cotter pin in
castle nut. Fig. I
~------------------------------~
7. Perform Toe Adjustment on page 6.19.

10/98 6.18 Polaris Industries Inc.

 BODY AND STEERING
Steering Adjustment - All IFS

Toe Adjustment, All Models

Toe adjustment on all models must be performed with the vehicle weight on the suspension (no rider), at Normal
Ride Height. Although not required, an alternate high performance method of toe alignment (using the travel bar
kit 2871537) can be used to set toe on models equipped with XTRA-10 CRC front suspension (use 11.65 travel
bars). On XC-10 CRC models, only the camber can be set with the travel bars (13.70 travel bars); toe on XC-10
CRC must be set with shocks installed and front end elevated. Refer to pages 6.20-6.25.

1. Make sure the track is properly aligned. This will be

used as a reference point for toe out measurement.

Lift 3-5" (7.6-12.7 em) and work

suspension to find average

2. To obtain normal ride height of the front suspension,

lift the front end 3-5" (7.6-12.7 em) with the front
bumper. Lift the machine several times, working the
suspension and front skis until an average is
obtained.
NOTE: To prevent carbide skags from grabbing, make
sure the surface under the skis will allow full side-to-side
movement. Avoid rough concrete, asphalt, or carpet
which may cause carbide skags to grab or catch and
restrict movement.

Toe Adjustment
Normal Ride Height

NOTE: Measurements A&B 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 "A" 1/8-1/4" greater than
play in the steering components. This will help achieve "B" at normal ride height
accurate measurement. If a strap is used be sure it is not
too tight or it will alter measurement (this is most impor-
tant on models with composite skis).
A

Skag
Centerline
Track
Straight
Edge

Polaris Industries Inc. 6.19 10/98

BODY AND STEERING

High Performance
XTRA-10 CRC and XC-10 CRC

Inspection and Alignment

Pages 6.20- 6.25 pertain to precise CRC front set up information for high performance or
racing applications. The following procedures can be performed only on XTRA-1 0 CRC or
XC-1 0 front suspensions if desired. These instructions should not be used for 38-RMK
CRC or non-CRC front suspensions.

10/98 6.20 Polaris Industries Inc.

 BODY AND STEERING
High Performance Controlled Roll Center (CRC) Steering Alignment

XTRA-10 CRC and XC-10 CRC Steering Alignment

The following steering alignment procedure can be performed on XTRA-1 0 CRC or XC-1 0 CRC front suspensions
only, and should not be used for 38-RMK CRC or non-CRC front suspensions.

General Set Up Tips

Before adjustments are performed on CRC steering, inspect all front suspension and steering components. 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:
(tcamber-XTRA-10CRC & XC-10 CRCJ)
• 5/8" alignment bar- PN 5333508
.. 13.70" ..
• 6' tape measure
• Travel location bars -13.70" long (PN 5211714) (f~oe Alignment-XTRA-10CR~*)
• Travel location bars -11.65" long (PN 5211822)
11.65"
• Chassis stand or blocking

NOTE:The CRC Travel Location Bars are included in kit PN 2871537, along with a 46" alignment bar, and as-
sorted hardware. Kit components are also available separately. See tool catalog for tool ordering information.

Refer to the chart below for travel bar application for width, camber, and toe adjustments on XTRA-1 0 CRC and
XC-1 0 CRC models. See text on following pages for specific procedures.

XTRA-10 CRC and XC-10 CRC Models

When Measuring Set To Inspect I Adjust To Inspect I Adjust Toe
Up Width Camber
Travel Location Bar Suspension Fully lnstall13.70 Bars Install 11.65 Bars
Length Extended - Shocks (XTRA-10 ONLY;
Installed Set Toe w/Shocks
Installed on XC-1 0
models

A WARNING

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 6.14
are maximum width measurements, and are critical to ensure adequate torsion bar engagement with the trailing
arm. If the suspension is set too wide, 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.

Polaris Industries Inc. 6.21 10/98

BODY AND STEERING
High Performance CRC Steering Adjustment
CRC Steering Adjustment
To ensure accurate adjustment of the CRC steering mechanism, all steps listed below must be performed in se-
quential order.
• Spindle to Chassis Centering (must also be checked after adjustment)
• Set-Up Width adjustment(must also be checked after adjustment)
• Camber Adjustment
• Handlebar Centering
• Toe Adjustment
• Verify Spindle to Chassis Centering and Set-up width are within limits
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 6.15.
Set Up Width Measurement
4. Follow procedure on page 6.15.

A WARNING
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 6.14 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, 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.

Camber Adjustment- XTRA-10 CRC and XC-10 CRC

5. Remove IFS shocks and install13.70" travel location bars. The travel location bars will locate the IFS at a
given point of travel where the camber should be neutral (0°).
6. Disconnect tie rods from steering arms. NOTE: If toe adjustment is correct, the spindles will not be
horizontally aligned with the 13.70" travel location bars installed. Therefore the alignment bar will not slide
through both spindles. 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.
7. Determine which spindle requires the greatest amount of correction by installing the alignment bar through
one side to the opposite spindle, then remove the bar and install it through the other side to the opposite
spindle.

Camber Adjustment
lnstall13.70"
Travel Location Bars

~:,','

CZ::: Alignment Bar

10/98 6.22 Polaris Industries Inc.
 BODY AND STEERING
High Performance CRC Steering Adjustment
Camber Adjustment- XTRA-10 CRC and XC-10 CRC, (Cont.)
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 through
both spindles.
9. When adjustment is correct, tighten jam nuts to 24-25 ft. lbs. (3.31-3.45 kg-m). Torque radius rod attaching
bolts to 28-30 ft. lbs. (3.86-4.14 kg-m).

,~~:o7lti~,~~,,~;
Radius rod ends must remain parallel to the mounting
brackets after the rod end jam nuts are tightened to Jam Nut
the specified torque. See illustration at right.

10. Tighten all jam nuts. Torque radius rod attaching

bolts to specification.
Rod end parallel to
11. Re-check set up width and compare to
mounting surface Rod End
specifications.
when jam nut is tight.

Handlebar Centering-CRC

12. With alignment bar in spindles and tie rod ends Handlebar Centering - CRC
disconnected, center the steering rack by pointing
the pitman arm and idler arm straight forward.
13. Center the handlebars by adjusting drag link length.
Tighten jam nuts to 24-25 ft. lbs. (3.31-3.45 kg-m).

14. The steering arms should be parallel to the ski

centerline or slightly inward.
Adjust Drag Link Pitman Arm and
To Center Bars Idler Arm Point
Straight Forward

15. Re-attach steering tie rod ends (C) to steering arms.

It may be necessary to loosen the tie rod adjustment
jam nuts (B) and adjust tie rod length (A) as required
until rod end studs can be installed in steering arm.
Torque tie rod end attaching nuts to 28-30 ft. lbs.
(3.86-4.14 kg-m). If tie rod adjustment was
necessary, do not tighten them until toe adjustment
is complete.
c
16. Perform toe adjustment on following page.
B

Polaris Industries Inc. 6.23 10/98

BODY AND STEERING
High Performance CRC Steering Adjustment

Toe Adjustment- XTRA-10 CRC I XC-10 CRC

17. Remove alignment bar from spindles.

18. Remove 13. 70" travel location bars and install
11.65" toe alignment bar on XTRA-10 CRC only.
Toe alignment is set with shocks installed on
XC-10 CRC.
19. Install skis.
20. With the front of the machine still securely supported 11.65 Travel Bars -
off the ground, install a block or spacer between the XTR -10 CRC ONLY
rear of the ski frame and the bottom of the trailing
I Toe Alignment
arm. The block should be 3. 75" - 4.0" long. The ~
Bar Installed
blocks will keep ski-to-ground surface orientation
correct for more accurate toe adjustment.

Ill. 1

21. Adjust toe so skis I carbides are parallel - zero toe

out or toe in with toe alignment travel bar installed. NOTE: Measurements A&B should be
Measure from equal point on skag centerline to equal and taken 10" (254 mm) fore and
aft of spindle center as shown with toe
straightedge to determine the amount of adjustment
alignment travel bars installed.
required per ski. Measuring from points on skis may
vary and should not be used. I I

A~
I
,------ I
.r
I 10" I
~.~
..
I~
~·
0

1 ' IT ~~~
1 "''
or==::=j~~ il
B
J] ~0 "" "'<'

w
Straightedge
I
I
v
) \\
I
I

Against Traclv \i
(fY

10/98 6.24 Polaris Industries Inc.

 BODY AND STEERING
High Performance CRC Steering Adjustment

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.

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 properly tightened, the tie rod should
rotate freely approximately 1/8 turn.

Incorrect Correct
Tie Rod Jam Nut Torque -

8-14ft. lbs. (1.1-1.9 kg-m)

Polaris Industries Inc. 6.25 10/98

BODY AND STEERING

All Models
Body and Steering

Continued

10/98 6.26 Polaris Industries Inc.

 BODY AND STEERING
Ski Spindle Bushing Replacement
Ski Spindle Bushing Removal
1. Using a a scribe, center punch, or paint, mark the
spindle and steering arm for reference during
reassembly. Note direction of steering arm bolt
and remove. Also note orientation of grease fitting
for ski pivot bushing. The fitting faces forward on
models with leading spindle, and rearward on
trailing spindles.

2. Remove steering arm.

3. Slide spindle and ski assembly out bottom of

trailing arm. Inspect spindle for wear or damage.

4. Remove old bushings and washer from bottom of

spindle tube with a drift punch. Inspect condition of Bushings
washer and replace if worn. Install new bushings,
tapered end first.

Polaris Industries Inc. 6.27 10/98

BODY AND STEERING
Ski Spindle Bushing Replacement
Ski Spindle Bushing Installation
5. Grease spindle shaft and new bushings with
Polaris All Season Grease.

6. Install spindle into trailing arm with grease fitting

facing forward (standard and leading spindles) or
rearward (trailing spindles).

Standard Leading Type Trailing '97+

7. With ski facing straight forward, attach steering

arm. Align with marks made in step 1.

8. Install steering arm bolt and torque to specification.

10/98 6.28 Polaris Industries Inc.

 BODY AND STEERING
Steering Arm Installation

Steering Arm Orientation

A WARNING

Steering arm orientation is important to ensure proper steering tie rod end thread engagement and steering perfor-
mance. Always mark steering arms and spindles before removal for reference upon reassembly. When installing
new parts or after steering arm installation, refer to the illustrations and text below. Always verify proper steering
operation after 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 (Ill. 1) the centerline of the
ski and centerline of the ski bolt hole in the spindle
will form (approximately) a goo angle or slightly
1 Forward
Correct
greater.
As Close To
goo As Possible

Threads engage ~----"-'-'-'·"n

tie rod at least
3/4" (1gmm).
Steering Arm
Bolt Torque
30ft. lbs.
(4.15 kg-m)
Ill. 1

2. If the steering arm is installed incorrectly the

threads of the steering tie rod end will not engage
the tie rod sufficiently, and the angle formed
between ski and ski bolt centerlines is considerably 1 Forward
i !
less than goo as shown at right.
ill
u

Incorrect
\
Threads do not
engage tie rod at
least 3/4" 1gmm)

3. Reinstall torsion bar linkage (where applicable).

Torque attaching bolts to specification.

Ill. 2

Polaris Industries Inc. 6.29 10/98

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.

Ski Skag Retaining Nut Torque-

Steel Ski, Steel w/skins - 15 ft.

lbs. (2.1 kg-m)

Plastic Ski- 20-25 ft. lbs. (2.76-

3.45 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. lnstaiiiFS carbide skag.

3. Reinstall nuts and torque to specification.

Ski Skag Retaining Nut Torque -

15ft. lbs. (2.1 kgm)

10/98 6.30 Polaris Industries Inc.

 BODY AND STEERING
Ski Skin Installation

Ski Skin Installation

1. Lift and support front end of machine for easier

access to skis.
Ski Toe
A WARNING

Be sure the machine is stable and solidly supported

before proceeding. Serious injury may result if ma-
chine 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. Check 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.

10. Repeat procedure for second ski.

Polaris Industries Inc. 6.31 10/98

BODY AND STEERING
Ski Skag Removal

Ski Installation

SKI INSTALLATION- STEEL SKIS

0 Install ski over spindle, slight- Ski Spindle

ly in front of ski saddle with ski
pointing outside.
0 Slide ski forward until spindle
is just behind ski saddle and turn
to the forward position.
0 Slide ski forward so spindle is
behind ski saddle.
0 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.
0 Push ski back to slide spindle
into place. From outside of ski,
install bolt and castle nut. Torque
to 36ft. lbs. Install cotter pin and
bend both legs

SKI INSTALLATION- COMPOSITE

0 Install ski stop

with large portion
toward front of ski.

0 Install cotter pin

and bend both legs.

0 Install ski to spindle. From outside of

ski, install bolt, washers and castle nut. 0 Carefully lower machine
Torque to 36ft. lbs. (4.97 kg-m).

10/98 6.32 Polaris Industries Inc.

 BODY AND STEERING
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.

4. Punch out the rivet body.

5. Remove support and torsion bar.

6. Repeat procedure for second torsion bar.

Torsion Bar Installation

1. Rivet support in place using Polaris PN 7621449

rivets. NOTE: These high strength "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. Refer to

Chapter 2.

Polaris Industries Inc. 6.33 10/98

BODY AND STEERING
Handlebar Torque

Handlebar Torque and Sequence- Indy Style

1. Remove handlebar cover and foam.

2. Using a 7/16" (11 mm) wrench, loosen four nuts on

bottom of adjuster block. NOTE: Turn handlebar to
left or right for access to back nuts.

3. Adjust handlebar to the desired height. Be sure that

handlebars, brake lever and throttle lever operate
smoothly and do not hit the fuel tank, windshield or
any other part of the machine when turned fully to
the left or right.

IMPORTANT: When adjusting the handlebar, be sure

the serrations in handlebar and adjuster block match be-
fore torquing.

4. Torque the handlebar adjuster block bolts to

specification following sequence shown. The gap Socket Screws
should be equal at front and rear.

Handlebar Adjuster Block Bolt Torque - 3

11-13 ft. lbs. (1.5 -1.8 kgm)

5. Replace handlebar cover and foam.

Handlebar Torque and Sequence -

Evolved and Aggressive Style
1. Remove two plastic fasteners holding console cover
located below handlebar cover on hood side of
steering post.
2. Using a 7/16" (11 mm) wrench, loosen four nuts on
bottom of adjuster block. NOTE: Turn handlebar to
left or right for access to rear nuts.
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 fully to
the left or right.
4. Torque the handlebar adjuster block bolts evenly to
specification. The gap should be equal at the front Bottom of Adjuster Block
and rear.
5. Replace console cover.

A WARNING

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.

10/98 6.34 Polaris Industries Inc.

 BODY AND STEERING
Fuel Tank and Seat Removal

A WARNING

Gasoline is extremely flammable and explosive under certain conditions. Do not smoke or allow open
flames or sparks in or near the area where work is being performed. If you should get gasoline in your
eyes or if you should swallow gasoline, see your doctor immediately. If you should spill gasoline on your
skin or clothing, immediately wash if off with soap and water and change clothing. Prolonged exposure
to petroleum based products may cause paint failures. Always protect finished surfaces and wipe up
any spills immediately.

Two Piece Fuel Tank/Seat Removal

1. Remove tank cover by disconnecting snaps.
2. Remove vent line at front LH side of tank.
3. Remove gas cap and rubber grommet.
4. Remove air silencer box.
5. 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.

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.

Polaris Industries Inc. 6.35 10/98

BODY AND STEERING
Fuel Tank and Seat Removal
One Piece Fuel Tank/Seat Removal
1. Remove front tank retaining spring located behind
driven clutch area.
2. Remove fuel cap and grommet.
3. Remove fuel lines.
4. If machine is equipped with gauges, unplug gauge
wires.
5. Remove two bolts in tool box.
6. Disconnect taillight wiring.
7. Remove two console bolts attaching console to
tunnel.
8. Remove two console bolts located under hood.
9. Remove fuel cap and lift console up. Replace fuel
cap.
10. Lift up at rear of seat and slide out.

10/98 6.36 Polaris Industries Inc.

 BODY AND STEERING
Seat Cover Replacement (Plastic Base)
Seat Cover Replacement
1. Remove seat assembly as outlined on page 6.36.

2. Remove seat and seat covering to be replaced.

Carefully remove staples by loosening with a small
flat blade screwdriver. Pull each staple straight out
with a pliers.

3. On some models, it will be necessary to drill out the

rivets holding the strap buckles. Reach inside the
tool box and rotate the "D" ring buckle which
secures the center hold down strap. Push the "D"
ring through the slot in the tool box and carefully
pull it through the foam cushion.
Reassembly Note: For ease of assembly, hook a wire
to the center strap. This will allow you to pull the center
strap back through the foam and into the storage box.

4. Place the seat foam on the seat base assembly as

shown in Ill. 1.

5. Drape the seat cover over the seat foam.

6. 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.
NOTE: Use the rear two holes for a longer length seat
and the forward two holes for the standard length seat.
Seat Foam

For Use With

Long Seat

Storage
Box Area

Plastic Seat
Base
Ill. 1

Polaris Industries Inc. 6.37 10/98

BODY AND STEERING
Seat Cover Replacement

7. 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 Ill. 1A.

Apply staples in the stapling channel only. See Ill 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.
8. 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.
9. Align the two sewn seams located at the rear of the seat cover with the two back corners of the seat base. See
Ill. 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.
10. Now that the seat cover is correctly positioned, and tacked to the plastic seat base in four places, turn the
assembly over and inspect it. If the seat cover seems to fit correctly and everything looks straight, including
the tool compartment flap, continue with step 11.

Bottom View Of Seat Assembly Staples Sewn Seams

Tack Cover Here
Second

Tack Cover
Here First

Location
Indicators

Stapling Channel

Ill. 1

11. Staple the remainder of the unattached seat cover to

the plastic seat base as shown in Ill. 1. HINT: Always Staple Here First
staple between two existing staples and follow this
procedure until the seat cover is completely stapled
to the seat base. See Ill. 2.
12. Turn the seat cushion assembly over and inspect for Staple
Here Second
wrinkles or imperfections. If imperfections are
visible, remove the staples in the affected area and
staple correctly.

Staple Here Third

Staple Sequence Ill. 2

10/98 6.38 Polaris Industries Inc.

 BODY AND STEERING
Seat Cover Replacement
Models With Grommets In Tool Flap

13. Close tool flap cover, making sure it is aligned

properly, and mark grommet holes.
Tool Flap
14. Align twist lock with mark from step 13. Verify Cover
alignment with grommet in tool flap.

15. Using twist lock as a template, drill two .160" to Grommets

.164" holes through vinyl and seat base.

16. Rivet twist lock to seat base using rivets provided.

All Models

17. Trim excess vinyl from the bottom around the back
of the seat area only after a satisfactory fit is
obtained. See Ill. 1, page 6.38.

18. Reinstall seat by reversing disassembly steps as

they apply to your particular model.

Hood Repair
Currently there is no procedures or materials recommended by Polaris for repairing hoods. Hoods for 1999 model
snowmobiles are made of Thermoplastic Olefin (TPO) and cannot be repaired. If a hood is broken it must be
replaced. For small cracks you may drill a small hole on both ends of the crack to limit spreading.

Drill Holes Here~

Polaris Industries Inc. 6.39 10/98

BODY AND STEERING
Taillight Assembly Replacement

Taillight Assembly Replacement - Standard Indy

1. After removal of seat cover, drill out three rivets

from top of taillight.

2. Remove taillight assembly and wire harness.

3. 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.

10/98 6.40 Polaris Industries Inc.

 BODY AND STEERING
Seat Interchangeability

Seat Length Matrix

The following chart lists seat interchangeability for 1999 models. Arrows indicate interchangeability. For produc-
tion seats only.

1 Up Standard Mid Long 2 Up XC Deluxe 2 Standard 2 Up

Indy Length Length Length Lite Performance Up Touring 2 Up WideTrak
(Lite) Touring

XLT Special, XCF w/o pads, Trail Trg.

Indy 340 w, bw flags 340 Trg w, bw flags Sport Trg. WideTrak LX
500 XC, w, Classic Trg.
340 Deluxe bw flags 500 XC SP, w, TranSport
600 XC, w, bw flags XLT Trg.
bw flags 600 XC SP, w,
700 XC, W, bw flags
bw flags 700 XC SP, w,
700 XCR, bw flags
w, bw flags
4400 XCR, w,
800 XCR, bw flags
w, bw flags Trail RMK, pb
Super Sport 600 RMK, pb
white 700 RMK, pb
:" 700 SKS, pb

Sport, pb ' v Trail #1, w

Trail #2 w j 500 #2, pb
500 #1, pb ·\ Classic, pb
I f' XLT Class, pt
500 RMK, pb

NOTE: All domestic and new 440/550 fans use 90 degree outlet on tank, making them unique.

w= white "Polaris"
pb= process blue fade "Polaris"
bw flags= black and white flags

• Any evolved seat will interchange with another evolved seat. However, some have a white "Polaris" decal and
others have a process blue fade "Polaris decal.
• Any Gen II one up standard style seat with a white "Polaris" decal will interchange with a Gen II one up standard
style seat with a process blue "Polaris" decal.

For example, a Super Sport with a white "Polaris" decal will interchange with a 700 SKS (process blue "Polaris"
decal) seat if a customer desires a different length seat.

Polaris Industries Inc. 6.41 10/98

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.

• Rivet from outside

o Rivet from inside

NOTE:
1. When transfer drilling holes do not force pan into a position which is not uniform with the
other side. (Use the same method to drill both sides)

2. Rivet holes across from one another in unison.

10/98 6.42 Polaris Industries Inc.

 BODY AND STEERING
Nosepan Replacement Procedure
Nosepan Replacement Procedure-GenII XTRA-10 Front Suspension

IMPORTANT: When installing a replacement nosepan, the open circles represent rivets installed from inside the
nosepan through the bottom. The filled in circles represent rivets installed from the under side of nosepan through
to the top.

NOTE: The rivet for polyethylene nosepans is PN 7621467.

NOTE: Rivet holes may require drilling into the bulkhead.

Non-tipped in trailing arm style

NOTE:
1. When transfer drilling holes do not force pan into a position which is not uniform with the
other side. (Use the same method to drill both sides)

2. Rivet holes across from one another in unison.

3. Liquid cooled models will have recesses on both sides like reference A. Fan cooled models will
not have recesses and will look like reference B on both sides.

Polaris Industries Inc. 6.43 10/98

BODY AND STEERING
Nosepan Replacement Procedure
Nosepan Replacement Procedure - Gen II XC-1 0 Front Suspension

IMPORTANT: When installing a replacement nosepan, the open circles represent rivets installed from inside the
nosepan through the bottom. The filled in circles represent rivets installed from the under side of nosepan through
to the top.

NOTE: The rivet for polyethylene nosepans is PN 7621467.

NOTE: Rivet holes may require drilling into the bulkhead.

Tipped In trailing arm style

NOTE:
1. When transfer drilling holes do not force pan into a position which is not uniform with the
other side. (Use the same method to drill both sides)

2. Rivet holes across from one another in unison.

10/98 6.44 Polaris Industries Inc.

 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 Ill. 2 for adjust-
ment 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 little at this

point, move hole in
If gap is too large at this hinge brace toward top
point, move hole in hinge of slot in hood brace.
brace toward bottom of
slot in hood brace.

Ill. 2

Hood Adjustment - Evolved Style

1. Check to see that hood and upper hood hinge are
properly aligned. To adjust, loosen nuts (A) and
;----------,
1I I
align properly. Tighten nuts. See Ill. 1.
11 Hood~lI
2. With hood open, loosen nut (B). See Ill. 1. I I
3. Close hood and remove both rubber plugs. Then, 1
using a 7/16" (.4 em) socket with an 8" (20 em) ,--------1 [ Upper o ,_, [

extension, loosen nut (C). Adjust hood to pan gap. I I I Hinge I

I __.-® I L _ _ _ _ _ _ _ _ _ _j
Tighten nuts.
1 A 1
I Hood and Hinge
4. Check outer perimeter alignment and front and rear I ~ I need not be flush
alignment of hood, side bumpers and side panels. I I
There should be 3/16"(.5cm) + 1/8"(.3cm) -0 I I
clearance between hood to side panels and side I I
bumpers. If adjustment is required, open hood and I I
I I
loosen nuts (D). Adjust and re-tighten one nut per
hinge. Close hood and recheck alignment.
5. After correct alignment is achieved, tighten all nuts.
B

Ill. 1

Polaris Industries Inc. 6.45 10/98

BODY AND STEERING
Hood Adjustment

Nosepan, Front Bumper and Side Bumper Adjustment - Evolved Style

Open hood and

t
1.
remove side
panels. FORWARD

2. Remove foil tape

Fill Hole w/
covering right side Rivet &
nose pan bracket. Washer

3. Drill out rivets (3)

and slide bracket
outward 1/4" (6.35 Lh Side Panel Bracket RH Side Panel Bracket
mm) as shown in Move Out 1/2" Move Out 1/4"
the illustration
below. Be sure to
mount the bracket
at the same angle as before, so the side panel fits squarely against the mounting bracket.

4. Transfer drill holes in bracket to 3.16" (.1875" or 4.75 mm) and rivet in new location using rivet PN 7621485.

5. Apply a new section of foil tape (PN 581 0908) over the bracket.

6. Repeat this procedure for the left side with the following exceptions: move the bracket outward 1/2" (12.7
mm). Fill the open hole at the tip of the bracket with a rivet and washer.

10/98 6.46 Polaris Industries Inc.

 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 Brite™ Graphics Removal Discs with a
No. 1 Roloc and holder, or an equivalent low RPM
buffing disc.

,
1
CAUTIQN:, 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. 3M Scotchbrite™ Graphics Removal Disc
5. Thoroughly clean area where the new decal will be 3M PN 048011-16855
installed using a solution of mild soap (such as
dishwashing liquid) and clean water. NOTE: Use No. 1 Roloc and holder
approximately four ounces soap to one gallon 3M PN 048011-15408
water.
Decal Installation
1. Apply a solution of mild soap mixed with clean
water to the area where the new decal is to be
applied. Do not wipe off.
2. Carefully remove decal backing and apply new
decal.
3. If decal does not have a pre-mask, apply additional
soapy water solution to top of decal after it is in
position.
4. Holding decal in 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. Fasten a straight edge to tail end of decal.
7. Pull or stretch remaining portion of decal around
radius and into position. NOTE: A small amount of
heat applied to the decal will aid in forming it to the
radius. The mass of the decal which was secured
in previous steps will hold it in position while pulling.
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
decal surface.
9. Apply a small amount of heat to the decal to fasten
it securely.
10. Carefully remove excess decal material.

Polaris Industries Inc. 6.47 10/98

BODY AND STEERING
Troubleshooting
Problem Possible Cause Solution
*Machine darts from side to side -Incorrect ski toe alignment -Adjust to correct toe alignment

-Incorrect camber -Adjust to correct camber

-Loose or worn steering compo- -Tighten or replace

nents or fasteners

-Cracked or broken skis, skags, or -Replace if necessary

carbides
Tie rod hits trailing arm -Steering arm installed incorrectly -Index correctly in relation to
-spindle

-Tie rod ends worn -Replace if necessary

Steering has excessive freeplay -Steering bellcrank bushing worn -Tighten or replace if necessary
or loose
. -Drag link worn or loose -Tighten or replace if necessary

-Steering post loose -Tighten as needed

-Steering post bushings worn -Replace if necessary

-Tie rod ends worn -Tighten as needed

-Spindle bushings worn -Replace if necessary

Front end bounces or sags -IFS shock spring preload too soft -Adjust spring tension on shocks

-Improper shock charge or valving -Recharge, service, or replace

(if so equipped) -shocks

*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.

10/98 6.48 Polaris Industries Inc.

 CHAPTER 7
SUSPENSION
Rear Suspension Operation ............................ 7.1-7.2
Rear Suspension Tuning .............................. 7.3
Tunnel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Hi-Fax Inspection/Replacement ........................ 7.5-7.6
Suspension Lubrication Points/Torque Specifications ...... 7.7
Wheel Kits ........................................... 7.8-7.10
Widetrak LX Rear Suspension Exploded View ............ 7.11
Rear Suspension Components Widetrak LX/Tran Sport . . . . 7.12
Tran Sport Rear Suspension Exploded View . . . . . . . . . . . . . 7.13
Rear Suspension Adjustment, Widetrak LX/Tran Sport . . . . 7.14
XTRA Lite Rear Suspension Exploded View .............. 7.15
Rear Suspension Components XTRA Lite . . . . . . . . . . . . . . . 7.16
Rear Suspension Adjustment, XTRA Lite ................ 7.17-7.18
XTRA 10 Rear Suspension Exploded View . . . . . . . . . . . . . . . 7.19
Rear Suspension Components XTRA 10 121" ............ 7.20-7.21
Rear Suspension Components XTRA 10 133.5, 136" ...... 7.22
Rear Suspension Adjustment, XTRA 10 . . . . . . . . . . . . . . . . . 7.23
Front Rear Scissor Stop (FRSS) XTRA-10 Style .......... 7.24
Rear Rear Scissor Stop (RRSS) XTRA-10 Style .......... 7.25
Rear Suspension Exploded View - XTRA 12 121" . . . . . . . . . 7.26
Rear Suspension Exploded View - XTRA 12 133.5" . . . . . . . 7.27
Rear Suspension Components XTRA 12 ................ 7.28-7.29
IFS Front Torque Arm Limiter Strap Adjustment, X-12 ..... 7.30
Rear Suspension Adjustments, XTRA 12 ................ 7.31-7.32
IFS Adjustments, XTRA 10 and 12 ...................... 7.33-7.34
Compression Adjustable Shocks ........................ 7.35-7.36
Suspension Springs and Rails .......................... 7.37
Optional Springs - 1999 XTRA Lite/Tran Sport!Widetrak LX 7.38
Optional Springs - 1999 XTRA-1 0 Style . . . . . . . . . . . . . . . . . . 7.39
Optional Springs- 1999 XTRA-12 Style .................. 7.40
Front Track Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
XTRA-12 Suspension- Shock Removal ................. 7.42
IFS Fox"' Shock Specifications ......................... 7.43
Rear Suspension Fox"' Shock Specifications ............ 7.44
Typical Shock Valving Arrangement . . . . . . . . . . . . . . . . . . . . . 7.45
1997-1999 Production Valving Chart . . . . . . . . . . . . . . . . . . . . 7.46
1999 Optional Valving by Shock Part Number ............ 7.47-7.48
Valve Washer Part Numbers ........................... 7.49
Fox"' Shock Maintenance ............................. 7.50-7.58
Polaris Position Sensitive Shock (PSS) .................. 7.59-7.68
Suspension Troubleshooting ........................... 7.69-7.72
 SUSPENSION
Rear Suspension Operation

Refer to Specifications Section in Chapter 1 for Suspension Type I Model Application

Rear Suspension Operation

The primary function of the rear suspension is to provide a comfortable ride in all types of riding conditions. It
separates the rider from the ground, while allowing for complete vehicle control. The rear suspension also must
provide weight transfer and maintain track tension.
The rear suspension has many adjustable features for fine tuning to achieve optimum comfort. The suspension
can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. It should
be noted, however, that suspension adjustments involve a compromise or trade off. A machine set up to perform
well in the moguls would not suit the preference of a groomed trail rider.

Weight Transfer
The shifting of weight from the
skis to the track is called weight
transfer. As engine torque is ap-
plied to the drive axle the torque
is transferred to the track, pulling
it forward. This energy also tries
to pull the suspension forward.
The front torque arm reacts to
this force by pushing down on
the front of the track, in effect ap-
plying more weight to the front of
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 for-
ward.

Changing the angle of the front torque arm changes the suspension's reaction to the force. Adjusting the length
of the limiter strap will change the front torque arm angle. Shortening the strap limits the extension of the front
of the suspension; reducing the angle of the torque arm and increasing ski pressure during acceleration. Length-
ening the strap allows the front of the suspension to extend further; increasing the angle of the torque arm and
decreasing ski pressure during acceleration. Limiter strap adjustment has a great affect on weight transfer. Limit-
er straps only affect acceleration. It is important to check track tension whenever limiter strap length is changed.

Front track shock spring preload also affects weight transfer. A stiffer spring and/or more preload on the spring
transfers more weight to the track. A softer spring and/or less preload keeps more weight on the skis. Keep your
riding application in mind when choosing springs and setting spring preload. Soft springs/preload will increase
ski pressure, but may bottom out. Stiff 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 compress and the IFS will extend, pivoting the machine about
the front torque arm. Because of this pivoting effect, rear spring and spring preload also have some effect on
weight transfer. Softer rear springs, or less preload, allow more weight transfer to the track and reduce ski pres-
sure. 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 vehicle and rider, as well as to provide
enough travel to absorb bumps and jumps.

Shock valving also has an effect on weight transfer. Refer to shock tuning information in this chapter.
Scissor stops also affect weight transfer. See scissor stop information in this chapter.

Polaris Industries Inc. 7.1 8/98

SUSPENSION
Rear Suspension Operation

Springs
Two types of springs are employed in Polaris suspen-
sions, coil springs and torsion springs. Following is some
of the terminology used when referring to coil springs.
Coil Spring
• Free length - the length of a coil spring with no load ap- Length
plied to the spring Installed
Length
• Installed length - the length of the shock absorber be-
tween 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 compress 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.
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 compress 3 inches.
If the suspension had 4 inches of spring travel the 100 #/in. spring would bottom out, while the 150 #/in. spring
would have one inch of travel remaining.

Torsion springs are much like coil springs, although

Torsion Spring
shaped differently. The rate of the torsion spring is con-
trolled by the free opening angle, the installed opening
angle, the wire diameter of the spring, and the number of
coils. Load reduces
opening angle

r:o~~ ~ ~ ~ ~

8/98 7.2 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Tuning
Many factors influence the overall handling characteristics of snowmobile suspensions. Rider weight, riding style,
course conditions, and the condition of suspension components are some of the things that you have to consider
when tuning a suspension.
On new machines, or whenever new suspension parts are installed, the sled should be ridden for at least one
tank of fuel to allow moving parts in the shocks and suspension to wear in. The shock springs will also take their
initial set and the setup will be more accurate.
• Front Suspension: The front suspension should sag (unloaded) about 1" (measured at the front bumper)
with the weight of the sled. Use stiffer or softer springs as needed to keep from bottoming too hard, and to ensure
the entire range of travel is used.
Rear Suspension Tuning
To begin suspension tuning, check the condition of shocks and other suspension parts.
• Inspect and grease all suspension parts, making sure they pivot freely. All suspension components should
be greased when disassembled. Regular maintenance greasing should be done with no weight on the component
to allow grease to reach important contact areas.
• Loaded Sag: Set the preload on the rear springs for the correct sag. There should be 1 1/2" of sag on the
rear suspension when the rider on the snowmobile, measured at the rear bumper. Bounce on the suspension
a couple of times to overcome any "stiction" and settle the sled to an accurate reference point. The rider should
have their weight placed correctly on the machine. Adjust spring preload to achieve the 1 1/2" sag dimension.

• Unloaded (Free) Sag: When the rider gets off the machine, the suspension should return to 1/2" of sag.
If the sag is less than 1/2" stiffer springs may be needed. If it is greater than 1/2" softer springs may be needed.
This may seem backwards at first, but if the spring is too soft, the preload must be greatly increased to prevent
excess loaded sag. This shows up in the form of less unloaded sag. Therefore, a stiffer spring is required. If
the spring is too stiff, the preload will have to be backed off, and unloaded sag will be excessive. This is a very
important step because the proper spring will also help ensure correct weight transfer.
Shock Tuning
The shocks work in two directions. Compression damping prevents the shock from bottoming hard while rebound
damping keeps the shock from springing back too fast. Both compression and rebound damping can be adjusted
for high and low speed damping characteristics. On Indy Select shocks, the compression damping can be
changed by turning the adjuster screw. Refer to shock section in this chapter for adjustment. NOTE: When we
refer to high and low speed, we are referring to the speed of the shock shaft or valve, not vehicle speed.
Rebuildable Shocks
Begin by taking the shocks apart, inspecting all parts for damage, and changing the oil. Even new shocks should
get an oil change after break in to clean break-in material from the shocks and valve body.
If oil is low, inspect seal cap 0-Ring and seals for damage. If air or foam is evident in the oil, the 0-Ring in the
floating piston must be replaced. After changing the oil reassemble shocks, making sure oil level, floating piston
depth (IFP), and nitrogen pressure are correct.
The use of nitrogen in Fox™ shocks provides consistent damping at extreme temperatures. Don't overcharge
the shocks. Excess nitrogen pressure may cause seal "stiction" 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.

