Polaris 1985-1995

CHAPTER 1
MODELS AND SPECIFICATIONS

Model Identification (1985) ......... . . .. . . . . .................. 1. 1
1985 Model s ... . ........ .. .... . . . . .. d . ... .. ...... 1.2 1.3
Modelldenlification (1986) ..... . .. . ... . .. . . . .. .. . ........... 1.4
1986 Models ... . ...... ...... .. .. .... . .. . .. . . . ... .... 1.5 1.6
Model Identification (1987) ...... .. . .... J . . .... . . . . . . .. . .. . ..... 1.7
1987 Models ............ " ..... ... . . . _, .. T .... . . .. . . . ...... . ..... 1.8-1 .9
Model Identification (1988) ...... .. . .. . ,. . . ... . . . ............ 1.10
1988Models .... . ...... ...... .. . .. . .. . . ....... 1.11-1.12
Model Identification (1989) ..... . . .. .. . . . .. . .. . . .. . ..... .. ...... . .. . ......... 1.13
1989Models ................. . ... . . .. . . .... . . ............ 1.14-1.16
Model Identification (1990) .. ....... .. . .. ...... .. ....... .............. 1.17
1990Models ....................... .......... . .......... .... .. 1.18-1 .20
Modelldenl ificalion (1991 ) .................... . ........................ . . ... 1.21
1991 Models ................. .. . ............ .. . ......... ........... 1.22-1.24
Model Identification (1992) .. . ............................ . .................. 1.25
1992 Models .............. . .... ............ .. ....... ............ 1.26-1.29
Modelldentilicalion (1993) .. . ........... .. ....... . .. ....... ........... . ..... 1.30
1993 Models . . ... . ........ ..... .... . .... . ......... . ... . . . ..... 1.31-1 .35
Model ldenlifi calion (1994) ...... . ......... . .. . ......... .. ..... .. , .... . ...... 1.36
1994 Models ....... .. .. . ........... . . .. . .. . . . ... ...... 1.37- 1.42
Modelldentilicalion (1995) .. . .. . . ...... . .. . ... . . . . ... . .. . . . . .. . . ............ 1.43
1995 Models ........................ .... . .. . . . . ...... 1.441.49
RIDERED
8/94
1985 Model Identification
SERIAL NUMBER IDENTIFICATION
The machine serial number may be used asan aid in identifying machine model year. Refer to the first digits in the serial number
for proper identification:
FIRST DIGITS MOOELYEAB
12 1985
1985 MODEL DESIGNATION
YEAR ENGINE DESIGNATION
1
08
'1'1'
MODEL DESIGNATION _________ ----=:::1---.J
1985
MODEL DESIGNATION
NUMBERS (Chassis)
07 - Indy Trail, 400, 600
08 - Indy 600 SE
09 - Star
13 - SS
14 - LongTrack
1985
ENGINE DESIGNATION
NUMBERS
27 - EC25PS-Single Fe
43 - EC44-2PM-210o-Twin Fe
49 - EC44-2PM-Twin Fe
57 - EC60Pl-02-Three LC
59 - EC40Pl -02-Twin LC
MOpEL NUMBER
0850927
MACHINE DESCRIPTION MODEL NUMBER MACHINE DESCRIPTION
0851349
0650743
0850759
Star 244cc Single Fe
S8 432cc Twin Fe
Indy Trail 432cc Twin Fe
Indy 400 398cc Twin LC
MODEL NO.
SERIAL NO.
MADE IN U. S.A.
THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S.
FEDERAL ANa STATE REQUIREMENTS AND
CANADIAN FEDERAL MOTOR VEHICLE STANDARDS
IN EFFECT ON THE OATE OF MANUFACTURE.
MFD. DATE:
0850757
0850847
0851449
Indy 600 596cc Three LC
Indy 600 SE 597cc Three LC
LongTrack 432cc Twin Fe
PDLRRIS
PATENT NOTICE
""". by P<>Iatt. Fdustne. L.P.
On AosMu. MN """'" one Of """8 01 10Uowil'l{l pllena;
U.S. Palents 3.605.5 \1 3.533.662 3.613.811
3.590.647 3.613.810
3.483.766 3.545.821 3.525.412
Patented Canada 8B2.491nl 883.6!14171
Ca/\a/Iian Ad l4.573lTl 34.572111
3.867.991
4.793.950
5.038.881