Polaris Industries Inc. 7.3 8/98

SUSPENSION
Tunnel Mounting

1999 Rear Suspension Set Up I Tunnel Mounting Positions

Model Front Limiter Rear Limiter Rear Torque Front Track Front Torque
Strap Strap Arm Tunnel Shock Mount Arm Tunnel
Mount Mount
340/340 Deluxe Std NIA No Options N/A
340 Touring Std N/A No Options N/A
Sport Std NIA No Options N/A
Sport Touring Std N/A No Options N/A
TranSport Std N/A No Options N/A
XCF Quick Adjust Quick Adjust No Options Lower
440 XCR Quick Adjust Quick Adjust No Options Lower
Trail Quick Adjust Quick Adjust No Options Lower
Trail Touring Std Std No Options Lower z
0
Trail RMK Std N/A No Options Upper 0
Super Sport Quick Adjust Quick Adjust No Options Lower "0
:!'.
WideTrak LX Std N/A No Options N/A 0
:l
!l)
500 Quick Adjust Quick Adjust No Options Lower
500 RMK Quick Adjust Quick Adjust No Options Upper :s::
0
500 XC/SP Quick Adjust Quick Adjust No Options Lower t:
:l
Classic Std N/A No Options N/A ::!:
:l
Classic Touring Std N/A No Options N/A c.c
XLT Special Quick Adjust Quick Adjust No Options Lower ""C
0
XLT Touring Std N/A No Options N/A en
XLT Classic Std N/A No Options N/A
a:
0
:l
600 XC/SP Quick Adjust Quick Adjust No Options Lower en
600 RMK Quick Adjust Quick Adjust No Options Upper
700 XC/SP Quick Adjust Quick Adjust No Options Lower
700 XCR Quick Adjust Quick Adjust No Options Lower
700 RMK Quick Adjust Quick Adjust No Options Upper
700 SKS Quick Adjust Quick Adjust Below(See Ill.) Lower
800 XCR Quick Adjust Quick Adjust No Options Lower

NOTE: There are no optional front torque arm mounting positions. Do not re-locate the front torque arm.

700 SKS stock mounting position.

Optional position - lower hole.

Rear

Optional mounting hole for deep snow.

*If mounting here place dummy bolt (PN Front torque arm
7517388) in upper hole to secure rear suspen- stock mounting position.
sion mounting pad. No optional positions.

8/98 7.4 Polaris Industries Inc.

 SUSPENSION
Hi-Fax Inspection I Replacement

Hi-Fax Replacement - All Models

Hi-Fax replacement on all Polaris models is similar. Hi Fax Wear Limit

When any area of the Hi-Fax is worn to 1/8" (.3 em), it
should be replaced. This will save wear on other vital
components.
The slide rail is designed to operate in conditions with ad-
equate snow cover to provide sufficient lubrication. Ex-
cessive wear may be due to improper alignment, improp-
er track adjustment or machine operation on surfaces
without snow.
Replace Hi-Fax when worn to 5/16" (.79 em) on XTRA
12 suspensions; 3/8" (.95 em) on XTRA 10 and Sport
style suspensions; 7/16" (1.1 em) on XTRA Lite style
suspensions.

1~!i~~\d~~f~\f~r,~:~~·
',)(J;RA12- 5/16"(.79 em) ,. ,,
:;q*··i~\~:)::¥,;:-l~··· fi~:// ~:0tk .~:~:. .·' .:· '.::
)
q
, XTRA"J ~ 3/8~i~(~95 em) .,
... ~'. ····· .

Hi-Fax wear patterns are somewhat different on machines equipped with the XTRA 12 suspension than on
conventional models. The rear of the rail will wear rapidly at first. After this initial break in period, the rapid wear will
cease. This area should be checked frequently, however, replacement 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.

Hi-Fax Removal

1. Remove suspension from machine.

NOTE: Some models may allow Hi Fax to be removed
by sliding it through track windows with the suspension
mounted in the machine.

2. Remove front Hi-Fax retaining bolt as shown.

Polaris Industries Inc. 7.5 8/98

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 WD-40 to ease installation.
NOTE: Wide Hi-Fax should be narrowed on the leading
sides to allow it to fit through narrow windows.

Track Clip Removal - All Types

1. 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.

>r+'·~~v\,\~" .,/'
).:.. ,,·'i;,,ttr. ·,<Bf*'. :\{;-;, .. ,,<r. iit;~~l'~'<···.· .~k~~· .
, .Tra~kwP!!P lns~f!!l~t.i,c)ll :rqo!~(Cam9plast)i
·~;N ~87~b4t4~~F:t<J~t ,%;:, .,
0 "''w~Jxf>.'~j
1
' ·.

Tra6k Clip lnst~·nationT~ol {Yokohama)··

l~\,,P~~,~~~~~~O •.•~~;?:.r•:;:~· . .· ,. .· ., ;

8/98 7.6 Polaris Industries Inc.

 SUSPENSION
Suspension Lubrication Points I Torque Specifications

* LUBRICATION POINTS- XTRA LITE

Grease at fittings * LUBRICATION POINTS- Widetrak LX/TranSport
Grease at fittings

*
*
--
Forward
*
(Both sides) --
Forward

* LUBRICATION POINTS- XTRA-1 0

Grease at fittings
*LUBRICATION POINTS- XTRA-12
Grease at fittings

*
*
(Both sides)

--
Forward
* --
Forward
*
Suspension Torque Specifications
3/8" top shock mounting bolts .................................. 28-30 ft. lbs. (3.85 - 4.14 kg-m)
3/8" suspension mounting bolts ................................ 35- 40ft. lbs. (4.8- 5.52 kg-m)
7/16" suspension mounting bolts ............................... 55-60ft. lbs. (7.61 -8.30 kg-m)
Shock rod bolts (do not over torque) ............................ 12ft. lbs. (1.66 kg-m)
* Shock rods must pivot freely after torquing

Polaris Industries Inc. 7.7 8/98

SUSPENSION
Wheel Kits

Wheel Kit Mounting Recommendations

The following illustrations indicate proper installation of optional wheel kits.

XTRA Lite

NOTE: If installing optional rear

wheel kit, rear scissor must be
mounted in rear hole.

XTRA 10 121"

Inside -
Kit PN 2870602 Outside-
Kit PN 2871582

8/98 7.8 Polaris Industries Inc.

 SUSPENSION
Wheel Kits

Wheel Kit Mountin g Recommendat·1ons

XTRA 10 133.5"

Outer_
Inner- Kit PN 2871582
Outer-
Kit PN 2871582
Kit PN 2870602

XTRA 10 136"

Outer-
Kit PN 2871582
Inner-
Kit PN 2871582
Outer-
Kit PN 2870602

Polaris Industries Inc. 7.9 8/98

 SUSPENSION
Wheel Kits

Wheel Kit Mounting Re commendations

XTRA 12 121"

Outer-
Kit PN 2870602

Outer-
Kit PN 2871582

XTRA 12 133.5"

No Wheel Kits re:commended

for this suspension

8/98
7.10 Polans
. Industries Inc.
 SUSPENSION
WideTrak LX Style - Exploded View

'

Front Torque Arm

Rear Torque Arm

'

Polaris Industries Inc. 7.11 8/98

SUSPENSION
Rear Suspension Components WideTrak LX I TranSport

Rear Torque Arm

Rear Shock

Adjuster
Eye bolt

Carrier Wheel

Rail Tip
Rear Pivot Arm

Front Track Shock Front Track Spring

-
Forward

Hi-fax

Bogie Wheel

Slide Rail

Rail Bumper

Idler Wheel

8/98 7.12 Polaris Industries Inc.

 SUSPENSION
TranSport Style - Exploded View

Front Torque Arm Rear Torque Arm

Polaris Industries Inc. 7.13 8/98

SUSPENSION
Suspension Adjustment - WideTrak LX I TranSport
The Polaris WideTrak LX and TranSport suspension has been designed and set up to deliver a soft ride under
average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension
action.

The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi-
tions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine
set up to perform well in the moguls would not suit the preference of a groomed trail rider.

Adjustable Features and Adjustment Options

• IFS compression spring preload
• Rear torsion spring preload
• Rear shock compression (if equipped with Indy Select shock)
• Optional coil springs for front track shock

Adjustment Procedures
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) before fine
tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions.
We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref-
erence. The machine should be methodically tested under the same conditions after each adjustment (trail and
snow conditions, vehicle speed,riding position, etc.) until a satisfactory ride is achieved. Adjustments should be
made to one area at a time, in order to properly evaluate the change.
The purpose of the front track shock coil spring is to control ride height. 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 high-
est rate spring.

Rear Suspension Adjustments - WideTrak LX

The primary adjustment for riding comfort is rear torsion spring preload adjustment. To check for the recom-
mended 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 Torsion Springs
light drivers or cargo loads can be made
by adjusting the rear torsion spring eye
bolt (A) length. Adjust spring tension so
there is equal tension on the long leg of
each spring.
NOTE: Rear torsion spring settings will
affect ski-to-ground pressure. It may be
desirable to tighten rear torsion springs
for an increase in ski-to-ground pres-
sure. If ski pressure is too light, the ma-
chine will be hard to steer around curves
and will tend to push, or drive straight
through curves.

8/98 7.14 Polaris Industries Inc.

 SUSPENSIC?N
Rear SuspensJ·on Explode d View- XTRA L1te

Front trac k shockPN

spring
preload washers
5210953.

~~,
I' ' \ '

Rear Torque
I' Arm
Fron t Torque
1' Arm

. Industries Inc.
Polans 7.15 8/98
SUSPENSION
Rear Suspension Components - XTRA-Lite

Rear Track
Shock

Rail Bumper

Front Track Shock Front Torque Arm

-
Forward

Rail Tip

Rail
Bumper Bogie Wheel
· Rear Track
Shock

Rail Bumper

8/98 7.16 Polaris Industries Inc.

 SUSPENSION
Suspension Adjustment - XTRA Lite
Suspension Adjustment
The Polaris suspension has been designed and set up to deliver a soft ride under average riding conditions. Rider
weight, riding styles, trail conditions, and vehicle speed each affect suspension action.
The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi-
tions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine
set up to perform well in the moguls would not suit the preference of a groomed trail rider.
Adjustable Features and Adjustment Options

• Rear torsion spring preload

• Optional coil springs for front track shock and spring preload washers
• Optional torsion springs
• Front limiter strap
• Optional coil springs for IFS shocks
Adjustment Procedures
It is a good idea to break the suspension in for approximately 150 miles (240 km) and re-grease all suspension
parts before fine tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions.
We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref-
erence. The machine should be methodically tested under the same conditions after each adjustment (trail and
snow conditions, vehicle speed,riding position, etc.) until a satisfactory ride is achieved. Adjustments should be
made to one area at a time, in order to properly evaluate the change.
The purpose of the front track shock coil spring is to control ride height and front IFS preload. If you find that in
order to obtain the desired ride effect the spring preload is over four additional washers (total of five), consider
removing the existing spring and installing the next highest rate spring.

Polaris Industries Inc. 7.17 8/98

SUSPENSION
Suspension Adjustment - XTRA Lite
For Recommended Optional Settings, Refer to Suspension Set Up Decal Under Hood
Rear Suspension Adjustments
The primary adjustment for riding com-
fort is rear torsion spring preload ad-
justment. To check for the recom-
mended initial settings: Torsion Springs

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.
Torsion Spring
4. Measure the distance between the
Preload Adjuster
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. See adjust-
-
Forward

ment information below.

Compensating adjustments for heavy
or light drivers or cargo loads can be
made by adjusting the preload adjust-
er. Remember, this is only the initial
settings. Final settings should be de-
termined by riding the snowmobile and
readjusting.
NOTE: Rear torsion spring settings will affect ski-to-ground pressure. It may be desirable to tighten rear torsion
springs for an increase in ski-to-ground pressure. If ski pressure is too light, the machine will be hard to steer
around curves and will tend to push, or drive straight through curves.
The XTRA Lite suspension comes from the factory with
the rear suspension pivot mounted in the second hole These holes
from the front of the rail. Do not move to the front used for
mounting hole. extra bogie
wheel
placement
only

#1 - stock position
#2 - use to stiffen

-
Forward rear suspension

8/98 7.18 Polaris Industries Inc.

 SUSPENSION
Rear Suspension
. Exp Io ded View - XTRA 10 Style

Front Torque Arm Rear Torque Arm

Polaris Industries Inc. 7.19 8/98

SUSPENSION
Rear Suspension Components - XTRA 10 Style

Rear Limiter Strap Adjuster

Compression Valve Adjustment Screw

(Ryde AFX /Indy Select Shocks}

~
Rear Scissor

Rear Torsion Spring

Adjuster Cam (low Posi-
tion Setting Shown}

FRSS (Front Rear RRSS (Rear Rear

Scissor Stop} Scissor Stop}

Limiter Strap (Adjustable}

Front Limiter

The front limiter strap controls the amount of weight transfer, ski pressure, and to some degree the ride height.
The rear limiter controls ride height and increases preload on the rear springs when tightened, which also de-
creases transfer (i.e. the lighter the torsion spring preload, the more weight transfer).

Setting Ski Pressure Weight Transfer

Longer Decreased Increased
Shorter Increased Decreased

NOTE: RRSS has greatest affect on weight transfer on XTRA 10 suspensions. See pages 7.24-7.25.

8/98 7.20 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Components- XTRA 10 121" Style

Rear Limiter
Front Track Shock Strap

Limiter
Strap

Front Torque Pivot Arm

Arm Shaft Shaft
Rear Torsion
Spring
Rear Torque
Arm

-
Forward
Carrier Wheel

Rear Torsion Spring

Limiter
Strap

I(J!I,I___ Bogie
Wheel

Slide Rail

Front Track Shock

Hi-fax

Polaris Industries Inc. 7.21 8/98

SUSPENSION
Rear Suspension Components - XTRA 10 133.5" /136" Style

Rear Limiter
Front Track Shock Strap
Rear Track Shock
Limiter
Strap

Pivot Arm Pivot Arm

Shaft Shaft
Rear Torsion Spring

-
Forward

Carrier Wheel
Rear Track Shock

Rear Torsion Spring

Front
Torque
Arm

Limiter
Strap Idler Wheel

Rail
Bumper

Slide Rail

Front Track Shock

Hi-fax

8/98 7.22 Polaris Industries Inc.

 SUSPENSION
Suspension Adjustment- XTRA 10 Style
The XTRA™ 10 suspension has been designed and set up to deliver a soft ride under average riding conditions.
Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action.
The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi-
tions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine
set up to perform well in the moguls would not suit the preference of a groomed trail rider.

Adjustable Features and Adjustment Options

Independent Front Suspension (IFS)

• Front shock spring preload (some models require washers)
• Optional springs
• Adjustable compression valving via Ryde AFX I Indy Select shock (on some models)
Rear Suspension
• Rear torsion springs
• Front rear scissor stop (FRSS)
• Rear rear scissor stop (RRSS)
• Optional coil springs for front track shock and spring preload (some models require washers)
• Optional torsion springs
• Adjustable compression via Ryde AFX I Indy Select rear track shock (on some models)
• Limiter straps - front and rear

Adjustment Procedures
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) before fine
tuning adjustments are made.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions.
We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref-
erence. 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.

Polaris Industries Inc. 7.23 8198

SUSPENSION
Front Rear Scissor Stop (FRSS) - XTRA 10 Style
The purpose of the front rear scissor stop (FRSS) is to control the bump attitude of the rear suspension. As the
front torque arm (FTA) hits the bump, it forces the rear scissor to collapse a predetermined amount, depending
on the FRSS block position.
This accomplishes two important things, it allows a lighter spring rate on the FTA because it can borrow spring
rate from the rear torsion springs; and it prepares the rear portion of the suspension for the bump, reducing secon-
dary kick back.
The FRSS is made of a resilient material allowing smooth action and preventing any suspension component dam-
age.
This unique feature is applied to the XTRA™ 10 rear suspension. Patents are pending.

Front Torque
Arm (FTA)

Rear Scissor

FRSS with short (low) leg to rear. Note the front torque arm must collapse further to collapse rear
torque arm.
Front Torque
Arm (FTA)

FRSS with long (high) leg to rear. Note this forces rear scissor to collapse with less front torque arm
movement than when in short position. This keeps the rails more parallel to the chassis.

8/98 7.24 Polaris Industries Inc.

 SUSPENSION
Rear Rear Scissor Stop (RRSS)- XTRA 10 Style
The RRSS controls weight transfer from the rear sus-
pension to the skis. It also influences the stiffness of the
ride by controlling the amount of coupling action be- RRSS -low
tween the front and rear torque arms. To increase the position shown
stiffness of the suspension, the RRSS should be set in
the high position.
NOTE: On XTRA-1 0 models only, the RRSS can be to-
tally removed for maximum weight transfer. However,
unless the torsion springs and rear shock valving are
changed, the ride will be compromised. Always
maintain equal adjustment on both sides.
FRSS - low position shown

FRSS- medium position shown

Be sure rear scissor stop face is square with the face of

the scissor arm to ensure complete contact.
Scissor Stop Block Position

Medium

Rear Spring Tension

Low
0 Low

High
Rear spring tension adjustments are made by rotating
the eccentric spring block (A) as shown with the engine
spark plug tool. The block provides three spring tension
positions. This adjustment is easier if the long spring leg
is lifted over the roller and replaced after the block is
properly positioned. Always maintain equal adjustment
on both sides.

A
0 "
Soft Tension Long End to Front Medium Tension (Short End Up) Firm Tension (Long End Up)

Polaris Industries Inc. 7.25 8/98

SUSPENSION
Rear Suspension Exploded View- XTRA 12 121" Style

Front Torque Arm Assembly

Front Torque Arm Assembly Rear Torque Arm Assembly

8/98 7.26 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Exploded View - XTRA 12 133.5" Style

Front Torque Arm Assembly Rear Torque Arm Assembly

Polaris Industries Inc. 7.27 8/98

SUSPENSION
Rear Suspension Components - XTRA 12 Style

Limiter Rear Torsion

Strap Spring Adjuster Cam -
low position shown

Front Track
Shock Preload Adjuster

FRSS

Front Track Spring

FRSS -"Front Rear Scissor Stop"

RRSS -"Rear Rear Scissor Stop"

8/98 7.28 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Components - XTRA 12 Style

Front Track Shock

Rear Track Shock

Limiter
Strap

Coil Spring
FRSS
Rear Torsion Spring RRSS

-
Forward

Rear Torsion Spring

Limiter Front Track Shock

Strap
Carrier Wheel

Rear Torque Arm

Front
Torque
Arm

Slide Rail

Pivot Arm Rear Scissor

Shaft Pivot Arm
Rail Shaft
Bumper
Idler Wheel

Polaris Industries Inc. 7.29 8/98

SUSPENSION
Suspension Adjutment- XTRA-12 Style
The XTRA™ 12 suspension has been designed and set up to deliver a soft ride under average riding conditions.
Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action.
The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of condi-
tions. It should be noted, however, that suspension adjustments involve a compromise or trade off. A machine
set up to perform well in the moguls would not suit the preference of a groomed trail rider.

Adjustable Features and Adjustment Options

Independent Front Suspension (IFS)

• Front shock spring preload
• Optional springs
• Compression adjust Indy Select I Ryde AFX shock

Rear Suspension
• Spring preload - front track shock
• Spring preload - rear track shock (Requires addition of washers)
• Rear torsion spring pre-load
• Front rear scissor stop (FRSS)
• Optional coil springs
• Optional torsion springs
• Limiter strap - front
• Compression adjust Indy Select Ryde AFX shock

Adjustment Procedures
It is a good idea to have customers break the suspension in for approximately 150 miles (240 km) and grease
all suspension pivots before fine tuning adjustments are made. Use Polaris Premium All Season Grease.
All settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions.
We recommend starting with factory settings and then customizing each adjustment individually to suit rider pref-
erence. 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.

8/98 7.30 Polaris Industries Inc.

 SUSPENSION
Rear Suspension Adjustments - XTRA 12 Style
The primary rear suspension adjustments are the front track spring preload and the rear torsion spring preload.
It is important to note that adjusting the limiter strap does not change weight transfer from the rear suspension
to the skis as in a conventional suspension. Instead it will increase the entire rear suspension preload and de-
crease travel. To increase ski pressure the front rear scissor stop (FRSS) should be set to low. To decrease ski
pressure the FRSS should be set to high.
To properly adjust the rear suspension, start with the lightest preload setting that will prevent heavy bottoming.
Remember: 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-ground pressure. If ski pressure is too light it may be desirable to
tighten rear springs for an increase in ski-to-ground pressure. It is also possible to reposition the FRSS for in-
creased ski pressure.
Front Track Shock Spring
Front track shock spring preload is adjusted by grasping
Forward
the spring and turning in a clockwise direction to in-
crease the preload. Turn in a counterclockwise direction
....----
to decrease preload. Mount limiter strap
Rear Track Shock Spring on front of bracket
The rear track shock coil spring does not have a as shown
threaded adjuster. Washers can be added to increase
preload. One option to decrease preload for extremely
light non-aggressive riders is removal of the rear track
shock spring. @

Front Rear Scissor Stop (FRSS)

To adjust the FRSS compress the rear portion of rear
suspension until the rear scissor pivots away from the FRSS shown in high posi-
FRSS (Support front of track on object). Turn adjuster tion, as indicated by dot on Rear
to desired position. The dot on the stop indicates the stop
high position. High position is with the dot located toward
the rear of the machine (See illustration). Medium posi- @low
tion is with the dot toward the front of the machine.
~medium

Be sure both blocks are in the same position or suspen-

~high
sion damage may occur.
NOTE: It may be necessary to loosen the FRSS mount-
ing bolts to adjust the position. Tighten after adjustment.
-
Forward
RRSS

If the FRSS is in the low position but additional ski pres-

sure is desired, move the FRSS to the optional front hole. Relocate FRSS to
Remove the attaching bolts and relocate the FRSS forwardmost hole in rail for
blocks in the forwardmost hole. Reinstall bolts and tight- additional ski pressure
en.
Rear Rear Scissor Stop (RRSS)
The RRSS is not adjustable but can be changed to pro-
vide more or less weight transfer. See chart below.

XTRA 12 RRSS Production Settings

Suspension

121"
Length

Short
Color

Black
Part Number

5410937 -more transfer

-
Forward

133" Long Gray 5411 041-less transfer

Polaris Industries Inc. 7.31 8/98

SUSPENSION
Rear Suspension Adjustments - XTRA 12 Style

Rear Torsion Spring

hear torsion spring preload is adjusted by turning the two
position cams (A) on the short leg of the spring as shown

~
with the engine spark plug tool. This adjustment is easier
if the long spring leg is lifted over the roller and replaced
after the cam is properly positioned.
Always maintain equal adjustment on both sides. A

Soft Tension Long End to Front

~ A
Firm Tension (Long End Up)

IFS ADJUSTMENTS

IFS Adjustments - XTRA-Lite I Widetrak LX I TranSport

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 Shims
length of the spring, the more the amount of preload. In-
creasing preload on the IFS spring will result in more bite
on the skis, but will require more effort to turn. The IFS
compression spring preload can be increased by adding
shims (PN 521 0953) under the spring.
Always verify ski alignment before making adjustments
to the IFS. See Body and Steering section.

8/98 7.32 Polaris Industries Inc.

 SUSPENSION
IFS Adjustments- XTRA 10 and 12 Style

Front Suspension Setup and Adjustments

Spring preload is one of the adjustment options which affects
ride. Preload is the amount of pressure at which the spring is
held. The longer the installed length of the spring, the less the
amount of 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.
Turning
To adjust front spring preload on threaded adjust models, grasp clockwise
the spring and turn in a clockwise direction (as viewed from the increases
bottom of the shock) to increase the preload. Turn in a counter-
preload
clockwise direction to decrease preload.

In the adjacent illustration, high preload and low preload posi-

tions are depicted.
Low Preload
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.
/ High Preload
Set the preload to use the full travel of the ski shock with occa-
sional light bottoming. ~

If the plastic nut is unscrewed from the threaded body the nut
will break. Always leave one thread showing above the plastic
nut or the spring coils will stack, resulting in damage.

Always
For the best ride the spring preload should be as low as pos-
leave at
sible. Set the preload to use the full travel of the ski shock with
least
occasional light bottoming. To determine if your machine is us- one thread
ing full travel, push the shock jounce bumper down as far as it showing
will go on the shock rod and test ride the machine. above nut

The bumper will move up on the rod in direct relation to the

amount of travel. For example, if the shock travel is full, the
bumper will be seated at the top of the shock.
• Remove the existing spring and install the next highest
rate spring, or
• Reduce the preload on the existing spring and change the Push
shock valving to obtain the desired effect. NOTE: Shock jounce
valving can only be adjusted or changed on models bumper
equipped with Ryde AFX, Indy Select or Fox™ shocks. down as
far as it will
go on
shock rod

Polaris Industries Inc. 7.33 8/98

SUSPENSION
IFS Adjustments- XTRA-10 and 12 Style

A WARNING

Changing shock valving on models equipped with Fox"' shocks requires special tools and a sound knowledge
of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Shocks
contain high pressure nitrogen gas. Extreme caution should be observed when handling and working with high
pressure service equipment. See Fox™ Shock rebuilding information later in this chapter.
Always verify ski alignment before making adjustments to the IFS. If the skis are misaligned, we recommend the
camber adjustment be checked as this may also be affected.

Front Torque Arm Limiter Strap Adjustment- XTRA-10 and 12 Style

Front Torque Arm Limiter Strap Adjustment- XTRA-10
One method of changing ski-to-snow pressure is to change the
Turn nut to adjust
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 limiter 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
counterclockwise. Turning clockwise shortens strap.
NOTE: Both limiter straps must be adjusted evenly and remain Turning counterclockwise lengthens
equal in length to avoid improper Hi-Fax and track wear. strap.

Front Torque Arm Limiter Strap Adjustment- XTRA-12

One method of changing ski-to-snow pressure is to change the

length of the front torque arm limiter straps using the holes provided.
The limiter strap is normally mounted in the fully extended position.
It is important to note that decreasing limiter strap length will stiffen
the whole suspension.
• Lengthening the straps decreases ski pressure.
• Shortening the straps increases ski pressure.
The preferred method for changing ski pressure is 1. Turn FRSS to
a lower position. 2. Move the FRSS to the forward most hole. 3.
Increasing or decreasing IFS preload.

8/98 7.34 Polaris Industries Inc.

 SUSPENSION
Compression Adjustable Shocks

Compression Damping Adjustable Shocks

Snowmobiles equipped with the Indy Select or Ryde AFX shocks allow the driver to make adjustments to the com-
pression valving by turning the screw located near the base of the shock.
Adjustment
Locate the adjustment screw near the base of the shock. NOTE: This adjustment is easiest to make with the
machine tipped on its side.

A WARNING
Be sure to shut off the fuel supply before tipping the machine to prevent fuel spillage and flooding of the carbure-
tors.
By turning the screw clockwise (a small screwdriver or dime work well), the compression valving is increased,
stiffening the ride. To soften the ride, reduce the compression by turning the screw counter-clockwise. A great
deal of ride performance is accomplished with a mere 1/2 to 1 turns. There are approximately 3 full turns of adjust-
ment available.
How to Adjust IFS
If the suspension is "bottoming," tighten the compression screw clockwise in 1/2 turn increments until the bottom-
ing 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 turned in full clockwise, the compression spring should be adjusted with
the threaded adjustment collar. Back the screw out to the original starting position after the compression spring
has been adjusted.
Riding conditions are ever changing. Keep in mind the compression damping adjustable can be adjusted at any
time to achieve the best possible ride in any condition.
NOTE: Whenever shocks are replaced or reinstalled for any reason, the adjustment screw should be located
toward the forward right side of the suspension. Access to the adjuster is not possible if reversed. Fox™ Shocks
should be installed with the charge fitting up.

Polaris Industries Inc. 7.35 8/98

SUSPENSION
Compression Adjustable Shocks

How to Adjust Rear Suspension

If the suspension is "bottoming," tighten the compression screw clockwise in 1/2 turn increments until the bottom-
ing 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 turned in full clockwise, the torsion spring should be adjusted using the
adjustment block. Back the screw out to the original starting position after torsion spring preload has been in-
creased.
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: Whenever shocks are replaced or reinstalled for any reason, the adjustment screw should be located
toward the forward right side of the suspension. Access to the adjuster is not possible if reversed.

Turn spring
Turn screw clockwise
clockwise to increase pre-
to tighten load
compression
(stiffen)
~

~
Xtra-1 0 Type
Adjus-
ment
Screw

Xtra-12 Type

8/98 7.36 Polaris Industries Inc.

 SUSPENSION
Suspension Springs and Rails
Round Springs vs Square Springs
Many 1999 model snowmobiles now utilize a square profile rear torsion spring. Square springs are lighter in
weight {1.5 lbs.), and smaller in packaging. The square coils take up less room, therefore allowing the carrier
wheels to be positioned more inward in the tunnel. Another benefit of the square profile spring is the ability to
maintain the same characteristics of the round spring, but have fewer coils of wire. NOTE: The 1999 square
profile springs will not retrofit to 1998 and previous models. The length of the coil stack is shorter on the square
springs and the inside diameter of the coil stack is also smaller.

_,

- /"' ~~ I
Last 3 digits of part number _l_ ~---' Last 3 digits of part number

Larger inside diameter Smaller inside diameter

Round Spring Square Spring

NOTE: The spring rates between the round wire springs and the square wire springs are identical. For example:
7041465-067 has same spring rate as 7041631-067 even though the wire diameter is different. The chart below
shows equal spring rates between round wire and square wire torsion springs.

NOTE: Square wire torsion springs will not fit in machines that come with round wire springs standard.

Spring Rates
.437" dia. wire spring rate=.375" dia. wire spring rate
.421" dia. wire spring rate=.359" dia. wire spring rate
.406" dia. wire spring rate=.347" dia. wire spring rate

Polaris Industries Inc. 7.37 8/98

SUSPENSION
Optional Springs- 1999 XTRA Lite Style
Following is a list of all available springs for the XTRA Lite front and rear suspension. These springs can be used
to better suit individual riding preference.

For Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood.

Torsion Spring Part No. Wire Dia./Degrees

7041555-067 LH .393/7r
7041556-067 RH .393/77°
7041521-067 LH .406/82°
7041522-067 RH .406/82°
7 041463-067 LH .406!7r
7041464-067 RH .406/77°

Front Track Spring Part No. Spring Wire Dia. x

Free Length - Rate
7041571-067 70 #/in
7041570-067 80 #/in
7041520-067 90 #/in

Optional Springs - 1999 TranSport I Widetrak

Following is a list of all available springs for the TranSport front and rear suspension. These springs can be used
to better suit individual riding preference.

Torsion Spring Part No. Wire Dia./Degrees

7041318-067 LH .375/75°
7041319-067 RH .375/75°
7041320-067 LH .406/75°
7041321-067 RH .406/75°
7041239-067 LH .468n4o
7041240-067 RH .468/74°

8/98 7.38 Polaris Industries Inc.

 SUSPENSION
Optional Springs - 1999 XTRA 10 Style
Following is a list of all available springs for the XTRA 10 front and rear suspension. These springs can be used
to better suit individual riding preference. NOTE: Square wire torsion springs cannot be substituted for round
wire springs.

For Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood.

Torsion Spring Part No. (Round Springs) Wire Dia./Degrees

7041463-067 LH .406/7JD
7041464-067 R H .406/7r
7041461-067 LH .421/7JD
7041462-067 RH .421/77°
7041465-067 LH .437/77°
7041466-067 RH .437/77°

Torsion Spring Part No. (Square Springs) Wire Dia./Degrees

7041627-067 LH .347/77°
7041628-067 RH .347/7JD
7041629-067 LH .359/77°
7041630-067 RH .359/7JD
7041631-067 LH .375/77°
7041632-067 RH .375/77°

Front Ski Spring Part No. Length/Rate- Application

7041554-067 80# Fox
7041576-067 100# Fox
7041575-067 120# Fox
704157 4-067 140# Fox
7041 573-067 160# Fox
7041553-067 60# Gabriel/Arvin
7041552-067 80# Gabriel/Arvin
7041551-067 100# Gabriel/Arvin
7041550-067 120# Gabriel/Arvin
7041549-067 140# Gabriel/Arvin

Front Track Spring Part No. Spring Wire Dia. x

Free Length- Rate
7041361-067 .343 x 7.0- 243 #/in
7041253-067 .312 x7.5 - 200Nar
7041362-067 .261 x 7.0- 85 #/in
7041364-067 .283 x 7.5 - 126 #/in

NOTE: The XTRA Lite 136 suspension used on the 1999 Trail RMK uses the square wire torsion springs listed
above.

Polaris Industries Inc. 7.39 8/98

SUSPENSION
1999 XTRA-12 Optional Suspension Springs
Following is a list of all available springs for the XTRA 12 front and rear suspension. These springs can be used
to better suit individual riding preference.

For Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood.

Xtra-12 IFS Shock Spring Part No. Rate - Application

7041398-067 75#/in
7041405-067 65#/in
7041554-067 80# Fox
7041576-067 100# Fox
7041575-067 120# Fox
704157 4-067 140# Fox
7041553-067 60# Gabriel/Arvin
7041552-067 80# Gabriel/Arvin
7041551-067 100# Gabriel/Arvin
7041550-067 120# Gabriel/Arvin
7041549-067 140# Gabriel/Arvin

Xtra-12 Front Track Shock Spring Part No. Spring Wire Dia. x
Free Length- Rate
7041351-067 .331 x 11.88-75/125 #/in
7041396-067 .283 x 11.88 - 50 #/in
7041398-067 .312 x 11.88-75 #/in
7041404-067 .343 x 11.88 - 90/150 #/in
7041405-067 .306 x 11.88 - 65 #/in
7041484-067 .406 x 9.0 - 275 #/in

Xtra-12 Rear Track Shock Spring Part No. Spring Wire Dia. x
Free Length - Rate
7041361-067 .343 x 7.0 - 246 #/in
7041362-067 .261 x 7.0 - 85 #/in
7041364-067 .283 x 7.5- 126 #/in
7041484-067 .331 x 11.88 - 275#/in
7041561-067 .261 x 7.5- 85 #/in
7041491-067 .438 x 13.00- 190 #/in

Xtra-12 Torsion Spring Part No. Wire Diameter I Degrees

7041394-067 - LH .406 I no
7041395-067- RH .406 I 7JO
7041406-067 - LH .421 I 7JO
7041407-067 - RH .421 I no

8/98 7.40 Polaris Industries Inc.

 SUSPENSION
Front Track Springs

For Optional Suspension Set Ups, See Suspension Tuning Decal Under Hood.

Following is a list of all available front track springs for Polaris snowmobiles and their part numbers.

Front Track Shock Spring Information

Part Number #of Total #of Active Rate {#/in.) Free Wire Dia. End Dia. #1 End Dia. #2
Coils Coils Length
7041570-067 11.7 9.7 80 #/in 10.50" .281" 1.89" 1.89"
7041569-067 11.8 9.8 60 #/in 10.50" .263" 1.89" 1.89"
7041253-067 10.0 8.0 200/var 7.50" .331" 1.90" 1.90"
704171 0-067 8.0 - 181 #/in 6.68"-6.88" .312" 1.90" 1.90"
7041712-067 8.0 - 181 #/in 7.50" .312" 1.90" 1.90"
7041 508-067 6.7 4.7 190 #/in 6.25" .343" 1.89" 2.25"
7041561-067 10.1 - 85 #/in 7.50" .261" 1.90" 1.90"
7041484-067 10.2 8.2 275 #/in 9.00" .406" 1.90" 1.90"
7041364-067 9.0 - 126 #/in 7.50" .283" 1.90" 1.90"
7041361-067 9.0 - 246 #/in 7.00" .343" 1.87" 1.87"
7041362-067 9.0 - 85 #lin 7.00" .261" 1.87" 1.87"
7041140 - 8.0 181 #/in 7.50" .312" 1.90" 1.90"
7041127 - 8.0 181 #/in 6.88" .312" 1.90" 1.90"
7041509-067 8.38 - 140/240 6.18" .343" 1.89" 2.25"
7041510-067 8.52 - 165/245 6.25" .362" 1.89" 2.25"
7041511-067 4.9 2.9 50 #/in 5.25" .225" 1.89" 2.25"
7041512-067 5.3 3.3 85 #/in 5.25" .263" 1.89" 2.25"
7041513-067 5.9 3.9 135 #/in 5.25" .295" 1.89" 2.25"
7041514-067 7.0 - 100/180 5.25" .297" 1.89" 2.25"

Fox"' upper retainer ID= 1.85"

Fox"' lower retainer 00= 1.85"/2.15"

Polaris Industries Inc. 7.41 8/98

SUSPENSION
XTRA 12 Suspension - Shock Removal
XTRA 12 Suspension Shock Removal

Steps 1-4 (immediately below) may be used for either front or rear track shock removal.

1. Turn fuel valve to off position. Front Track Shock Installation

2. Loosen rear idler bolts (A), lock Fox Shocks - Gas fitting positioned downward
nuts (C), and track adjuster bolts (toward track)
(B). Indy Select Shocks -Adjuster screw positioned
upward
3. Remove (4) suspension mounting
bolts.
4. Place a protective mat along side
of machine. Tip the machine on its
side onto protective mat.
5. Note orientation of shocks before
removal - gas valve (Fox) or
adjuster screw (Select) up or down.
6. Remove suspension.
7. Lift rear torsion springs (D) from
their lower mounts.
8. Remove top bolt from front track
shock.
9. Remove lower front track shock
bolt (lift torque arm to gain
access).
10. With front track shock removed, Rear Track Shock Installation
loosen and remove top and bottom Fox Shocks- Gas fitting positioned upward (toward
bolts from rear track shock. rear)
Indy Select Shocks - Adjuster screw positioned
XTRA 12 Suspension Shock upward (toward rear)
Installation
1. Reverse steps above for
assembly, with the following
notes:
• Use new Flex-Loc™
nuts for installation. Tighten
shock bolts to 15-18 ft. lbs.
(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 60ft. lbs. (8.28 kg-m).
• Secure jam nuts and tighten
rear idler bolts.

8/98 7.42 Polaris Industries Inc.

 SUSPENSION
INDEPENDENT FRONT SUSPENSION Fox TM Shock Specifications

IFS SHOCKS
Body Shaft Max. *Max.
Shock PN IFP Depth (in) Shaft Part#
Length (in) Length (in) Length (in) Travel (in)
7041255 6.075 6.850 13.145 4.150 1.700 1500133
7041266 6.175 6.900 13.145 4.150 2.000 1500133
7041291 6.380 6.800 13.250 4.050 0.728 1500008
7041292 6.380 6.800 13.250 4.050 0.728 1500008
7041346 6.380 6.800 13.250 4.050 0.728 1500008
7041349 5.850 6.350 12.270 3.600 0.616 1500076
7041385 8.995 9.125 18.150 6.375 1.142 1500068
7041401 8.180 8.310 16.560 5.810 1.139 N/A
7041474 6.380 6.800 13.250 4.050 0.728 1500008
7041490 6.040 6.350 12.710 3.850 0.600 1500076
7041494 7.900 7.730 15.700 5.230 1.000 1500136
7041536 7.900 7.730 15.700 5.230 1.000 1500136
7041537 8.720 7.600 16.140 4.850 2.000 1500140
7041540 7.900 7.730 15.700 5.230 1.000 1500136
7041545 6.720 6.850 13.640 4.350 0.675 1500133
7041593 7.900 7.730 15.700 5.230 1.000 1500136
7041612 7.900 7.730 15.700 5.230 1.000 1500136
7041692 7.900 7.730 15.700 5.230 1.000 1500136
7041697 7.900 7.730 15.700 5.230 1.000 1500136

* Jounce Bumper Removed

Measure IFP depth from flat of piston

as shown using the IFP depth tool (PN
2871351) or a dial caliper.
IFP
Depth

Polaris Industries Inc. 7.43 8/98

SUSPENSION
REAR SUSPENSION SHOCKS Fox TM Shock Specifications
FRONT TRACK SHOCKS
Body Shaft Max. Max.
Shock PN IFP Depth (in) Shaft Part#
Length (in) Length (in) Length (in) Travel (in)
7041294 5.050 5.350 10.470 2.850 0.544 1500040
7041386 8.955 9.125 18.150 6.375 1.140 1500068
7041402 5.430 5.570 11.070 3.070 0.586 1500153
7041413 5.050 5.350 10.470 2.850 0.544 1500040
7041493 5.430 5.570 11.070 3.070 0.590 1500153
7041507 5.330 6.400 11.060 3.150 4.570 1500076
7041584 5.430 5.570 11.070 3.070 0.586 1500153
7041589 5.430 5.570 11.070 3.070 0.586 1500153
7041641 5.330 5.570 10.970 3.070 0.600 1500153
7041642 5.330 5.570 10.970 3.070 0.600 1500153
7041706 5.330 5.570 10.850 3.070 0.600 1500153
7041735 5.330 5.570 10.850 3.070 0.600 1500153
REAR TRACK SHOCKS
Body Shaft Max. Max.
Shock PN IFP Depth (in) Shaft Part#
Length (in) Length (in) Length (in) Travel (in)
7041293 7.440 7.450 14.523 4.700 0.835 1500152
7041345 7.440 7.450 14.523 4.700 0.835 1500152
7041347 7.440 7.450 14.523 4.700 0.835 1500152
7041387 5.850 6.350 12.320 3.650 0.633 1500076
7041403 6.825 6.850 13.560 4.350 0.795 1500133
7041444 7.440 7.450 14.523 4.700 0.835 1500152
7041480 5.850 6.350 12.320 3.650 0.630 1500076
7041492 7.440 7.450 14.520 4.700 0.835 1500152
7041585 7.440 7.450 14.523 4.700 0.835 1500152
7041588 7.440 7.450 14.523 4.700 0.835 1500152
7041595 7.440 7.450 14.523 4.700 0.835 1500152
7041599 7.440 7.450 14.520 4.700 1.500 1500152
7041695 7.440 7.450 14.523 4.700 0.835 1500152
7041707 7.440 7.450 14.520 4.700 1.500 1500152
7041728 7.440 7.450 14.523 4.700 0.835 1500152
7041751 7.440 7.450 14.523 4.700 0.835 1500152
7041779 5.330 5.570 10.850 3.070 0.600 1500153

* IFP depth for limited build 1996 440 XCR SP with handlebar shock adjuster=4.570"

8/98 7.44 Polaris Industries Inc.

 SUSPENSION
Typical Shock Valving Arrangement
Shown below is an example of how valving stacks are arranged. The tables on page 7.46 contain production
valving specifications and piston orifice sizes. Optional valving (by shock part number) is listed in the tables on
following pages.

Parts in box are an example of standard valving.

*Note direction of valve piston before disassembly. The side with the greater number of slots should face the
IFP (nut end of the shaft).

standard Valving Typical Valve Stack

UV shaft End
Compression Stack ~
~---------,

I @ .800x .010 : Piston Orientation

I Side with greater# of
I @ .900x .010 : slots must face nut end
I ~ I
Toward Shaft (Toward nut 9,. IFP)
: ~ 1.00x.010 I (Fewer slots)
Slots'-.... •
II~ I ' 0~
~ 1.100x.010 I
Piston* 0
:1® 1.300 X .01 0 : I
Orifice
0

I®
I

II 1.300 X .012 I
I I
I
Orifice must be drilled to required size on
replacement valve pistons.
I
I
I
I IFP Deoth Adjustment For Limited Travel Setup
I Spacer Thickness IFP Depth Modifier

®
Rebound Stack : .25 .029 (Subtract)
.50 .058
I 1.250x.010
.75 .088
I 1.0 .117
I
I
I
@) 1.100x.010
1.25
1.50
.146
.175 Spacer
1.75 .204 PN
II~
~ 1.000x.010 2.00 .234 5431355
I 2.25 .263
I ~ .900x.010
2.50 .292
I~ I 2.75
3.00
.321
.350
: @ .800x.010 I 3.25 .380
I ~ I 3.50 .409

:>
1 ~ .7oox.o1o I 3.75 .438
L _________ j
4.00 .467
NutEnd 4.25 .496
4.50 .526
4.75 .555
5.00 .584
Changing oil on Fox™ Shocks is recommended annually and should be included when performing end of season stor-
age preparation. For competition use, shocks should be disassembled, inspected and serviced more frequently.

Polaris Industries Inc. 7.45 8/98

SUSPENSION
1997-1999 Production Valving Listed By Shock Part Number

Shock PN 7041385 7041494 7041536 7041537 7041540 7041545 7041593 7041692 7041697
IFS IFS IFS IFS IFS IFS IFS IFS IFS
Compress. 8C N/A N/A N/A N/A N/A N/A N/A 1.250x.010 1.250x.010
Stack 7C N/A N/A N/A N/A N/A N/A N/A .800x.008 .800x.008
6C 0.700X.008 1.250x.010 N/A .700x.008 N/A N/A 1.250x.010 .900x.010 .900x.01 0
5C 0.800X.008 .800x.010 .800x.008 .800x.008 .800x.008 .800x.008 .800x.010 1.000x.010 1.000x.008
4C 0.900X.008 .900x.010 .900x.008 .900x.008 .900x.008 .900x.008 .900x.010 1.100x.008 1.100x.008
3C 1.000X.008 1.000x.01 0 1.00x.008 1.000x.008 1.000x.010 1.000x.008 1.000x.01 0 1.300x.01 0 1.300x.008
2C 1.100X.008 1.00x.010 1.1 OOx.008 1.100x.008 1.100x.008 1.100x.008 1.100x.01 0 1.000x.006 1.000x.006
1C 1.300X.008 1.300x.010 1.300x.010 1.300x.008 1.300x.010 1.300x.010 1.300x.01 0 1.300x.008 1.300x.008
Orifice 0.078 0.081 0.078 0.078 0.078 0.078 0.081 0.081 0.086
Rebound 1R 1.250X.008 1.250x.01 0 1.250x.010 1.250x.008 1.250x.015 1.250x.010 1.250x.010 1.250x.010 1.250x.01 0
Stack 2R 1.100X.008 1.1 00x.008 1.1 00x.010 1.1 00x.008 1.100x.012 1.1 00x.01 0 1.1 00x.008 1.100x.01 0 1.1 OOx.OO
3R 1.000X.008 1.000x.008 1.000x.01 0 1.000x.008 1.000x.010 1.000x.01 0 1.000x.008 1.000x.008 1.000x.OOb
4R 0.900X.008 .900x.008 .900x.010 .900x.008 .900x.008 .900x.010 .900x.008 .900x.008 .900x.008
5R 0.800X.008 .800x.008 .800x.008 .800x.008 .800x.008 .800x.008 .800x.008 .800x.800 .800x.008
6R 0.700X.008 .700x.008 .700x.008 .700x.008 N/A .700x.008 .700x.008 .700x.008 .700x.008

Shock PN 7041507 7041584 7041589 7041641 7041642 7041706 7041779 7041735

Front Track Front Track Front Track Front Track Front Track Front Track Front Track Front Track
Compress. 8C N/A N/A N/A N/A N/A 1.250x.010 N/A 1.250x.01 0
Stack 7C N/A 1.250x.010 .700x.010 N/A .700x.010 .800x.010 .700x.010 .800x.012
6C 1.250x.01 0 .900x.010 .800x.010 1.250x.01 0 .800x.010 .900x.012 .800x.010 .900x.012
5C .800x.008 1.000x.012 .900x.010 .800x.008 .900x.010 1.000x.012 .900x.010 1.00x.010
4C .900x.012 1.1 00x.012 1.000x.01 0 .900x.012 1.000x.010 1.100x.01 0 1.000x.010 1.1 00x.01 0
3C 1.000x.012 1.300x.012 1.1 00x.01 0 1.000x.012 1.100x.010 1.300x.012 1.100x.010 1.300x.012
2C 1.100x.012 .900x.006 1.250x.012 1.100x.012 1.250x.012 1.000x.006 1.250x.012 .900x.008
1C 1.300x.012 1.300x.008 1.300x.012 1.300x.012 1.300x.012 1.300x.010 1.300x.012 1.300x.010
Orifice 0.075 0.075 0.075 0.075 0.075 0.075 0.076 0.076
Rebound 1R 1.250x.01 0 1.250x.01 0 1.250x.01 0 1.250x.01 0 1.250x.01 0 1.250x.010 1.250x.010 1.250x.012
Stack 2R 1.1 00x.01 0 1.100x.01 0 1.1 oox.010 1.100x.010 1.1 00x.01 0 1.100x.010 1.100x.010 1.100x.010
3R 1.000x.010 1.000x.010 1.000x.012 1.000x.010 1.000x.012 1.000x.01 0 1.000x.012 1.000x.010
4R .900x.010 .900x.010 .900x.010 .900x.010 .900x.01 0 .900x.01 0 .900x.010 .900x.01 0
5R .800x.01 0 .800x.01 0 .800x.010 .800x.010 .800x.01 0 .800x.01 0 .800x.010 .800x.010
6R .700x.01 0 .700x.010 .700x.01 0 .700x.01 0 .700x.010 .700x.010 .700x.010 .700x.010

Shock PN 7041480 7041492 7041585 7041588 7041595 7041599 7041695 7041707 7041728
Rear Track Rear Track Rear Track Rear Track Rear Track Rear Track Rear Track Rear Track Rear Track
Compress. 8C N/A 1.250x.010 N/A N/A N/A 1.250x.01 0 1.250x.010 1.250x.01 0 N/A
Stack 7C N/A .900x.010 1.250x.010 .700x.008 1.250x.010 .900x.010 .900x.012 .900x.012 N/A
6C 0.700X.006 1.100x.012 .900x.010 .800x.008 .900x.010 1.000x.012 1.000x.008 1.000x.012 .900x.010
5C 0.800X.006 1.100x.015 1.000x.010 .900x.010 1.000x.012 1.1 00x.015 1.000x.012 1.100x.015 1.000x.01 0
4C 0.900X.006 1.250x.010 1.100x.015 1.000x.008 1.100x.015 1.250x.010 1.100x.015 1.250x.01 0 1.100x.010
3C 1.000X.006 1.300x.015 1.300x.015 1.1 OOx.008 1.300x.015 1.300x.015 1.300x.015 1.300x.012 1.250x.012
2C 1.1 OOX.006 1.000x.006 1.000x.006 1.250x.008 .900x.012 1.000x.006 .900x.012 1.000x.006 .900x.006
1C 1.300X.006 1.300x.012 1.300x.01 0 1.300x.008 1.300x.012 1.300x.012 1.300x.012 1.300x.012 1.300x.008
Orifice 0.067 0.072 0.086 0.078 0.086 0.072 0.086 0.072 0.063
Rebound 1R 1.250X.010 1.250x.010 1.250x.012 1.250x.012 1.250x.012 1.250x.010 1.250x.012 1.250x.010 1.250x.015
Stack 2R 1.100X.010 1.1 OOx.012 1.100x.012 1.100x.012 1.1 00x.012 1.100x.012 1.100x.012 1.250x.01 0 1.250x.012
3R 1.000X.01 0 1.000x.012 1.000x.012 1.000x.012 1.1 00x.012 1.000x.012 1.100x.012 1.100x.012 1.1 oox.012
4R 0.900X.010 .900x.012 .900x.012 .900x.012 .900x.012 .900x.012 1.000x.012 1.000x.012 1.000x.010
5R 0.800X.01 0 .800x.012 .800x.012 .800x.012 .800x.012 .800x.012 .900x.012 .900x.012 .900x.01 0
6R 0.700X.010 .700x.012 .700x.012 .700x.012 .700x.012 .700x.012 .800x.012 .800x.012 .800x.01 0

N/A =Not Applicable

8/98 7.46 Polaris Industries Inc.
 SUSPENSION
1999 Optional Valving Listed By Shock Part Number
1999 500 XC SP I 600 XC SP I 700 XC SP

LIGHT HEAVY
Shock PN 7041697 7041735 7041728 7041697 7041735 7041728
IFSX-10 Front Track Rear Track IFS X-10 Front Track Rear Track
CRC X 10 X10 CRC X 10 X10

Compres- 8C NIA NIA NIA 0.8x.010 1.25x.010

sion Stack
7C 0.8x.008 0.8x.010 NIA 0.9x.012 0.8x.012

6C 0.9x.008 0.9x.010 NIA 1.0x.012 0.9x.015 LD

m
C\J
5C 1.0x.006 1.0x.008 NIA 1.1x.010 1.0x.012 C\J
I'-
4C 1.1x.008 1.1x.008 NIA 1.3x.010 1.1x.012 ro
C\J
,__
3C 1.3x.008 1.3x.008 NIA 1.0x.006 1.3x.012 (l)
_o
E
2C 1.0x.008 0.9x.008 NIA 1.25x.008 0.9x.006 :J
z
1C 1.3x.008 1.3x.008 NIA 1.3x.008 1.3x.01 0 t
C\l
0..
Orifice .086 .076 NIA .086 .076
~
Rebound 1R 1.25x.008 1.25x.01 0 NIA 1.25x.010 1.25x.012 (l)
Stack (l)
2R 1.1x.008 1.1x.010 NIA 1.1x.010 1.1x.012 (f)

3R 1.0x.008 1.0x.01 0 NIA 1.0x.008 1.0x.010

4R 0.9x.008 0.9x.01 0 NIA 0.9x.008 0.9x.010

5R 0.8x.008 0.8x.010 NIA 0.8x.008 0.8x.012

6R 0.7x.008 0.7x.010 NIA NIA 0.7x.010

1999 440 XCR

LIGHT HEAVY
Shock PN 7041692 7041706 7041707 7041692 7041706 7041707
IFS X-10 Front Track Rear Track IFSX-10 Front Track Rear Track
CRC X 10 X 10 CRC X 10 X10

Compres- 8C 1.25X.008 1.25x.01 0 1.25x.010 1.25X.010 1.25x.010 1.25x.010

sion Stack
7C 0.8X.008 0.8x.010 0.8x.010 0.8X.01 0 0.8x.012 0.9x.012

6C 0.9X.01 0 0.9x.010 0.9x.012 0.9X.012 0.9x.015 1.0x.012

5C 1.0X.008 1.0x.012 1.0x.01 0 1.0X.01 0 1.0x.015 1.1x.015

4C 1.1X.008 1.1x.008 1.1x.01 0 1.1X.010 1.1x.012 1.25x.012

3C 1.3X.008 1.3x.01 0 1.3x.01 0 1.3X.012 1.3x.012 1.3x.015

2C 1.0X.008 0.9x.008 1.0x.008 1.0X.006 1.0x.006 1.0x.006

1C 1.3X.008 1.3x.008 1.3x.008 1.3X.010 1.3x.01 0 1.3x.012

Orifice 0.081 .075 .072 0.081 .075 .072

Rebound 1R 1.25X.01 0 1.25x.010 1.25x.010 1.25X.010 1.25x.012 1.25x.012

Stack
2R 1.1X.008 1.1x.010 1.1x.012 1.1X.010 1.1x.012 1.25x.012

3R 1.0X.008 1.0x.008 1.0x.012 1.0X.008 1.0x.01 0 1.1x.012

4R 0.9X.008 0.9x.008 0.9x.012 0.9X.008 0.9x.010 1.0x.012

5R 0.8X.008 0.8x.008 0.8x.012 0.8X.008 0.8x.01 0 0.9x.012

6R 0.7X.008 0.7x.01 0 0.7x.012 0.7X.008 0.7x.010 0.8x.012

7R NIA NIA NIA NIA NIA 0.7x.012

Polaris Industries Inc. 7.47 8/98

SUSPENSION
1999 Optional Valving Listed By Shock Part Number
1999 700 XCR I 800 XCR

LIGHT HEAVY
Shock PN 7041540 7041779 7041695 7041540 7041779 7041695
IFS X-10 Front Track Rear Track IFS X-10 Front Track Rear Track
X10 X10 X 10 X 10

Compres- 8C N/A N/A N/A N/A N/A N/A

sion Stack
7C N/A 0.7x.010 1.25X.010 N/A 0.7x.010 1.25X.010

6C N/A 0.8x.008 0.9X.008 N/A 0.8x.012 0.9X.012

5C 0.8X.008 0.9x.008 1.0X.008 0.8X.010 0.9x.012 1.0X.010

4C 0.9X.008 1.0x.008 1.1X.010 0.9X.010 1.0x.012 1.10X.015

3C 1.0X.008 1.1x.01 0 1.3X.012 1.0X.012 1.1x.015 1.3X.015

2C 1.1X.006 1.25x.01 0 0.9X.012 1.1X.012 1.25x.012 0.9X.008

1C 1.3X.008 1.3x.010 1.3X.010 1.3X.012 1.3x.012 1.3X.012

Orifice 0.078 .076 0.086 0.078 .076 0.086

Rebound 1R 1.25X.012 1.25x.01 0 1.25X.012 1.25X.015 1.25x.012 1.25X.012

Stack
2R 1.1X.012 1.1x.008 1.1X.010 1.1X.012 1.1 x.012 1.10X.012

3R 1.0X.012 1.0x.010 1.0X.01 0 1.0X.012 1.0x.015 1.0X.012

4R 0.9X.010 0.9x.010 0.9X.010 0.9X.01 0 0.9x.012 0.9X.012

5R 0.8X.008 0.8x.010 0.8X.01 0 0.8X.008 0.8x.01 0 0.8X.012

6R 0.7X.008 0.7x.01 0 0.7X.010 0.7X.008 0.7x.01 0 0.7X.012

7R N/A N/A N/A N/A N/A N/A

Refer to the appropriate parts manual for a complete listing of Fox shock parts. Fox, Registered Trademark of
FOX Shox.
Shock Travel Limiting Spacer (1/4") - Part Number 5431355
Valve Washer Part Numbers
Part No. Description Part No. Description
1500052 1.300 X 0.006 1500046 ... 0.900 X 0.010
1500050 1.250 X 0.006 1500047 ... 0.800 X 0.010
1500049 1.100x0.006 1500044 ... 0. 700 X 0.010
1500048 1.000 X 0.006 1500079 ... 1.300 X 0.012
1500053 .... 0.900 X 0.006 1500078 ... 1.250 X 0.012
1500054 .... 0.800 X 0.006 1500060 ... 1.100 X 0.012
1500055 .... 0.700 X 0.006 1500059 ... 1.000 X 0.012
1500030 1.300 X 0.008 1500058 ... 0.900 X 0.012
1500051 1.250 X 0.008 1500057 ... 0.800 X 0.012
1500031 1.100 X 0.008 1500056 ... 0.700 X 0.012
1500032 1.000 X 0.008 1500087 . . . 1 .300 X 0.015
1500033 .... 0.900 X 0.008 1500086 ... 1.250 X 0.015
1500028 .... 0.800 X 0.008 1500085 ... 1.100 X 0.015
1500029 .... 0.700 X 0.008 1500084 ... 1.000 X 0.015
1500062 1.300x0.010 1500083 ... 0.900 X 0.015
1500026 1.250x0.010 1500082 ... 0.800 X 0.015
1500027 1.100x0.010 1500081 ... 0.700 X 0.015
1500045 1.000x0.010
Note: Subtract .029" from IFP depth for each 1/4 inch spacer added to the shock damper rod for limiting.
For example: If standard (full shock travel) IFP depth is .835", and 6 spacers are added to reduce shock travel by
1.5 inches, multiply .029 x 6 to calculate the amount to subtract from IFP depth .
.835-.174 = .661 (± .025") New IFP Depth

8/98 7.48 Polaris Industries Inc.

 SUSPENSION
Fox™ Shock Maintenance

Changing oil on Fox™ 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 serviced more fre-
quently.

When performing maintenance on Fox™ Shocks, use Gas Shock Recharging Kit PN 2200421. It consists of the
necessary valves, pressure gauge, and fittings to deflate and pressurize the shocks. The Body Holder Tool, Inter-
nal Floating Piston (IFP), and Shock Rod Holding Tool are not included in the Recharging Kit and must be ordered
separately. Refer to your Victor Specialty Tool catalog for part numbers.

Gas Shock Recharging Kit

PN 2200421

A WARNING

Extreme caution should be observed while handling and working with high pressure service equipment. Wear
a face shield, safety glasses, and ear protection during service of these shocks.

Care should be observed while handling the inflater needle and pressure gauges. Maintain your equipment and
keep it in good condition. If injury should occur, consult a physician immediately.

Extreme cleanliness is of utmost importance during all disassembly 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 direction and position of all internal parts for reas-
sembly.
Bleed Screw

Ref.# Qty. Description Internal Floating 3

1 1 Pressure Valve Piston (IFP)
2 2 0-Ring
Shock Body
3 1 Retaining Ring
4 1 Spring Retainer Body
5 2 0-Ring
6 1 Piston Ring (Floating)
7 1 Piston Ring (Damping) 8
8 1 Spring Retainer, Slotted

Polaris Industries Inc. 7.49 8/98

SUSPENSION
Fox™ Shock Maintenance

Disassembly

1. Remove spring and bushings from shock eyes.

Thoroughly wash shocks in a parts washer or with
soap and water to remove dirt and other debris. Dry
thoroughly with compressed air. Position and clamp
body cap of shock in soft jaws (aluminum or brass) of
vise. Remove Allen screw from pressure valve.

2. With valve outlet pointed in a safe direction, insert red

tip of safety needle assembly into recess in shock
pressure valve. Depress safety pin on safety needle
and push gauge and needle assembly slowly toward
shock, inserting needle. Be sure to push needle
completely into shock valve. Release nitrogen in a
safe direction away from everyone by turning
T-handle clockwise (if equipped) or by depressing
Schrader valve pin.

I CAUTION: I
It is possible for some residual pressure to remain in the
shock regardless of the gauge reading. Always com-
pletely remove valve from body cap before further disas-
sembly of shock.

3. Remove valve and sealing 0-ring from body cap.

4. Extend shock shaft by pulling up on shock eyelet.

Using a 1" (25 mm) wrench, loosen shaft bearing cap.

8/98 7.50 Polaris Industries Inc.

 SUSPENSION
Fox™ Shock Maintenance

Disassembly, Cont.
5. If body of shock starts to unscrew from body, tighten
and try again. To keep body from turning, it may be
necessary to use Body Clamp Tool clamped lightly
around body in soft jaws of vise as shown.
NOTE: Position body clamp at least 1 1/2" below bearing
cap.

Shock Body Clamp Tool

PN 2871071

6. Pull shock rod and piston straight out to avoid seal or

valve damage. Be prepared to catch piston ring
when removing the damper rod/valve piston.

7. Remove shock from vise and dispose of used oil

properly in suitable container. Set shock body aside.

8. Mount damper rod in soft-jawed vise as shown.

Loosen valve nut and clean the valve piston and
valving washers with electrical contact cleaner. Dry
thoroughly with compressed air. Tighten nut and
torque to 12ft. lbs. (1.66 kg-m).

Valve Nut Torque -

12ft. lbs. {1.66 kg-m)

Polaris Industries Inc. 7.51 8/98

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 damper rod nut (toward IFP).

Seal Replacement

1. Remove bearing cap from damper rod. Inspect

seals, o-ring, and bushing inside cap. Inspect cap
0-ring and replace if torn or damaged.

2. Using a small screwdriver or scribe pry upper seal,

main seal, and 0-ring out of bearing cap. Use care to
avoid scratching the seal cavity.

3. Clean seal cavity and inspect bushing for wear or

damage and replace bearing cap if necessary.

4. Lubricate new seals and 0-ring with Polaris shock oil

and install. Be sure the seals are seated completely
in the seal cavity.

5. Inspect jounce bumper (where applicable) and

replace if damaged.

6. Inspect damper rod for nicks, scratches or abrasion.

Install bearing cap and thick backing washer on
damper rod. Install compression valve washer stack
in same order as disassembly. Install valve piston
with greater number of slots facing damper rod nut
(toward IFP). Install rebound stack, washer, and a
new nut. Torque nut to 12ft. lbs.

Valve Nut Torque -

12ft. lbs. (1.66 kg-m)

8/98 7.52 Polaris Industries Inc.

 SUSPENSION
Fox™ 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.

Shock Body Clamp Tool

PN 2871071

9. Using an open end or large adjustable wrench,

unscrew the body cap from the body.

10. Inspect 0-ring in body cap for damage.

11. Note location of Allen screw in internal floating piston

(IFP) for reassembly in body tube. Remove IFP
through body cap end (external threaded end) using
IFP tool. Be prepared to catch piston ring and piston
as it comes out. Remove Allen screw from center of
piston. Inspect bleeder screw 0-ring and IFP sealing
0-ring for wear or damage. Replace 0-rings upon
reassembly.

12. Carefully clean all parts thoroughly with electrical

contact cleaner or solvent and dry with compressed
air. Inspect shock body for scratches or wear.

Polaris Industries Inc. 7.53 8/98

SUSPENSION
Fox™ Shock Maintenance
Reassembly
1. Install bleeder screw in IFP until 0-ring is lightly
seated.
NOTE: Bleeder screw must be positioned toward body
cap (externally threaded) end of shock body.

2. Compress flexible piston ring around valve piston

and install piston into shock body.

3. Screw in bearing cap by hand until 0-ring is fully

seated.

4. Invert shock and mount bearing cap flats lightly in

vise. Caution: Be sure damper rod is fully extended.

8/98 7.54 Polaris Industries Inc.

 SUSPENSION
Fox™ Shock Maintenance

Reassembly, Cont.
5. Fill with shock fluid to approximately 1" (2.54cm) from
end of body.

6. Install body cap until 0-ring is lightly seated.

7. Mount shock in vise by top eyelet as shown. Support

shock and strike body cap end 2-3 times with a soft
faced hammer to remove all air trapped inside the
valve piston. Allow shock to stand for 3-5 minutes.

Do not over-tighten vise or bearing cap may be damaged

8. Unscrew body cap and remove.

9. Remove IFP bleeder screw.

10. Set IFP tool to specified depth with a dial caliper as

shown.

IFP Tool PN 2871351

Polaris Industries Inc. 7.55 8/98

SUSPENSION
Fox™ Shock Maintenance

Reassembly, Cont.

11. Place a shop towel over the end of IFP tool and slowly
push IFP to specified depth.

12. With the IFP set and the bleeder screw removed,
slowly stroke shock to force air through piston
oriface. Move the shock body slowly to prevent
aeration of the oil. Allow all air to purge throught the
bleeder screw hole.

13. Install the bleeder screw with a new 0-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 lFP, not to the tapered outer edge.

14. Reinstall body cap with a new 0-ring and tighten by

hand. Mount shock with body cap end down in the
soft jaws of a vise. Torque bearing cap to 8-10ft. lbs.
(1.1 0-1.38 kg/m). This will also tighten the body into
the body cap.

I CAUTION: I
Do not over tighten or damage to the bearing may result.

Bearing Cap Torque -

8-10 ft.lbs. (1.10-1.38 kg-m)

8/98 7.56 Polaris Industries Inc.

 SUSPENSION
Fox™ Shock Maintenance

Reassembly, Cont.

15. Install pressurizing valve with new 0-ring and tighten

securely.

16. Set the nitrogen tank pressure regulator to 200 - 205

PSI.

17. 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.

18. 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.

Polaris Industries Inc. 7.57 8/98

SUSPENSION
Fox™ Shock Maintenance

Reassembly, Cont.

19. To check for leaks, submerge the shock in water and

look for bubbles or oil seepage around the bearing
and body caps.

20. When reinstalling shocks on the machine, torque

only to required specifications. If the shock is over
tightened it will not pivot, possibly resulting in damage
to shaft and seals.

21. When installing IFS shocks, tighten top mount first.

Pivot shock body into lower mount and determine if
spacer washers are necessary to prevent twist or
side loading of shock. Suspension assemblies
should always be moved through entire travel without
springs to verify free movement and proper
alignment of all components.

Shock Eyelet Replacement

Top Shock Eyelet

b Damper Rod Holding

nn/ol PN 2871352

Y~ 1 1
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

8/98 7.58 Polaris Industries Inc.

 SUSPENSION
Polaris Position Sensitive Shock (PSS)

COMPRESSION STROKE
INITIAL MID-COMPRESSION END-COMPRESSION
COMPRESSION STROKE STROKE
STROKE

BASIC No bypass
PRINCIPAL #1 available.
For pi stan travel
as shown, oil Increased
must get from compression
this side of ---++-++-- damping for
piston to this anti-bottom-out.
side of piston.

BASIC
PRINCIPAL #2
Oil must either
go through
piston valving,
or into outer PISTON
chamber MOVEMENT PISTON
On initiation of (bypass).
compression
MOVEMENT
stroke, all flow Maximum
occurs through bypass of oil
the piston only. middle of
compression
No bypass flow stroke.
is available in
this travel range. PISTON Lowest
MOVEMENT compression
damping

Very plush ride.

Valves on this
side of piston
flex open to
regulate flow.

Polaris Industries Inc. 7.59 8/98

 SUSPENSION
Polaris Position Sensitive Shock (PSS)

REBOUND STROKE
INITIAL MID-REBOUND END-REBOUND
REBOUND STROKE STROKE
STROKE

Valves on this
side of piston
flex open to
regulate flow.

No bypass flow
is available in
this travel
range.

Rebound bypass
is limited to
these holes ~-..,..,

Flow is restricted
on hole(s)
covered by one
way check valve.

Maximum
PISTON bypass of oil
MOVEMENT into outer
chamber at
this stage.
t
PISTON
MOVEMENT
PISTON No bypass
MOVEMENT available
into outer
chamber.

Increased
rebound
damping for
anti-top-out.

8/98 7.60 Polaris Industries Inc.

 SUSPENSION
Polaris Position Sensitive Shock (PSS)

SHOCK VALVJNG
COMPRESSION:
1. 1.300 X .008
2. .900 X .006
3. 1.250 X .012
4. 1.100 X .010
5. 1.000 X .010
7.450" 6. .900 X .010

REBOUND:
1. 1 .250 X .015
2. 1.250 X .012
3. 1 .1 00 X .012
4. 1.000 X .010
5. .900 X .010
6. .800 X .010
/ /
// A PISTON ORIFICE: .063
B
//
/ /
/
/ /
c
D SHOCK DESIGN DETAILS:
E
Travel 4.70"
Extended Length 14.52"
Compressed Length 9.82"
IFP Depth .835"
Bearing 1.15"
Nitrogen Pressure 200 PSI

BY-PASS HOLE DETAILS:

LOCATION QUANTITY CHECK VALVE DIAMETER
A. 1.80 1 NO 0.0787"
B. 2.00 3 NO 0.0787"
C. 3.50 1 NO 0.0787"
D. 4.25 2 YES 0.0787"
E. 4.50 1 NO 0.0787"

Polaris Industries Inc. 7.61 8/98

SUSPENSION
Position Sensitive Shock Maintenance

Disassembly

1. Remove bushings from body cap. Thoroughly wash

shock 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, body
cap down (as shown).

2. Remove Allen screw from pressure valve.

3. With valve outlet pointed in a safe direction, insert red

tip of safety needle assembly into recess in shock
pressure valve. Depress safety pin on safety needle
and push gauge and needle assembly slowly toward
shock, inserting needle. Be sure to push needle
completely into shock valve. Release nitrogen in a
safe direction away from everyone by turning
T-handle clockwise (if equipped) or by depressing
Schrader valve pin.

·. CAUTION; I
It is possible for some residual pressure to remain in the
shock regardless of the gauge reading. Always com-
pletely remove valve from body cap before further disas-
sembly of shock.

4. Remove valve and sealing 0-ring from body cap.

5. Extend shock shaft by pulling up on shock eyelet.

Using a 1" (25 mm) wrench, loosen shaft bearing cap.

8/98 7.62 Polaris Industries Inc.

 SUSPENSION
Position Sensitive Shock Maintenance

Disassembly, Cont.
6. If bearing comes loose first, unscrew bearing from
body and remove the shaft assembly from the body.
Pull shock rod and piston straight out to avoid seal or
valve damage. Be prepared to catch piston ring
when removing the damper rod/valve piston.

7. Remove shock from vise and dispose of used oil

properly in suitable container.

8. Clamp the exposed portion of the shock body in a

vice using shock body clamp tool, body cap up. DO
NOT clamp on bypass sleeve or damage to the shock
will occur.

Shock Body Clamp Tool

PN 2871071

9. Remove the body cap

Polaris Industries Inc. 7.63 8/98

SUSPENSION
Position Sensitive Shock Maintenance

Disassembly, cont.

10. Remove IFP

11. Remove bypass Sleeve.

1. If body cap comes loose first, reclamp shock in vice,

gripping on bearing flats with the body cap up.

2. Remove body cap.

NOTE: Make sure bypass sleeve remains in contact with
collar during this procedure. Oil will spill if bypass sleeve
separates from collar.

8/98 7.64 Polaris Industries Inc.

 SUSPENSION
Position Sensitive Shock Maintenance

Disassembly, Cont.

3. Remove IFP and dispose of shock oil properly.

4. Remove bypass sleeve and clamp shock body in vise

using body clamps.

5. Unscrew bearing from body and remove shaft

assembly from body. Be prepared to catch piston
ring.

6. Follow procedures in Fox"' shock maintenance

section for inspection, cleaning, and valving if
needed.

Polaris Industries Inc. 7.65 8/98

SUSPENSION
Position Sensitive Shock Maintenance

Assembly

1. Compress piston ring and insert shaft assembly into

shock body.

2. Inspect bypass sleeve for burrs, dents, or other

physical damage.

3. Lube collar 0-ring and replace bypass sleeve over

body. Be sure of a snug fit - do not pinch or cut 0-ring.

4. Clamp eyelet of shock in the vise body up. Fill shock

and bypass sleeve through shock body. Oil should
cover all bypass holes. Fill to approximately one inch
(2.54cm) from end of body.