1.227.823.187
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).
1.1
RIDE RED
8/94
BOOSE
0850857
Engine Type LC Triple
Displacement (ee) 597
Bore x Stroke (mm) 65)( 60
Ca/buretion/Thronle Body 3 Mikuni
VM38SS Slide
Oillnjecled Standard
Ignition COl
Atlernalor Output 12V!20W
Length (inJcm.) 106.25/269.7
Width (in./ern.) 41 .62/105.6
Height (in.fern.) 31 .5f79.9
Ski Stance (in.fern.) 36.5192.7
Track Width (inJcm. ) 15138.1
Track Lenglh Overall (in.fern.) 121/ 307. 1
Fuel Capacity (U.S. gal.llmp. gal.ll iters) 715.8126.5
Recommended Fuel 88 Octane Min.
Front Suspension Coil Spring IFS
Chrome Trailing Arms
Brake Type Liquid Cooled
Hydraulic Disc
Storage Rear of Seal
Speedometer Standard
Tachometer Standard
Trip Odometer Standard
Accessory lights Temp
Ele<:tric Start NtA
Handwarmers Option
Two-Up Seat NfA
Backrest NtA
Storage Rack Option
Tow Hitch Option
8/94
1.2
BOO
0850757
LC Triple
597
65 )( 60
3 Mikuni
VM38SS Slide
Standard
COl
12V t20W
106.25/269.7
41.62/105.6
31.5179.9
36.5/92.7
15138.1
1211307.1
7f5.8/26.5
88 Octane Min.
Coil Spring IFS
Liquid Cooled
Hydraulic Disc
Rear of Seat
Standard
Standard
Standard
Temp
NfA
Option
NfA
NfA
Option
Option
400 Long Track
0850759 0851449
LCTwin Fan Cooled Twin
398 432
65 )(60 67.62 x 60
2 Mikuni 1 Mikuni
VM34SS Slide VM30SS Slide
Standard Standard
CDI COl
12V 120W 12V 120W
106.251269.7 120.251305.2
41.621105.6 401101.5
31.5179.9 33/83.7
36.5192.7 31/78.7
15138.1 15/38. 1
121/307.1 148/375.6
7f5.8126.5 5.4/4.5120
88 Octane Min. 88 Octane Min.
Coil Spring IFS Mono Leaf
Liquid Cooled Mechanical Disc
Hydraulic Disc
Rear 01 Seat Rear of Seat
Storage Rack
Standard Standard
Standard Option
Standard Standard
Temp NfA
NfA NfA
Option Option
NfA NfA
NfA NfA
Option Standard
Option Standard
RIDE RED
Engine Type
Displacement fcc)
Bore x Stroi<e (mm)
CarburetionITt1ronle Body
Oil Injected
Ignition
Alternator Output
Length (in.lem.)
Width (in.tern.)
Height (inJcm.)
Ski Stance (inJcm.)
Track Width (in.fern.)
Track length Overall (in.fem.)
Fuel Capacity (U.S. gaUlmp. gal./Iitersj
Recommended Fuel
Front Suspension
Brake Type
Storage
Speedometer
Tachometer
Trip Odometer
Accessory lights
Electric Start
Handwarmers
Two-Up Seat
Backrest
Storage Rack
Tow Hitch
1.3
Indy Trail SS Star
0850743 0851349 0850927
Fan Cooled TWin Fan Cooled Twin Fan Cooled Single
432 432 244
67.62 x 60 67.72x60 72 x 60
1 Mikuni 1 Mikuni 1 Mikuni
VM34SS Slide VM34SS Slide VMJOSS Slide
Standard Standard Standard
COl COl COl
12V 120W 12V 120W 12V WOW
106.25/269.7 1021258.9 1021258.9
41.621105.6 401101.5 401101.5
31.5183.7 33183.7 33/83.7
36.5192.7 31178.7 31/78.7
15/38.1 15138.1 15/38.1
121 /307.1 120/304.6 108/274.1
7/5.8126.5 6.8/5.7/25.7 5.4/4.5120
88 Octane Min. 88 Octane Min. 88 Octane Min.
Coil Spring IFS MollO leal Mono leaf
Hydraulic Disc Mechanical Disc Mechanical Disc
Rear 01 Seat Rear of Seat Rear of Seat
Standard Standard Option
NlA NIA NIA
Option Option NIA
Standard Option NIA
NlA NIA NIA
NlA NIA NIA
Option NIA NIA
Option Option Option
RIDE RED
8194
The machine serial number may be used as an aid in identifying machine model year. Belerta the lirsldigilS in the serial number
lor proper identification:
flBST DIGITS
12
13
MODEL YEAR
1985
1986
YEAR DESIGNATI O''i- J ------r:::;::'\;--.,
I O ~ 6 1 0 9 r
ENGI NE DESIGNATION
MODEL DESIGNATION ____ ____ _ --'=::::rl-l
1986
MODEL DESIGNATION
NUMBERS (Chassis)
1986
ENGI NE DESIGNATION
NUMBERS
27 - EC25P5-Single Fe
1986
ENGI NE DESIGNATI ON
NUMBERS
07 - Indy Trail , 400, 600
De - Indy 600 lE
09 - Star/Sprint 340 (ES)
13-$5
31 - EC342PM-OtTwin Fe (ES)
33 - EC34-2PM-02-Twin Fe
59 - EC40PL-02-Twin LC
61 - EC50PM.()1Twin Fe
14 - LongTrack
49 - EC44-2PM-5100-Twin Fe
57 - EC60Pl-()2-Triple LC
MODEL NO.
SERIAL NO.
MADE IN U.S.A.
THIS VEHICLE CONFORMS TOALl APPUCABlE u.S.
FEOERAl AND STATE REQUIREMENTS AND
CANADIAN FEDERAL MOTOO VEHICLE STANDARDS
IN EFFECT ON THE DATE Of MANUFACTURE.
MFD. DATE:
PDLRRIS
PATENT NOTICE
MId. c,. Polan,.....,.. .. LP.
in AotHu, Lf'I IJ'KIer _ Of mati 01 ... fOIIoMnQ 1>1*'1$:
u.s. Pat_ 3.605.5" 3,S33.662 3,613.8"
3,S80.&U 3,613.810 3,605,510
3.483.766 3.545.821 3.525 . 12
P_lIod c...... 882 . 91171 883.694171
c...- Ad. 34.573171 34.572171
These numbers should be referred to in any correspondence regarding warranty, service or replacement parts.
3.867.991
. 793.950
5.038.881
""'''''' 1.227.B2:W7
7072133
permanently stamped into the tunnel. The model number is embossed on the deca1.
8194
1.4
AIDE RED
600 LE
0860857
Engine Type lCTriple
Displacement (cc) 597
Bore )( Stroke (mm) 65)( 60
CarbufetlOnlThrotUe BOdy 3 Mikuni
VM38SSShde
O,llnjecled Standard
Igrnllon COl
Allernator OutpUt 12'0' t20W
length (inJcm.) 106.251269.7
Width (inJcm.) 41.621105.6
Height (inJem.) 31.5/79.9
Ski Stance (inJcm.) 36.5192.7
Track Width (inJcm.) 15138.1
Track length Overall (in.lem.) 1211307. 1
Fuel Capacity (U.S. gal.llmp. galJlltersj 715.8126.5
Front Suspension Coil Spring IFS
Chrome Trailing Arm
Hydraulic DISC
Storage Real 01 Seat
Tachometer Standard
T np Odometer Standard
Accessory LlQhts Tomp
Eleclfic Start NJA
Handwarmers Opton
Two-Up5eat NIA
Backrest NJA
SlOfage Rack Option
Tow Hitch Option
1.5
600 400 Long Track
0860757 0860759 0861449
LC Triple LeT ..... in Fan Cooled TWin
597 39B 432
65)( 60 65)( 60 66.72)( 60
3 Mlkuni 2 Mlkum , Mlkum
VM38SS Slide VM34SS Slide VM30SS Slide
Standard St andard Standard
COl COl COl
12'0' ,20W 12'0' l20W 12V 120W
106.251269. 7 106.251269.7 120251305.2
41.62/105.6 41.62/105.6 401101.5
31.5179.9 31.5179.9 33183.7
36.5192.7 36.5192.7 31nB.7
15138,1 15138.1 15/38.1
1211307.1 1211307.1 1481375.6
7/5.8126.5 7f5.8126.5 7.516.2128
Coil Spring IFS COil Spring IFS Mono Leal
Liquid Cooled liquid Cooled Mechanical Disc
Hydraulic Disc Hydraul IC DISC
Rear of Seat Real of Seat Rear of Seat
Storage Rack
T.".., T.".., NJA
NJA NIA NJA
0",,,," Option 0pIl0n
NJA NIA NJA
NJA NIA NJA
Opt"'"
Option Standard
Option Option Standard
8/94
RIDERED
Indy Trail 55
0860761 0861349
Engine Type Fan Cooled Twin Fan Cooled Twin
DIsplacement (cx:) 488 432
Bore x Stroke (mm) 72.60 67.72 x 60
CarburelionfThrottle 2 Mikuni 1 Mikuni
Body VM34SS Slide VM34SSSbde
011 Injected Standard Standard
Ignition COl COl
Allernalor Output 12V 120W 12V 120W
Length (inJcm.) 106.251269.7 1021258.9
Width (inJcm.) 41 .62/105.6 401101.5
Height (inlcm.) 31.5179.9 33J83.7
Ski Stance (InJcm.) 36.5192.7 31ne.7
Track Width (inJcm.) 15138.1 15138.1
Track Lenglh Overall 1211307.1 120J304.6
(inJcm.)
Fuel Capacity (U.S. 7/5.8126.5 7.516.2/28
gal.llmp. gal.lliters)
Recommended Fuel es Octane Min. 88 Octane Min.
Front Suspension Coil Spring IFS Mono Leal
Brake Type Hydraulic DIsc Mechanical DIsc
Storage Rear 01 Seat Rear 01 Seat
Speedometer Standard Standard
Tachometer Standard Standard
T np Odometer Standard Standard
Accessory lights N/A N/A
Electric Sian Option Option
Handwarmers Standard Option
Two-Up Seat N/A N/A
Backrest NlA N/A
Storage Rack Option N/A
Tow Hitch Option Option
8/94
1.6
Sprint Sprint ES Star
0860933 086093\ 0860927
Fan Cooled Twin Fan Cooled Twin Fan Cooled Single
339 339 244
62 II. 55.6 62 )(55.6 72.60
COl COl COl
12V 120W 12V 120W 12V WOW
102J258.9 1021258.9 1021258.9
401101.5 401101 .5 401101 .5
33183.7 33183.7 33/63.7
31(78.7 31f78.7 31178.7
15138.1 15138.1 15138.1
1081274.1 1081274.1 1081274.1
5.4/4.5120 5.414.5120 5.4/4.5120
88 Octane Min. es Octane Min. es Octane Min.
Mono Leaf Mono Leaf Mono Leal
Mechanical Disc Mechanical Disc Mechanical Disc
Rear of Seat Rear of Seat Rear 01 Seat
Option Standard
Opt""
Option Standard Option
.. A N/A N/A
.. A Standard N/A
Option Option N/A
"A
N/A N/A
.. A N/A N/A
"A
N/A NlA
Option Option Opl<>n
RIDE RED
The machine serial number may be used as an aid in identifying machine model year. Refer 10 the first digits in the serial number
f1BST DIGITS
12
13
14
MOOELYEAB
1985
1986
1987
YEAR DESIGNATION,-------r=::;;="-,,

ENGINE DESIGNATION
MODEL DESIGNATION
1987
MODEL DESIGNATION
NUMBERS (Chassjs)
09 - Star/Spri nt 340 (ES)
10- StarTrak
14 - LongTrack
15 - Long Track ALA
04 - Indy Sport
05 - Indy 133 SKS
07 - Indy Trail , 400, 600
MODEL NO.
SERIAL NO.
19B7
ENGINE DESIGNATION
NUMBERS
3 1 - EC34-2PM-02-Twin Fe ES
33 - EC34-2PM-Ol"()3-Twin Fe
49 - EC44-2PM-5100-Twin Fe
57 - EC60Pl -02-Triple LC
1987
ENGINE DESIGNATION
NUMBERS
59 - EC40Pl-Q2-Twin LC
61 - EC50PM-Ol-Twin Fe
62 - EC50PM-D2-Twin Fe ES
MADE IN U.S.A.
PDLRRIS
PATENT NOTICE
Mid. by PoLan.lnolouSl .... ' t.P.
In RoHeu. MN UI'IOer 01'11 Of rnorlO! palenl,
FEDERAL AND STATE REOUIREMENTS AND
IN EFFECT ON THE DATE OF MANUFACTURE.
U.S, Pllenl, 3.605.511 3.533.662 3.613.8\\
3.613.810 3.605.510
3.483.766
Palenled C.nOO, 882 ,491n 1 883.694/71
C;onaaoan Ad 34,573/71 34.572>71
MFD. DATE:
3,867.991
4,793,!/50
5,038,881
864.39oInl
1,227.823187
7072133
The machine model and serial number identi fication 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 ()(l the decal.
Whenever corresponding about an engine it is important that the engine model and serial numbers be called out laser
1.7
RIDERED
8/94
E"",oa Type
,
,'(oc)
Bo," S"o'" Imm)
GarburetionfThrottle Body
m toje<.ed
',rt_
Output
Lengt h (inlcm.)
-"""" ('rtJom.)
('rt1om.)
, Sk' Staoce ('rt1om.)
10rtJom.)
,
,"",
. .

"""
I '",rt"
Stake Type
I
I E.ectric Start
Sto",. R,oJ<
8194
Indy 600
0870757

597
65.60
3 Mikuni
VM38$S Slide
CD'
t2V t20W
109/276.6

'.7
15138.1
sa,

R .. , 0' Sea.
T.mp
NlA
Op' oo
NIA
NJA
Op","
Opt<m
1,8
Indy 400
400SKS
0870759
0870559
LC TMrt
398
65 . 60
2 Mikuni
VM34SS Slide
CD.
'2V'2OW
109/276.6
113/286.8SKS

'.7
15/38.

715.
sa ,
f*-

R." o' S ...
Tamp
NJA
Op'''''
NIA
NJA
Optiort
Opt""
Indy Trail Long Track
Trail ES I SKS LTR
0870761 0871449
0870762/0870561 0871549
'ao
''''''
,sa 432
72.60 67.72 . 60
2 Mikuni 1 Mikuni
CD'
.2V.20W .2V.20W
109/276.6 120.251305.2
11 3/286.8 SKS

33183.7
31/78.7
15138.1 15138.

1481375.6
l.5
' M' rt. sa "'''eo M'rt.
Coil
,
Hydraulic Disc Mechanical Disc
R .. ,o' S . .. R." 01 Se ..
Op"'"
NlA NlA
Opt"';' ES
NJA