8/98 7.66 Polaris Industries Inc.

 SUSPENSION
Position Sensitive Shock Maintenance

Aassembly, Cont.

5. Cycle shock through the first couple inches of travel

to release trapped air. Take care not to spill oil over
the bypass sleeve or introduce air through bypass
holes.

6. Ensure that the shaft is fully extended and set the IFP
to the proper depth. Remove IFP bleeder screw to be
sure no air is trapped under the IFP. Install IFP.

IFP Depth:

.835" (21.2mm)

7. Replace the IFP bleed screw with a new 0-ring and

tighten securely. Hold shock fully extended and fill oil
in bypass sleeve to the top.

8. Replace the body cap. Oil will drain over the edge of
the bypass sleeve until the 0-ring seals.

Polaris Industries Inc. 7.67 8/98

SUSPENSION
Position Sensitive Shock Maintenance

9. Once the body cap 0-ring seals, re-position the

shock in the vice by clamping on the body cap with
the shaft up.

10. Continue to tighten the body cap utilizing flats on the

bearing. Torque cap to 55 ft lbs. Install pressure
valve with new 0-ring and tighten securely.
Pressurize shock to 200 psi.

Body Cap Torque

55 ft. lbs.

8/98 7.68 Polaris Industries Inc.

 SUSPENSION
Suspension Troubleshooting - WideTrak Style
Problem Solution
Rear suspension bottoms too easily -Increase torsion spring preload
-Increase rear shock compression valving by turning
screw clockwise (if equipped with optional Indy Select
shock)
-Install overload kit PN 2871042 for extreme use
Rides too stiff in rear -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 shock)
-Check for proper track tension
Machine darts from side to side -Make sure skis are aligned properly (straight
forward with rider on machine)
-Make sure spindles and all steering components are
free turning
-Make sure skags are straight on skis
-Check hi-fax and replace if worn
-Reduce ski pressure:
•Increase front track spring preload
•Reduce IFS spring preload if shims have
been added
•Reduce rear torsion spring preload
Front end pushes -Check for worn skags
-Check for binding suspension shafts and grease all pivot
points
-Increase IFS spring preload by adding shims
Steering is heavy -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
Setting up for deep snow operation -Change worn hi-fax
-Lower front and rear torque arms (see Performance sec-
tion at the back of this manual)

Polaris Industries Inc. 7.69 8/98

SUSPENSION
Suspension Troubleshooting - XTRA Lite Style
Problem Solution
Rear suspension bottoms too easily -Increase torsion spring preload
-Increase rear shock compression valving by turning
screw clockwise (if equipped with optional Indy Select
shock)
Rides too stiff in rear -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 shock)
Machine darts from side to side -Make sure skis are aligned properly (straight
forward with rider on machine)
-Make sure spindles and all steering components are
free turning
-Make sure skags are straight on skis
-Check hi-fax and replace if worn
-Reduce ski pressure:
•Increase front track spring preload
•Reduce IFS spring preload if shims have
been added
•Reduce rear torsion spring preload
Front end pushes -Check for worn skags
-Check for binding suspension shafts and grease all pivot
points
-Increase IFS spring preload by adding shims
Steering is heavy -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
Setting up for deep snow operation -Change worn hi-fax
-Lower front and rear torque arms (see Performance sec-
tion at the back of this manual)

8/98 7.70 Polaris Industries Inc.

 SUSPENSION
Suspension Troubleshooting- XTRA 10 Style
Problem Solution
Rear suspension bottoms too easily -Increase torsion spring preload
-Increase rear shock compression valving by turning
screw clockwise (if equipped with optional Indy Select
shock) or refer to optional valving on Suspension Wall-
chart for Fox equipped models
-Change RRSS to highest setting
Rides too stiff in rear -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 shock) or refer to optional valving on Suspension
Wallchart for Fox equipped models
-Set RRSS to lowest position or totally remove
Machine darts from side to side -Make sure skis are aligned properly (straight
forward with rider on machine)
-Make sure spindles and all steering components are
free turning
-Make sure skags are straight on skis
-Check hi-fax and replace if worn
-Reduce ski pressure:
•Increase front track spring preload
(requires shims)
•Reduce IFS spring preload by adjusting
cam
•Reduce rear torsion spring preload
•Lengthen front limiter strap
Front end pushes -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
Steering is heavy -Check ski alignment
-Check skags and skis for damage
-Reduce ski pressure:
•Increase front track spring preload
•Reduce IFS spring preload by adjusting
cam
•Reduce rear torsion spring preload
Setting up for deep snow operation -Change worn hi-fax
-Lower rear torque arms (see Performance section at the
back of this manual)
-Increase front limiter strap length
-Based on rider preference, RRSS may be removed to
increase weight transfer

Polaris Industries Inc. 7.71 8/98

SUSPENSION
Suspension Troubleshooting - XTRA 12 Style
Problem Solution
Rear suspension bottoms too easily -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
-Change to .421 torsion springs (PN 7041405, 7041406)
-Change to next heavier coil spring (e.g. 75/125 #/in. to
90/150 #/in.
-Change to stiffer shock valving (refer to wallchart)
-Check charge in shocks on models equipped with Fox™
shocks
Rides too stiff in rear -Check for binding suspension shafts and grease all pivot
points
-Decrease spring preload adjustments
-Remove rear track shock spring or reduce rate of spring
(refer to wallchart)
-Change front track shock to lighter spring
-Change to lighter shock valving on models equipped
with Fox™ or Indy Select shocks (refer to wallchart)
Machine darts from side to side -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
Front end pushes -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
Steering is heavy -Check ski alignment
-Check skags and skis for damage
-Change FRSS to high setting
-Decrease IFS spring preload
Setting up for deep snow operation -Rotate FRSS to lowest setting, depending upon rider
preference
-Decrease preload on front track spring
-Move FRSS to forwardmost hole
-Tighten limiter strap one hole

8/98 7.72 Polaris Industries Inc.

CHAPTER 8
BRAKES I FINAL DRIVE
Jackshaft Speed vs. MPH Chart ...................................... 8.1-8.2
HYVO"' Chains & Sprockets ......................................... 8.3
Sprocket I Chain Combinations 6 5/8" Chaincase ....................... 8.4
Sprocket I Chain Combinations 7.05" Chaincase ........................ 8.5
1999 Track Drive Data .............................................. 8.6
Driveshaft Sprocket Installation Tips ................................... 8.7
Track Specifications ................................................ 8.8
Hydraulic Brake System Operation .................................... 8.9
Type 3 Master Cylinder .............................................. 8.10
Type 3 Master Cylinder Inspection and Assembly ....................... 8.11-8.13
Brake Bleeding - Fluid Change ....................................... 8.14-8.15
Hayes"' Master Cylinder ............................................ 8.16
Hayes"' Inspection and Replacing Cartridge Subassembly ............. 8.16-8.20
Hayes"' Master Cylinder Lever and/or Pin Replacement ................ 8.21-8.22
Hayes"' Park Brake Lever and/or Spring Replacement .................. 8.23-8.24
Type H4 Friction Pad Replacement ................................... 8.25-8.26
Type H4 Caliper Disassembly ........................................ 8.27
Type H4 Cleaning and Inspection ..................................... 8.28
Type H4 Assembly .................................................. 8.28-8.29
Type H5LC Friction Pad Replacement ................................. 8.30-8.31
Type H5LC Caliper Disassembly ...................................... 8.32
Type H5LC Cleaning and Inspection .................................. 8.33
Type H5LC Assembly ............................................... 8.33-8.34
Type M3 Disassembly ............................................... 8.35
Type M3 Assembly to Chaincase ..................................... 8.36
Type M3 Adjustment ................................................ 8.37
Type WT Disassembly .............................................. 8.38
Type WT Assembly to Transmission ................................... 8.39
Type WT Adjustment ................................................ 8.39
Type 3 Drive System Disassembly .................................... 8.40-8.43
Type 3 Drive System Assembly ....................................... 8.44-8.51
Transmission, Suspension and Track Removal- WideTrak ............... 8.52-8.54
Transmission, Suspension and Track Assembly- WideTrak .............. 8.55-8.59
Transmission Disassembly, Wide Trak LX .............................. 8.60-8.66
Transmission Assembly, Wide Trak LX ................................ 8.66-8.67
Brake Caliper Removal- Type WT2 ................................... 8.67
Brake Caliper Assembly/Installation - Wide Trak LX ..................... 8.68
Reverse Kit Service Tips ............................................. 8.69
Reverse Kit Maintenance ............................................ 8.70-8.72
Traction ........................................................... 8.73
Stud Recommendations ............................................. 8.74-8.76
 INDY JACKSHAFT SPEI:...., VS. MILES PER HOUR
SPROCKET COMBINATION/GEAR RATIO/CHAIN PITCH- STD. CHAINCASE
~ The following chart should be used to select optimum gearing for special applications. The chart is calculated for models with the P85 drive clutch at a 1 to 1 ratio between drive clutch and driven
er clutch front drive sprocket diameter is 7.06 inches. To use the chart, select the jackshaft rpms (equal to engine rpm). MPH is shown to the right of jackshaft rpm. Shown on top is optimum gearing
CiJ· for mph and engine rpms.
s-
~
...... Gearing 23/37 20/33 21/35 20/35 19/35 21/37 21/39 18/35 20/39
20/41
19/39 17/35 19/40 19/41 18139 16135 18/41 17/39 15/35 17/40 17/41 16/39 16/40 14/35 16/41 15/39 15/40 15/41 14/39 14/40 14/41

~- Ratio 1.61 1.65 1.67 1.75 1.84 1.76 1.86 1.94 1.95 2.05 2.06 2.11 2.16 2.17 2.19 2.28 2.29 2.33 2.35 2.41 2.44 2.50 2.50 2.56 2.60 2.67 2.73 2.79 2.86 2.93

s-
~
Pitch
Jackshaf1
66 64 64 64 64 66 66 64 66 66 62 68 66 66 62 68
MILES PER HOUR
66 62 66 66 64 66 62 66 64 64 66 64 64 64

RPM

6500 85.5 83.4 82.4 78.7 74.8 78.2 74.0 70.9 70.6 67.1 66.8 65.2 63.7 63.4 62.8 60.4 60.1 59.1 58.6 57.1 56.4 55.1 55.1 53.8 52.9 51.6 50.4 49.3 48.1 47.0
6600 86.8 64.7 83.7 79.9 76.0 79.4 75.1 72.0 71.7 68.2 67.8 66.2 64.7 64.4 63.8 61.3 61.0 60.0 59.5 58.0 57.3 55.9 55.9 54.6 53.8 52.3 51.2 50.1 48.9 47.7
6700 88.1 86.0 85.0 81.1 77.1 80.6 76.3 73.1 72.8 69.2 68.9 67.2 65.7 65.4 64.8 62.2 62.0 60.9 60.4 58.9 58.1 56.7 56.7 55.4 54.6 53.1 52.0 50.9 49.6 48.4
-~--
+----- f-·-
6800 89.4 87.3 86.2 82.3 78.3 81.8 77.4 74.2 73.8 70.2 69.9 68.2 66.7 66.4 65.7 63.2 62.9 61.8 61.3 59.7 59.0 57.6 57.6 56.2 55.4 53.9 52.7 51.6 50.3 49.1
6900 90.8 88.6 87.5 83.5 79.4 83.0 78.6 75.3 74.9 71.3 70.9 69.2 67.6 67.3 66.7 64.1 63.8 62.7 62.2 60.6 59.9 58.4 58.4 57.1 56.2 54.7 53.5 52.4 51.1 49.9
7000 92.1 89.8 88.8 64.7 80.6 84.2 79.7 76.4 76.0 72.3 72.0 70.2 68.6 68.3 67.7 65.0 64.7 63.6 63.1 61.5 60.7 59.3 59.3 57.9 57.0 55.5 54.3 53.1 51.8 50.6
7100 93.4 91.1 90.0 85.9 81.7 85.4 80.8 77.5 77.1 73.3 73.0 71.3 69.6 69.3 68.7 65.9 65.7 64.5 64.0 62.4 61.6 60.1 60.1 58.7 57.8 56.3 55.1 53.9 52.6 51.3
7200 94.7 92.4 91.3 87.1 82.9 86.6 82.0 78.6 78.2 74.4 74.0 72.3 70.6 70.3 69.6 66.9 66.6 65.4 64.9 63.3 62.5 61.0 61.0 59.6 58.6 57.1 55.8 54.6 53.3 52.0
7300 96.0 93.7 92.6 88.3 84.0 87.8 83.1 79.7 79.3 75.4 75.0 73.3 71.6 71.2 70.6 67.8 67.5 66.3 65.8 64.1 63.4 61.8 61.8 60.4 59.5 57.9 56.6 55.4 54.0 52 8
7400 97.3 95.0 93.8 89.5 85.2 89.0 84.2 80.8 80.4 76.4 76.1 74.3 72.5 72.2 71.6 68.7 68.4 67.3 66.7 65.0 64.2 62.7 62.7 61.2 60.3 58.7 57.4 56.2 54.8 53.5 c..
D,)
7500 98.6 96.3 95.1 90.8 86.3 90.2 85.4 81.9 81.4 77.5 77.1 75.3 73.5 73.2 72.5 69.7 69.4 68.2 67.6 65.9 65.1 63.5 63.5 62.0 61.1 59.5 58.2 56.9 55.5 54.2 0
7600 100.0 97.5 96.4 92.0 87.5 91.4 86.5 83.0 82.5 78.5 78.1 76.3 74.5 74.2 73.5 70.6 70.3 69.1 68.5 66.8 66.0 64.4 64.4 62.9 61.9 60.3 58.9 57.7 56.3 54.9 ~

--
(X) (/)
7700 101.3 98.8 97.6 93.2 88.6 92.6 87.7 84.0 83.6 79.5 79.2 77.3 75.5 75.1 74.5 71.5 71.2 70.0 69.4 67.7 66.8 65.2 65.2 63.7 62.7 61.1 59.7 58.4 57.0 55.6 ~
....... D,)
7800 102.6 100.1 98.9 94.4 89.8 93.8 88.8 85.1 64.7 80.6 80.2 78.3 76.5 76.1 75.4 72.4 72.1 70.9 70.3 68.5 67.7 66.1 66.1 64.5 63.5 61.9 60.5 59.2 57.8 56.4
---
7900 103.9 101.4 100.2 95.6 90.9 95.0 89.9 86.2 85.8 81.6 81.2 79.3 77.4 77.1 76.4 73.4 73.0 71.8 71.2 69.4 68.6 66.9 66.9 65.3 64.3 62.7 61.3 60.0 58.5 57.1
CJ)
8000 105.2 102.7 101.4 96.8 92.1 96.3 91.1 87.3 86.9 82.6 82.2 80.3 78.4 78.1 77.4 74.3 74.0 72.7 72.1 70.3 69.4 67.8 67.8 66.2 65.2 63.4 62.1 60.7 59.2 57.8
"'0
8100 106.5 104.0 102.7 98.0 93.2 97.5 92.2 88.4 88.0 83.7 83.3 81.3 79.4 79.0 78.3 75.2 74.9 73.6 73.0 71.2 70.3 68.6 68.6 67.0 66.0 64.2 62.8 61.5 60.0 58.5 (1)
(1)
8200 107.8 105.2 104.0 99.2 94.4 98.7 93.4 89.5 89.0 64.7 84.3 82.3 80.4 80.0 79.3 76.2 75.8 74.5 73.9 72.0 71.2 69.5 69.5 67.8 66.8 65.0 63.6 62.2 60.7 59.3
a.
8300 109.2
110.5
106.5 105.2 100.4
101.6
95.5 99.9 94.5 90.6 90.1 85.7 85.3 83.3 81.4
82.3
81.0 80.3 77.1
78.0
76.7 75.4 74.8
75.7
72.9 72.0 70.3
71.1
70.3 68.7
69.5
67.6
68.4
65.8
66.6
64.4
65.2
63.0
63.8
61.5
62.2
60.0
60.7
<
(/)
8400 107.8 106.5 96.7 101.1 95.6 91.7 91.2 86.8 86.3 64.3 82.0 81.2 77.7 76.3 73.8 72.9 71.1
8500
8600
111.8
113.1
109.1
110.4
107.8
109.0
102.9
104.1
97.8
99.0
102.3
103.5
96.8
97.9
92.8
93.9
92.3
93.4
87.8
88.8
87.4
88.4
85.3
86.3
83.3
64.3
82.9
83.9
82.2
83.2
78.9
79.9
78.6
79.5
77.2
78.2
76.6
77.5
74.7
75.6
73.8
74.6
72.0
72.8
72.0
72.8
70.3
71.1
69.2
70.0
67.4
68.2
65.9
66.7
64.5
65.3
62.9
63.7
61.4
62.2
:s:
""0
8700 114.4 111.7 110.3 105.3 100.1 104.7 99.0 95.0 94.5 89.9 89.4 87.3 85.3 84.9 84.1 80.8 80.4 79.1 78.4 76.4 75.5 73.7 73.7 72.0 70.9 69.0 67.5 66.0 64.4 62.9 ::I:
8800 115.7 112.9 111.6 106.5 101.3 105.9 100.2 96.1 95.6 90.9 90.5 88.3 86.3 85.9 65.1 81.7 81.4 80.0 79.3 77.3 76.4 74.5 74.5 72.8 71.7 69.8 68.3 66.8 65.2 63.6 (")
8900 117.1 114.2 112.9 107.7 102.4 107.1 101.3 97.1 96.6 91.9 91.5 89.3 87.2 86.8 86.1 82.7 82.3 80.9 80.2
·-····- · - · · -
78.2 77.2 75.4 75.4 73.6 72.5 70.6 69.0 67.5 65.9 64.3 ~OJ
9000 118.4 115.5 114.1 108.9 103.6 108.3 102.5 98.2 97.7 93.0 92.5 90.3 88.2 87.8 87.0 83.6 83.2 81.8 81.1 79.1 78.1 76.2 76.2 74.4 73.3 71.4 69.8 68.3 66.6 65.0 ~ JJ
9100 119.7 116.8 115.4 110.1 104.7 109.5 103.6 99.3 98.8 94.0 93.5 91.3 89.2 88.8 88.0 84.5 84.1 82.7 82.0 80.0 79.0 77.1 77.1 75.3 74.1 72.2 70.6 69.1 67.4 65.8 -l>
9200
9300
121.0
122.3
118.1
119.4
116.7
117.9
111.3
112.5
105.9
107.0
110.7
111.9
104.7
105.9
100.4
101.5
99.9
101.0
95.0
96.1
94.6
95.6
92.3
93.3
90.2
91.2
89.8
90.8
89.0
89.9
85.4
86.4
85.1
86.0
83.6
84.5
82.9
83.8
80.8
81.7
79.8
80.7
77.9
78.8
77.9
78.8
76.1
76.9
74.9
75.7
73.0
73.8
71.4
72.1
69.8
70.6
68.1
68.9
66.5
67.2
0)"'
. m
O'lCJ)
9400 123.6 120.6 119.2 113.7 108.2 113.1 107.0 102.6 102.1 97.1 96.6 94.3 92.2 91.7 90.9 87.3 86.9 85.4 84.7 82.6 81.6 79.6 79.6 77.8 76.6 74.5 72.9 71.3 69.6 67.9 1\)-
68.7
CJl'TI
73.7 72.1 70.3
~z
9500 124.9 121.9 120.5 115.0 109.3 114.3 108.2 103.7 103.2 98.1 97.7 95.3 93.1 92.7 91.9 88.2 87.8 86.3 85.6 83.5 82.4 80.5 80.5 78.6 77.4 75.3
9600 126.3 123.2 121.7 116.2 110.5 115.5 109.3 104.8 104.2 99.2 98.7 96.3 94.1 93.7 92.8 89.2 88.8 87.2 86.5 84.3 83.3 81.3 81.3 79.4 78.2 76.1 74.5 72.9 71.1 69.4
75.2 73.6 71.8 70.1 ~l>
9700 127.6 124.5 123.0 117.4 111.6 116.7 110.4 105.9 105.3 100.2 99.7 97.3 95.1 94.7 93.8 90.1 89.7 88.2 87.4 85.2 84.2 82.2 82.2 80.2 79.0 76.9
w r
9800 128.9 125.8 124.3 118.6 112.8 117.9 111.6 107.0 106.4 101.2 100.7 98.3 96.1 95.6 94.8 91.0 90.6 89.1 88.3 86.1 85.0 83.0 83.0 81.1 79.5 77.7 76.0 74.4 72.6 70.8
:i' c
...... 9900 130.2 127.1 125.5 119.8 113.9 119.1 112.7 108.1 107.5 102.3 101.8 99.4 97.1 96.6 95.7 91.9 91.5 90.0 89.2 87.0 85.9 83.9 83.9 81.9 80.6 78.5 76.8 75.1 73.3 71.5 0 JJ
__84.7______84.7 w-
~ (/1<
10000 131.5 128.3 126.8 121.0 115.1 120.3 113.8 109.2 108.6 103.3 102.8 100.4 98.0 97.6 96.7 92.9 92.5 90.9 90.1 87.9 86.8 .. 82.7 81.4 79.3 77.6 75.9 74.0 72.3
Cl:) Cl)m
BRAKES/FINAL DRIVE
Jackshaft Speed vs. MPH Chart 7.05" Chaincase

Top Sprokect 25 23 23 23 22 22 20 21 19 19 18 18 17
Lower Sproket 41 39 40 41 40 41 39 41 39 40 40 41 41

Chain Length 72 70 70 70 70 70 68 70 68 68 68 68 68
Jackshaft MILES PER HOUR
RPM

64;6' 59;9 5.6.7 55,3 52.3"

6100 78.1 75.6 73.7 71.9 70.5 68.7 65.7 65.6 62.4 60.9 57.7 56.2 53.1
6200
6300 80.7 78.0 76.1 74.2 64.5 62.9 59.5 58.1 54.9
:);' 7~.3 .·•

6500 83.2 80.5 78.5 76.6 75.1 73.3 70.0 69.9 66.5 64.8 61.4 59.9 56.6

t~:~A7~n; m~"·'· " .:~,·:·"· y' ~·:~<-r:J.·E·~· .':.-.~..~8~5.~8

:> ~~~83~.o~[l=+·~:::-::9~1: ·+-1'7: : 8~9;~ ·:•~ ir:'~: 6.:. ;: .; .·
.;;.
.. _..;;
.. .• _.; .1' -+1·7: :72,:-:•;:·:~· i+:r•;: 21: ;:f.~ ··~mmr::~:-:::-··_.;;.-+. "":!El:6~s6~8~=:~&;-J-+IT~.·~6~ 3:-;.'*3:-'";.; :.,•, , .; . ; . J.J'ir: -:1·~ ;. ;·:; .~
_.;;.-+1%.::7"¥::-5'.-::1:!5% ...
• .;;;:
.•. 1_.;;. •. !.;;.···+':7::"::-':····.;;;':......:...t'
.

·6800 .
6900 88.4 85.5 83.3 81.3 79.7 77.8 74.3 74.2 70.6 68.8 65.2 63.6 60.1

7100 90.9 87.9 85.7 83.7 82.0 80.0 76.5 76.4 72.7 70.8 67.1 65.5 61.8
71.8::''::

7300 93.5 90.4 88.2 86.0 84.3 82.3 78.6 78.5 74.7 72.8 69.0 67.3 63.6

79.6 . 175.7_ :: 73.8

7500 96.1 92.9 90.6 88.4 86.6 84.5 80.8 80.7 76.7 74.8 70.9 69.2 65.3
h7600.
7700 98.6 95.4 93.0 90.7 88.9 86.8 82.9 82.8 78.8 76.8 72.8 71.0 67.1
83.9./ . 79.8.
7900 101.2 97.9 95.4 93.1 91.3 89.0 85.1 85.0 80.8 78.8 74.7 72.8 68.8

8100 103.7 100.3 97.8 95.4 93.6 91.3 87.2 87.1 82.9 80.8 76.6 74.7 70.5
•8200 .: •_101.6 'i 71.4 •.. ;
8300 106.3 102.8 100.2 97.8 95.9 93.5 89.4 89.3 84.9 82.8 78.4 76.5 72.3
104.() ... ;; JQf:
8500 108.9 105.3 102.7 100.2 98.2 95.8 91.6 91.4 87.0 84.8 80.3 78.4 74.0

102.5 100.5 98.1 93.7 93.6 89.0 86.8 82.2 80.2 78.5

104.9 102.8 100.3 95.9 95.7 91.1 88.8 84.1 82.1 77.5

9100 116.5 112.7 109.9 107.2 105.1 102.6 98.0 97.9 93.1 90.8 86.0 83.9 79.2
9200 ··:• )106.3 .. ·. 103.7

9300 119.1 115.2 112.3 109.6 107.4 104.8 100.2 100.0 95.2 92.8 87.9 85.8 81.0
~:j ·· ... :j,10f!:~ .• 81•. 9. -~··;-
9500 121.7 117.7 114.7 111.9 109.7 107.1 102.3 102.2 97.2 94.8 89.8 87.6 82.7

[110.9
9700 124.2 120.2 117.1 114.3 112.1 109.3 104.5 104.4 99.3 96.8 91.7 89.4 84.5

9900 126.8 122.6 119.6 116.6 114.4 111.6 106.6 106.5 101.3 98.8 93.6 91.3 86.2
:;)CJP()().. . i •

10/98 8.2 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
HYVO TM Sprocket Part Numbers

HYVO Sprocket Part Numbers

TM

Top Sprockets For 3/4" HYVO TM Drive Systems

17T 3221084
18T 3221085
19T 3221086
20T 3221087
21T 3221088
22T 3221089
23T 3221090
24T 3221091
25T 3221092

HYVO ™ Drive Chain

Chain Length (Pitch) Part Number
66P 3224071
68P 3224070
70P 3224069

Bottom Sprockets For 3/4" HYVO TM Drive Systems

Standard Bottom Sprockets Reverse Sprockets
39T 3222105 40T 1341224
40T 3222094 41T 1341225
41T 3222095

Polaris Industries Inc. 8.3 10/98

BRAKES/FINAL DRIVE
Sprocket I Chain Combinations
Sprocket I Chain Combinations - 6 5/8" Chain Case
Acceptable gearing I chain combinations are listed below for the 6.625" (center distance) chaincase. Do not use
this chart for models with 7.05" chaincase Refer to page 8.5 for 7.05" chaincase. Refer to Specifications section
of chapter 1 for chaincase center distance by mode. Combinations listed as "not recommended" should not be
installed.
Upper Sprocket Lower Sprocket Chain Length
(#of Teeth} (#of Teeth} (6.625 Chain Case)
16 35 62
16 37 64 NOT RECOMMENDED
16 39 64
16 40 66 NOT RECOMMENDED
16 41 66
17 35 62
17 37 64
17 39 64
17 40 66 NOT RECOMMENDED
17 41 66
18 35 64 NOT RECOMMENDED
18 37 64
18 39 66 NOT RECOMMENDED
18 40 66
18 41 66
19 35 64 NOT RECOMMENDED
19 37 64
19 39 66
19 40 66
19 41 66
20 35 64
20 37 66 NOT RECOMMENDED
20 39 66
20 40 66
20 41 68 NOT RECOMMENDED
21 35 64
21 37 66 NOT RECOMMENDED
21 39 66
21 40 68 NOT RECOMMENDED
21 41 68
22 35 64
22 37 66
22 39 68 NOT RECOMMENDED
22 40 68
22 41 68
23 35 66 NOT RECOMMENDED
23 37 66
23 39 68 NOT RECOMMENDED
23 40 68
23 41 68
24 39 68
24 40 68
24 41 70 NOT RECOMMENDED
25 39 68
25 40 70 NOT RECOMMENDED
25 41 70 NOT RECOMMENDED

10/98 8.4 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Sprocket I Chain Combinations
Sprocket I Chain Combinations- 7.05" Center Distance Chain Case
Acceptable gearing I chain combinations are listed below for the 7.05" (center distance) chaincase. Refer to
Specifications section of chapter 1 for chaincase center distance by model. Combinations listed as "not recom-
mended" should not be installed. Refer to page 8.4 for 6 5/8" (center distance) chaincase gearing/chain recom-
mendations.

Upper Sprocket Lower Sprocket Chain Length

(#of Teeth) (#of Teeth)
16 35 64
16 37 66 NOT RECOMMENDED
16 39 66
16 40 68 NOT RECOMMENDED
16 41 68
17 35 64 NOT RECOMMENDED
17 37 66
17 39 68 NOT RECOMMENDED
17 40 68
17 41 68
18 35 66 NOT RECOMMENDED
18 37 66
18 39 68 NOT RECOMMENDED
18 40 68
18 41 68
19 35 66
19 37 66 NOT RECOMMENDED
19 39 68
19 40 68
19 41 70 NOT RECOMMENDED
20 35 66
20 37 68 NOT RECOMMENDED
20 39 68
20 40 70 NOT RECOMMENDED
20 41 70 NOT RECOMMENDED
21 35 66
21 37 68
21 39 70 NOT RECOMMENDED
21 40 70 NOT RECOMMENDED
21 41 70
22 35 68 NOT RECOMMENDED
22 37 68
22 39 70 NOT RECOMMENDED
22 40 70
22 41 70
23 35 68
23 37 68
23 39 70
23 40 70
23 41 70 NOT RECOMMENDED
24 39 70
24 40 70
24 41 72 NOT RECOMMENDED
25 39 70
25 40 72 NOT RECOMMENDED
25 41 72

Polaris Industries Inc. 8.5 10/98

BRAKES/FINAL DRIVE
Specifications

1999 Track Drive Data

Model No. of Drive Drive Shaft Drive DRIVE SPROCKET POSITION
Drive Type Bearing Sprocket Reference Page 8.7
Sprockets Lock Diameter A 8 c D

Indy 340 2 3* Pressed 6.94 7.48 12.32 All 1999 models,

Indy 340 Deluxe 2 3* Pressed 6.94 7.48 12.32 sprocket positions
are measured to
Indy 340 Touring 2 3* Pressed 6.94 7.48 12.32 sprocket hub and
Indy Sport 2 3* Pressed 6.94 7.48 12.32 not idler center. See
Indy Sport Touring 2 3* Pressed 6.94 7.48 12.32 page 8.7.
Indy TranSport 2 3* Pressed 6.94 7.48 12.32
Indy XCF 2 3* Pressed 6.94 7.48 12.32
Indy XCR 440 2-wide 3* Pressed 6.94 6.95 11.79
Indy Trail 2 3* Pressed 6.94 7.48 12.32
Indy Trail Touring 2 3* Pressed 6.94 7.48 12.32
Indy Trail RMK 2 3* Pressed 6.94 7.48 12.32
Indy Supersport 2 3* Pressed 6.94 7.48 12.32
Indy 500 2 3* Pressed 6.94 7.48 12.32
Indy Classic 2 3* Pressed 6.94 7.48 12.32
Indy 500 RMK 2 3* Pressed 6.94 7.48 12.32
Indy Classic Touring 2 3* Pressed 6.94 7.48 12.32
Indy XLT Special 2-wide 3* Pressed 6.94 6.95 11.79
Indy XLT Classic 2-wide 3* Pressed 6.94 6.95 11.79
Indy XLT Touring 4 3* Pressed 6.94 4.35 7.48 12.32 16.32
Indy 500 XC/SP 2 (wide) 3* Pressed 6.94 6.95 11.79
Indy 600 XC/SP 2 (wide) 3* Pressed 6.94 6.95 11.79
Indy 700 XC/SP 2 (wide) 3* Pressed 6.94 6.95 11.79
Indy 600 RMK 2 (wide) 3* Pressed 6.94 6.95 11.79
Indy 700 RMK 2 (wide) 3* Pressed 6.94 6.95 11.79
Indy 700 SKS 2 (wide) 3* Pressed 6.94 6.95 11.79
Indy 700 XCR 4 3* Pressed 6.94 4.35 7.48 12.32 16.32
Indy 800 XCR 4 3* Pressed 6.94 4.35 7.48 12.32 16.32
Indy Widetrak LX 4-w'trak 4* Pressed 6.94 1.26 4.41 15.97 17.47
* Denotes driveshafts with press-fit bearings on left side (no lock collar) and flangette studs (welded).

10/98 8.6 Polaris Industries Inc.

 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 splined end of the shaft.

• 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.

• For measurements shown below (A-D) see page 8.6.

~ Direction of press of shaft

~ Direction of press of shaft

Logo Orientation
~---~- s-~---l

• - -A~

Use straight edge against

sprocket hub
~
Square
2 Drive Sprocket
4 Drive Sprocket

~ Direction of press of shaft

r-----s--------~

Left Side
Coupler
2 Drive Sprocket - Wide WideTrak LX

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 coupler as shown.

Polaris Industries Inc. 8.7 10/98

BRAKES/FINAL DRIVE
Track Specifications

1999 Track
Model Length x Width Pattern Lug Wheels
Height Bogie/
Idler
Indy 340/340 Deluxe 121 X 15" Block .66" 4/2
Indy 340 Touring 133.5 X 15" Lightning .82" 6/3
Indy Sport 121 X 15" Block .71" 4/2
Indy Sport Touring 133.5 X 15" Lightning .82" 6/3
Indy TranSport 141 X 15" Wiper 1.125" 8/3
Indy XCF 121 X 15" New Yokohama .82" 6/4
Indy Super Sport 121 X 15" Lightning .82" 6/3
Indy 440 XCR 121 X 15" Lightning .82" 6/4
Indy WideTrak LX 156 X 20" Shockwave 1.00" 8/4
Indy Trail 121 X 15" Lightning .82" 6/3
Indy Trail Touring 133.5 X 15" Lightning .82" 6/3
Indy Trail RMK 136 X 15" Deep Lug 1.25" 4/3
Indy 500 121 X 15" Lightning .82" 6/3
Indy 500 RMK 133.5 X 15" Deep Lug 1.25" 4/3
Indy 500 Classic 121 X 15" Lightning .82" 6/3
Indy Classic Touring 133.5 X 15" Lightning .82" 6/3
Indy 500 XC/SP 121 X 15" Shockwave .82" 6/4
Indy XLT Classic 121 X 15" Shockwave .82" 6/3
Indy XLTSpecial 121 X 15" Shockwave .82" 6/4
Indy XLT Touring 133.5 X 15" Lightning .82" 6/3
Indy 600 XC/SP 121 X 15" Shockwave .91" 6/4
Indy 600 RMK 1.75" Track 136 X 15" Deep Lug 1.75" 4/3
Indy 600 RMK 2.00" Track 136 X 15" Deep Lug 2.00" 4/3
Indy 700 XC/SP 121 X 15" Shockwave .91" 6/4
Indy 700 SKS 136x15" Deep Lug 1.25" 6/3
Indy 700 RMK 1.75" Track 136 X 15" Deep Lug 1.75" 4/3
Indy 700 RMK 2.00" Track 136 X 15" Deep Lug 2.00" 4/3
Indy 700 XCR 121 X 15" Shockwave .91" 6/4
Indy 800 XCR 121 X 15" Shockwave .91" 6/4

10/98 8.8 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Hydraulic Brake System Operation

End
View
A
\:f)
E

0-----
The Polaris snowmobile hydraulic brake system consists of the following components or assemblies: brake lever,
master cylinder, hydraulic hose, brake caliper (slave cylinder), brake pads, and a brake disc which is secured to
the drive line.

When the hand activated brake lever (A) is applied, it contacts a piston (B) within the master cylinder. As the
master cylinder piston moves inward it closes a small opening called a compensating port (C) within the cylinder
and starts to build pressure within the brake system. As the pressure within the system is increased, the piston (D)
located in the brake caliper moves outward and applies pressure to the moveable brake pad. This pad contacts
the brake disc, moves the caliper in its floating bracket and pulls the stationary pad into the brake disc. As the lever
pressure is increased, the braking effect is increased.

The friction applied to the brake pads will cause the pads to wear. As the pads wear, the piston within the caliper
self-adjusts and moves further outward.

Brake fluid level is critical to proper system operation. A low fluid level allows air to enter the system causing the
brakestofeelspong~
Compensating Port
Located within the master cylinder is a small compensating port (C) which is opened and closed by the master
cylinder piston assembly. The port is open when the brake lever is released and the piston is outward. As the
temperature within the hydraulic system changes, this port compensates for fluid expansion caused by heat, or
contraction caused by cooling. During system service, be sure this port is open. Due to the high temperatures
created within the system during heavy braking, it is very important that the master cylinder reservoir have
adequate space to allow for the brake fluid to expand. Master cylinder reservoirs should be filled to the top of the
fluid level mark on the inside of the reservoir, 1/4"- 5/16" (.6- .8 em) below lip of reservoir opening.

A WARNING

Never overfill the reservoir. This could alter brake function, resulting in system component damage or sever
personal injury or death.
This system also incorporates a diaphragm (E) as part of the cover gasket and a vent port (F) located between the
gasket and the cover. The combination diaphragm and vent allow for the air above the fluid to equalize pressure
as the fluid expands or contracts. Be sure the vent is open and allowed to function. If the reservoir is overfilled or
the diaphragm vent is plugged, the expanding fluid may build pressure in the brake system and lead to brake
failure.

Polaris Industries Inc. 8.9 10/98

BRAKES/FINAL DRIVE
Type 3 Master Cylinder
Type 3 Master Cylinder

1. Cover Screw
2. Cover
3. Cover Gasket
4. Cylinder Housing
5. Brake Lever Bushing
6. Brake Lever
7. Park Lever Return Spring
8. Pivot Bolt Nut
9. Park Lever
10. Park Lever Pivot Bolt
11. Park Lever Pivot Bushing
12. Spring Seat Washer
13. Compression Spring
14. U-Pack Seal
15. Piston
16. 0-Ring Seal
17. Clamp Bolt Optional
18. Attaching Clamp 0
at customer PARK BRAKE
19. Lever Pivot Bolt request LOCK
RELEASE BEFORE
20. Baffle DRIVING OR BRAKE
SYSTEM FAILURE
21. Baffle Washer OR FIRE MAY
RESULT. APPLY
BRAKE LEVER
TO RELEASE.

Park Brake Lever Lock

A WARNING

Release park brake lock before driving or brake sys-

tem failure or fire may result. Apply brake lever to re-
lease.
Type 3 Master Cylinder Removal

1. Position clean shop cloths to catch spilled fluid and remove brake hose.

Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces.
2. Remove brake clamp attaching bolts (Item 17).
3. Remove park brake lever (Item 9) and brake master cylinder lever (Item 6), noting position of bushing, spring,
etc., for proper reassembly.
4. Using the master cylinder service tool, position push rod
through small hole in spring seat washer (Item 12) as
shown. Remove piston assembly, spring and washer.

Mast~r Cyli~d~~ Service Tool Kit

PN 2870962 .
..'-/ '

10/98 8.10 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type 3 Master Cylinder Inspection and Assembly
Inspection
NOTE: Due to the critical nature of these parts and pro-
cedures, be sure you have thoroughly read and under-
stand Hydraulic Brake Operation, page 8.9.
1. Thoroughly clean all brake parts with isopropyl
alcohol. Inspect piston for wear, scratches, or
corrosion. Check master cylinder bore for
scratches, score marks, or corrosion and replace
any worn or damaged parts.

Assembly
1. Always replace 0-Ring seal, U-pack seal and
cover gasket (diaphragm) upon reassembly. Use
only genuine Polaris service parts.
2. Apply clean DOT 3 brake fluid on piston, piston
seals and cylinder bore. Install seals onto piston
positioning U-pack seal lip (A) towards spring.
Snap spring into place on piston.

Polaris DOT 3 Brake Fluid.:

PN 2870990
..

3. Install piston assembly into master cylinder service

tool until U-pack seal is covered by tool as shown.
NOTE: This tool is used to guide the seal lip into the
cylinder bore without damage.

Polaris Industries Inc. 8.11 10/98

BRAKES/FINAL DRIVE
Type 3 Master Cylinder Assembly
Assembly, 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 nut.
6. Reinstall master cylinder onto handlebar and
reconnect brake line. Partially insert fittings (one to
two threads) and apply Loctite™ 242 to remaining
threads of fittings. Torque brake line fittings to
specification.

Brake Line Fitting Torque -

Master Cylinder End - Finger tight

plus 2 turns

Caliper End -
12-14 ft. lbs. (1.66 -1.93 kg-m)

7. Adjust master cylinder to a level position on

handlebar. Torque clamp screws to specification.

Master Cylinder Clamp Torque -

45-55 in.lbs. (.52- .63 kg-m)

8. Bleed brake system. Maintain fluid level in

reservoir at 1/4"- 5/16" (.6- .8 em) below lip of
reservoir opening while bleeding brakes. Do not
allow air into system while bleeding. See bleeding
procedure on page 8.14.

Master Cylinder Fluid Level

1/4"'- 5/16" (.6- .8 em) below

top of master cylinder

10/98 8.12 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type 3 Master Cylinder Assembly

Assembly, Cont.
9. Field test machine before putting into service.
Check for proper braking action and lever reserve.
With lever firmly applied, lever reserve should be
no less than 1/2" (1.3 em) from handlebar.

Brake Lever Reserve Limit

Not less than 1/2" (1.3 em)

from handlebar

10. Check brake system for fluid leaks.

Polaris Industries Inc. 8.13 10/98

BRAKES/FINAL DRIVE
Brake Bleeding - Fluid Change

Brake Bleeding - Fluid Change

This procedure should be used to change fluid or bleed brakes during regular maintenance, or after complete
brake service. Brake fluid may damage painted or plastic surfaces. Take care not to spill, and wipe up any spills
immediately. Cover parts to avoid damage.
1. Clean reservoir cover thoroughly.
2. Remove screws, cover, and diaphragm from c
reservoir.
3. Inspect vent slots (A) in cover and remove any
debris or blockage.
4. If changing fluid, remove fluid from reservoir with a
Mity Vac™ pump or similar tool.
NOTE: Do not remove brake lever when reservoir fluid
level is low. D

5. Add brake fluid to within 1/4-5/16" (.6-.8 em) of

reservoir top.

6. lnstall.a box end wrench on caliper bleeder screw fitting. Attach a clean, clear hose to fitting and place the
other end in a clean container. Be sure the hose fits tightly on fitting.
NOTE: Fluid may be forced from compensation port (B) when brake lever is pumped. Place diaphragm (C) in
reservoir to prevent spills. Do not install cover.
7. Slowly pump lever (D) until pressure builds and holds.
8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. Do not
release lever before bleeder screw .is tight or air may be drawn into caliper.
9. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as
necessary to maintain level in reservoir.

Maintain at least 1/2" (1.27 em) 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.

10/98 8.14 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Brake Bleeding- System Rebuild

Brake Bleeding - Fluid Change, Cont.

13. Field test machine before putting into service. Check for proper braking action and lever reserve. With lever
firmly applied, lever reserve should be no less than 1/2" (1.3 em) from handlebar.

No Closer Than
1/2" (1.3 em)

14. Check brake system for fluid leaks.

Polaris Industries Inc. 8.15 10/98

BRAKES/FINAL DRIVE
Hayes Master Cylinder
TM

Hayes ™ Master Cylinder

The Hayes'" brake is standard on all 1999 Gen II snowmobiles except for Widetrak LX and TranSport.
1. Cover Screw Kit
2. Cover Asm. Kit (Incl. 1,3) 2
3. Cover Gasket
4. Parking Lever Spring
5. Master Cylinder Assembly
3
6. Screw
7. Lever and Pivot Pin Kit
8. Screw
9. Body/Reservoir Clamp Kit 14
10. Brakelight Switch
11. Cartridge Kit
12. LH Control Asm 12
13. Pivot Pin Kit
14. Parking Lever and Spring Kit 5

Park Brake Lever Lock

A WARNING

Release park brake lock before driving or brake sys-

tem failure or fire may result. Apply brake lever to re-
lease.
Hayes ™ Master Cylinder Removal

1. Position clean shop cloths to catch spilled fluid.

Brake fluid will damage finished surfaces. Do not allow brake

fluid to come in contact with finished surfaces.
2. Remove the handlebar protector pad from the outlet end
of the handlebar master cylinder to access the brake fluid
line connector.
•Remove handlebar cover strips
•Remove two screws
•Remove holding clip in front of cover
•Remove handlebar pad
3. Loosen the connector approximately 1/4 to 1/2 turn.
4. Loosen and remove the four switch pack and handlebar
master cylinder mounting screws. Put screws aside for
later installation.

10/98 8.16 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Hayes TM Master Cylinder Inspection and Replacing Cartridge Subassembly
5. Remove master cylinder from switch pack and
handlebar.

Remove switch pack wires from the master cylinder

housing with extreme care and note where they are
routed for later installation.
6. Remove master cylinder cover screws and cover.
Pour out the fluid in the resrevoir into a container.
Unscrew the brake fluid line from the master
cylinder outlet using a shop cloth to catch the
remaining fluid. Drain the fluid from the brake line
into the aforementioned container and discard the
fluid.
Inspection
NOTE: Due to the critical nature of these parts and pro-
cedures, be sure you have thoroughly read and under-
stand Hydraulic Brake Operation, page 8.9.
1. Thoroughly clean all brake parts with isopropyl
alcohol and either wipe dry with a clean lint free
cloth or lightly blow dry with an air hose. Examine
all parts carefully for signs of excessive wear,
damage, or corrosion. Replace any parts found to
be damaged. Check park lever spring for
breakage.

Replacing Cartridge Subassembly

1. Remove master cylinder assembly as described
previously.
2. To remove the lever from the housing, squeeze the
lever handle and actuate the parking brake lever
enough distance for the head of the pivot pin to
clear the park brake lever.

3. Squeeze the two spring tabs on the end of the pivot

pin at the same time pushing the pivot pin up
throught the hole. Remove the pivot pin and the
lever.

Polaris Industries Inc. 8.17 10/98

BRAKES/FINAL DRIVE
Hayes Master Cylinder Inspection and Replacing Cartridge Subassembly
1M

4. Lift the housing tab on the outlet end of the housing

to release the cartridge assembly, allowing the
cartridge to be pushed out the back of the housing.

5. Clean housing bore with alcohol. Inspect bore for

scratches, dents, cuts, or digs that might cause a
leak. Replace housing if severe damage is found.

6. Paint housing bore and cartridge o-rings with

D.O.T. 3 brake fluid.

Polaris DOT 3 Brake Fluid

PN 2870990

7. Align slots in cartridge with tabs in housing bore

and insert cartridge. Push cartridge through until
outlet end of cartridge snaps into place.

10/98 8.18 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Hayes"" Master Cylinder Inspection and Replacing Cartridge Subassembly
8. Install the lever and pivot pin by actuating the
parking brake lever enough distance for the head of
the pivot pin to clear the park brake lever.

9. Align the lever pivot hole with the housing pivot

hole. Squeeze the two spring tabs on the end of the
pivot pin at the same time pushing the pivot pin
down through the pivot hole until the pivot pin snaps
into place.

10. Apply thread sealant, install brake line and tighten

snug.

11. Mount the master cylinder and switch pack to the

handlebars making sure the wires are not pinched
or twisted.
NOTE: Start all four screws prior to tightening. Tighten
tip two screws first, followed by bottom two. Do not
over tighten. This will create a gap approximately
.050-.1 00" between LH control and master cylinder at
the bottom of the assembly. There should not be a gap
at the top when correct tightening/torque sequence
has been followed. Torque to 24-28 in.lbs.(.27-.32
kg-m).

Master Cylinder Control Torque -

24-28 in. lb. (27-32 kg-m)

Polaris Industries Inc. 8.19 10/98

BRAKES/FINAL DRIVE
Hayes Master Cylinder Inspection and Replacing Cartridge Subassembly
TM

12. Tighten brake line connector at outlet to 1 ft.lb. plus

two turns.

Brake Line Torque -

1 ft. lb. (.14 kg-m) plus 2 turns

13. Fill reservoir with clean D.O.T. 3 brake fluid.

Polaris DOT 3 Brake Fluid

PN 2870990

14. Bleed brakes as outlined on pages 8.14 and 8.15.

Check entire systemfor leaks and fill reservoir to
fluid level line.

15. Install master cylinder reservoir cover and gasket.

Torque screws to 15-18 in.lbs. (.17-.20 kg-m.)

Cover Screw Torque -

15-18 in. lb. (.17-.20 kg-:m) ·

10/98 8.20 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Hayes TM Master Cylinder Lever and/or Pivot Pin Replacement
Lever and/or Pivot Pin Removal
1. For ease of service, remove master cylinder
assembly as outlined on pages 8.17 and 8.18.

2. Squeeze the lever handle and actuate the parking

brake lever enough distance for the head of the
pivot pin to clear the park brake lever.

3. Squeeze the two spring tabs on the end of the pivot

pin at the same time pushing the pivot pin up
through the hole.

4. Remove the pivot pin and the lever.

Polaris Industries Inc. 8.21 10/98

BRAKES/FINAL DRIVE
Hayes ™ Master Cylinder Lever and/or Pivot Pin Replacement
Lever and/or Pivot Pin Installation
1. Install the new lever by actuating the parking brake
lever enough distance for the head of the pivot pin
to clear the park brake lever.

2. Align the lever pivot hole with the housing pivot

hole.

3. Squeeze the two spring tabs on the end of the pivot

pin at the same time pushing the pivot pin down
through the hole until the pivot pin snaps into place.

4. Reinstall master cylinder assembly.

10/98 8.22 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Hayes 1M Master Cylinder Park Brake Lever and/or Spring Replacement
Park Brake Lever and/or Spring Removal
1. Remove master cylinder cover screws and cover.

Brake fluid will damage finished surfaces. Do not allow

brake fluid to come in contact with finished surfaces.

2. Using a small screwdriver, lift long spring arm out of

its notch in the housing.

3. While pulling in an upward direction with the brake

lever slightly activated, gently wiggle the park
brake lever and spring from its pivot hole.

Park Brake Lever and/or Spring Installation

1. Place the spring on the upper pivot post of the park

lever with the formed spring arm fit into its position
on the outer part of the park lever. The straight
spring arm will be pointing towards the back.

Polaris Industries Inc. 8.23 10/98

BRAKES/FINAL DRIVE
Hayes Master Cylinder Park Brake Lever and/or Spring Replacement
TM

2. Rotate the straight spring arm counterclockwise

while tilting the park lever down and inserting the
pivot post into the pivot hole.

3. Release the straight arm of the spring and push the

park lever pivot post down into position.

4. With a small screwdriver, push the straight spring

arm down until it snaps into the notch in the
housing.

5. Fill reservoir. Replace the master cylinder cover

and screws. Torque screws to 15-18 in.lbs.
(.17-.20 kg-m).

Cover Screw Torque -

15-18 in. lb. (.17-.20 kg-m)

10/98 8.24 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type H4 Brake System
The Type H4 system is a hydraulic brake. The caliper assembly is mounted on the chaincase, which allows ease
of brake pad and caliper service. Measure brake pads from the back of the backing plate to the surface of the
friction material as shown in illustration.

NOTE: Replace pads when worn beyond service limit.

Minimum Pad
Thickness
.250"
(6.35mm)
Type H4 Friction Pad Replacement
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
11. Rope Guide

A"WARNING

The rider's safety depends on cor- 2

rect installation. Follow proce-
dures carefully.

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 washers from bracket. Remove rope guide. NOTE: Do not
disconnect brake line.
3. Lift bracket and brake assembly off vehicle. Remove all dirt from caliper assembly using brake cleaner and
clean shop cloths.
4. Use a drop cloth to protect surfaces from brake fluid spillage. Remove reservoir cover from master cylinder
assembly. Using a large hardwood dowel, or a C clamp vise grip on the center of the old pads, apply pressure
toward the caliper piston. Compress piston back into caliper assembly. Apply pressure slowly to prevent
excessive spillage from master cylinder assembly.
NOTE: Pushing the piston back into the bore will cause the fluid level to rise in the reservoir and possibly overflow.
Remove excess fluid and discard.

Piston must not be forced back into the caliper at an angle or bore damage may occur.

5. Slide caliper and brake pads out of bracket. Discard old pads and clips.
NOTE: Pad and holders must be replaced as a set.

Polaris Industries Inc. 8.25 10/98

BRAKES/FINAL DRIVE
Type 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 8.25.
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 caliper. Caliper assembly must fit freely onto disc and
chaincase.
10. Replace 3/8 bolts, washers, and rope guide. Torque to specification.

11. Actuate brake several times to set brake pads to proper operating position.
12. Check for proper fluid level in master cylinder and replace cover Torque cover bolts to specification.

13. Inspect entire system for leaks and repair if necessary.

14. Field test at low speeds and verify proper brake action. If pads drag on disc, check caliper and pad assembly.

10/98 8.26 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type H4 Brake System
Type H4 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
11. Rope Guide

A WARNING

The rider's safety depends on cor-

rect installation. Follow proce-
dures carefully.

Refer to the exploded view above while performing the following steps.
1. Remove bracket bolts.
2. Disconnect brake line. Drain brake fluid into appropriate container and dispose of properly.
3. Disassemble on a clean bench.
4. Open bleeder screw and drain brake fluid from caliper assembly into appropriate container. Dispose of
properly.

Protect eyes from brake fluid at all times.

5. Slide brake assembly out of bracket and remove old pads and clips.
6. Place caliper on bench with piston down.
7. Remove piston from caliper using a caliper piston pliers (commercially available) or by covering the piston with
a shop cloth and applying compressed air to the hydraulic 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.

To avoid scratching bore or burring edge of seal groove, do not use a metal tool such as a screwdriver.
9. Discard old seal.

Polaris Industries Inc. 8.27 10/98

BRAKES/FINAL DRIVE
Type H4 Brake System

Type H4 Cleaning and Inspection

Check all parts for wear or damage and replace as required. Always replace caliper piston seal and dust seal
(where applicable).
1. Clean all parts with denatured alcohol and wipe dry with a clean, lint free cloth.

2. Using compressed air, blow out the drilled passages and piston bore. Be sure piston seal groove is thoroughly
clean and free from corrosion or brake fluid build up.

3. Inspect piston bore for scoring, pitting or corrosion. A corroded or deeply scored casting should be replaced.
Light scores and stains may be removed by polishing with a crocus cloth only. Use finger pressure and rotate
the crocus cloth in the cylinder bore. Do not slide the cloth in and out of the bore under pressure. Do not use
any other kind of abrasive cloth.
4. Check piston to see if it is pitted, scored or worn. If so, discard and replace the piston.

Do not attempt to polish or sand piston.

5. Clean piston with denatured alcohol and wipe dry with a clean, lint free cloth. Using compressed air, blow dry.
6. Check inlet and bleeder hole threads for damage. Be sure bleeder screw is clear.

7. Inspect brake line seat for damage and replace caliper if necessary.

Type H4 Assembly

1. Reassemble by reversing disassembly process. Be sure all parts are clean and serviceable before
reassembling the unit.
2. Coat a new piston seal in clean DOT 3 brake fluid and place in groove in the caliper piston bore. Seal should be
positioned at one point in groove and then gently worked around the groove by hand until properly seated.

Never reuse an old seal.

3. Coat piston thoroughly with brake fluid and work down into bore carefully with a rotating motion until bottomed.

Apply even pressure to avoid cocking the piston in the bore.

10/98 8.28 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type H4 Brake System

Type H4 Assembly, Cont.

1. 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.
2. Connect hose or line to caliper.
3. Place new pads with friction material facing each other into housing. Hold in place using clips.
4. Slide brake assembly into bracket until both clips snap into grooves in bracket.
5. Separate pads for installation over disc.
6. Place brake assembly over disc and push bracket into chaincase.
7. Replace 3/8" bolts, rope guide, and washers. Torque to specification.

8. Perform brake bleeding procedure as outlined after System Rebuild, page 8.14-8.15.

Polaris Industries Inc. 8.29 10/98

BRAKES/FINAL DRIVE
Type HSLC Brake System
The Type H5LC system, like the Type H4, is a top mounted hydraulic brake system. The difference between the
two systems is the the H5LC is equipped with a brake cooler.

Type HSLC Friction Pad Replacement

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 2
10. Caliper (Liquid Cooled)
11. Rope Guide
12. Water Cooler Manifold
13. Screws (Cooler Manifold)

A WARNING

The rider's safety depends on cor-

rect installation. Follow proce- 7
dures carefully.

I· CAUTiON:'·!

Protect eyes from brake fluid.

1. Clean any dirt from mount bracket and bolts.
2. With a 9/16" socket, remove two 3/8 hex bolts and washers from bracket. Remove rope guide. NOTE: Do not
disconnect brake line.
3. Remove hose clamp from engine side of cooler. Twist and remove hose from cooler, catching and disposing
of antifreeze properly.
4. Use a drop cloth to protect surfaces from brake fluid spillage. Remove reservoir cover. Using a large
hardwood dowel, or a C clamp vise grip on the center of the old pads, apply pressure toward the caliper piston.
Compress piston back into caliper assembly. Apply pressure slowly to prevent excessive spillage from
master cylinder assembly.
NOTE: Pushing the piston back into the bore will cause the fluid level to rise in the reservoir and possibly overflow.
Remove excess fluid and discard.
5. Lift bracket and brake assembly off vehicle. Raise open end of cooler and pad assembly to trap antifreeze in
cooler and plug the opening of both cooler and engine hose open end.

10/98 8.30 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type HSLC Brake System

Type HSLC Friction Pad Replacement, Cont.

6. Place new pads with friction material facing each other into housing. Hold in place using clips. See illustration
above.
7. Slide brake assembly into bracket until both clips snap into grooves in bracket.
8. Clean top of chaincase where brake mounts.
9. Separate pads for installation over disc. If brake assembly does not slide easily over the disc with loose pads
the piston is not compressed far enough into the caliper. The caliper assembly must fit freely onto the disc and
chaincase.
10. Remove plugs. Install coolant hose and clamp on cooler assembly.
11. Replace 3/8" bolts, washers, and rope guide. Torque to specification.

12. Actuate brake several times to set brake pads to proper operating position.
13. Check for proper fluid level in master cylinder and replace cover. Torque to specification.

14. Be sure to bleed coolant system as outlined in Engine section.

15. Bleed brake system as outlined on pages 8.14-8.15.
16. Field test at low speeds before putting into regular service.

Polaris Industries Inc. 8.31 10/98

BRAKES/FINAL DRIVE
Type HSLC Brake System
Type HSLC 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)
2
11. Rope Guide
12. Water Cooler Manifold
13. Screws (Cooler Manifold)

A WARNING

The rider's safety depends on cor-

rect installation. Follow proce-
dures carefully.

Refer to the exploded view above while performing the following steps.
1. Remove bracket bolts.
2. Disconnect brake line. Drain brake fluid into appropriate container and dispose of properly.
3. Disconnect and plug coolant lines, catching and disposing of antifreeze properly.
4. Disassemble on a clean bench.
5. Open bleed screw. Drain brake fluid into appropriate container and dispose of properly.

Protect eyes from brake fluid.

6. Slide brake assembly out of bracket and remove old
pads and clips.
7. Place caliper on bench with piston down.
8. 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.
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.

10/98 8.32 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type HSLC Brake System

Type HSLC Cleaning and Inspection

Check all parts for wear or damage and replace any found to be defective.

1. Clean all parts with denatured alcohol and wipe dry with a clean, lint free cloth.
2. Using compressed air, blow out the drilled passages and bores.
3. Inspect casting cylinder bore for scoring, pitting or corrosion. A corroded or deeply scored casting should be
replaced. Light scores and stains may be removed by polishing with a crocus cloth only. Use finger pressure
and rotate the crocus cloth in the cylinder bore. Do not slide the cloth in and out of the bore under pressure. Do
not use any other kind of abrasive cloth.
4. Check piston to see if it is pitted, scored or worn. If so, discard and replace the piston.

Do not attempt to polish or sand piston.

5. Clean piston with denatured alcohol and wipe dry with a clean, lint free cloth. Using compressed air, blow dry.
6. Check inlet and bleeder hole threads for damage.
7. Inspect seat insert for damage and replace if necessary.

Type HSLC Assembly

1. Reassemble by reversing disassembly process. Be sure all parts are clean and serviceable before
reassembling the unit.
2. Coat a new piston seal in clean DOT 3 brake fluid and place in groove in the caliper bore. Seal should be
positioned at one point in groove and then gently worked around the groove by hand until properly seated.

Never reuse an old seal.

3. Coat piston thoroughly with brake fluid and work down into bore by hand carefully until bottomed.

Apply even pressure to avoid cocking the piston in the bore.

4. 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 Industries Inc. 8.33 10/98

BRAKES/FINAL DRIVE
Type HSLC Brake System
Type HSLC Assembly, Cont.

10. Install coolant lines and hose clamps and tighten securely.
11. Replace 3/8" bolts, rope guide, and washers. Torque to specification .

. Caliper Bolt Torque-

< 25-30 ft. lbs. (3.45-4.14 kg-m)

12. Perform brake bleeding procedure as outlined on pages 8.14-8.15.

13. Inspect entire system for leaks.
14. Field test at low speeds before putting into regular service.

10/98 8.34 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type M3 Mechanical Brake System
The Type M3 system is the mechanical brake system used only on Indy 340 models.

1. Brake Cable and Jam Nuts

2.
3.
Bracket, Brake
Washer ~1 5
6
4. Washer, Spring Lock 18
5. Bolt, Top Mount 7 / 8
6. Bracket, Brake Top Mounting
7. Bushing
8. Nut, Bi-Lock
9. Spacer, Alignment
10. Caliper, Stationary, Cast
11. Pad, Brake
12. Puck, Moveable Brake
13. Spring, Brake Return
14. Nut
15. Bushing, Brake Arm
16. Bolt, Cable Swivel A C D
24 B 12 11
17. Clevis, LT
18. Bolt, Caliper
19. Retaining Ring
20. Brake Disc
21. Seal
22. Jackshaft
23. 0-Ring
24. Adjuster Bolt

Type M3 Brake Disassembly

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 nut and remove adjuster bolt (B).
2. Remove actuating lever (C) and return spring. Do not detach cable from lever arm.
3. Remove top mount bracket and brake assembly mounting bolts (Item 5). Remove washers (Items 3 and 4)
and alignment spacers (Item 9). Remove brake assembly. NOTE: Be prepared to catch brake pads as
assembly is lifted out.
4. Remove brake pads and inspect for wear and damage. Replace if necessary.

5. Inspect rotor disc and replace if necessary.

Polaris Industries Inc. 8.35 10/98

BRAKES/FINAL DRIVE
Type M3 Mechanical Brake System

1. Brake Cable and Jam Nuts

2.
3.
Bracket, Brake
Washer ~1 5
6
4. Washer, Spring Lock 18
5. Bolt, Top Mount
7 / 7 8
6. Bracket, Brake Top Mounting
7. Bushing
8. Nut, Bi-Lock
9. Spacer, Alignment
10. Caliper, Stationary, Cast
11. Pad, Brake
12. Puck, Moveable Brake
13. Spring, Brake Return
14. Nut
15. Bushing, Brake Arm
16. Bolt, Cable Swivel A C D
24 B 12 11
17. Clevis, LT
18. Bolt, Caliper
19. Retaining Ring
20. Brake Disc
21. Seal
22. Jackshaft
23. 0-Ring
24. Adjuster Bolt

Type M3 Assembly to Chaincase

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 chaincase. Remove rubber bands once
system is bolted into place.
2. Install alignment spacers (Item 9), washers (Items 3 and 4) and bolts (Item 5). Torque assembly to
specification.

Caliper Mounting Bolt Torque -

25~30 ft.Jbs. (3.45-4.14 kg-m) . .

3. Loosen cable sleeve jam nuts (Item 1) and adjust brake cable sleeve to its shortest position.

10/98 8.36 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type M3 Mechanical Brake System

Type M3 Brake Adjustment

A WARNING

The following step is critical for proper positioning of the actuating arm to the caliper helix shaft. Improper
positioning will result in minimal resistance and ineffective brakes.
4. With brake lever bottomed on handlebar (as if brakes were applied) and helix shaft (D) bottomed in caliper,
install actuating arm, jam nut locking tab, jam nut and adjuster bolt. Release brake arm slightly to index lever
for installation on helix shaft.
5. Insert a .015" (.04 em) feeler gauge between brake disc and moveable brake pad. Release brake lever. Install
return spring (Item 13) and finger tighten bolt (Item 24). Set adjuster bolt jam nut, bend locking tab and remove
feeler gauge.

Friction Pad Air Gap -

.015" (.38 mm}

6. Field test machine for proper braking action before putting into service. If braking action is soft, re-index helix
shaft and repeat steps 3. - 6.

Polaris Industries Inc. 8.37 10/98

BRAKES/FINAL DRIVE
Type WT Mechanical Brake System
The Type WT system is the mechanical brake system used only on Indy WideTrak models.

1. Brake Cable and Jam Nuts

2.
3.
Bracket, Brake Cable
Washer
5----f
4. Washer, Spring Lock 4----4
l 2
5. Bolt, Top Mount 3-
-----
6. Bracket, Brake Top Mounting
7. Bushing
8. Nut, Bi-Lock
9. Adjuster Bolt
1 0. Caliper, Stationary, Cast
11. Pad, Brake
12. Puck, Moveable Brake
13. Spring, Brake Return
14. Nut
15. Bushing, Brake Arm
16. Bolt, Cable Swivel
17. Clevis, LT
18. Bolt, Caliper
10 11 12 20
19. Brake Disc
21. Seal
20. Caliper (Moveable Puck)
21. Transmission

Type WT Brake Disassembly

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 nut and remove adjuster bolt (B).
2. Remove actuating lever (C) and return spring. Do not disconnect lever arm from cable.
3. Remove caliper bolts, spacers, bracket nuts {Items 1, 2, 7, & 8). Remove stationary caliper casting and
stationary pad (Items 10 & 11).
4. Remove top mounting bolts and washers {Items 3, 4, & 5). Pull outward on disc with the balance of the caliper
assembly. Once disc is free of shaft separate components.
5. Remove brake pads and inspect for wear and damage. Replace if necessary. If stationary pad {Item 11) is
stuck to stationary casting, tap on the side of the pad with a punch and hammer to break it loose.
6. Inspect rotor disc and replace if necessary.

10/98 8.38 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type WT Mechanical Brake System

Type WT Assembly and Installation to

Transmission
1. Clip moveable brake pad into position under
holder clip. Hold moveable and stationary
pads in place with a rubber band while placing
assembly over rotor disc and mounting to
transmission. Remove rubber bands once
system is bolted into place.
2. Apply a light coating of RTV silicone to
transmission shaft. Position moveable caliper
pad assembly along with mounting bracket
(Item 6) and brake disc onto transmission as a
unit. Slide disc fully over shaft.
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.

Caliper Bolt Torque

8 ft.lbs~ (1.10 kg-m)

,, ,',.j_!,

Type WT Adjustment
1. Loosen cable sleeve jam nuts (Item 1) and adjust brake cable sleeve to its shortest position.

A 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 (D) bottomed in caliper,
install actuating arm, jam nut locking tab, jam nut and adjuster bolt. Release brake arm slightly to index lever
for installation on helix shaft.
3. Insert a .015" (.04 em) feeler gauge between brake disc and moveable brake pad. Release brake lever. Install
return spring (Item 13) and finger tighten bolt (Item 9). Set adjuster bolt jam nut, bend locking tab and remove
feeler gauge.

Friction Pad Air Gap -

.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.

Polaris Industries Inc. 8.39 10/98

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 of a right side mounted
chaincase with right side mounted brake assembly.

Rear Suspension Removal

1. Mark hood hinges for ease of alignment when

reassembling. Remove hood (to prevent
damage), air silencer, exhaust system and
battery, if so equipped. Place drip pan under
chaincase and remove drain plug. Dispose of
used chaincase oil properly.
2. Turn fuel valve off.
3. Remove drive belt and driven clutch. Note
position of washers for controlling drive to driven
offset (A) and washers to control clutch free
floating (B).

4. Loosen jackshaft bearing lock set screws (if

equipped).
NOTE: Some models are equipped with set screw or
Skwez-loc"' style jackshaft bearings. Some models
are equipped with press-fit bearings which have no
locking device.

Set Screw Bearing Press On Bearing

Skwez-loc™ Bearing

5. Remove two upper flangette attaching bolts.

10/98 8.40 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type 3 Drive System
Rear Suspension Removal, Cont.
6. Remove three bolts, nuts, and washers securing angle
drive and bearing flangettes. Remove and discard
adaptor key.
7. 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: Unhook the rear torsion springs to relieve pressure
on the torque arm for ease of removal. Loosen rear shaft
bolts and adjuster bolts, slide rear shaft forward for ease
of removal.

Chaincase Removal
1. Remove third jackshaft flangette attaching bolt.
Tip machine back to upright and support rear with jack-
stand.

2. Remove chaincase cover attaching bolts and remove

cover.
3. Remove cotter pin and nut.
4. Loosen chain adjustment bolt and remove chain
tensioner assembly.
5. Remove bottom sprocket attaching bolt, chain and
sprockets.
6. Remove two bolts securing caliper carrier bracket to
chaincase.
NOTE: Inspect brake pad condition and replace if worn to
less than 1/2 the original thickness. See Brake Pad Re-
placement in this chapter.

7. Remove three chaincase to bulkhead attaching nuts

and bolts. The front bolt is a through bolt, rear and
bottom bolts are carriage bolts.
NOTE: On some machines it may be necessary to remove
the rear exhaust bracket prior to lifting chaincase or remov-
ing drive shaft assembly.

Polaris Industries Inc. 8.41 10/98

BRAKES/FINAL DRIVE
Type 3 Drive System
Chaincase Removal, Cont.

8. Tap on end of driveshaft with a soft face hammer and

slide the chaincase off of the driveshaft. Remove
chaincase.

Chaincase Bearing Removal

1. Remove bearing retaining snap rings.
2. Pry out old seal from back side of chaincase.

3. Press out old bearing from side shown. If bearing

appears tight, use heat to expand chaincase
bore. Always press bearing toward snap ring
side of chaincase when removing. Inspect
chaincase for any damage and replace if
required.

Jackshaft Removal

1. Remove 0-Ring, seal sleeve and brake disc by tapping

on jackshaft end with a soft face hammer as shown.
2. Remove jackshaft.
3. For set screw and Skwez-loc 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.

··Jackshaft and DriveshaftService Limit-

'/)!='',<;~· '

NOTE: On models with pressed bearing on jackshaft, shaft

will have to be brought through bulkhead slot in order to re-
move from unit.

10/98 8.42 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type 3 Drive System

Driveshaft Removal
1. Tip machine back on left side.
2. Remove driveshaft by pushing through bearing hole on
the bulkhead, then pulling driveshaft toward you.

3. After drive shaft has been removed, inspect

condition of drive sprockets and replace if required.
NOTE: On models with pressed bearings on drive shaft:
If bearings are loose internally or rough they should
be replaced.
• If bearings are loose on the shaft the shaft must be
replaced.

Polaris Industries Inc. 8.43 10/98

BRAKES/FINAL DRIVE
Type 3 Drive System
Chaincase Assembly
1. Apply Loctite 680 to outer race of new bearing and
press into position. Press on outer race only, or
bearing damage may result.

Loctite™ 680

PN 2870584

2. Reinstall 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 chaincase.
NOTE: Do not tighten chaincase bolts at this time.

Jackshaft Installation
1. Replace seal sleeves and 0-Rings with new and
grease.
2. Install jackshaft installation tool on the threads of
the jackshaft

' ' '

Jackshaft Installation Tool .

PN 2870974-13 Tooth Jackshafts

PN 2871296 -15Tooth Jackshafts

3. Insert jackshaft through bearing in chaincase

4. Install jackshaft alignment tool and secure with
castle nut and flat washer. Tighten jackshaft nut
securely to ensure positive bearing and jackshaft
seating to chaincase.

NOTE: Use of a standard nut and flat washer for this align-
ment process will simplify the process as well as preserve
the locking features of the lock nut for reassembly.

Jackshaft Alignment Tool ·.<

PN 2870399- 13 Tooth Jackshafts

PN 2871535 - 15 Tooth Jackshafts

10/98 8.44 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type 3 Drive System
Jackshaft Installation, Cont.

5. If shaft is not centered, tap shaft with a soft faced

hammer until centered. This will align the upper
chaincase bearing in the chaincase bore.

6. Once correct jackshaft alignment has been achieved,

install lock nuts on chaincase mounting bolts and
torque to specification. Remove alignment tool from
chaincase.

7. Install jackshaft flangette gasket and bolts. Align

grease hole (A) in bearing with hole or fitting in
flangette (B) to within .1 00" to ensure greasability.
Torque nuts to specification. Do not lock set screws on
retainer ring (if so equipped).

Chaincase Mounting Bolt Torque - Flangette Nut Torque -

28-30 ft. lbs. (3.86- 4.14 kg-m) 15 - 17 ft. lbs. (2.07 - 2.35 kg-m)

Driveshaft Installation

1. Tip machine back on its left side. Set track into

machine making note of correct direction of travel.
Most tracks have an arrow pointing which direction the
track turns.

Polaris Industries Inc. 8.45 10/98

BRAKES/FINAL DRIVE
Type 3 Drive System

Driveshaft Installation, Cont.

2. Insert driveshaft through bearing hole in

bulkhead. Place inner driveshaft bearing flange
bolts in the bulkhead.

3. Insert chaincase side of driveshaft through

bottom chaincase bearing.

4. Tip machine upright. Replace speedometer key

with a new one and install angle drive. Torque
nuts to specification.

Speedometer Angle Drive

Mounting Nut Torque -

15 -17ft. lbs. (2.07- 2.35 kg-Ill)

5. Link together the upper and lower chaincase

sprockets with the chain. Install both the upper
and lower sprockets and chain at the same time.
Finger tighten the top sprocket nut and turn in
bottom sprocket bolt until snug.
NOTE: On Hyvo '" sprockets, the beveled side goes
toward the chaincase bearing.