Op'''''
NIA
NIA NIA

RICE RED
Indy Sport
0870433
Engine Type Fan Cooled TWin
Displacement (ee)
33'
Bore II: Stroke (mm) 62 K 55.6
CarboretionlThronle Body 2 Mikuni
VM30SS Slide
Oil Injected Standard
Ignition COl
Alternator Output 12V t20W
Length (inJcm.) 1091276.6
Width (inJcm.) 41.62/105.6
Height (inJcm.) 33183.7
Track Length Overall (inlcm.) 1211307.1
Fuel Capacity (U.S. g a l . f l ~ . gal.lll ters) 7/5.8126.5
Recommeooed Fuel 88 Octane Min.
FrOllt Suspension Coil Spring IFS
Hydraulic Disc
Storage Rear of Seat
Tachometer Option
Accessory lights NJA
Electric Start Option
Handwarmers Option
Two-Up Seat NlA
Backrest NlA
Storage Rack Op-
Tow Hitch Option
1.9
Sprint Star Star Trak
Sprint ES
0870933 0870927 0871027
0870931
Fan Cooled Twin Fan Cooled Single Fan Cooled Single
33'
244 244
62 II: 55.6 72.60 72 x60
2 Mikuoi 1 Mikuni 1 Mikuni
COl COl COl
12V 120W 12V l00W 12V WOW
1021258.9 102/258.9 1091276.9
40/101.5 40/101.5 40/101.5
33/83.7 33183.7 34186.3
31178.7 31178.7 3lf78.7
15138.1 15138.1 15138.1
1081274.1 1081274.1 133.51338.9
5.4/4.5120 5.4/4.5120 7.516.2128
Mono Leaf Mono Leal Mono Leal
Mechanical Disc Mechanical DISC Mechanical Disc
Rear 01 Seat Rear 01 Seat Rear of Seat
Option Sprint Option Standard
Standard ES
Standard ES
Standard ES
NJA NJA NIA
Sprint ES Only NlA NIA
Option NlA NJA
NlA NlA NlA
NlA NlA NJA
NlA NlA Standard
RIDE RED
8194
The machineserial number maybe used asan aid in identifying machine model year. Aelerle the firSI digits in the serial number
FIRST DIGI TS
12
13
14
15
MOOEL YEAA
1985
1986
1987
1988
YEAR DESIGNATION,-------r=::;;="01
1
088
1
9
1'
ENGINE DESIGNATI ON
MODEL DESIGNATION _________ ---=::::rl---"
1988
MODEL DESIGNATION
NUMBERS (Chassis)
1988
ENGINE DESIGNATION
NUMBERS
27 - EC2SPS-Single Fe
1988
ENGINE DESIGNATION
NUMBERS
09 - Star/Sprint (ES)
10 - SlarTrak
15 - Long Track ALA
04 - Indy Sport
05 - Indy 133 SKS
06 - Indy Trail SP
31 - EC34-2PM-02-Twin Fe ES
33 - EC34-2PM-Ol-03-Twin Fe
49 - EC44-2PM-4100-Twin Fe
58 - EC65Pl -Ol-Triple lC
59 - EC4QPL-02-Twin LC
61 - EC50PM-O,-Twin Fe
62 - EC50PM-()2-Twin FC ES
07 - Indy Trail, 400, 650
MODEL NO.
SERIAL NO.
MADE IN U.S.A.
THIS VEHICLE CONFORMS TO ALLAPPUCABLE U.S.
MFD. DATE:
PDLRRIS
PATENT NOTICE
MId. Dy PolarIs Indu$IneS LP.
in AosHu. MN """'" OM 01' """ ot ~ IoIIow>ng PIII!to1IS:
u.s. PallKlIS 3.605.511 3.$33.662 3.613.811
3.580.&47 3.613.810 3.605.510
3.483.766 3.5<1-5.821 3.S25.412
PaI<!011ed Gar>.llda 882 91/71 883.6901171
c-Ad. 34.573171 3-6.572171
These numbers should be reI erred to in any correspondence regarding warranty. service or replacement parts.
3.867.991
4.7Q3.!I&O
5.038.981
S&4.3901171
1.227.821187
7072133
The machine model and serial number identification decal is located on the right front side 01 the tunnel. The serial number is
Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. laser
8/94
1.10
RIDERED
Indy 650
Indy 650 SKS
0880758
0880558
Engine Type lC Triple
Displacemenljcc) 648
Bore x Stroke (mm) 67.72 x 60
CarburetionIThrotile Body 3 Mikuni
VM38SS Slide
Dillnjected Standard
Ignition CDI
Alternator Output 12V 120W
Length (in.lcm.) 106.251269.9
1131287 SKS
Width (in.lcrn.) 41.62/105.7
Height (inJcm.) 42/106.7
Track Widlh (in.lcm.) 15/ 38.1
Track length Overall (in.lcm.) 120.96/307.2
133.56/339.2 SKS
Fuel Capacity (U.S. gaL/Imp. gal.lliters) 7.3/6.1 /27.7
Front Suspension Coil Spring lFS
Brake Type liquid Cooled
Hydraulic Disc
Tachometer Standard
Accessory lights HighTemp Ind.
Electric Start NlA
Handwarmers Option
Two-Up Seat Option
Backrest Option
Storage Rack Option
Tow Hitch Option
1.11
Indy 400 Indy 400 Indy Trail, SP
400 SKS Classic Deluxe, ES,
SKS
0880759 0880859 0880761/08806611
0880559 0880262108807621
0880561
lC Twin LC Twin Fan Cooled Twin
398 398
'88
65 x 60 65 x60 72 x60
CDI CDI CDI
12V 120W 12V 120W 12V 120W
106.25/269.9 106.251269.9 106.25/269.9
1131287 SKS 1131287 SKS
41.62/105.7 41.62/105.7 41.62/ 105.7
43.12Jl09.5SP
421106.7 421106.7 42/106.7
36.5/92.7 36.5192.7 36.5192.7
38196.5 SP
15/38.1 15/38.1 15/38.1
120.96/307.2 120.96/307.2 121/307. 1
133.56/339.2 SKS 133.561339.2SKS
7.3/6.1 f27.7 7.3/6.1127.7 7.316.1127.7
Coil Spring IFS Coil Spring IFS Coil Spring IFS
Hydrauhc Disc Hydraulic Disc Hydraulic Disc
Rear of Seat Rear of Seat Rear of Seat
High Temp Ind. Standard NJA
NlA Standard Option
Standard ESJOel
Option Standard Standard
Option Option Opllon
Standard Deluxe
Standard Deluxe
Opllon Option Opt ion
RIDE RED
8/94
Indy Sport Sprint
0880433 0880931
Engine Type Fan Cooled Twin Fan Cooled Twin
Displacement (cc)
33" 33"
Bore x Stroke (mm) 62 x 55.6 62 x 55.6
CarburetiolYThtonle 2 Mikuni 2 Mikuni
Body VM3O$S Slide VM30SS Slide
Oil Injected Standard Standard
Ignition COl COl
AltematOl' Output 12V 1lOW 12V 120W
Length (inJcm.) 106.251269.9 102/259.1
Width (inJcm.) 41.621105.7 401101 .6
Height (inJcm.) 42/106.7 44.51113
Ski Stance (inJcm) 36.5192.7 31f78.7
Track Width (InJcm.) 15138.1 15138.1
Track Length Overall 120.9613072 1081274.3
(inJcm. )
Fuel Capacity (U.S. 7.316.1/27.7 7.516.2128.1
g a l J l ~ . galJlilers)
Rewmmended Fuel 88 Detane Min. 88 Delane Min.
Front Suspension Coit Spring IFS Mono Leaf
Brake Type Hydraulic Disc Mechanical Disc
Storage Rear of Seat Rear of Seat
Tachometer
0_
Option
Trip Odometer Standard NlA
Accessory Lights NlA NlA
Electnc Start
0_
NlA
Hanct.varmers
0_
Option
Two-Up Seat NlA NlA
Backrest NlA NlA
Storage Rack Option Option
Star
0880927
Fan Cooled Single
244
72 x60
1 Mlkuni
VMJOSS Slide
Standard
COl
12V l00W
1021259.1
4()(101.6
44.51113
31n8.7
15138.1
1081274.3
7.516.2128.1
88 OClane Min.
Mono Leal
Mechanical Oisc
Rear of Seat
Option
Option
NlA
NlA
NlA
NlA
NlA
NlA
Option
Option
8/94
1.12
Long Track Star Trak
Reverse
0881549 0881027
Fan Cooled Twin Fan Cooled Single
432 244
67.72 x 60 72 x 60
2 Mikuni 1 Mikuni
Standard Standard
COl COl
12V!lOW 12V WOW
120.51306. , 1091276.9
401101.6 401101.6
44.51113 44.51113
31178.7 31178.7
15138. 1 15138.1
1481376 1331337.8
7.516.2128.1 7.516.2128.1
Mono Leal Mono Leaf
Mechanical Disc Mechanical Disc
Rack/Rear of Seal Rack/Rear of Seat
Standard Standard
Option Option
N/A NlA
Neutraltnd. NlA
N/A NlA
0pI1on NlA
N/A NlA
NlA NlA
Standard Standard
Standard Option
RIDERED
The machine serial number may be used as an aid in identifying machine model year. Belerlo the first digits in the serial number
FIRST DIGITS
12
13
14
15
16
MODEL YEAR
1985
1986
1987
1988
1989
YEAR DESIGNATIONf--------;=2""