6. Install chain tensioner. Finger tighten adjustment

bolt.
7. Install brake caliper assembly in chaincase.

On models with hydraulic brakes, make sure caliper

piston is fully retracted into caliper to prevent brake
binding from preload of pads. On models equipped
with mechanical brakes make sure cam is fully re-
tracted.

8. Torque caliper mounting bolts to specification.

Caliper Mounting Bolt Torque -

28-30 ft. lbs. (3.86- 4.14 kg-m}

10/98 8.46 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type 3 Drive System

Track Installation

1. Tip machine back onto left side. Insert suspension,

rear first, into the track.

2. Move the suspension back and forth until front

torque arm mounting bolts can be started. Tighten
finger tight.

3. Rotate the suspension until the rear mount bolts can

be installed in the same manner as the front.

NOTE: For ease of installation, turn the front rear scis-

sor stops (FRSS) to low position. This allows the rear
torque arm to move forward more to line up holes.

4. Torque suspension mounting bolts to specification.

5. Return front rear scissor stops (FRSS) to original

position.

6. Install suspension springs.

FRSS (Front Rear Scissor Stop)

XTRA-10 Shown

7. Align track (outlined in suspension section) and

tighten adjuster and rear shaft bolts to specification.

3/8" Suspension Bolt Torque - :

35-40 ft. lbs (4.83-5.52 kg-m)
.< '··.. ..' ••• • '

7/16"Suspension Bolt Torque-

45-50 ft. lbs. (6.21-6.9 kg-m)

Polaris Industries Inc. 8.47 10/98

BRAKES/FINAL DRIVE
Type 3 Drive System

Final Assembly

1. Check speedometer cable routing.

Polaris Cable Lube

PN 2870510

2. Grease angle drive and bearing with Polaris grease.

Polaris Premium All Season Grease

PN 2871423

3. Torque bottom chaincase sprocket bolt to

specification.

Bottom Chaincase Sprocket Bolt

Torque-

19ft. lbs. (2.62 kg-m)

4. Torque jackshaft nut to specification. On models

with castle nut, if cotter pin does not align, tighten
nut until it does. Apply brake to hold jackshaft
while torquing.

Jackshaft Castle Nut Torque -

50 ft. lbs. (6.9 kg-m)

5. To obtain correct chain tension, place a slight

reverse tension on the chain as indicated in the
illustration at right (A).
6. There should be approximately 1/4-3/8" (.6-.95
em) total deflection on the chain at point (B).
Loosen adjuster bolt locknut and turn adjuster
bolt (C) until correct chain deflection is obtained.

Chain Deflection -
1/4-3/8" (.6- .95 em)

10/98 8.48 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type 3 Drive System

Final Assembly, Cont.

7. Tighten adjuster bolt locknut (A) securely while

holding the adjuster bolt (8).

8. Install chaincase cover gasket in chaincase with

gap at the top. Install chaincase cover and torque
cover bolts to specification.

Chaincas'e t~~er Bolt Torque -

8 -1oft. lbs. (1.1 o~ 1.38 kg-m}

9. Add 9 oz. (11 oz. on models equipped with

reverse) of Polaris chaincase oil to the
chaincase. Verify proper level with dipstick.

.Polaris Synth~tic Gearcase Lube

PN2871477 (Gallon} · ·.
Pr-J 2871478 (12 oln1ces} "

10. Torque jacks haft bearing set screws to

specification (if so equipped).

. .
•\ ',~;):i~t:;~ < ::: f
Driveshaft anq Jackshaft Bearing
Set Screw;Torque- · ·

80 in. lbs. (.92 kg-m)

~,:',, ~' \->j~i>',,

11. Lubricate bearings with Polaris Premium All

Season grease.

PN 2871423

Polaris Industries Inc. 8.49 10/98

BRAKES/FINAL DRIVE
Type 3 Drive System

Final Assembly, Cont.

12. Reinstall clutch offset washers on jackshaft and

install driven clutch. Using the clutch alignment
tool adjust driven clutch to achieve proper offset.

. Clutch Alignment Tool

P90 - PN 2870914
P85 • PN 2870426

P90 Offset 21/32": P90 Electric Start Off-

set: 1.28" (straight edge}
P85 Offset 5/8": P85 Electric Start Off-set:
1" (straight edge}

13. With proper offset achieved, the driven clutch must

float on the jackshaft. This is done by adding or
subtracting spacer washers (PN 7555734) to the
clutch retaining bolt. When properly adjusted, the
driven clutch will have .020 - .1 00" (.5 - 2.5 mm)
float.

[: CAUTt()N: <I
Incorrect float can cause jackshaft bearings to be side
loaded, resulting in premature bearing failure.

14. Torque driven clutch retaining bolt to specification.

Driven Clutch Retaining Bolt Torque -

12 ft.lbs. (1.66 kg-m)

10/98 8.50 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Type 3 Drive System

Final Assembly, Cont.

15. Reinstall air box, adjusting box properly.

16. Reinstall battery (if so equipped). Always attach
ground cable last to prevent sparks.
17. Replace exhaust system.
18. Install hood, (if removed) aligning with marks made
during disassembly. Ensure proper hood closure
and readjust if necessary.

Hood Bolt Torque ;..

8-10 ft.lbs. (1.10-1.38 kg-m)

19. Test ride the unit to ensure all components are

functioning properly before putting into service.

Polaris Industries Inc. 8.51 10/98

BRAKES/FINAL DRIVE
Transmission, Suspension and Track Removal - WideTrak LX

1. Hood can be removed to prevent damage. Mark

hood hinges for ease of alignment when
reassembling unit.

2. Remove battery.

3. Turn off fuel valve. Move oil tank for access.

4. Remove air intake and coolant recovery bottle from

its mounting.(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 (A) and remove cable

bolt, nut and spacer (B). Use care not to loose
spacer.

9. Remove cable from transmission.

10. Note location of shift linkage on transmission (A) to

assure proper location during reassembly. Remove
cotter pin, washers, and pin from transmission arm.

11. Remove brake light wire connector from sensor.

10/98 8.52 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Transmission, Suspension and Track Removal - WideTrak LX

12. Loosen rear idler wheels and bolts.

13. Loosen jam nuts on adjustment bolts on both sides.

Back out adjustment bolts to allow rear idler
assembly to come forward, relieving track tension.

14. Tighten idler wheel bolts so that spacers on shafts

do not rotate and lose alignment.

8 A

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 flangettes supporting
jackshaft bearing. Loosen and slide back lock ring
from transmission end of jackshaft.
19. Remove jackshaft by pulling towards driven clutch
side and lifting upward through bulkhead. It may be
necessary to lightly tap on bearing collar to free
coupler of jackshaft from transmission end.
20. Inspect bearing. If loose on the shaft the shaft must
be replaced. If bearing is rough when turned, the
bearing must be replaced. The bearing is pressed
onto the shaft and will require a puller for removal.

Polaris Industries Inc. 8.53 10/98

BRAKES/FINAL DRIVE
Transmission, Suspension and Track Removal - WideTrak LX

21. Loosen and remove three carriage bolts and nuts

retaining angle drive housing and flangettes.

22. Remove angle drive housing, adaptor key,

flangettes, gasket, and bearing from drive shaft and
tunnel.

NOTE: It is not necessary to remove speedometer cable

from angle drive. Replace adaptor key any time drive
train assembly is serviced.

23. Tip machine back onto floor.

24. Remove right side bumper plug (A).

25. Remove bolt retaining rear of bumper to foot rest.

26. Bend muffler mount out of the way to allow

transmission removal.

27. Remove three transmission retaining bolts. Note all

alignment shim quantities and locations for
reassembly.
NOTE: Retaining bolts have to be held in place from un-
derside while removing nuts. The lower front bolt cannot
be removed at this time. It must be lowered to the drive
sprocket.

28. Lift and maneuver transmission to free drive shaft

coupler.

29. Lower drive shaft and remove lower front bolt.

30. Maneuver transmission until it can be removed from

the unit. Use care not to damage coolant lines.
Refer to page 8.61 for transmission disassembly.

31. With transmission removed, tip unit onto right side.

Notice direction of track rotation for reassembly. The
arrow in the photo at right indicates track bottom,
rear of unit.

32. Remove front and rear carrier shafts ..

33. Remove suspension by pulling rear of track out of

tunnel. Slide suspension forward to driveshaft. Lift
up and out at the rear.

NOTE: On some models it may be necessary to unhook

rear torque arm springs to allow torque arm to lower.

34. Inspect transmission, brakes, suspension and track

for excessive wear. Check bearings for excessive
movement or rough feeling. Replace if necessary.

10/98 8.54 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Transmission, Suspension and Track Installation - WideTrak LX
Installation

1. Tip unit onto right side.

2. Insert track in unit, making sure direction of rotation

is correct.

3. Place drive shaft in unit, aligning drive sprockets and

track drive lugs.

4. Install lock collar, flangette, bearing, gasket, and

flangette on drive shaft, positioning bearing flush
with end of drive shaft.

5. Lightly tighten set screws to hold bearing in place.

6. Align flangette holes with tunnel.

7. Replace adaptor key in drive shaft. Install angle

drive housing aligning adaptor key with angle drive.

8. Install nuts and finger tighten.

9. Tip machine onto its left side.

10. Replace 0-rings on input and output shafts. Apply

Polaris All Season Grease to drive shaft coupler
splines.

Polaris All Season Grease

PN 2871423

11. Reinstall transmission, using care not to damage

coolant hoses. 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 transmission 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: Proper transmission/jackshaft alignment is critical
for bearing service life. Use a standard nut and flat washer
for initial installation of transmission, and install new
mounting hardware after jackshaft alignment is complete.

14. Tip machine onto its right side.

Polaris Industries Inc. 8.55 10/98

BRAKES/FINAL DRIVE
Transmission, Suspension and Track Assembly - WideTrak LX
Assembly, Cont.
15. Loosen set screws and seat drive shaft in
transmission coupler stub shaft. For ease of
assembly, make sure track has no pressure against
drive shaft.
16. Tighten nuts retaining angle drive housing to tunnel.
Torque to specification.

Angle Drive Housing

Retaining Nu~ Torque -

15-17 ft. lbs. (2.07- 2.35 kg-m)

17. Using "T" handle Allen wrench, torque set screws to

specification.

Set Screw Torque

80 in. lbs. (.92 kg-m)

18. Reinstall suspension inside track and align with tunnel

mounting holes.

19. Install and hand tighten suspension bolts (B).

20. Install front carrier shaft assembly inside track and
mount to tunnel with bolts. Hand tighten bolts.

21. Install rear carrier shaft assembly. Make sure bolts

are not cross threaded and hand tighten (A).

22. Tip machine back onto floor and tighten all suspension
bolts to specification.

Suspension Bolt Torque -

35-40 ft. lbs (4.83-5.52 kg~m) ·

10/98 8.56 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Transmission, Suspension and Track Assembly- WideTrak LX
Assembly, Cont.
23. If jackshaft was removed from unit, grease coupler
spline with Polaris Premium All Season Grease and
install on transmission.

Polaris Premium All Season Grease

PN 2871423

24. Check for bearing to bulkhead alignment and shim

transmission as required to center jackshaft in
bulkhead mount. Shims may be required between
transmission and bulkhead. Seat jackshaft firmly.

Shim Kit PN 2200126

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 specification.

Transmission Retaining Nut Torque -

28-30 ft.lbs. (3.86-4.14 kg-m)

27. Install bolts and nuts securing flangettes to bulkhead.

Torque to specification.

Bearing.Fiangette Nut Torque-

15-17 ft. lbs. (2.07-2.35 kg-m)

28. Set lock ring at transmission coupler and torque to

specification.
......
~ _ 0
Lock Ring Torque - t
80 in. lbs. (.92 kg-m)
A

Polaris Industries Inc. 8.57 10/98

BRAKES/FINAL DRIVE
Transmission, Suspension and Track Assembly - WideTrak LX
Assembly, Cont.

29. Reattach transmission shift linkage and brake light

connector. Check transmission fluid level and fill if
necessary.

Polaris Synthetic Gearcase Lube

PN 2871477 Gallon
PN 2871478 12 oz.

30. Attach brake cable to transmission mounting with

bolt, nut and spacer.
31. Install bumper onto footrest bolt and tighten.
32. Reinstall bumper plug.
33. Reinstall and secure muffler.
34. Install battery, air box, oil tank, and coolant recovery
bottle.
35. Loosen rear idler bolts.
36. Reinstall driven clutch and spacers onto jackshaft and
tighten.
37. Reinstall clutch offset washers on jackshaft and
install driven clutch. Using the clutch alignment
tool adjust driven clutch to achieve proper offset.

P85 Electric Start Offset: 1" with

straight edge

38. WideTrak models have no float on driven

clutches. Use shim washers (PN 7555734) to
create gap between shaft and cover washer only.

10/98 8.58 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Transmission, Suspension and Track Assembly - WideTrak Models
39. Torque driven clutch retaining bolt to specification.

Driven Clutch Retaining Bolt Torque .;;

12 ft.lbs. (1.66 kg-m)

40. Lift and support rear of unit and align track to

specifications found in the Maintenance section.
Make sure rear idler wheel spacer location is correct
before tightening idler wheels.
41. Reinstall hood.

Polaris Industries Inc. 8.59 10/98

BRAKES/FINAL DRIVE
Transmission Disassembly WideTrak LX

Disassembly/Inspection

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 alignment upon reassembly.

3. Remove detent spring and ball.

4. Remove case bolts evenly in a criss-cross

pattern.

10/98 8.60 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Transmission Disassembly WideTrak LX

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.

Polaris Industries Inc. 8.61 10/98

BRAKES/FINAL DRIVE
Transmission Disassembly WideTrak LX

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.

10/98 8.62 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Transmission Disassembly WideTrak LX

Gear, shaft, and chain cluster assembly shown.

Low gear output power flow ...

High gear output power flow ...

Reverse output power flow...

Polaris Industries Inc. 8.63 10/98

BRAKES/FINAL DRIVE
Transmission Disassembly WideTrak LX

Low I Reverse Shaft Disassembly

13. Press bearing from end of shaft using a bearing

separator.

14. Remove snap ring and spacer washer.

10/98 8.64 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Transmission Disassembly WideTrak LX

15. Remove low reverse shaft low gear...

needle bearing, thrust washer, low/reverse dog

gear...

snap ring, thrust washer (.050"), reverse idler, needle

bearing, and thrust washer (.065").

16. Closely inspect drive dogs. Replace gear and

mating gear if rounded, chipped or broken.

17. Inspect needle bearings for wear or cracks on cage.

Shiny spots on cage indicate wear and the bearing
should be replaced. Inspect shaft and thrust washers
for galling or wear. Always replace snap rings if
removed.

Polaris Industries Inc. 8.65 10/98

BRAKES/FINAL DRIVE
Transmission Disassembly, 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-loaded upon installation. Refer to photo and illustration below.

Locate spring in retainer

slot as shown

Hook spring here

Arm of detent plate must

be positioned between
ends of spring. Install key.

Transmission Assembly
Lubricate all parts before assembly with Premium Synthetic Chaincase Lubricant.
1. Install chain on input and reverse shaft. Photo 1.
2. Add output gear assembly with chain. Photo 2.

Photo 1 Photo 2
3. Add shift fork assembly.
4. Install entire assembly in case half.
5. 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™ 1215 Sealant to case halves.
7. Install outer case half and replace brake cable bracket.
Torque bolts in three steps to 8-10ft. lbs. (1.10-1.38
kg-m) using a criss-cross pattern. Remove dowel from
tensioner and install access plug (where applicable).
8. Install transmission. Add 20 oz. Premium Synthetic
Chaincase Lubricant.

Transmission Case
.
Bolt Torque--
. .
.. I

8-10ft. lbs. (1.1o-1.38 kg-m).

10/98 8.66 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Brake Caliper Removal WideTrak LX
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 Chaincase lubricant:..

Gallon PN2871477
12 oz. PN 2871478

Brake Caliper Removal -Type WT2

1. Remove brake cable.
2. Remove retaining bolts, making note of location of hex
head bolt (with flat washer) and recessed Allen bolt.
NOTE: Before performing next step, note position of two
spring clips.
3. Remove upper guide bushing and pads. Remove
lower guide bushing. Inspect pads and replace if worn Minimum Pad
beyond service limit. Thickness
.250"
(6.35mm)
Brake Pad Thickness -Type WT2

. Service limit .250" (6.35mm)

4. With actuating arm facing up, carefully remove tension

from the return spring.
5. Remove the arm using care not to lose the balls, ball
spacer, or lifter ramp.
6. Inspect balls, ball spacer, lifter ramp and caliper
housing for galling or wear. Replace if necessary.

Polaris Industries Inc. 8.67 10/98

BRAKES/FINAL DRIVE
Brake Caliper Assembly WideTrak LX

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 2.25a of the Maintenance Section.
Tighten cable lock nuts securely.

Lock
Nuts

Move cable up or
down in bracket
to adjust freeplay

10/98 8.68 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Reverse Kit Service Tips
The following illustration indicates sprocket position with the Polaris Reverse Kit in the forward and reverse selec-
tion.

Installation Tips (Refer to Illustration on page 8.70)

• 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.

-I
Forward Position Reverse Position

Top Sprocket - ; - /Top Sprocket

~-- Drive Chain -~

Chain Pinion Gear
(Narrow Face)

Spur Pinion Gear

.........._ Spur Pinion Gear
Shift Fork Groove

Reverse Kit Option Sprocket Reverse Kit Option Sprocket

Drive Coupler

Polaris Industries Inc. 8.69 10/98

BRAKES/FINAL DRIVE
Reverse Kit Maintenance

Washer

Washer

Washer

Pinion Shaft

Pinion
Gear Drive

Washer
Drive Coupler
Reverse Gear

Chain Tension Adjustment

1. Elevate the rear of machine and support so track is
off the floor.
2. Loosen adjuster bolt lock nut.
3. Loosen adjuster bolt slightly (about one turn out).
4. Tighten adjuster to specified torque.
',,
Adjust~r Bolf;Torque -
,> '·\'- ,:',\\'"·~\ {«;,,j

20, in.'i~s. (:23 kg-m)

5. Loosen adjuster bolt 1/2 turn.

6. Hold adjuster bolt in position and tighten locknut
securely.

10/98 8.70 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Reverse Kit Maintenance
Oil Level
1. Using Polaris chaincase lubricant, maintain proper
oil level. Proper level is checked by removing
dipstick.
2. Wipe off any metal particles from the dipstick.
Small amounts of particles will be common.
3. Add lubricant until the level is in the "safe" zone on
the dipstick (11 oz.) Do not mix or use other types of
lubricant.

Polaris Synthetic Chaincase Lube

PN 2871477- Gallon
PN 2871478 -120unces

Adjustment
Due to break-in or replacement of components, the re-
verse shift mechanism may require adjustment. Adjust
with the shifter in the forward position.
Indy 340 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.

Reverse Cab,le End Play - ·· 1/32" Adjustment

(.08 em)
1/32" (.08 em) .,·,

Evolved and Aggressive Style

1. Lift shift lever slowly while observing shift arm on

transmission. Shift Lever

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. 1-1 1/2" (2.5-3.8 em)
3. Loosen jam nuts on lower end of cable. free play

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
adjust beyond this point.
Shift
5. Tighten jam nuts and re-check adjustment.
Arm

Reverse Shift Lever Freeplay -

1 - 11/2" (2.5.- 3.8 em)

Polaris Industries Inc. 8.71 10/98

BRAKES/FINAL DRIVE
Reverse Kit Maintenance - Gen II Style
Oil Change
1. Change annually, prior to off season storage.

Adjustment
Due to break-in or replacement of components, the re-
verse shift mechanism may require adjustment. Adjust
with the shifter in the forward position. Clevis Pin
GenII Style

1. Pull shift lever slowly while observing shift arm on

transmission.
J
2. If adjustment is correct, the sprockets will mesh fully - t - - - ShiftLever
when the lever is pulled and no grinding will occur Actuator
indicating incomplete engagement. If incomplete
engagement is suspected perform the following
steps.
1. Move lever to forward position.
2. Loosen jam nuts on linkage rod.
3. Adjust linkage rod until endplay movement is 1/32"
(.08 em). Do not adjust beyond this point.
4. Tighten jam nuts and re-check adjustment.

Reverse Linkage Rod End Play-

Linkage Rod
1/32" (.08 em)
'

Chaincase Cover Assembly

10/98 8.72 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Traction
The amount of traction required varies depending upon the type of riding and the snowmobile's horsepower.

A WARNING

A proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control
on hard packed snow and ice. Loss of control can result in severe personal injury or death.
Track studding will enhance braking control on hard packed snow or ice, but extreme caution is still required on
such surfaces. Use extra caution when track studding is employed as steering ability may be reduced on hard
packed snow or ice. The addition of carbide skags (if not already installed) is recommended with studded tracks
to aid in maintaining proper vehicle steering and control. Proper balance must be maintained between the number
of studs and the length and sharpness of carbide on skags.
If you are adding studs to the track of a machine it will probably be advisable to add carbide skags or change to
more aggressive skags in order to maintain proper vehicle control while turning on hard packed snow or ice. If
the machine is equipped with carbide skags or if you are adding them or changing to more aggressive skags than
standard equipment, it may also be necessary to add track studs in order to maintain proper vehicle control while
turning on hard packed snow or ice.
As a rule of thumb, the more studs, the longer and sharper the carbide on the skags should be. The recommenda-
tions in the chart on page 8.74 should be used as guidelines in achieving a proper balance of ski and track traction
products on Polaris snowmobiles.

Studs are designed specifically for each riding category. They're made in various lengths, shapes, and materials.
Improperly applied studs can cause poor traction and premature wear. Studs which are too long can cause dam-
age to the tunnel and heat exchangers.

Stud points fall into two categories: conical and scoopers. Conical studs (or picks) penetrate into the ground for
increased traction. Scoopers use a flat surface to hold more ground for traction. Generally, a penetrating point
is used for hard ground surfaces and ice. Scoopers are used on softer 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 center of
the track because there is poor support in this area. The track's center belt controls acceleration. The two smaller
outside track belts contribute to acceleration, but also increase the amount of ski pressure required for turning.
The chart on page 8.74 is a guideline for the quantity of studs to install.

• Be sure to check allowable clearance between the track and tunnel or heat exchangers, factoring
in suspension travel.
• Do not place studs under the tunnel protector/heat exchanger strips (directly above slide rails on un-
derside of tunnel). Tunnel protectors are vital components and must not be subjected to stud dam-
age.
• V-shaped stud patterns with the least repetition work best. Studs should cover as many different lines
in the ice as possible.
• Studs closest to the slide rails provide the most effectiveness, because the weight of the sled is con-
centrated in this area; however do not place studs closer than 1" to the edge of the track window.

Polaris Industries Inc. 8.73 10/98

 BRAKES/FINAL DRIVE
Traction
Polaris Push-Through Stud and Skag Recommendations

TRAIL AGGR Performance

TRACK LUG TUNNEL STUD STUD TRAIL STUD AGGR STUD Performance
Model L&W HEIGHT PROTECTOR SIZE QTY SKAG QTY SKAG QTY SKAG
Indy 340 121 X 15 .66 2871689 0.75 48 B 72 D 96 D
*340 Deluxe 121 X 15 .66 2871689 0.75 48 c 72 N 96 J
Sport 121 X 15 .71 2871911 0.75 48 D 72 D 96 p
*Super Sport 121 X 15 .82 2871544 1 48 c 72 N 96 J
XCF 121 X 15 .82 2871544 1 48 R (COMP) 72 R (COMP) 96 S (COMP)
*Trail 121 X 15 .82 2871544 1 48 N 72 N 96 J
Indy 500 121 X 15 .82 2871544 1 48 D 72 D 120 p
*500 Classic 121 X 15 .82 2871544 1 48 R (COMP) 72 R (COMP) 120 R (COMP)
XLT SP 121 X 15 .82 2871544 1 96 R (COMP) 120 R (COMP) 144 S(COMP)
*XLT Classic 121 X 15 .82 2871544 1 96 R (COMP) 120 R (COMP) 144 S(COMP)
500XC 121 X 15 .82 std(coolers) 1 96 R (COMP) 120 R (COMP) 144 S (COMP)
500XC SP 121 X 15 .82 std(coolers) 1 96 R (COMP) 120 R (COMP) 144 S (COMP)
600XC 121 X 15 .91 std(coolers) 1.075 96 R (COMP) 120 S(COMP) 144 S (COMP)
600XC SP 121 X 15 .91 std( coolers) 1.075 96 R (COMP) 120 S (COMP) 144 S (COMP)
700XC 121 X 15 .91 std( coolers) 1.075 96 R (COMP) 120 S (COMP) 144 S (COMP)
700XC SP 121 X 15 .91 std(coolers) 1.075 96 R (COMP) 120 S (COMP) 144 S (COMP)
440XCR 121 X 15 .82 std(coolers) 1 96 R (COMP) 120 S (COMP) 144 S (COMP)
700XCR 121 X 15 .91 std 1.075 96 R (COMP) 120 S (COMP) 144 S (COMP)
800XCR 121 X 15 .91 std 1.075 96 R (COMP) 120 S(COMP) 144 S (COMP)
340 Touring 133.5 X 15 .82 2871543 1 53 D 80 D 106 p
Sport Touring 133.5 X 15 .82 2871541 1 53 D 80 D 106 p
*Trail Touring 133.5 X 15 .82 2871541 1 53 N 80 N 106 J
*Classic Touring 133.5 X 15 .82 2871541 1 53 R(COMP) 80 R (COMP) 106 S (COMP)
*XLT Touring 133.5 X 15 .82 2871541 1 80 R (COMP) 106 R (COMP) 132 S(COMP)
*700 SKS 136 X 15 1.25 N/A N/A N/A R (COMP) N/A R (COMP) N/A S (COMP)
Trail RMK 136 X 15 1.25 N/A N/A N/A R (COMP) N/A R (COMP) N/A S(COMP)
500 RMK 133.5 X 15 1.25 N/A N/A N/A R (COMP) N/A R (COMP) N/A S (COMP)
600 RMK 136 X 15 1.75 N/A N/A N/A R (COMP) N/A R (COMP) N/A S (COMP)
600 RMK0pt2 136 X 15 2.0 N/A N/A N/A R(COMP) N/A R(COMP) NIA S (COMP)
700 RMK 136 X 15 1.75 N/A NIA N/A R (COMP) N/A R (COMP) N/A S (COMP)
700 RMK Oj>l 2 136 X 15 2.0 N/A N/A NIA R (COMP) N/A R (COMP) N/A S (COMP)
Transport 141 X 15 1.125 N/A N/A N/A DorM N/A N/A N/A N/A
"WideTrak LX 156 X 20 1.0 STD N/A N/A J orP N/A N/A N/A N/A

*EZ Steer skag

10/98 8.74 Polaris Industries Inc.

 BRAKES/FINAL DRIVE
Traction
Polaris Push-Through Stud and Skag Recommendations
B 7/16 x 3" 120°, 2870693 Stud Kits
C 7/16 x 3" 120° EZ, 2870997 See Accessory Order Forms for Stud Kits

D 7/16 X 4" 60°, 2871288

J 7/16 x 6" 60° EZ, 2871416

N 7/16 x 4" 60° EZ, 2871603

P 1/2x6"60°,2871601

1/2 X 8" 60°, 2871602

Polaris Composite Ski

R 7/16 X 4" 60°, 2871688

S 1/2 X 6" 60°, 2871687

Wear Strip Kits**

2871911 1 piece tunnel Sport 1.05
2871540 1 piece tunnel SKS .625

2871541 1 piece tunnel SKS .75

2871544 121" .75

2871542 2 piece tunnel SKS .625

2871543 2 piece tunnel SKS .75
2871545 121" .625
2871689 .751ndy 340

* Patent Pending Carbide 60° Point

** Production set up of wear strips will be located over the windows of the track. An optional position is available
for using hooker plates. Only the outer end holes are punched in the tunnel. The wear strip will serve as the
template for drilling the remaining holes.

Polaris Industries Inc. 8.75 10/98

BRAKES/FINAL 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-cutting portion of the drill shank in the hole at high speed to melt the cords together, or melt them
with a 1/4-9/32" heated probe. This will prolong track life.

T-nut Studs
1. Push a T-nut tool through the hole from the outside of the track.
2. With the barrel end of the T-nut toward the track, spin aT-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™ 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. lbs. and let dry for 24 hours at room temperature.
6. Check for loose studs after each event.

Push Through Studs

1. 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.
Refer to the diagrams below for stud length recommendations.

Penetration Stud Length

A= Stud Height Maximum Maximum
B =Washer Thickness Penetration Stud Length
C =Track Lug Height
A + B - C = Penetration
Standard Low Profile Track

3/8" "\J v "\J .750"

Deep Lug Track

3/8" "'J lf "'J .875"

-~/l'----'---1__ Steel Cleated Track

Backer Plates
=
3/8" I vI .700"
Steel .195

Aluminum .220 c:,===~

Stud Mate .148 ~

Hooker ~ Alum.
Washer .025 "0dY @ Shim .055

10/98 8.76 Polaris Industries Inc.

CHAPTER 9
ELECTRICAL
Ignition Timing Specifications . . . . . . . . . . . . . . . . . . . . . . . 9.1
Routing Diagram - Indicator Lights - 340 Touring . . . . . . . . 9.2
Multimeter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3-9.5
Typical Timing Advance Curves . . . . . . . . . . . . . . . . . . . . . . 9.6
Timing Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7-9.13
Conversion Chart- Degrees to Piston Position . . . . . . . . . 9.14
Timing Procedures - Exploded Views . . . . . . . . . . . . . . . . . . 9.15-9.20
Timing Procedures -All Models . . . . . . . . . . . . . . . . . . . . . . . 9.21
Operating RPM Timing Check . . . . . . . . . . . . . . . . . . . . . . . . 9.22
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23-9.24
Dynamic Testing of Electric Starter System . . . . . . . . . . . . . 9.25
Static Electric Starter System Testing . . . . . . . . . . . . . . . . . . 9.26
Electric Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
Lighting System Output Test . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
Alternator Output- Pulse System . . . . . . . . . . . . . . . . . . . . . 9.30
Typical Exciter, Pulser or Lighting Coil Replacement . . . . 9.31
Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32-9.33
Coolant High Temperature Indicator Testing . . . . . . . . . . . . 9.34
Speed Control Assurance Operation . . . . . . . . . . . . . . . . . . 9.35
Speed Control Assurance Testing . . . . . . . . . . . . . . . . . . . . . 9.36
Electric Fuel Gauge Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 9.37
Handlebar Warmer Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38
Ignition System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9.39
1999 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.40-9.49
 ELECTRICAL
Ignition Specifications

1999 Ignition Timing Specifications

Operating
Timing 0 8TDC
Engine MM Inches Degrees Acceptable Range RPM
Model BTDC BTDC BTDC@
RPM
MM Inches
EC34-2PM051 3.67 .145 26.5±1.5 3.28-4.08 .129-.161 15.5° @ 7000
@ 3000
EC44-3PM025 3.81 .150 26±1.5 3.39-4.25 .133-.167 16° @ 6500
@ 3000
EC45PM011 4.45 .175 27±1.5 3.97-4.93 .157-.195 1r @ 6500
3000
SN44-44-98A 1 3.72 .146 25±1.5 3.29-4.16 .129-.163 16°@ 8250
@ 3500
EC50PM044 3.81 .150 26±1.5 3.39-4.25 .133-.167 16° @ 6500
3000
EC55PM011 (021) 4.45 .175 27±1.5 3.97-4.93 .157-.195 1r @ 6500
@3000
EC50PL 162{172) 4.40 .173 28±1.5 3.91-4.87 .156-.191 16° @ 7500
(192)(202) @3000
EC58PL 160 4.40 .173 28±1.5 3.91-4.87 .156-.191 20° @ 7500
@3000
EC58PL 131 4.40 .173 28±1.5 3.91-4.87 .156-.191 20° @ 7500
@3000
SN50-44-99A2 .872 .034 12±1.5 .664-1.08 .026-.042 16° @ 8250
@3000
SN60-70-99A 1(A2) .220 .009 6±1.5 .115-.325 .004-.013 13°@7500
@1750
S N70-70-99A 1(A2) .220 .009 6±1.5 .115-.325 .004-.013 1r@ 7500
@1750
SN70-70-99A3 .930 .037 12±1.5 .710-1.15 .033-.041 16° @ 8250
3000
EC70PL011 2.476 .098 20±1.5 2.10-2.81 .083-.111 18°@8100
@1750
EC79PL011 4.104 .162 26±1.5 3.65-4.56 .144-.179 15°@ 8300
@3250
* Engine at room temperature

Coil Resistance Specifications

For ignition system component specifications, refer to wiring diagrams at the end of this chapter for the specific
model you are working on.

Polaris Industries Inc. 9.1 10/98

ELECTRI~AL
Routing Diagram _ Indicator Lights

1999 340 Touring

10/98 9.2 Polaris Industries Inc.

 ELECTRICAL
Multimeter Usage
Multimeter Usage
The easiest and most accurate method for testing modern
electrical components is with a digital multitester. Any good
quality multitester will work. However, due to ease of opera-
tion and durability, Polaris recommends the Fluke Model73
(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 COMMON
(BLACK LEAD)

V- = Volts AC - measuring alternator output

Used to measure AC voltage in an electrical system. AC volt-
age 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 VQ (+) 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.
Usage
• Test unregulated voltage output of a stator coil
• Test regulated voltage to the lights and handwarm-
ers

V :-:-:- =Volts DC - measuring battery voltage, volt drop, etc.

Used to measure DC voltage produced by a battery or rectifier.
Test Method
1. Connect black lead to Com (-) meter terminal
2. Connect red lead to VQ (+) meter terminal.
3. Turn selector dial to V :-:-:- setting.
4. Connect test leads parallel with test component.
Observe polarity.
Usage
• Test battery voltage
• Test DC regulator
• Test voltage drop for bad connections
• Test supply voltage to electric fuel gauge
• EFI electrical testing

Polaris Industries Inc. 9.3 10/98

ELECTRICAL
Multimeter Usage

Q = Ohms, resistance - measuring component resistance values -testing coils, wiring, etc.
Used to test resistance to the flow of electricity in a circuit or
component. A reading of OL means an open circuit or infinite
resistance. Sometimes the leads themselves will have some
resistance. Touch the leads together and subtract this resis-
tance from the component reading to achieve the actual
reading.
Test Method
1. Connect black lead to Com (-) meter terminal
2. Connect red lead to VD. (+) meter terminal.
3. Turn selector dial to Q setting.
4. Isolate test component from the rest of the electrical
circuit by disconnecting wires from harness.
5. Connect test leads to the circuit to be tested.
Usage
• Testing coil resistance
• Testing switch operation
• Testing wire continuity

A-= Amps AC - used to test lighting coil output

Used to test the power of an alternator coil.
Test Method
1. Connect black lead to Com (-) meter terminal
2. Connect red lead to 1OA (+)meter terminal.
3. Disconnect engine harness from system.
4. Connect across the specified coil wires.
5. Start engine and let it idle.
6. Readings should be above 5 Amps at any RPM. NOTE:
It is not necessary to increase RPM. The reading can be
obtained at idle.
Usage
• Testing stator coil power output.

10/98 9.4 Polaris Industries Inc.

 ELECTRICAL
Multimeter Usage

A -::-:-:- = Amps DC - used to check battery charge rate, system draws, etc.
Used to check the current flow to and from the battery.
Test Method
1. Make sure red lead is in the 1OA terminal of the meter and the black lead is in the Com (-) terminal of the meter.
2. Disconnect battery ground wire(s) from battery(-) terminal.
3. Connect red meter lead to battery (-) terminal.
4. Connect black meter lead to harness ground wires and cable.

Do not operate electric starter (if equipped) or meter damage may occur.
Usage
• Testing key off current draw
• Testing key on current draw
• Testing charging system break even RPM
• Testing DC current flow (direction), is battery charging?
NOTE: When using the DC Amp settings, the red test lead must be moved to the 1OA socket on the front of the
instrument.

Polaris Industries Inc. 9.5 10/98

ELECTRICAL
Typical Timing Advance Curves
Ignition Timing

Maximum Advance
(Depending on Model)

~
w
a:
(9
w
0
w
()
z
~ Operating RPM
0 (Depending On
<(
(9 Engine) See
z Data
~
i=

1000 2000 3000 4000 5000 6000 7000 8000

RPM

NOTE: Always verify timing of engine at room temperature only (68° F I 20° C) and at the proper RPM.
To obtain the best ignition timing accuracy and reduce the chance of error, the ignition timing specification is given
at a "flat" portion of the advance curve. This flat portion on the curve is where the ignition timing is specified.
Refer to chart on page 9.1. Ignition timing must be checked at the specified RPM, or inaccurate timing will result.
Refer to timing specifications at the beginning of this chapter.
If engine damage has occurred due to a suspected ignition related problem, verify the ignition timing is correct
at the specified operating RPM as outlined on page 9.1.