ENGINE DESIGNATION
MODEL DESIGNATION
1989
MODEL DESIGNATION
NUMBERS (Chassis)
1989
ENGINE DESIGNATION
NUMBERS
1989
ENGINE DESIGNATION
NUMBERS
61 - EC50PM...Ql-Twin Fe
10 - SlarTrak
15-LongTrakLTA
01 -Indy Trail SuperTrak
02 - Indy Trail Deluxe
31 - EC34-2PM-02-Twin FC ES
33 - EC34-2PM-01-03-Twin FC
49 - EC44-2PM-4100-Twin FC
58 - EC65PL-01 -Triple LC
62 - EC50PM-02-Twin Fe ES
64 - EC50PL..Ql-Twin LC
04 - Indy Sport
05 - Indy 133 SKS
06 - Indy Trail SP
07 -Indy 440, 500, 650
08 - Indy 500 Classic
24 Indy Sport GT
MODEL NO.
SERIAL NO.
MADE IN U.S.A.
MFD. DATE:
65 - EC50PL-02-Twin LC ES
PDLRRIS
PATENT NOTICE
MIa. by Polaris Indvslries l.P .
... Roseau. MN under one Of more of me ICMIOww">g palenll:
u.s. PalOOI$ 3.605.511 3.533.662 3.613.811
3.580.647 3.613.810 3.605.510
3.483.766 3.545.821 3.525.412
Palenl9dCar\ada B62A91nl 883.694171
Canadian Ad. 34.573171 34.572m
3.867.991
4,793.950
5.038.881
"',..",
1.227.823187
7072133
1.13
RIDE RED
8/94
-
Engine Type
Displacement (ee)
Bore x Stroke (mm)
CarburetiorVThronle Body
Oil Injected
Ignition
Alternator Output
length (in./cm.)
Width (in.lcm.)
Height (inJcm. )
Ski Stance (in./cm.)
Track Width (inlcm.)
Track Length Overall (inJcm.)
Fuel Capacity (U.S. gaUlmp. gal.liilers)
Recommended Fuel
Front Suspension
Brake Type
Storage
Speedometer
Tachometer
Trip Odometer
Accessory lights
Electric Start
Handwarmers
Two-Up Seat
Backrest
Storage Rack
Tow Hitch
8/94
Indy 650
Indy 650 SKS
0890758
0890558
LC Triple
648
67.72 x 60
3 Mikuni
VM38SS Slide
Slalldard
COl
12V 120W
106.25/269.9
113/287 SKS
41.62/105.7
44/111.8
36.5192.7
15/38.1
120.96/307.2
133.56/339.2 SKS
7.316.1127.7
88 Octane Min.
Coil Spring IFS
liquid Cooled
Hydraulic Disc
Rear 01 Seat
Standard
Standard
Standard
High TefTll Ind.
NlA
Standard
Option
Option
Option
Option
1.14
Indy 500 Indy 500 Indy 500 SP
500 SKS Classic
0890764 0890865 0890664
0890564
LCT ..... in LCTwin lC Twin
488 488 488
72:<.60 72 x 60 72 x 60
VM38S5 Slide VM38SS Slide VM38SS Slide
COl COl COl
12V 120W 12V 120W 12V 120W
106.25/269.9 106.25/269.9 106.25/269.9
1131287 SKS
41.62/105.7 41 .62/105.7 43.121109.5
44/111.8 44/111.8 42/106.7
36.5192.7 36.5192.7 38/96.5
15138.1 15138.1 15/38.1
120.96/307.2 120.961307.2 120.96/307.2
133.561339.2 SKS
7.316.1/27.7 7.316. 1127.7 7.316.1127.7
88 Octane Min. es Octane Min. es Octane Min.
Hydraulic Disc Hydraulic Disc Hydraulic Disc
Rear of Seat Rear 01 Seat Rear of Seat
Slandard Standard Standard
High Temp Ind. Standard NlA
NIA Standard NIA
RIDE RED
Indy 400 Indy Trail, SP
Deluxe, ES,
SKS
0890759 0890761/08906611
OB90262108907621
0890561
Engine Type LCTwin Fan Cooled Twin
Displacement (ee) 398 488
Bore x Stroke (mm) 65 x 60 72 x 60
Carburetion/Throtlle Body 2 Mikuni 2 Mikuni
Ignil ion CDI CDI
Alternator Output 12V 120W 12V 120W
length (inJcm.) 106.25/269.9 106.251269.9
113/287 SKS
Width (in.lcm.) 41.62/105.7 41.62/ 105.7
43.121109.5SP
Height (inJcm.) 44/ 111.8 421106.7
45/ 114.3 Del
Ski Si ance (inJcm.) 36.5192.7 36.5/92.7
38/96.5 SP
Track Width (in.lcm. ) 15/38.1 15/38. 1
Track Length Overa!! 120.96/ 307.2 120.96/307.2
(in.lcm.) 133.56/ 339.2 SKS
Fuel Capacity (U.S. 7.3/6. 1127.7 7.3/6. 1127.7
gaL/Imp. gaL/liters)
Recommended Fuel 88 Octane Min. 88 Octane Min.
Front Suspension Coit Spring IFS Coit Spl"lng IFS
Brake Type Hydraulic Disc Hydraulic Disc
Trip Odometer Standard Standard
Accessory Lights High Temp Ind. NlA
Electric Start N/A Option
Standard ESlDel
Handwarmers Option Standard
Two-Up Seat Opllon Option
Standard Deluxe
Backrest Option Option
Standard Deluxe
1.15
Indy Trail Indy Sport Indy Sport GT
SuperTrak
0890161 0890433 0892433
Fan Cooled Twin Fan Cooled Twin Fan Cooled Twin
488 339 339
72)( 60 62.3 x 55.6 62.3 x 55.6
2 Mikuni 2 Mikunl 2 Mikuni
CDI CDI CDI
12V 120W 12V 120W 12V 120W
1281325. 1 106.251269.9 118/299.7
41.62/ 105.7 41 .62/105.7 41.62/105.7
45/ 114.3 421106.7 45/114.3
36.5192.7 36.5/92.7 36.5/92.7
15/38.1 15/38.1 15138.1
156/396.2 120.96/307.2 141/358.1
7.3/6.1127.7 7.3/6.1/27.7 7.3/6. 1127.7
Coil Spring IFS Coit Spring IFS Coil Spring IFS
Mechanical Disc Hydraulic Disc Hydraulic Disc
Rack/Rear of Seat Rear of Seat Rack/Rear of Seat
Standard Option Option
NlA N/A NIA
Staooard Option Opt ion
Standard Option Standard
8/94
RIDE RED
Sprint ES
I E"<II" Type Foo
,
I
I 339
I Bo<. , Stroke (mm)
,. Body
2
Oil "jeo'ed
I lgnilior COt
12V 120W
Le",,'h
I W<lth (In)om.)
I H"gh. (In-"m.
I Ski (I'-"m.) 31178.7
h(ln.l,m.
'5138
I
I F",'
..
,
. I
88 Oct,no Min.
I F,on'
Star
Foo Coo'ed SI",,'e
244
72,6<)
1 MIk",
I
CO,
12V tOOW
31178.7
15138.
88 I
Mono Le,'
I B,"'. Type I Disc
I S.or,g.
Re" a' 5." R", a' 5."
Option
Option Option
NlA NlA
NlA NlA
I E"",. Start NlA
Option NlA
NfA NlA
Op,'on NlA
I S'o"g. R",
Option Option
I Tow HiI,h Option Option
8194
1.16
Long Track Star Trak
Reverse
dSlng'.
432 244
67.72,60 72 , 6<)
I .
,-iii'de
1 MIk",
CO, CO,
12V 120W 12V lOOW
401101.6
31178.7 31178.7