Dial Indicating The Timing Marks

Due to differences between engines, it is necessary to dial indicate the timing marks on all engines before attempt-
ing to adjust the ignition timing. To indicate the marks:
1. Remove the mag (RH) cylinder spark plug and install the dial indicator.
2. Rotate the crankshaft by hand while observing the dial indicator. As the piston touches the indicator plunger,
the dial will begin to rotate. Find the point where the pointer stops rotating and reverses direction. This will be
TDC (Top Dead Center).
3. While holding the crankshaft with the piston at TDC, zero the indicator by rotating the bezel until the 0 on the
dial and the pointer align.
4. Rotate the crankshaft opposite the direction of rotation about .250 BTDC (2 1/2 pointer revolutions).
5. Determine the correct ignition timing position from
the ignition data charts and rotate the crankshaft in
the normal direction of rotation to that position.
(Example: If engine timing is .150 BTDC, the
crankshaft must be rotated in the normal direction
of rotation so that the dial indicator pointer does
one complete revolution and stops on 50. This
should be 1 1/2 pointer revolutions before top
center, or .150 BTDC.
6. While holding the crankshaft at the correct timing
position, mark the flywheel (with chalk or a white
marker) directly in-line with the stationary pointer
(or line) on the fan or recoil housing through the
timing inspection window.

10/98 9.6 Polaris Industries Inc.

 ELECTRICAL
Timing Curves
Timing Curve 1999 600 XC /600 XC SP /600 RMK
20
.
...
.. 4
18 ~·
..
, ~- .
, .
16 ..
14

12
-
J.
,, ,
, ..
..
. .
.. . .... . ..4•
10
.. . ... '
'
'
.
...
8 '
6 -
,r
. '
'

,,
4

,,
2
0
0 1000 2000 3000 4000 5000 6000 7000 8000

Timing Table
1999 600 Twin
RPM Degrees
600 60
2000 60
4500 12°
5000 1r
6000 19°
7500 13°
8000 110
8500 60

Polaris Industries Inc. 9.7 10/98

ELECTRICAL
Timing Curves
Timing Curve 1999 700 XC /700 XC SP /700 SKS
20
... ....
18
16
,.
I~· .
.. -- .4
.. .. _- .
, .. 4..
14
,, ''
12
.. -
. .... . ""
'
'
•
10
..
.. .. .
8
.. .
6 - ...
,1"
4
,,
,,
2
0
0 1000 2000 3000 4000 5000 6000 7000 8000

Timing Table
1999 700 XC, XC SP, SKS
RPM Degrees
600 60
2000 60
4500 12°
5000 17°
6000 19°
7500 16°
8000 15°
8500 11°

10/98 9.8 Polaris Industries Inc.

 ELECTRICAL
Timing Curves
Timing Curve 1999 700 RMK

•
....
• •
•• •
20 • •• ••
II
• • •• •
•• •••.
••

•· ....
15
•
•• ''
•• • ''
10
•• •
... ''
•• • '~
~
5 •
••
0 ••
0 1000 2000 3000 4000 5000 6000 7000 8000 9000

Timing Table
1999 700 RMK
RPM Degrees
500 60
2700 12°
3500 12°
4800 18.5°
5500 23°
8000 16°
8400 15.5°
9000 5.5°

Polaris Industries Inc. 9.9 10/98

ELECTRICAL
Timing Curve Template
Timing Curve 1999 440 XCR

25
,,
, -. . .
,, . . ._
20
,,
, , - ~ ..
..
....
15
,,
,,
,,
••\

' \

,, '
\
10
,,
,
\

,, '
'
5
'
_\_

' '
' 4
'
'
0 '
0 1000 2000 3000 4000 5000 6000 7000 8000 9000

Timing Table
1999 440 XCR
RPM Degrees
500 6
3000 25
4500 25
5500 20
7000 20
8000 16
8300 16
9000 3

10/98 9.10 Polaris Industries Inc.

 ELECTRICAL
Timing Curve Template
Timing Curve 1999 500 XC I 500 XC SP
30

25 .'
·--. -----
' •..
.. ..
' .. ..
'
20 '
' ..
' ..
' .. ..
' .._
15
'
--
·-- .
~

10 '
------ -----· -----·
'
'
'

'
'
' -- -~
5 '
'
'
'
'
0 '
0 1000 2000 3000 4000 5000 6000 7000 8000 9000

Timing Table
500 XC I 500 XC SP
RPM Degrees
500 12
3900 12
4500 28
5800 28
7400 15
7900 15
8300 8.5
9000 8.5

Polaris Industries Inc. 9.11 10/98

ELECTRICAL
Timing Curve Template
Timing Curve 1999 700 XCR

• __ .. 4
~'
25

20
I
- ---
';'
,,
, ~
·-· '•
'
'
'
4. .
I
I '
15 , '
'

.
• ---- --------
I
I '
10 ' '
I '
I
I
-- 4
I
5
,'
I

0
0 2000 4000 6000 8000 10000 12000
Timing is measured with throttle position sensor (TPS) unplugged.

Timing Table
1999 700 XCR
RPM Degrees
1500 20
2000 20
2500 20
3000 20
3500 20
4000 20
4500 24
5000 26
5500 26
6000 27
6500 24
7000 24
7500 22
8000 18
8250 18
8500 12
8750 8
12750 8

10/98 9.12 Polaris Industries Inc.

 ELECTRICAL
Timing Curve Template
Timing Curve 1999 800 XCR

25
. ,,
·- -
, J~- -·- -4 ·-- · - - 4 . -- --•-·o'
'
'
20
I
I
I
,, '
-
'
~

'
'
'
4~---
I

15
• --
I

'
•'
'
I
I

, I

10
,,
I
I
5 I
I

, I

I
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
Timing is measured with throttle position sensor (TPS) unplugged.

Timing Table
1999 800 XCR
RPM Degrees
1500 14
2000 20
2500 22
3000 26
3500 26
4000 26
4500 26
5000 26
5500 26
6500 26
7000 26
7500 20
8000 16
8250 15
8500 15
8750 12
12750 10

Polaris Industries Inc. 9.13 10/98

 ..... == s·
eno. ......
~ om
or
. . . . -· ::r
~
EC40PL EC45PM EC59PL EC34-2PM EC25PF Domestic 440 Domestic 600 ' -C"lCD :::s m
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EC44-2PM EC55PM EC68PL EC25PS Domestic 500 Domestic 700 0 OJ -·
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............ (Q
() 0 :::J
EC44-3PM EC70PL EC44PT 0 ...... -· CD-i
EC45PL EC75PL EC44PQ ~ 0 g· CilJJ
EC50PL EC60PL EC79PL EC44PM CD < :::J
S.m.-+ 0 0
EC58PL EC65PL EC80PL
CD ~ ~r
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DEG. 112 MM ROD 120 MM ROD 125 MM ROD 103 MM ROD 120 MM ROD 128 MM ROD 136 MM ROD :::J '< -·
(Q <::!". :::J
or
BTDC 60 MM STROKE 65MM STROKE 65 MM STROKE 55.6 MM STROKE 60MM STROKE 64 MM STROKE 68 MM STROKE I s· 3 (Q ::r
CD -·en Q)
MM INCHES MM INCHES MM INCHES MM INCHES MM INCHES MM INCHES MM INCHES • :::J "0
0.0065 0.0003 <OCD ;:l.
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2 0.0232 0.0009 0.0252 0.0010 0.0249 0.0010 0.0215 0.0008 0.0228 0.0009 0.0244 0.0010 0.0259 0.0010 ~
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6 0.2083 0.0082 0.2261 0.0089 0.2242 0.0088 0.1933 0.0076 0.2053 0.0081 0.2190 0.0086 0.2327 0.0092 -· CD
0 en en
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7 0.2833 0.0112 0.3076 0.0121 0.3050 0.0120 0.2630 0.0104 0.2793 0.0110 0.2979 0.0117 0.3166 0.0125
8 0.3698 0.0146 0.4016 0.0158 0.3981 0.0157 0.3432 0.0135 0.3646 0.0144 0.3889 0.0153 0.4132 0.0163
9 0.4677 0.0184 0.5079 0.0200 0.5036 0.0198 0.4341 0.0171 0.4612 0.0182 0.4919 0.0194 0.5226 0.0206 0 0. "'tJ
0.5770 0.0227 0.0239 0.6448 0.0254 c -· -·
10 0.6265 0.0247 0.6212 0.0245 0.5355 0.0211 0.5689 0.0224 0.6068
0.7795 0.0307
co :::J en
11 0.6976 0.0275 0.7575 0.0298 0.7510 0.0296 0.6474 0.0255 0.6878 0.0271 0.7336 0.0289 ...... 0.
12 0.8294 0.0327 0.9006 0.0355 0.8930 0.0352 0.7698 0.0303 0.8178 0.0322 0.8723 0.0343 0.9268 0.0365 0 CD 0-
O.(Q :::s
13 0.9724 0.0383 1.0559 0.0416 1.0470 0.0412 0.9025 0.0355 0.9588 0.0377 1.0227 0.0403 1.0867 0.0428 =ii(D "'tJ
14 1.1265 0.0444 1.2232 0.0482 1.2129 0.0478 1.0456 0.0412 1.1108 0.0437 1.1849 0.0466 1.2589 0.0496 CD CD
<0 :::::!. en 0
....... 15 1.2917 0.0509 1.4026 0.0552 1.3908 0.0548 1.1989 0.0472 1.2737 0.0501 1.3586 0.0535 1.4435 0.0568 :::J en
16 1.4678 0.0578 1.5804 1.3624 0.0536 1.4474 0.0570 0.0608 1.6404 0.0646 (Q 0 -·
~ 1.5938 0.0627 0.0622 1.5439 ...... :::J -
0 - -·
17 1.6548 0.0652 1.7969 0.0707 1.7818 0.0701 1.5359 0.0605 1.6318 0.0642 1.7406 0.0685 1.8494 0.0728 0.~ 0
18 1.8526 0.0729 2.0117 0.0792 1.9948 0.0785 1.7195 0.0677 1.8269 0.0719 1.9487 0.0767 2.0705 0.0815 ro 8 :::s
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19 2.0611 0.0811 2.2380 0.0881 2.2193 0.0874 1.9130 0.0753 2.0326 0.0800 2.1681 0.0854 2.3036 0.0907
20 2.2802 0.0898 2.4759 0.0975 2.4552 0.0967 2.1163 0.0833 2.2487 0.0885 2.3986 0.0944 2.5485 0.1003 <8. Cii
::r ...... •o::J
21 2.5098 0.0988 2.7252 0.1073 2.7024 0.1064 2.3294 0.0917 2.4752 0.0974 2.6402 0.1039 2.8052 0.1104 en ...... ~
OJ.-+
22 2.7497 0.1083 2.9857 0.1175 2.9608 0.1166 2.5521 0.1005 2.7119 0.1068 2.8927 0.1139 3.0735
3.3532
0.1210
0.1320
0
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b
23
24
3.0000
3.2603
0.1181
0.1284
3.2574
3.5401
0.1282
0.1394
3.2303
3.5107
0.1272
0.1382
2.7843
3.0260
0.1096
0.1191
2.9587
3.2156
0.1165
0.1266
3.1560
3.4300
0.1243
0.1350 3.6444 0.1435
(D.-+
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.0
25 3.5307 0.1390 3.8336 0.1509 3.8019 0.1497 3.2769 0.1290 3.4824 0.1371 3.7146 0.1462 3.9467 0.1554 s· :.
26 3.8110 0.1500 4.1379 0.1629 4.1038 0.1616 3.5370 0.1393 3.7590 0.1480 4.0096 0.1579 4.2602 0.1677 CD :::J
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27 4.1010 0.1615 4.4528 0.1753 4.4161 0.1739 3.8062 0.1498 4.0452 0.1593 4.3149 0.1699 4.5846 0.1805 en::r
qCD
28 4.4007 0.1733 4.7782 0.1881 4.7389 0.1866 4.0843 0.1608 4.3410 0.1709 4.6303 0.1823 4.9197 0.1937 o en
0.1951 5.2655 0.2073 "'o
29
30
4.7098
5.0282
0.1854
0.1980
5.1138
5.4595
0.2013
0.2149
5.0719
5.4149
0.1997
0.2132
4.3712
4.6667
0.1721
0.1837
4.6461
4.9604
0.1829
0.1953
4.9558
5.2911 0.2083 5.6218 0.2213
m...
0.2358
- 3
5.9884
31 5.3559 0.2109 5.8152 0.2289 5.7679 0.2271 4.9708 0.1957 5.2839 0.2080 5.6361 0.2219
83
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0
32 5.6926 0.2241 6.1807 0.2433 6.1306 0.2414 5.2832 0.2080 5.6163 0.2211 5.9907 0.2359 6.3651
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a- 34
35
6.3924
6.7552
0.2517
0.2660
6.9405
7.3343
0.2732
0.2888
6.8845
7.2754
0.2710
0.2864
5.9326
6.2693
0.2336
0.2468
6.3073
6.6656
0.2483
0.2624
6.7278
7.1099
0.2649
0.2799
7.1482
7.5543
0.2814
0.2974 :Yo
s- 7.9698 0.3138
CD OJ
g. 36
37
7.1263
7.5057
0.2806
0.2955
7.7372
8.1491
0.3046
0.3208
7.6753
8.0840
0.3022
0.3183
6.6138
6.9658
0.2604
0.2742
7.0322
7.4069
0.2769
0.2916
7.5010
7.9007
0.2953
0.3111 8.3945 0.3305
CD :::J
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8.8282 0.3476
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~ 38 7.8931 0.3108 8.5696 0.3374 8.5015 0.3347 7.3253 0.2884 7.7896 0.3067 8.3089 0.3271 :::J en
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(/)
40 8.6912 0.3422 _Jl.4~Q__ ~.37!§ 9:3616 ~0.3686 8.0659 0.3176 8.5782 0.3377 9.1501 0.3602 9.7220 0.3828 3 OJ
s- Oo.
0. -·
~ ~~
 ELECTRICAL
Twin Cylinder Fan COl Ignition - Exploded View - Timing
1999 Indy 340, 340 Dlx, 340 Touring, Sport, Sport Touring, Transport, Trail, Trail Touring

Stator Plate

Lighting Coil

CDI Control Unit

180 and 200 Watt Pulseless

NOTE: Always verify timing of engine at room temperature only (68° F/20° C).

Refer to ignition timing procedure on page 9.22.

Blower Housing NOTE: Acceptable variance

Stationary is usually one line on either
Lines side of the dial indicated
blower housing stationary
line.

Polaris Industries Inc. 9.15 10/98

ELECTRICAL
Twin Cylinder Fan COl Ignition - Exploded View -Timing
1999 XCF, Super Sport, Trail RMK

Stator

~
~~\
fP~~ qp~,
o. . . CDI System

~ " ·~
~ ~ RFI Caps I

Ignition Coil

240 Watt System

NOTE: Always verify timing of engine at room temperature only (68° F/20° C).

Refer to ignition timing procedure on page 9.22.

Blower Housing NOTE: Acceptable variance

Stationary is usually one line on either
Lines side of the dial indicated
blower housing stationary
line.

Flywheel
Mark

10/98 9.16 Polaris Industries Inc.

 ELECTRICAL
Fuji Twin Cylinder Liquid CDI Ignition - Exploded View -Timing
1999 Indy 500, 500 RMK, 500 Classic, Classic Touring, Widetrak LX

Lighting Coil

200 Watt System

NOTE: Always verify timing of engine at room temperature only (68° F/20° C).

Refer to ignition timing procedure on page 9.22.

Acceptable Variance

Flywheel Flywheel Lines

Rotation

! Stationary
Pointers

NOTE: Acceptable variance is usually

one line on either side of the dial indicated
timing mark.

Polaris Industries Inc. 9.17 10/98

ELECTRICAL
Domestic Twin Cylinder CDI Ignition - Exploded View -Timing
1999 440 XCR, 500 XC/SP, 600 XC/SP, 600 RMK, 700 XC/SP, 700 SKS, 700 RMK

Stator~&

Flywheel 0
~ ~!},
<f?

·---------, ©~
:
I
1

( ) :
~~a
0
I
I
CDI~ RF~~
~ ~---------:~
600/700 only

~
280 Watt System

NOTE: Always verify timing of engine at room temperature only (68° F/20° C).

Refer to ignition timing procedure on page 9.22.

Acceptable Variance

Flywheel Flywheel Lines

Rotation
Stationary
t Pointers

NOTE: Acceptable variance is usually

one line on either side of the dial indicated
timing mark.

10/98 9.18 Polaris Industries Inc.

 ELECTRICAL
Three Cylinder CDI Ignition Timing - Exploded View (Typical)

XLT Special, XLT Classic, XLT Touring

Pulser Coil
Stator
*Lighting/Exciter

COl Control Box

*The Exciter Coil can be

identified by wire color
and smaller windings.

280 Watt System

NOTE: Always verify timing of engine at room temperature only (68° F/20° C).

Refer to ignition timing procedure on page 9.22.

Flywheel \
Rotation
! w
Acceptabl( Variance

-
Flywheel Lines

Stationary
Pointers

NOTE: Acceptable variance is usually

one line on either side of the dial indicated
timing mark.

Polaris Industries Inc. 9.19 10/98

ELECTRICAL
Three Cylinder COl Ignition - Exploded View

1999 700 XCR, 800 XCR

Stator
*Lighting/Exciter

CDI Control Box

*The Exciter Coil can be

Secondary Coils identified by wire color
and smaller windings.

280 Watt System

NOTE: Always verify timing of engine at room temperature only (68° F/20° C) with TPS unplugged.

Refer to ignition timing procedure on page 9.22.

Acceptable Variance

Flywheel Flywheel Lines

Rotation

~
Stationary
Pointers

NOTE: Acceptable variance is usually

one line on either side of the dial indicated
timing mark.

10/98 9.20 Polaris Industries Inc.

 ELECTRICAL
CDI Ignition Timing

Timing Procedure - All Models

NOTE: Always check ignition timing with the 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 9.7).
3. Connect an accurate tachometer and a good quality timing light to the engine according to manufacturer's
instructions. Disconnect the TPS (Throttle Position Sensor) connector from carburetor on 700 XCR and BOO
XCR.
4. Start engine and increase RPM to the point
specified in the timing specification chart on page Acceptable Variance
9.1 (1750, 3000, 3250). Hold the throttle to
Flywheel
maintain specified timing RPM.
Rotation
5. Point the timing light at the timing inspection hole.
6. With your head positioned so there is a straight
line between your eye, the stationary pointer and
!
the crankshaft center line, note the relative
position between the marked flywheel line and the NOTE: Acceptable variance is usually
stationary pointer. If the stationary pointer is one line on either side of the dial indicated
aligned with the mark made in Step 2, (or within timing mark.
the acceptable ± variance) the timing is correct.
7. If the pointer is outside the variance, the stator will Liquid Cooled
have to be rotated either with crankshaft rotation
(to retard the timing) or against rotation to
advance it.
NOTE: Rotate stator plate approximately the same
distance as the marks must move.
Blower Housing
NOTE: In most cases, the recoil starter housing, re-
Stationa
coil drive hub, and flywheel must be removed to loos- Lines
en the stator bolts and change the timing. On some
engines, the stator plate retaining screws can be ac-
cessed through the flywheel.
Flywheel
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
Specifications section for torque specifications
and flywheel installation procedure for engine Fan Cooled
type.

Polaris Industries Inc. 9.21 10/98

Due to the high RPM necessary and the possible danger involved, special care must be obseNed whenever per-
forming an operating RPM timing check to avoid serious personal injury.
This check need not be performed unless symptoms leading to poor performance and possible engine damage
are present.
• Never operate the engine with the clutch guard open or removed.
• Do not stand over or around the clutch while performing this test.
• Perform the test as quickly as possible. Avoid prolonged periods of engine free-rev.

Operating RPM Timing Test Procedure

1. Using the charts at the beginning of this unit, determine the ignition advance BTDC at the operating RPM.

2. Remove the mag side spark plug and install a dial indicator in that cylinder.

3. Zero the dial indicator as explained on page 9.6.

4. Turn the crankshaft in the opposite direction of rotation to a point approximately .1 00" (2.5 mm) before the
operating ignition timing point.

5. Turn the crankshaft in the proper direction of rotation until the dial indicator shows the proper piston position
BTDC for operating RPM ignition timing. NOTE: The charts only indicate degrees BTDC. This figure must be
converted using the tables on page 9.14. Example: The operating timing and RPM for an engine is 16° at
7500 RPM. Using the chart, 16° on this engine is .058 BTDC at 7500 RPM. Using a properly installed and
zeroed dial indicator, back the engine up to approximately .150 BTDC. Then rotate the crank in the proper
direction of rotation to .058 BTDC.

6. While holding the crankshaft at the ignition timing point (as shown on dial indicator), make a timing mark on the
flywheel or fan blade using a piece of chalk or marker.

7. Remove the dial indicator and reinstall spark plug.

8. Start the engine. Advance and hold the throttle at the operating RPM specified on the charts. View the timing
mark with the timing light. The marks should be between the allowable +1- variance indicated on the operating
RPM timing specification.

9. If the operating RPM timing greatly varies from the specification, but the standard ignition timing (1750, 3000,
or 3250 RPM) is correct, refer to the ignition troubleshooting section in this unit for corrective action.

10/98 9.22 Polaris Industries Inc.

 ELECTRICAL
Battery Service
Preparing a New Battery for Service
To ensure maximum service life and performance from a battery, it must have proper initial servicing. To service
a new battery, the following steps must be taken. NOTE: Do not service the battery unless it will be put into regular
service within 30 days.
1. Remove vent plug from vent fitting.
2. Fill battery with electrolyte to the upper level marks on the case.
3. Set battery aside and allow it to cool and stabilize for 30 minutes.
4. Add electrolyte to bring the level back to the upper level mark on the case. NOTE: This is the last time that
electrolyte should be added. If the level becomes low after this point, add only distilled water.
5. Charge battery at 1/10 of its amp/hour rating.
Example:1/10 of 9 amp battery= .9 amps, 1/10 of 14 amp battery= 1.4 amps, 1/10 of 18 amp battery= 1.8
amps (recommended charging rates).
6. Check specific gravity of each cell with a hydrometer to ensure each has a reading of 1.270 or higher.
Battery Testing
There are three easy tests which can determine battery condition. Whenever the complaint is related to either
the starting or charging systems, the battery should be checked first.
Lead-acid batteries should be kept at or as near full charge as possible. If the battery is stored or used in a partially
charged condition, hard crystal sulfation will form on the plates, reducing their efficiency and possibly ruining the
battery.
Open Circuit Voltage Test (OCV)
Battery voltage should be checked with a digital multitester. Readings of 12.6 or less require further battery testing
and charging.
Specific Gravity Test
A tool such as the battery hydrometer (PN 2870836) can be used to measure electrolyte strength or specific grav-
ity. As the battery goes through the charge/discharge cycle, the electrolyte goes from a heavy , more acidic state
at full charge to a light, more water state when discharged. The hydrometer can measure state of charge and
differences between cells in a multi-cell battery. Readings of 1.270 or greater should be observed in a fully
charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to
replace the battery.

State Of Charge Conventional Yumacron

Lead-acid Type
100% Charged 12.60V 12.70V
75% Charged 12.40V 12.50V
50% Charged 12.10V 12.20V
25% Charged 11.90V 12.0V
0% Charged Less Than Less Than
11.80V 11.9V

State Of Charge* Conventional Yumacron

Lead-acid Type
100% Charged 1.265 1.275
75% Charged 1.210 1.225
50% Charged 1.160 1.175
25% Charged 1.120 1.135
0% Charged Less Than Less Than
1.100 1.115
*at 80° F

NOTE: Subtract .01 from the specific gravity for electrolyte at 40° F and compare these values to the chart.

Polaris Industries Inc. 9.23 10/98

ELECTRICAL
Battery Service
Load Test
NOTE: This test can only be performed on machines equipped with electric start. This test cannot be performed
if the engine or starting system is not working properly.
A battery may indicate a fully charge condition on the OCV test and the specific gravity test, but still not have the
storage capacity necessary to properly function in the electrical system. For this reason, a battery capacity or
load test should be conducted whenever poor battery performance is encountered.
To perform the test, hook a multitester to the battery in the same manner as in the OCV test. The reading should
be 12.6 volts or greater. Engage the electric starter and view the registered battery voltage while cranking the
engine. Continue the test for 15 seconds. During this cranking period, the observed voltage should not drop below
9.5 volts. If the beginning voltage is 12.6 or higher and the cranking voltage drops below 9.5 volts during the test,
replace the battery.
Refilling a Low Battery
The normal charge/discharge cycle of a battery causes the cells to give off gases. These gases, hydrogen and
oxygen, are the components of water. Because of the loss of these gases and the lowering of the electrolyte level,
it will be necessary to add pure, clean distilled water to bring the fluid to the proper level. After filling, charge the
battery to raise the specific gravity to the fully charged position (1.270 or greater).
Off Season Storage
To prevent battery damage during extended periods of non-use, the following basic maintenance items must be
performed.
1. Remove battery from machine and wash the case and battery tray with a mild solution of baking soda and
water. Rinse with lots of fresh water after cleaning. CAUTION: Do not allow any of the baking soda solution to
enter the battery or the acid will be neutralized.
2. Using a wire brush or knife, remove any corrosion from the cables and terminals.
3. Make sure the electrolyte is at the proper level. Add distilled water if necessary.
4. Charge at a rate no greater than 1/10 of the battery's amp/hr capacity until the electrolyte's specific gravity
reaches 1.270 or greater.
5. The battery may be stored either in the machine with the cables disconnected, or on a piece of wood in a cool
place. NOTE: Stored batteries lose their charge at the rate of 1% per day. They should be fully recharged
every 30 to 60 days during a non-use period. If stored during winter months, the electrolyte will freeze at
higher temperatures as the battery discharges. The chart indicates freezing points by specific gravity.

Specific Gravity of Electrolyte Freezing Point

1.265 -75° F
1.225 -35° F
1.200 -17" F
1.150
1.100
+5° F
+18° F
A WARNING
1.050 +27" F Battery electrolyte is poisonous. It contains acid!
Serious burns can result from contact with the skin,
eyes, or clothing.
Charging Procedure
ANTIDOTE:
Charge battery with a charger no larger than 1/10 of EXTERNAL: Flush with water.
the battery's amp/hr rating for as many hours as need- INTERNAL: Drink large quantities of water or milk.
ed to raise the specific gravity to 1.270 or greater. Follow with milk of magnesia, beaten egg, or vegeta-
ble oil. Call physician immediately.
EYES: Flush with water for 15 minutes and get prompt
A WARNING
medical attention.
The gases given off by a battery are explosive. Any Batteries produce explosive gases. Keep sparks,
spark or open flame near a battery can cause an explo- flame, cigarettes, etc. away. Ventilate when charging
or using in closed space. Always shield eyes when
sion which will spray battery acid on anyone close to working near batteries.
it. If battery acid gets on anyone, wash the affected KEEP OUT OF REACH OF CHILDREN.
area with large quantities of cool water and seek im-
mediate medical attention.

10/98 9.24 Polaris Industries Inc.

 ELECTRICAL
Dynamic Testing of Electric Starter System
Condition: Starter fails to turn motor or motor turns slowly.
NOTE: Be sure the engine crankshaft is free to turn before proceeding. For this test a digital multitester must
be used. Meter connections are shown on page 9.24.

With tester on VDC, place tester black lead on bat- Remove battery, test and/or service. Install a fully
tery negative (-)terminal and tester red lead on bat- charged shop battery to continue the test.
tery positive (+)terminal. (A) Page 9.26. Reading
should be 12.6V or greater. Is it? (Continue with left column)
No_,
Yest

Disconnect red engagement coil wire from start sole- With black tester lead on ground, check for voltage
noid. Connect black tester wire to an appropriate at large relay in terminal, circuit breaker in and out
ground and red lead to red harness wire at solenoid. terminals, and across both sides (red and red/white)
(F) page 9.26. Rotate ignition key to the start posi- of the ignition switch with switch on start. Repair or
tion. Meter should read battery voltage. Does it? replace any defective parts.
NO->
Yest
Reconnect solenoid, connect tester black lead to Clean battery to solenoid cable ends or replace
battery positive terminal and red tester lead to sole- cable.
noid end of battery to solenoid cable. (B) Page 9.26.
Turn key to start position. The reading must be less
than .1 V DC. Is it?
NO->
Yest

Connect black tester lead to solenoid end of battery Replace starter solenoid.
to solenoid cable and red tester lead to solenoid end
of solenoid to starter cable. (C) Page 9.26. Turn
key to start position. The reading must be less than
.1VDC. lsit?
No_,
Yest

Connect black tester lead to solenoid end of solenoid Clean solenoid to starter cable ends or replace
to starter cable and red tester lead to starter end of cable.
same cable. (D) Page 9.26. Turn key to start posi-
tion. The reading must be less than .1 V DC. Is it?
No_,
Yest

Connect black tester lead to starter frame. Connect Clean ends of engine to battery negative cable or
red tester lead to battery negative (-)terminal. (E) replace cable.
Page 9.26. Turn key to start position. The reading
should be less than .1 V DC. Is it?
NO->
Yest

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.

Polaris Industries Inc. 9.25 10/98

ELECTRICAL
Electric Starter System Testing (Static)
Starter Motor Static Testing
IGNITION
SWITCH

IGNITION SWITCH

SYSTEM
BAN- GRO\JND

}J_-,
IGNITION WIRE COLORS
ALTERNATOR
OUTPUT
'u r

~:
G TERMINAL · BROWN · GROUND I

fl TERMINAL · RED · flATTERY ' -'-

M TERMINAL · BLACK - IGNITION
S TERMINAL - RED/WHITE · STARTER

' - - - - - - - R'.W-------f(F) (Disconnect RIW Wire)

OFF RUN START R (.C)

::~:
A B CIRCUIT BREAKER
18 liMP!
R/W S '
IGNITION SWITCH ''
' STARTER RELAY
li"'""--~-H- _________ {8) CHASSIS GND
1
COLOR CODE ,----------(E) _________ ! -
A ' RED
BAN = BROWN I
I
I
I
ENGINE GND -=-
flLK = BLACK
Y ' YELLOW I
R/W = RED WITH WHITE TRACER ! --=- BATTERY 1
I "':"" I
t_.S:t!il..!'!.E_G_tJQ. _______ _!
A-E See page 9.25
1. Remove starter motor and disassemble. (See page 9.27 for exploded view) Mark end covers and housing for
proper reassembly.
2. Remove pinion retaining snap ring, spring and pinion gear.
3. Remove brush end bushing dust cover.
4. Remove housing through bolts.
5. Slide brush end frame off end of starter. NOTE: The electrical 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 plate.
7. Clean and inspect starter components. NOTE: Some cleaning solvents may damage the insulation in the
starter. Care should be exercised when selecting an appropriate solvent. The brushes must slide freely in
their holders. If the commutator needs cleaning, use only an electrical contact cleaner and/or a non-metallic
grit sandpaper. Replace brush assembly when worn to 5/16" (.8 em) or less.
Starter Housing and Field Coil Inspection
1. Using a digital multitester, measure resistance between starter 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. Measure resistance between commutator and armature shaft. Reading should be infinity.
3. 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.

10/98 9.26 Polaris Industries Inc.

 ELECTRICAL
Electric Starter Assembly
Starter Assembly

Ring Gear

ffi~
~w
/ { G~
® ®
Armature

1. Slide armature into field coil housing.

2. Lightly grease drive end bushing and install drive end
frame on armature.
3. Mount starter vertically in a vice with brush end up.
4. While holding negative brushes out against their
springs, slide brush plate down onto the commutator.
5. While holding positive brush springs to the side, slide
positive brushes into their holders and correctly
position the springs on top of the brushes.
6. Using a non-petroleum grease, lubricate brush end
bushing and slide it onto end of armature.
7. Align threaded holes in brush plate and install dust
cover and screws.
8. Reinstall through bolts and properly tighten all
screws.
9. Lightly grease pinion shaft and install pinion, spring
stopper and snap ring.

Polaris Industries Inc. 9.27 10/98

ELECTRICAL
Starter Installation

Starter Solenoid Bench Test

The only test which can be done on the bench is the pull
in coil resistance, which should be 3.4 ohms.

Starter Installation
1. Position starter motor so there is no less than .1 00"
clearance between the ring gear and the starter
motor pinion gear.

2. Torque through bolt mount bracket nuts to

specification.
3. Torque 8mm (drive end) mount bolts to specification.
4. Torque 6mm (brush end) bracket to specification.

Starter Pinion
Gear

Unregulated Voltage - continued

1. Test resistance of lighting coil and compare to

specifications in the model specific wiring diagram.
Reminder: Meter resistance must be subtracted from
reading.
NOTE: 0.3 to 0.5 ohms may be less than the internal resistance of your meter leads or meter. Before measuring
the stator resistance, short the meter leads together and read the display and record this measurement. Subtract
this reading from the stator resistance readings.
EXAMPLE: Short meter leads together, meter reads 0.7 ohms. Measure stator resistance, meter reads 1.10
ohms. Subtract 0.7 ohms (meter/lead resistance) from 1.10 ohms (reading obtained when checking yellow lead
to brown lead). True reading is: 1.10 ohms (observed reading when checking stator)
-0.7 ohms (meter/lead resistance)
=
0.4 ohms (true stator resistance)

10/98 9.28 Polaris Industries Inc.

 ELECTRICAL
Lighting System Output

Unregulated Voltage - continued

2. Turn the multitester dial to the Volts AC (Vr-v) position.

3. Disconnect the alternator to main harness connector at
engine. ( 15-45 VAC)
4. Connect one of the tester leads to the yellow alternator
wire and the other lead to the brown alternator wire.
NOTE: On floating alternators, the yellow/red stator
wire should connect to the brown stator wire. If it does
not, the system will not have a ground and will not 0 +
operate.
5. Start the engine. While observing the voltage reading,
increase the engine speed to about 3000 RPM.
Readings of between 15 and 45 VAC are considered
normal.

Short Circuit Current (AC Amp Test)

1. Turn multitester dial to Ar-v.
2. Connect red lead to 1OA terminal.
3. Connect black lead to Com (-) meter terminal.
4. Disconnect lighting/charge coil wires from system.
Connect meter leads to coil wires leading to stator coils.
5. Start and idle engine. Readings should be above 5
amps. Refer to Amps AC on page 9.4.
Regulated Voltage

1. Connect the alternator to main harness connector.

2. Insert one of the tester leads along the side of the yellow
regulator wire connector between the insulation and the
terminal.
3. Ground the other tester lead.
4. Start engine and observe headlight output. Increase
engine RPM. If the headlights seem dim above 3500
RPM, let the engine return to idle and disconnect the
yellow wire from the regulator. Carefully observe the
voltage reading. Do not allow voltage to increase above
14.0 volts.
5. Slowly increase RPM. Voltage above 12 volts at 2500 -
3000 and a bright headlight, indicates a good lighting
coil. Voltage below 10 volts at 3000 indicates excessive
system loads, poor flywheel magnets, lighting coil
problems, or wires harness problems. Check for
partially grounded (shorted) yellow wire.
6. Reconnect the yellow regulator wire and increase the
RPM. If the headlight was bright with the regulator
disconnected and dim when connected at the same
RPM, the regulator or regulator ground is at fault.

Polaris Industries Inc. 9.29 10/98

ELECTRICAL
Alternator Output- Pulse System

2-pulse, 3-pulse, 6 pulse Alternators

The difference between a 2 pulse, 3 pulse, and 6 pulse alternator system is the number of AC sine waves created
by the alternator in one revolution of the crankshaft. For example, on a 6 pulse system, the alternator will create 6
pulses, or 6 complete AC sine waves, in one crankshaft revolution. The tachometer reads these sine waves,
therefore giving you accurate RPM readings. A 3 pulse tachometer cannot be used on a 6 pulse system. If this is
done, the tachometer will read double RPM. Refer to the following text for applications.

All Polaris Snowmobiles:

All Fuji single cylinder and twin cylinder engines . . . . . . . . . . . . . . . . . . . . . 2 pulse

All Polaris Domestic twin cylinder engines/1999 440 & 550 fan cooled . . 6 pulse
Early model three cylinder engines (500, 600, 650, 750, early 800) . . . . 3 pulse
Late model three cylinder engines (580, 600, 680, 700, 800) .......... 6 pulse

All Polaris ATVs:

All 150 watt alternators and earlier ..... 2 pulse

All 200 watt and 250 watt ............. 6 pulse

All Polaris PWC:

All PWC ...... 6 pulse

6 Pulse 3 Pulse 2 Pulse

Tachometers:
Tachometers for snowmobiles will have an identification marking on the back side. For example: The tachomter
for a 500 XC will have "6 pulse" (or 6P) written on it.