15138
M'". 88 Oct, .. Min .
Mono L",
II Disc
" 01"
"5".

Opt""
NlA
NfA NlA
NfA NlA
Option NlA
NfA NlA
NfA NfA
RIDE RED
The machine serial number may be used as an aid in identifying machine model year. Belerto the firs! digits in the serial number
FIRST DIGITS
12
13
14
15
16
17
MODEL YEAR
1985
1986
1987
1988
1989
1990
YEAR
I
09
I
09
r
ENGINE DESIGNATION
MODEL DESIGNATION
1990
MODEL DESIGNATION
NUMBERS (Chassis)
1990
ENGINE DESIGNATION
NUMBERS
1990
ENGINE DESIGNATION
NUMBERS
59 - EC40PL-02-Twin LC 09 - Star/Sprint (ES)
10 - StarTrak
15 -longTrak LIB
01 - Indy Trail SuperTrak
49 - EC44-2PM-4100-Twin Fe
58 - EC65PL-Ol-Triple LC
61 - EC50PM-Ql /02-Twin FC
62 - EC50PM-03-Twin FC ES
64 - EC50PL-01/03-Twin LC
04 - Indy Sport
05 -Indy 133 SKS
06 - Indy Trail SP/500 SP
07 - Indy 440, 500, 650
20 - WideTrak
24 Indy Sport GT
MODEL NO. MADE IN U.S.A.
SERIAL NO.
FEDERAL AND STATE REQUIREMENTS AND
MFD. DATE:
POLRRIS
PATENT NOTICE
MId. by Polaris Ind..stries LP .
., Roseau. MN uro::le< one Of more ot the IoIIowu'1g pale<11S:
U.S. Palenl. 3.605.511 3.ru.662 3.613.811
3.!;80,647 3.613.810 3,605.510
3.4113,766 3.545.821 3,525.412
Palool9dCana!la 8B2.491f11 8113.694171
Canadian Rd. 34.573171 34.57:2171
3.867.991
4.793.950
5.038.881
S64.394f11
1.227.823J1!7
7072133
permanenlly 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 oul. Laser
engraved model and serial numbers are located on the crankcase (intake side),
1.17
RIDE RED
8194
Engine Type
Displacement (cc)
Bore )[ Stroke (mm)
CarburetiON'Throltle Body
Oil Injected
Ignition
Alternator Output
length (inJcm.)
Width (inJcm.)
Height (inJcm.)
Ski Stance (in.lcm.)
Track Width (inJcm.)
Track Length Overall (in.lcm.)
Fuel Capacity (U.S. galJlmp. gaLlliters)
Recommended Fuel
Front Suspension
Brake Type
Storage
Speedometer
Tachometer
TfipOdometer
Accessory lights
Electric Start
Handwarmers
Two-Up Seat
Backrest
Storage Rack
Tow Hitch
8/94
650
650SKS
0900758
0900556
LC Triple
648
67.72)[ 60
3 Mikuni
VM38SS Slide
Standard
COl
12V 120W
106.25/269.9
\131287 SKS
41.621105.7
441111.8
36.5192.7
15/38.1
120.96/307.2
133.561339.2 SKS
7.3f6.1127.7
88 Octane Min.
Coil Spring IFS
liquid Cooled
Hydraulic Disc
Rear 01 Seat
Standard
Standard
Standard
High Temp Ind.
NlA
Standard
Option
Option
Option
Option
1.18
500 500 Classic 500SP
500 SKS
0900764 0900865 0900664
0900564
lC Twin LC Twin LC Twin
, .. , .. , ..
72x60 72 x 60 72 x 60
COl COl COl
12V 200W 12V 200W 12V2OQW
106.251269.9 106.251269.9 106.25/269.9
113/287SKS
41.62/105.7 41.621105.7 43.121109.5
441111.8 441111.8 42/106.7
36.5192.7 36.5192.7 3&'96.5
15/38.1 15138.1 15/38.1
120.96/307.2 120.961307.2 120.96/307.2
133.561339.2 SKS
7.316.1/27.7 7.1I6.1127.7 7.1I6.1127.7
Coil Spring IFS Coil Spting IFS Coil Spring IFS
Rear 01 Seat Rear of Seat Rear of Seat
High Temp Ind. Standard NlA
RIDE RED
Indy 400 Indy Trail
Trail Deluxe
0900759 0900761
0900262
Engine Type LC Twin Fan Cooled Twin
Displacement (ee) 39B 488
CarburetionIThrotl le Body 2 Mikuni 2 Mikuni
Oillnjec1ed Standard Standard
Ignition COl COl
Ahernalor Output t2V 200W 12V200W
Length (in.lcm. ) 106.25/269.9 106.251269.9
113/287 Del
Width (in./cm.) 41.62/105.7 4 t .6211 05. 7
Height (in./cm.) 44/111 .8 42/106.7
45/114.3 Del
Ski Stance (inl cm.) 36.5192.7 36.5/92.7
Track Width (in./cm.) 15138.1 15/38.1
Track Length Overall 120.961307.2 120.96/307.2
(in.lcm.) 133.56/339.2 Del
Fuel Capacity (U.S. 7.316.1 /27.7 11 .25/9.4/42.6
gal.llmp. gal.lliters)
Recommended Fuel 88 Octane Min. 88 Octane Mi n.
Front Suspension Coil Spring IFS Coil Spring IFS
Brake Type Hydraulic Oisc Hydraulic Disc
Trip Odometer Standard St andard
Accessory Lights High Temp Ind. NIA
Electric: Start NIA Option
Standard Deluxe
Handwarmers Option Standard
Two-Up Seat Option Option
Standard D e l u ~ e
Backrest Option Option
Standard Deluxe
1.19
SuperTrak
0900161 0900433 0902433
488 339 339
72 x 60 62.3 x 55.6 62.3 x 55.6
COl COl COl
12V 200W 12V 15DW 12V 150W
128/325. 1 106.25/269.9 11&'299.7
41 .62/ 105.7 41.62/105.7 41.62/105.7
45/ 114.3 42/106.7 45/114,3
36.5192.7 36.5192.7 36.5192.7
15138.1 15/38.1 15/38. 1
156/396.2 120.96/307.2 141/358.1
11.2519.4/42.6 7.316.1127.7 7.3/6. 1/27.7
88 Octane Min. 88 Octane Min. 88 Octane Mi n.
Rack/Rear 01 Seat Rear of Seat RackJRear of Seat
NIA NIA NIA
8/94
RIDE RED
=a" ...
Spri nt ES
0900931
Engine Type Fan Cooled Twin
Bore )( Stroke (mm) 62.3)( 55.6
CarburetioolThrotl le Body 2 Mikuni
VM30SS Slide
Ignition COl
Alternator Outpu1 12V 150W
Lenglh (inJcm.) 102/259. 1
Width (in./cm.) 401101.6
Height (inJcm.) 44.51113
Ski Stance (inJcm.) 31178.7
Track Width (inJcm.) 15/38.1
Track Length Overall (inJcm.) 1081274.3
Fuel Capacity (U.S. galJl mp. gal.lliters) 7.5/6.2128.1
Recorrmended Fuel 88 Oclane Min.
Froot Suspension Mono Leaf
Brake Type Mechanical Disc
Tachometer Option
Trip Odometer NlA
Accessory Lights NlA
Electric Start Standard
Handwarmers Option
Two-Up Seat NlA
Backrest Option
Storage Rack Option
Tow Hitch Option
8194
1.20
Star
0900927
Fan Cooled Single
244
72 )( 60
1 Mikuni
VM30SS Slide
Standard
COl
12V 150W
1021259.1
401101 .6
44.5/113
31178.7
15/38.1
1081274.3
7.516.2128
88 Oclane Min.
Mono Leal
Mechanical Disc
Rear 01 Seat
Option
Option
NfA
NfA
NfA
NfA
NfA
Option
Option
Option
\
Star Trak WideTrak
0901027 0902064
Fan Cooled Single LCTwin
244 488
72 x 60 72 x 60
1 Mikuni 2 Mikuni
Standard Standard
COl COl
12V 150W 12V 200W
1091276.9 1281325.1
401101.6 41.621105.7
44.51113 49/124.4
31176.7 36.5192.7
15138.1 15138.1
133/337.8 156/396.2
7.516.2128 1018.3137.8
88 Oclane Min. 88 Octane Min.
Mono Leaf Coil Spring IFS
Mechanical Disc Hydraulic Disc
Rack/Rear of Seat Rack/Under Seat
Standard Standard
Option Standard
NlA Standard
NlA Temp/Rev
NlA Option
NlA Standard
NlA Standard
Option Standard
Standard Standard
Standard Standard
RIDE RED
The machine serial number may be used asan aid in identifying machine model year. Refer to the first digits in the serial number
FIRST DIGITS
'2
'3
14
'5
'6
'7
'8
MODEL YEAR
'985
,9S6
1987
'988
1989
1990
1991
1991 MODEL OESIGNATION
YEAR DESIGNATIONI-------r=::;;:o.' '"" ENGINE DESIGNATION
I 0 9 '1
2
0 1 4
MODEL DESIGNATION _________ ---'::::1-'
1991
MODEL DESIGNATION
NUMBERS (Chassis)
10 - SlarTrak
15-LongTrakLTA
01 - Indy Trail SuperTrak
04 - Indy Sport
05 - Indy 133 SKS
06 - Indy Trail SP/SOO SP
07 - Indy 440, 500, 650
OB - Indy 500 Classic
20 - WideTrak
24 - Indy Sport GT
30 - Starlite/lite
MODEL NO.
SERIAL NO.
1991
ENGINE DESIGNATION
NUMBERS
27 EC25PS-Single Fe
43 - EC44-3PM-Ol-Twin Fe
49 - EC44-2PM-4100-Twin Fe
58 - EC65PL-Ol-Triple LC
1991
ENGINE DESIGNATION
NUMBERS
59 - EC40PL-02 Twin LC
61 - EC5QPM-Olf02-Twin FC
62 - EC50PM-03-Twin FC ES
64 - EC50PL-QlI03-Twin LC
65 - EC50PL-Q2-Twin LC
68 - EC65PL-Q3-Triple LC
MADE IN U.S.A.
PATENT NOTICE
PDLRRIS
MId. by Pojans """-'"Iries LP.
THIS VEHICLE CONFORMS TOALl APPLICABLE U.S.
i n ~ . MN under OM Of mQl8 II! (he loUow"'ll pa(en1S:
u.s. Pa(MIS 3.605.511 3.533.662 3.613.811
3.580.647 3.613.810 3.605.510
3.483.7613 3.545.Ml 3.525.'12
PP(e<>I9d Canada BB2.491fl1 883.694/71
Canad;an Rd. 34.573111 34.572/71
MFD. DATE:
3.867.991
4.793.950
5.038.881
964.394171
1..227.823187
7072133
1.21
RIDE RED
8/94

RXLSKS
0910768
09'0568
0910564
, E ...... Type LC T"'n LC T';n LC T';n
Bodies
..
O,\pU1 .2V '20W
Length (inJcm.) 106.25/269.9
I W"," (in 10m.)
I (in1om1
I Ski Siano, (in1om.)
, (in./om.:
Track length Overall (in.lcm.)
I (U,5, I ,
I '",n!:
Brake Type
IS ......
i
AccessOfy lights
IEI"".5.an
I 5"Ia.' RaoJ<
8194
113/287SKS
44/1' 1.6
3ll/96.5
'S/36.
120.961307.2
133.56/339.2SKS
86 De" .. Min.
R,,, 01 .. "
Terlllli VAcclHi
Beam
"A
Option
Option
0",,,"

1.22
106.251269.9
113I287SKS
4' .
36.5192.7 36.5192.7
'S/36.' 's/36,'
120.96/307.2 120.961307.2
133.561339.2SKS
I2V2OQW
36/96,5
'S/36.'
120.96/307.2
, Min. Min, 86 Delano Min,
Coil 5p<ing 1F5
Hydraulic Disc
R,,, 01 5,a'
TemplOiVHi Beam
Option
Opt""
Opt""
Opt""
Opllon

Co' Sp<ing IFS
HydraulIC Disc Hydraulic Disc
TemplOiVAccJHi
Beam
""'on
Option
AICERED
Temp/Oil/Hi Beam
Option
Option
Opt""
Opt""