10/98 9.30 Polaris Industries Inc.

 ELECTRICAL
Typical Exciter, Pulser or Lighting Coil 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.

4. Clean solder terminals (B) on the replacement coil

and re-solder to their proper wires.
NOTE: Always position with numbers towards the outsid1

5. Reinstall retaining screws and spacers.

6. Using a moisture-proof sealant, seal solder joints
as shown. NOTE: All soldering must be done using
rosin core solder.
7. Test resistance of each coil prior to stator plate
installation.
NOTE: Lighting and pulseless coils are replaced in a
similar manner.
IMPORTANT: After the stator plate is reinstalled on the
engine, check placement of all coil leads to prevent pos-
sible contact with the flywheel.

Polaris Industries Inc. 9.31 10/98

ELECTRICAL
Electrical Testing
Headlight Bulb Filament Continuity Test
1. Turn the Multitester dial to the ohms (Q) position.
2. Disconnect the wire harness from the headlight bulb.
3. Viewing the end of the bulb with the terminal blades at
the 9, 12 and 3 o'clock position, connect the black
multitester lead to the 9 o'clock blade.
4. Touch the red tester lead to the 12 o'clock terminal and
then to the 3 o'clock terminal, noting the resistance
value of each. A reading of between 2 and 5 ohms is
good. An open reading indicates a bad element.

Hi/Lo Beam Switch Testing

1. Set the multitester dial to the ohms (Q) position.
2. If the Hi/Lo switch has not been removed from the
machine, disconnect the switch to harness plug in
connector.
3. With the Hi/Lo switch in the La beam position, check the
resistance between the yellow and the green switch
wires. The reading should be less than .4 ohms.
4. Turn the Hi!Lo switch to the Hi beam position and the
multitester should 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 La beam position and
the meter should again read an open circuit (OL}. Grn

Yel

Yei/Rd
Seat Harness Troubleshooting
High/Low Switch
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. Tip the seat over and remove the right side seat cover
staples. Locate and repair the harness problem.
8. Reinstall the staples and re-check the seat harness.

10/98 9.32 Polaris Industries Inc.

 ELECTRICAL
Electrical Testing
Ignition Switch Testing (Non-Electric Start)
1. Set the multitester dial to the ohms (.Q) position.
Connect one of the tester leads to either of the switch On
Off
terminals and the other tester lead to the other switch
terminal. Blk
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). I I Brn !
3. Check the resistance between each of the switch Ignition 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.

Ignition Switch Testing (Electric Start Models)

NOTE: Refer to the appropriate model and year wiring

diagram for ignition switch wire colors and connections.

1. Disconnect wires. Set the multitester dial to the ohms

(.Q) position.
2. With the key in the off position, check the resistance
between the G (Ground, brown) terminal and the M
(Mag, black) terminal. This reading must be less than .4
ohms.
3. Turn the key to the on position. The multitester should
now read an open circuit (OL). 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 Brn
open circuit (OL). T
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
Blk •
an open circuit (OL) reading.
R
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. ~
R/W

Ignition Switch - Electric Start

Polaris Industries Inc. 9.33 10/98

ELECTRICAL
Coolant High Temperature Indicator Testing

Ground the Black/White wire here

Circuit (with the engine running) to test
Power the light.
In - Yel------,1 Blk!W------..

II Temp II
Engine
Ground

The indicator light is controlled by a temperature/warning switch installed into the engine cooling system. When
engine coolant temperature reaches approximately 205° F, the switch closes, completing the circuit through the
indicator light to ground. The system should be tested periodically for proper operation.

Lamp Circuit Test

1. Remove wire from temperature sensing switch located under thermostat housing.
2. With engine idling, ground wire to engine. The temperature warning lamp on the console should light. If not,
replace the lamp assembly or inspect wiring for shorts or open circuit.

Temp Light Temperature Sensor Test

The temperature/warning switch is normally open.

1. Set the multitester on the ohms (Q) scale.

2. Disconnect the lamp wire.
3. Connect one test probe to the switch terminal and the other to engine ground. The meter should show an open
circuit (OL). This indicates a normally open switch. If the switch were heated to approximately 205° F, the
contact in the switch would close and the reading would be less than .4 ohms.

If attempting to heat the sensor to close the contacts, heat only in a water bath. Never subject the sensor to an
open flame to attempt to close the contacts as sensor damage will result.

10/98 9.34 Polaris Industries Inc.

 ELECTRICAL
Speed Control Assurance Operation
Insulator
Auxiliary Kill
Switch Contacts

Ignition Primary

Engine Ground

B
Throttle Control
Cutaway
The speed control assurance consists of two series connected switches. If one or both switch plungers are posi-
tioned inward, the circuit is open and the engine will run.
At idle, with the throttle lever properly adjusted, the bottom switch circuit is open and the plunger is inward. The
top switch circuit is closed, and the plunger is outward. The speed control circuit is open, allowing the engine to
run.
As the throttle lever is actuated to an off idle position, the top switch circuit is opened (plunger in) and the bottom
switch circuit is closed (plunger out). The speed control circuit is still open, allowing the engine to run.
In the event the carburetor or controls malfunction and allow the throttle cable to become slack, the circuit will
close (both switch plungers out), grounding the ignition system and causing the engine to stop.
Speed Control Assurance Adjustment
Throttle lever free play must always provide a specified
clearance between throttle lever (A) and throttle block (B).
This clearance is controlled by the throttle cable sleeve(s)
and the idle speed screw(s).

Throttle Lever Freeplay -

Regular Throttle- .010 • .030" (.25- .8 mm)

EZ Throttle - .050 - .060" (1.27 - 1.5 mm)

If the idle speed screw(s) is adjusted inward and the cable

sleeve(s) is not adjusted to take up the throttle lever to
throttle block clearance, the engine may misfire or kill upon
initial throttle opening.

After any idle speed adjustments are made, the throttle lever to throttle block clearance and oil pump adjustment
must be checked and adjusted.
NOTE: When adjustments are made on models which have more than one carburetor, refer to Section 6, Car-
buretion, for proper carburetor synchronization adjustments.

Polaris Industries Inc. 9.35 10/98

ELECTRICAL
Speed Control Assurance Testing

1. Set the multitester in the ohms (Q) position.

2. Disconnect the switch harness from the main wire harness.

3. Connect the two multitester leads to the two switch wires.

Test 1 - Open Circuit - Run

With the auxiliary shut-off switch in the ON position, the
multitester should read an open circuit (OL). As the throttle
lever is moved from idle to off idle, the tester should continue
to read an open circuit. If the tester fluctuates and the
throttle lever to throttle block clearance is adjusted properly,
the switch assembly must be replaced.

Test 2 - Closed Circuit - Kill

The two speed control switches must make a complete cir-
cuit to kill the engine. To check the switches, pull the throttle
lever out away from the throttle block. With the switch plung-
ers outward and the auxiliary shut-off switch in the ON posi-
tion, the multitester must read less than .4 ohms resistance.
Inspect wires and repair if damaged, or replace switch as-
sembly.

Test 3 - Auxiliary Shut-Off

The multitester should read less than .4 ohms in the OFF position and an open circuit in the the ON position.
Inspect wires and repair if damaged, or replace switch assembly.

Speed Control Assurance Replacement

Auxiliary shut-off and speed control assurance switches are connected and replaced as a unit from the back side
of the throttle block.

1. Remove the handlebar pad and/or throttle block backing plate.

2. Slide oat the auxiliary shut-off portion of the switch.

3. Remove the two screws securing the two speed control assurance switches.

4. Remove the switches noting their placement in the throttle block.

5. Replace the assembly and check its operation.

10/98 9.36 Polaris Industries Inc.

 ELECTRICAL
Electric Fuel Gauge Testing

Use the multitester ohmmeter to test the resistance of the fuel sender.

Position Ohms Range

Empty 95Q 90-97.5 n
Full 7Q 4.5- 13 n

The supply voltage to the gauge should be 13.5 VAC.

Fuel Gauge

Fuse
(0.2A}

Pur/Wh Brn Yel

Polaris Industries Inc. 9.37 10/98

ELECTRICAL
Handlebar Warmer Testing

High-Low Handwarmer Toggle Switch

Below are the correct wire to PIN numbers:

1. Blue - High Circuit
2. Yellow - Regulated Power (A.C.) HANDLEBAR HARNESS WIRE CONN.
3. Blue/Red - Low Circuit
BLUE
4. Blank
5. Blank
6. Blank
7. Brown - Ground Circuit YELLOW
8. Blank
BROWN
Testing
BLUE/RED
1. Disconnect handwarmer connector at the
handwarmer.
2. Measure the low range resistance between the SWITCH- HANDWARMER
Blue and Brown wires. The resistance should HI-LOW
be 19.2 D..
3. Measure the high range resistance between the
Brown and Blue/Red. The resistance should be
9.6Q.

Thumbwarmer Toggle Switch

Below are the correct wire to PIN numbers:

1. White/Gray - To Thumbwarmer
2. Yellow - Regulated Power (A.C.)
3. White/Gray - To Thumbwarmer WHITE/GRAY
4. Blank BROWN
5. Blank
6. Blank YELLOW
7. Brown - Ground Circuit
8. Blank

WHITE/GRAY

SWITCH - THUMBWARMER

10/98 9.38 Polaris Industries Inc.

 ELECTRICAL
Ignition System Troubleshooting

Condition: No Spark

Disconnect the single black (black/white) wire from the CDI Module to Check the ignition switch, wire harness, throttle safety switches
the ignition kill circuit. Does it have a spark? and kill switch for proper adjustment or short to ground. Repair
Yes-+ or replace as necessary.
Not

Disconnect the stator to CDI module wires. Test the resistance values All except 3 cylinders: If the parts of the ignition system under
of the stator coils as per the wiring diagrams. Are the resistance val- the flywheel check OK, the only remaining component is the
ues within specs? coii/CDI module assembly. Replace the module with another
with the same CU number. (See ignition data)
All 3 cylinders: Disconnect and check the secondary ignition coil
resistances. Refer to the resistance values listed in wiring
Yes-+ diagrams. If the coil resistance values are within specs, replace
Not the CDI module.

Isolate which component's resistance is not within specs. Remove

the flywheel and stator. Recheck the resistances; look for pinched or
bare harness wires; or replace the coil. Refer to page 9.31 for coil
replacement procedures.

Condition: Incorrect Advance/Retard

Follow the engine timing procedure for checking running timing at Adjust the ignition timing by rotating the stator plate to correct the
recommended RPM. Is the timing within limits? timing. After adjusting the recommended RPM timing, continue
No-+ with operating RPM timing if poor performance exists. (Continue
Yes t on with left column.) See ignition timing page 9.1.
Follow the engine timing procedure for checking operating RPM timing If the running and operating RPM timing are within limits, no
from page 9.22. Is the timing within limits? other testing is necessary.

Yes-+
Not
Remove the ignition kill circuit by disconnecting the single black wire Check the ignition switch, throttle safety switches, kill switch and
between the CDI module and the machine harness. Is the timing now harness for damage which can cause intermittent shorting
correct? problems. Correct the problem.

Yes-+
Not
Verify the correct CDI module by comparing the CU code on the box Replace the module with the correct part and readjust the ignition
to the information listed in the ignition data charts at the beginning of timing.
this section. Is it the right module? -

No-+
Vest
Check the resistance of the coils under the flywheel. Compare these Check the wiring connecting the coils and/or replace the coils as
values on wiring diagram. Are they within limits? necessary.

No-+
Vest
If the running RPM timing is within limits but the operating RPM timing
is not acceptable, replace the CDI module.

NOTE: 3 cylinder engines fire three times per revolution. At 7500 RPM the ignition is firing 21 ,500 times per
minute. Use of a timing light not capable of handling these RPMs may provide an incorrect operating RPM timing
reading. Use timing light PN 2870630 or equivalent.

Polaris Industries Inc. 9.39 10/98

 ~m
.... CDj'
~ 99 SPORT
SPORT TOURING
CDm
CDO
co
TRANSPORT
I BRAKE LIGHT
SWITCH
:lE-i
-------------OR fAT BRAKE LEVERJ
-·
' " ' IJ:J
_
LEFT HANDLEBAR GRN~-J -·o
~l>
SWITCH ASM

i-Y/R - r LOW BEAM LIGHT

or-
BAN l_____r o;·
(Q
'"'I
D)
3
REGULATOR

W/GRY
CJ)
"'0
- 0
;1-
BLU/R ---++-J--J-----'

I
1 1 r-r .g>0
THUMB
BRN WARMER ~

BLK/R

BRN/W
TAIL LIGHT
d
s::::
BRAKE lIGHT
<0 :::::!.
~ :::J
I I I I BRN TAIL LIGHT (Q
0 .______._________________ BRN
KEY AUXILIARY

~--------------------- BLK
SWITCH SHUT-OFF
BRN
OR
:;I
D)
STOP
1
RUN
STc>'
THROTTLE SAFETY SWITCHES.
BOTH SWITCHES CLOSE WHEN
THROTTLE CABLE 15 LOOSE,
Y/R :::J
CJ)
"'0
L---,---BRN~~L-----+-L--~

-
0
'"'I

t~
SPARK PLUG SPARK PLUG

LOW 0 I L LEVEL
SENDER

COLOR CODE
'"tJ STATOR COILS RESISTANCE ±10/.
BLK BLACK
0 BRN/W TO BLK/R 164 OHMS ENG I NE GROUND
Qr BRN BROWN
Y TO Y/R .2- .5 OHMS
~·
BLU BLUE

0 OHMS GRN GREEN

Y/R, BRN, W, GROUNO CHASS I 5 GROUND TACHOMETER
:J OR ORANGE
L---------------------~------------BRN------~----"

~
PUR PURPLE
REO

!:J
w WHITE
YELLOW

TWO COLOR WI RES ARE SHOWN

~ WITH MA [ N/TRACE COLORS
EXAMPLE:
BLU/R : BLUE WITH REO TRACER
 LEFT HANDLEBAR
SWITCH ASM
"J
Q) y I BRAKE LIGHT
~- ,--------OR
SWITCH
!AT BRAKE LEVER!

5"
~
:::-
~-
REGULJ\TOR

s-~

L__,
W/GRY

KEY J\UX I L1 ARY THUMB

SW [ TCH SHUT~OFF WARMER

STOP
RUN 1 THROTTLE SAFETY SWITCHES, ~~---t-,~B~R~N~
<0 WIRE STOP BOTH SWITCHES CLOSE WHEN

~
SIDE OF THROTTLE CABLE I 5 LOOSE, TAIL LIGHT
COl BOX
...... CONNECTOR

L-----BRN BRN--~J__ _~_J_ _ _

t~
BLK I

fiJ
R ' - - - - - - - BLK
BRN

COLOR CODE TAIL LIGHT

-. BLK BLACK
~
' BRN BROWN
(0
' BLU BLUE '---~----------OR------7~
(0
GRN GREEN (0
OR DRJ\NGE .-+--------PUR I ~
PUR PURPLE
REO
~
SPARK PLUG SPARK PLUG
WHITE
:::!.
YELLOW
w ENG I NE GROUND
::J
c.c
TWO COLOR WI RES ARE SHOWN
c
WITH ~A

EXJ\f-4PLE:
IN/TRACE COLORS

BLU/R : BLUE W[ TH REO TRACER

w CHASS I 5 GROUND

.________, YJ o;·
c.c
""'I
D)
STATOR COILS RESISTANCE ±10% IGNITION COIL RESISTANCE ±10% 3
BROWN TO ENGINE ZERO BLACK TO ORANGE . I OHMS .m
YELLOW/REO TO BROWN ZERO BLACK TO SECONDARY LEAD OPEN cnr
YELLOW/REO TO YELLOW .25 OHMS 4.2 K OHMS + c: m
WHITE/YELLOW TO BLACK 213 OHMS
PLUG LEAD TO PLUG LEAD 10 K OHMS FOR CAPS
T!\CHOMETER
I OPTIONAL ON "Co
SOME MODELS I CD-i
BLUE/REO TO BROWN 27 OHMS ""'I :IJ
RED/WHITE TO GREEN/RED 442 OHMS tn -
...... "CO
~
RED/WHITE TO ENGINE OPEN 0)>
0;) ::l.r
 01 ...... m
...... BRAKE LIGHT

~~
O<Or-
~
SW! TCH
!AT CAL!PERI BRN O<Om
Q) THUMBWARMER
GRN
0<00
-:E-1

ON~
Q) -· :IJ
W-BRN en""'-
~.:;· 0
RESISTANCE OFF
IB=~GRY 0 (Q :t>
ON
164 OHMS
.2- .5 OHMS C,gr-
GROUND 0 OHMS -Q)

LOW~ ~
Q)(Q
en ""'
~.Q)
0 3
OFF BAN

HIGH ~LU

BLU/R
(}:.._
H"NDWARMER c: ::l
~.a.
::l'<
tOOl
~ 0
-lo
ELECTRIC START
IGNITION SWITCH
BRN ~OFF
RUN START
""'
~.0
R£5-BRN
R/W BLK
~- ~
R
""'-10"
~
~. :IJ
BLK
R/W

<0
WIRE COLOR IGNITION SWITCH
' -:s:

yy (}7'.
BROWN· GROUND OPT
~ RED-BATTERY
1\) BLACK-IGNITION
REO/WHJ TE ·STARTER
AUXILIARY
SHUT· OfF THROTTLE SAFETY SWITCHES.
ONE SWITCH I 5 OPEN FUEL
c: ~
I N NORMAL OPERA T I ON • GAUGE ~.
BRN
:J
PUR/W
(Q
BRN
-BRN
BLK 0.2t\
FUSE
-PNK

SPARK PLUG

OPT

\:)
0 COLOR CODE

til BLK : BLACK STARTER RELAY

~-
BRN BROWN
BLU BLUE

::J GRN
OR
GREEN
ORANGE
- --~ T"CHOMETER

~<:::;'
!OPT I
PUR PURPLE
REO
TWO COLOR WI RES ARE SHOWN
Wl TH ~A IN/TRACE COLORS
w ENG I NE GROUND OPT : OPT J ONAL ON SOME MODELS

w
WHl TE EXAMPLE:
(i)• BLU/R : BLUE WJ TH RED TRACER CHASS [ 5 GROUND
(/) YELLOW

::J
~
'1:l
0
ru- r---------------- -
~- ----------------------------------------------~
OPT I ON"'L ON 1NDY 340' 5
9.6 OHMS
S"
g.
~
INDY 340 RN.-

f'
99
~
~­
CD
(I)
INDY 340 TOURING
INDY 340 DELUXE

ST 1'1 TOR RESIST "'NCES

BLU'R

r - L - BLU'R-=1
.;::,.---1 !--........._
I ~
HANOWARMERS
SINGLE HEAT

S" BRN/W TO BLK/R I 164 OHMS

THUMBW,..,RMER
ACCESSORY
~ SWITCH
y TO BRN OR Y/R I .3 TO .6 OHMS 9.6 OHMS

GNO TO BRN TO w I 0 0-~~-~---~

y u · L BAN
=nLD:R~E~-NL-OE-LR_E_V_EL
ACC.
_____ ~
BLU/R LIGHT
ll'Yl' y
~---------------.-------------L-----------------y ------------------------~ SPEEDOMETER ......
(0
ELECT A I C START (0
IGNITION SWITCH OFF RUN START
(0

G0 BRN~G ;;
v
7 BLK M
ENGINE
GROUND. R B
::::!.
R/W 5 ::l
<0 WIRE COLOR (0
IGNITION SWITCH
G TERMINAL BROWN GROUND
~ BRN B TERMINAL RED • BATTERY 0
(J.) M TERMINAL BLACK · IGNITION
REGULA TOR S TERMINAL RED/WHITE • STARTER Q)
CHASS I 5 GNO. (0
BLK\.R Y'R
"''
Q)
L__fl'-fi'---~~-~-------BRN-------~--, AUX I L I "'RY
SHUT ·OFF
RUN.l
STOP
THROTTLE SAFETY SWITCHES.
BOTH SW I TCHES CLOSE WHEN
3
THROTTLE CABLE I 5 LOOSE.
BLK - - - - - - ,
HI LO ::l
BRN--~--_f
BEAM
a.
'<
(t.)

~
LOW HIGH

:RN~
(t.)
Y'R C::===fj ~
HI /LOW SW! TCH
ENGINE GNO.
dt:
COLOR CODE
::::!.
::l
BLK BLACK
BRN BROWN ~m
BLU
GRN
PUR
OR
BLUE
GREEN
PURPLE
ORANGE
Y/R
w'
~m
R
W
RED
WHITE
oO
Y YELLOW o--4
TWO COLOR WI RES ARE SHOWN
WITH MAIN/TRACE COLORS. STARTER RELAY
CHASS I 5 GNO.
(l) :IJ
EXAMPLE:
....... BLU/R : BLUE WITH RED TRACER ~0
>< )>
~
OJ
mr-
ENGINE GNO. ST ANOARO ON 340 DELUXE ENGINE GND •
~----------------- - ------- -------------------------------
.....
...a.m
<Or-
~ <Om
CX> LEFT HANDLEBAR
<00
SWITCH ASM :E--4
-· J:J
-·o
""'1-

~)>
Y ----~ BRAKE l JGHT
SW [ TCH
,-------OR !AT BRAKE LEVER/

!2'
D)
(Q
BAN Y/A~LOW
BEAM LIGHT
REGULATOR
""'
D)
BAN 3
---+-++-1_B--,A~~~-y~A"
1 111 -c.
LIGHTS

::::s
'<
F
\_I
W/GRY
><
0
~.,

~
e!.
KEY f.UXILJARY THUMB J:J
<D SWITCH SHUT-OFF WARMER
:5:
~
~
WIRE
SIDE OF
COl BOX
CONNECTOR
STOP
RUN_!_
STOP
THROTTLE SAFETY SWITCHES.
BOTH SW I TCHES CLOSE WHEN
THROTTLE CABLE IS LOOSE. "
L----BRN BRN--r-~---r-L---

~ t~
BLK

R L - - - - - - - - OLK -------+----~----~--, BRN

COLOR CODE Y/R

TAIL LIGHT
-, BLK BLACK
' BRN BROWN
' BLU BLUE
L---f---------OR----~~

GRN GREEN
OR ORANGE .-+-------PUR I r-=-rtf\1
PUR PURPLE

R REO
SPARK PLUG SPARK PLUG
WHITE
YELLOW w ENGINE GROUND

w
TWO COLOR WI RES ARE SHOWN

YJ
WITH MAIN/TRACE COLORS CHASSIS GROUND

"'0 EXAMPLE:
0 BLU/R : BLUE WI TH REO TRACER

ill
~- STATOR COILS RESISTANCE ± 10% IGNITION COIL RESISTANCE ±10%
5'" BROWN TO ENGINE ZERO BLACK TO ORANGE . I OHMS

~t:;"
YELLOW/REO TO BROWN ZERO BLACK TO SECONDARY LEAD OPEN
YELLOW/REO TO YELLOW .2S OHMS 4.2 K OHMS + TACHOMETER
PLUG LEAD TO PLUG LEAD 10 K OHMS FOR CAPS I OPT [ ONAL ON
WHITE/YELLOW TO BLACK 213 OHMS
(i)• SOME MODELS I
(/) BLUE/REO TO BROWN 27 OHMS
REO/WHITE TO GREEN/REO 442 OHMS
5'"
r> REO/WHITE TO ENGINE OPEN
'1:J
0
iir
~- ~~
BRAKE LIGHT
SWITCH
!AT BRAKE
LEVER I
'C_oYR I II GRN eRN
5" STATOR COILS RES I STANCE ±I 0% 1

~
LOW BEAM L I GHT
BRN/W TO BLK/R 164 OHMS
Y TO Y/R .2-.5 OHMS HEAOLAMP
t:;"
Y/R, BRN, W, GROUND 0 OHMS HANOWARMER
~- SWITCH
, - - - - - - - - - - - - - BLU/R - - - - - - - ,

-·
REGULATOR
5" ! UNDER HOOD BY

~
RIGHT FOOTREST I

W~
Y/R
' - - - - - - - - BLU BLu--------,-------------,
- W/BLU - - - - - - - - - - - ,
c L-f-t+-r--eLU/R----------,---1------~~~~------,
6RN 6RN ------------------+---+-+-i PASSE.NGER
HANOW"RI.!ERS
SAME
RESJST"NCE

f-1------- BRN ~_ _ _.
IGNITION SWITCH HAND H"NO THUMB
eRN~OFF
RUN START W"RMEn WARMCR WARMCR

RffBRN 6LK
R/W
R
BLK - R/W TAIL
LAMP
BRN IGNITION SWITCH
WIRE COLOR W/BLU
[]LK/R BROWN- GROUND
co RE0-01\TTERY
BLACK-IGNITION
1\UXILIARY
SHUT-OFF
RUN .1 THROTTLE SAFETY SWITCHES.
BRN/W
~ STOP ONE SWITCH I 5 OPEN REVERSE
REO/WHITE-ST ARTER LIGHT SWITCH
I N NORM"L OPERA T I ON,
ION TRANSMISSIONJ
01
......

r
._----~--------f-----L----6RN----.----------,----------j~---' Ol
OPEN WHEN co
r--------------+---- 6LK --------+-------,---}--------_L---, FLIPPER co
PUSHED
co
f-. ~
6RN :::::!.
::::J
(C
SPARK PLUG SPARK PLUG
c
D)
(C
""'l
D)

COLOR CODE 3
BLK BLACK W/l3LU
BAN BROWN
6LU BLUE TI\CHOMCTEn ::::J
GRN
OR
GREEN
ORANGE
I w/6LU -----------------' c.
'<
:E~
PUR PURPLE TWO COLOR WI RES ARE SHOWN ENGINE GROUND
R REO WITH MAIN/TRACE COLORS
-·m
WHITE
YELLOW
EXAMPLE I
BLU/R = BLUE WI TH REO TRACER
w CHASS I 5 GROUND
g.o
-1-1
""'~::0
D)_
_.. ~0
r:t>
~
co ><r
 ... m
...... <Or
~ <am
<00
Q)
:E-1
BRAKE LIGHT
SWITCH
(AT CALIPER!
\ OYA BAN C991~
-·o -
..,-· ::0
THut.IBWARMER
GAN
LOW BEAM Ll GHT c5)>
o~.A
~r
~BAN
HE,a,OLM.IP

Sl)
m=~GAY cc
Y/All
ON~ Sil
y 3

~ ~f:/-----'--A
REGULATOR
IU"'IOEA HOOD BY LOW
RIGHT ~OOTAESTI :::::s
OFF
c.

~l
GAN f!
HIGH
'<
BLK
><
STATOR
WIRES
RES !STANCE
(±20%1
A
c HM.OWARMER ---------------~
'
'
!:i
Y TO Y/R .IS 0Ht.45 cj
GRN TO BLK/R 15 OHMS
c
GRN TO GROUN OPEN
:::!.
GRN TO R 15 OHMS ELECTRIC 5 TART BAN ~OFF
RUN STAAT :::::s
W TO W/R 185 OHMS
IGNITION SWITCH
cc
co COIL PRII.IARY .4 Ot-1.45 A:a=BAN
BLK

~
SECONDARY 4000 Ot-1.45

I B~N
A/W
A
><
()) Y/R OR BAN GROUND
BLK
AUXILIARY
SHUT·iff"
A/W

IGNITION SWITCH !:i

0

yg
WIRE COLOR OPT

BROWN· GROUND RUN 1. THROTTLE SAFETY SWITCHES. Sl)

REO-BATTERY STOP
BLACK· I GN I T1 ON
ONE SW I TCH I 5 OPEN
IN f'.IORMAL OPERAT I ON.
FUEL
GAUGE en
AEO/WH I TE ·STARTER
BAN
en
PUR/W 0
BAN
r---~~--------t-------,-~c--BLK-----L--~
-PNK

BLK/W

L SPARK PLUGS
·--~---------------------------BLK
~R~-------------------~ BAN
CLOSED
WHEN
LOW

LOW OIL
COLOR CODE
BLK BLACK
"'" __________, LEVEL
SENDER
(IN OIL
TANK I

~
BAN ·BROWN
OPT
BLU BLUE
i:U GAN GREEN

~-
OR ORANGE
PUR PURPLE

5'" A REO

~
WHITE
YELLOW

~ '
'~---------------------------
~- TWO COLOR WI RES ARE SHOWN ----------------------~

5'"
WI TH lolA IN/TRACE COLORS
EXAI.IPLE:
BLU/R ; BLUE WITH REO TRACER
w ENGINE GROUND OPT OPTIONAL ON SOME MODELS

~
w CHASSIS GROUND
 '1:l
0
iii
~-
5"
~ 99 XLT SPECIAL
~
~- NOT ALL EQUIPMENT SHOWN IS STANDARD.
5"

r
~

~ ,-fflff~ '!'BRN
,I
OR Y/R
I
PUR

11-;:L;;;O._;::.e=!-1---.,~rr=::~==E:"'il LOW OIL

'
BLU/R~ LEVEL SENDER
'
GRN R HANOWARMERS ;-----------------;-: I I I I I ,

BRNEJ
DUAL HEAT BLK j
/W /
STATOR RESISTANCE TEMP
WIRES lt20%1 BLU SWITCH
GROUND
Y TO Y/R .15 OHMS BLU/R WHEN
HOT BAN 1 Y/R
GRN TO BLK/R 15 OHMS HANOWARMER RES I t0.31 OR I Y
GRN TO GAClllt>IJ OPEN BRf\I·BLU/R 9,6 0!-t.IS
<0 GRN TO R 15 OHMS
BRN-BLU 18.2 0Ht.4S ENGINE
GND
______________ ....
~ W TO W/R !85 OHMS
·-------------------
-.....! COIL PRit.4ARY .4 Ol-to4S

COIL SECONDARY

BAN~
OR--R--,BRAI<E LIGHT
W/OUT CAP 4000 OHMS BRNG
ONOSTART
FF
----tjJ--J

~
y
y SW I TCH
WI TH C"P 9000 OHMS
Y/R OR I:'HN GROLNJ BLKrr=J BLK

0 IGNITION SWITCH R
lt.4ANUAL START I

"7
7 R/W
......
BAN
REGULATOR IGNITION SWITCH
I ELECTRIC START I
B~~.:=:c(j:g BRAKELI GHT
co
CHASSIS GNO
+ I III co
co
;;
RN ::::!.
::::s
AUX I L I AAY SHUT OFF
co
BLK/W
SW I TCH & THROTTLE
SAFETY SW I TCH c
ij"
L SPARK PLUGS ENGINE GND
· - - - - - - - - - - - BL"

COLOR CODE
I I I I I' I
L-f---------~_L__
I

L __ _ _ BRN--------------------------------~
BAN Y/R Q)

...
co
Q)
BLK
BAN
BLACK
BROWN
3
><~
BLU BLUE
GRN GRN
PUR PURPLE
OR ORANGE

~~
R RED
W WHITE
Y : YELLOW
TWO COLOR WI RES ARE SHOWN
WITH MAIN/TRACE COLORS.
EXAMPLE: en -I
BLU/R : BLUE WI TH REO TRACER
"'C:IJ
.... STARTER RELAY CD-
CHASSIS G~ __.___ nO
~
co
ENGINE GNO ENGINE GNO -:;:- -· )>
e!.r-
 I .....,. ..... m
...... y BRAKE LIGHT
OCDr
B~~~~CtEVERI OCD
~
,-------OR Jf.T

><com
Q) LEFT HANDLEBAR
o:E~
F
GRN~)
SWITCH ASM
>< :::;· ::D
Y/Rl _ __::LIGHT
oS'o
BAN en <e )>
BAN - - - 1 - - - - j :cor
. . . . c;·
o<e
REGULATOR o""'~
L_,
W/GRY en3
--~
STATOR RES J STANCES

BAN TO Y 0.12·0. 15 OHMS ,en •

:;, :t:
BAN TO BASE 0 OHMS

W TO GRN 5.3·6,0 OHMS

BLU/R ---t-+++-~
I
W TO BASE 0 OHMS .. 1 1 . :o o
,,,: ...BAN~
.......... THU"Br·ox
A TO BLU 150-190 OHMS F
R TO B.A.SE OPEN
'J
r=;= y ---------- ' W'R"ER .AI .. ,
..., -
3: JJ
l'~
BLK OPEN
- -·· -···
TAIL LIGHT :
'
.....,.o
-
BR.A.KE LIGHT
SPA~ SP.A.RK PLUG 00
I I I I : BAN TAIL LIGHT
o><
:cO
<0
~
KEY
SWITCH
AUXILI.A.RY
SHUT -OFF
BAN
RMK, XCR, XC
~-------
SP, SKS :s:><
~0
CX>
STOP
RUN 1 THROTTLE S.A.FETY SWITCHES,
TAILLIGHT en
STOP BOTH SWITCHES CLOSE WHEN
THROTTLE CABLE IS LOOSE, '
1
:0
BRAKEL I GHT
I 0')
0
BAN --1--ll-----+__L-__! OR BRAKEL I GHT I 0

t~
'
BLU
~-" ~ ~'
R__y '-------'' TAILLIGHT 1 ><
L-----------BRN------L--t~
Y/R
·-----------------------------~
'
~0
L------------BLK-------~ L------------+---------OR ;~ en
~"'C
COLOR CODE
BLK BLACK

COIL RESISTANCES
BRN BROWN '-----'Y/R I ~
BLU BLUE
I 5000 OH~S
"1)
C'P
WIRE
CAP • CAP
WIRE I 1000-1300
JJK-JZK OHMS
OHMS
GRN
PUR
OR
GREEN
PURPLE
OR.A.NGE
w ENGINE GROUND

0
ill
i;3·
YELLOW
WHJ TE
REO
w CHASS I S GROUND
LOW 0 I L LEVEL
SENDER

TWO COLOR WIRES .A.RE SHOWN

5" WJ TH MAIN/TRACE COLORS.
EXAMPLE:
TEMP.

~ BLU/R : BLUE WITH REO TR.A.CER

~·
(/)
T .A.CHOMETER

L-------------------~-------------BRN------~--___!
5"
~
ll
0
i:U
1;3·
5"
~
~
gg 700 XCR
BOO XCR
~-
5"
~ COLOR CODE
BLK BLACK

~~~ ~~8~N I
~~~ ~~~~~~ ym~?ll
y /A

: =~?TE II OR !
I
y YELLOW y RN OR y /R PUR
~PINK

' T!r
PK .B

:.~n-··c B~~
TWO COLOR WIRES
ARE SHOWN WITH
MIIIN/TRACE COLORS. T
EXA1.4PLE:
BLU/R : BLUE W1TH
REO TRACER

f?jJ
LAMP

BAN
STATOR RESISTANCE
WIRES I tZ0/.1
BRN=el
Y TO Y /R .15 OHMS BLU SPEEDOMETER
BLU/R
GAN TO BLK/R IS OHMS
BANI Y/R
HANDWARMER RES I t0.31 OR I Y
GRN TO GROUN[ OPEN BRN·BLU/R 9.6 OHMS
~---- ...1.
<0 GAN TO A 15 OHMS
BRN-BLU 18,2 OHI.4S LOW OIL
LEVEL SENDER
y
(0
~ W TO W/R 185 ()1-!MS (0
<0 (0
COIL PRIMARY
SECONDARY
,34 OH~S
7900 Of-NS
I KEY SWITCH
CBI\CK VIEW!
I I II Ill I W/OR-----'
~

l ~y
Y/R OR BAN GROUND
DIODE
OFT
REGULAR
FUEL
PREM I U1.4
FUEL
- - o - f ' : j PK
:::::!.
0 ::l
~~~ LIGHT:~ c.c
1 PUR/W
7 OR----QJ---J BR'Sw ITCH
--R--,
j II I B:N~::ILLIGHT
KE
c
~ \:3 ~
ENGINE 7 REGULATOR FUEL SENDER
GND BAN PUR/W-6RN
CHASSIS GNO EMPTY I 00 OHMS
FULL 0 OH~S
D)
,-- BLK
c.c
-~BRN=l
/W
SPARK PLUG , - - - - - - - - - BLK
OR ""''
D)
ENGINE
GND I I I I r== B~~ -==D:}:g BRAKELI GHT 3
~
AUX ILl ARY
SHUT ·OFF
SPARK PLUG
1 I I I I t==BRN DR=C(j:g BRAKELIGHT ::l
_ENGINE
GND
RUN
STOP
THROTTLE SIIFETY SWITCHES.
ONE SWITCH I 5 OPEN a.
GRN
IN NOAI.4AL OPERATION.
'<
PK/ .......
BLK 0
0
!-----------
~
BLK
><m
Or-
:Dm
~ ("')
OPEN WHEN
FLIPPER CXI--4
yr
RELEASED
g~
..... I- ><o
0 0)>
(0 :Dr-
CXl