o
400
0910759
Engine Type lC Twin
Bore J( Stroke (mm) 65x 60
CarourelionfThrottle Body 2 Mikuni
VM34SS Slide
OHlnjected Standard
Ignition COl
Allernalor Output 12V 200W
Length (in.fern.) 106.251269.9
Width (in.fern.) 41.621105.7
Height (inl cm.) 44/ 111.8
Ski Stance (in.fern.) 36.5192.7
Track Width (in.fern.) 15138. 1
Track Length Overall (inJcm.) 120.96/307.2
Fuel Capacity (U.S. gal.llmp. gal.lliters) 12. 16/10.6/46
Front Suspension COil Spring IFS
Brake Type Hydraulic Disc
Tachometer St andard
Accessory lights TemplOiVHi 8eam
Electric Start Opllon
Handwarmers Option
Two-Up Seat Option
Backrest Opllon
Storage Rack Option
Tow Hitch Option
1.23
1991 Model Idenlification
Trail Deluxe
0910761 0910443 0912443
0910262
488 432 432
72 x 60 67.72 x 60 67.72)( 60
Standard St andard Standard
COl COl COl
12V 200W 12V 200W 12V 200W
106.25/269.9 106.251269.9 118/299.7
41.62/ 105.7 41 .62/105.7 41.621105.7
421106.7 42/106.7 45/114.3
45/114.3 Deluxe
36.5192.7 36.5/92.7 36.5192.7
15/38. 1 15/38.1 15138.1
120.96/307.2 120.961307.2 141/358.1
12. 16/10.6/46 7.316. 1/27.7 7.316.1 /27.7
Rear 01 Seat Rear of Seat Rack/Rear of Seat
TemplOi VAcclHi Option Option
8eam
Standard Deluxe
Standard Deluxe
Standard Deluxe
8/94
RIDE RED
EnglO8 Type
Displacement (cc)
Bore x Stroke (mm)
Garbur8tionlThrottle Body
Qillnjected
Igni tion
Atternat()( Output
Length (inlcm.)
Width (inJcm.)
Height (inicm.)
Ski Stance (inJcrn.)
Track Width (inJcm.)
Fuel Capacity (U.S. galJlmp. galJlitersj
Recommended Fuel
Front Suspension
Brake Type
SuperTrak
0910161
Fan Cooled Twin
4"
72 )(60
2 Mikuni
VM34SS Slide
Standard
COl
12V 200W
1281325.1
41.621105.7
451114.3
36.5192.7
15138.1
1561396.2
12.16110.6146
88 Octane Min.
Coil SPI"ing IFS
Hydraulic Disc
Storage Rack/Rear 01 Seat
Tachometer Standard
Accessory Lights Ace/Rev
Hana.....81mers Standard
Two-Up Seat Standard
Backrest Standard
Storage Rack Standard
Tow Hitch Standard
8194
1.24
WldeTrak
0912064
LC Twin
4"
72x60
2 Mikuni
VM38SS Slide
Standard
COl
12V200W
1281325. 1
41 .62/105.7
49/124.4
36.5192.7
15138.1
1561396.2
1018.3137.8
88 Octane Min.
Coil Spring IFS
Hydraulic Disc
Under Seat
Standard
Standard
Standard
TemplOi URev/Hi
Beam
Option
Standard
Standard
Standard
Standard
Standard
Indy LIte Star LIte
0913033 0913027
Fan Cooled Twin Fan Cooled SlJ'lgle
339 244
62.3155. 6 72)(60
2 Mlkuni 1 Mikuoi
VM30SS Slide VM30SS Slioe
Standard Standard
COl COl
12V 150W 12V 150W
1031261 1031261
37.9196.3 37.9f96.3
461116.8 461116.8
36.5192.7 36.5192.7
15138.1 15138.1
1161294.6 116/294.6
7.6616.4/29 7.66/6.4129
Coil SPI"ing IFS Coil SPI"ing IFS
Mechanical Disc Mechanical DISC
Topol Hood Topol Hood
Rear 01 Seal Rear 01 Seat
Standard Option
NlA NfA
NfA N/A
NlA N/A
Option N/A
Option Option
NlA NlA
NlA NlA
Option Option
Option Option
RIDE RED
The machine serial number may be used as an aid in identifying machine model year. Refer to the first digits in the serial number
FIRST DIGITS
12
13
14
15
16
17
18
19
MODEL YEAR
1985
1986
1987
1988
1989
,990
1991
1992
YEAR DESIGNATIONI-------;=;?"
I 09107j 8
ENGINE DESIGNATION
MODEL DESIGNATION
1992
MODEL DESIGNATION
NUMBERS (Chassis)
09 - Slar/Sprint (ES)
10 - StarTrak
15 -longTrak LIB
1992
ENGI NE DESIGNATI ON
NUMBERS
31 - EC34-2PM-Q2-Twin FC ES
33 - EC34-2PM-Ol-03-Twin FC
43 - EC44-3PM-Ol -Twin FC
1992
ENGI NE DESIGNATION
NUMBERS
59 - EC40Pl-02-Twin LC
60 - EC45Pl-Ol /02-Twin l C
61 EC5QPM-OlI02-Twin FC
62 - EC50PM-03-Twin FC 01 - Indy Trail SuperTrak
04 - Indy Sport
05 - Indy 133 SKS
49 - EC442PM-4100-Twin FC
58 - EC65Pl-Ol -Triple lC
64 EC50Pl-01103I04Twin LC
65 - EC50Pl-02Twin l C ES
68 EC65Pl-03-Triple lC
06 - Indy Trail SP/SOO $P
07 - Indy 440, 500, 650
17 - Indy 440 XeR
20 - WideTrak
24 - Indy Sport GT
30 - Starlite/Lile
MOOELNO.
SEAI-'LNO.
MADE IN U.S.A.
THIS VEHICLE CONFORMS TO All APPLICABLE U.S.
MFD. DATE:
74 - EC50Pl-C7Twin LC
PDLRRIS
PATENT NOTICE
""". Dy PIlla... industMI L.P.
"RosMu. MN .....s..on. Of trIOf. oIlP>I ~ paten":
u.s . P81enlS 3.605.511 3.533.662 3.613.811
3.SBO.&H 3.613.810 3.605.510
3.483.766 3.545.821 3.525.412
Pal..,18d Canac!a B82._!l1171 863.694f71
Cl\l"IIIOatI RO. 34.573171 34.572171
3.867.991
4.193.!l5O
5,038.881
8 6 4 . l ~ l
1.227.1123181
7072133
permanently stamped i nto 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 caUed out. Laser
engraved model and serial numbers are located on the crankcase (i ntake side).
1.25
RIDE RED
8194
'1992 Model Identification
RXL
RXLSKS
0920768
0920568
Bore )( Stroke (mm) 67.72 x 60
CarburetionIThrottle Body 3 Throttle Body
46 mm Butterfly
Ignition COl
Alternator Output 12V 1SOW
Length (in.lcm.) 106.25/269.9
113/287 SKS
Width (in.fcm.) 43. 12/ 109.5
41.621105.7 SKS
Height (inJcm. ) 38.5197.7
44/ 111.7SKS
Ski Stance (in.lcm.J 38/96.4
36.5/92.7 SKS
Track Length Overall (in.lcm.) 1211307. 1
133.51338.9 SKS
Fuel Capacity (U.S. gal./llTll. gal.lliters) 11 .919.9/45
Recommended Fuel 8B Octane Min.
Front Suspension Parallel Unk
Trailing Arm IFS
Hydraulic Disc
Tachometer Standard
Accessory Lights OilfTemplAccJHi
Beam
Electric Start NIA
Handwarmers Standard HIL
Two-Up Seal Option
Backrest Option
Storage Rack Option
Tow Hitch Option
8194
1.26
650
0920758
LC Triple
648
67.72 x 60
3 Mikuni
VM38SS Slide
Standard
COl
12V 1 SOW
106.251269.9
41.621105.7
44/ 111.7
36.5192.7
15/38.1
121/307. 1
11 .9/9.9/45
88 Octane Min.
Paraliel Link
Trailing Arm IFS
Liquid Cooled
Hydraulic Disc
Rear of Seat
Standard
Standard
Standard
OilfTempJAccJHi
Beam
NIA
Standard HlL
Option
Option
Option
Option
Classic 500SP EFI
500 SKS EFI
0920865 0920674
0920574
LCTwin LC Twin
488 488
72 )(60 72 x 60
2 Mikuni 2 Throttle Body
VM38SS Slide 46 mm Butterfly
Stal'ldard Standard
COl COl
12V200W 12V 200W
1131287 106.251269.9 SP
113/287 SKS
41.62/105.7 43.12Jl09.SSP
41.621105.7 SKS
44/ 111.7 44/111.7
36.5192.7 38196.4 SP
36.5/92.7 SKS
15138.1 15/38.1
133.51338.9 121 /307.1
133.5/338.9 SKS
11 .9/9.9/45 11.9/9.9/45
Parallel Link Parallel Link
Trailing Arm IFS Trailing Arm IFS
Hydraulic Disc Hydraulic Disc
Rear of Seat Rear of Seat
Standard Standard
Standard Standard
Standard Standard
OilfTempJAccJHi OilfTempIHl Beam
Beam
Standard T8A
Standard HI L Option
Standard Option
Standard Option
Option Option
Option Option
RIDE RED
500
0920764
Engine Type LC Twin
Bore x Stroke (mm) 72 :l60
CarburelionlThrottle Body 2 Mikuni
VM38SS Slide
Ignition COl
Length (in.fcm.) 106.25/269.9
Width (inJcm.) 41 .621105.7
Height (in.lcm.) 44/ 111.7
Ski Stance (inJcm.) 36.Sf92.7
Track Width (in.lcm.) 15/38.1
Track Length Overall (in.lcm.) 121 1307. 1
Fuel Capacity (U.S. gaJJlmp. gaJ./liters) 11.9f9.9f45
Front Suspension Parallel link
Trailing Arm IFS
Brake Type Hydraulic Oisc
Tachometer Standard
Accessory lights OiVTempiHi Beam
Handwarmers Option
Two-Up Seat Option
Backrest Opt ion
Storage Rack Option
Tow Hitch Option
1.27
WideTrak 440 XCR 440
0922064 0921760 0920760
LCTwin lC Twin LC Twin
488 432 432
72 x 60 67.72)( 60 67.72)( 60
COl COl COl
12V 200W 12V200W 12V 200W
128/324.9 106.25/269.9 106.251269.9
41.62/105.7 43. 12/109.5 41.621105.7
49/124.4 38.5197.7 44f l11.7
36.5192.7 38/96.4 36.5192.7
20/50.8 15/38. 1 15/38.1
156/396 121/307.1 121/307. 1
10/8.3/38 7.316.1/28 11.9/9 .9/45
Parallel link Parallel link Parallel link
Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS
Gas Shock
Mechanical Disc l iquid Cooled Hydraulic Disc
Hydraulic Disc
Under Seat Rear of Seat Rear 01 Seat
Storage Rack
OiVTemplRevl Hi Temp/Ace OiVTemp
Beam Hi Beam Hi Beam
Single Heat Std. Hl l Option
RIDE RED
8194
Engine Type
Displacement (ee)
SOfe x Stroke (mm)
CarburetionIThrottle Body
Oil Injected
Ignition
Alternator Output
Length (inJcm.)
Width (inJcm.)
Height (in.lcm.)
Ski Stance (in./cm.)
Track Width (in.fcm.)
Fuel Capacity (U.S. galJlmp. gaL/liters)
Recommended Fuel
Front Suspension
Brake Type
Storage
Speedometer
Tachometer
Trip Odometer
Accessory Lights
Electric Start
HancMrarmers
Two-Up Seat
Backrest
Storage Rack
Tow Hitch
8/94
SuperTrak
0920161
Fan Cooled Twin
488
72x60
2 Mikuni
VM345S Slide
Standard
COl
12V 200W
128/324.9
41.62/105.7
45/114.2
36.5192.7
15/38.1
1561396
11.9/9.9/45
88 Octane Min.
Parallel Link
Trailing Arm IFS
Mechanical Disc
Rear of Seat
Storage Rack
Standard
Standard
Standard
Rev/OiV
Hi Beam/Ace
Option
Single Heat
Standard
Standard
Standard
Standard
1.28
Trait Deluxe
0920262
Fan Cooled Twin
488
72x60
2 Mikuni
VM34SSSlide
Standard
COl
12V 200W
1131287
41.62/105.7
45/114.2
36.5192,7
15/38.1
133.51338.9
11.9/9.9/45
88 Octane Min.
Parallel Link
Trailing Arm IFS
Hydraulic Disc
Rear of Seat
Standard
Standard
Standard
OiVAcclHi Beam
Standard
Single Heat
Standard
Standard
Option
Option
Trail Sport GT
0920761 0922443
Fan Cooled Twin Fan Cooled Twin
488 432
72)(60 67.72 x 60
2 Mikuni 2 Mikuni
Standard Standard
COl COl
12V 200W 12V200W
106.251269,9 1181299.5
41.621105.7 41.62/105.7
44/111.7 45/114.2
36.5192.7 36.5/92.7
15138.1 15/38.1
120.96/307.1 1411358
11.919.9145 7.3/6.1128
Storage Rack
Standard Standard
Standard Option
Standard Standard
OiVAcclHi Beam NIA
Option Option
Single Heat Option
Option Standard
Option Standard
Option Standard
Option Standard
RIDE RED
Sport 440
0920443
I E""I". T,,.

I
rti"I
I 80" SI"ke Imml 67.72.60
,Body 2 Mikuni
VM34SS Slide
01110;",1'"

COl
I 0,\001
Le""lh (lo./om.1
I Width (lo./om.1 41 .62/105.7
I Height CinJcm.:

I T,,,k "o./om.1
I T,,,k Le""lh O,e,," "o./om.
I Foel I I 7.316.1/28
",,"
, Mlo.
Fronl Suspensioo I
iii o IFS
Ii Disc
I S""'9'
ReM 01 Se"
Optloo
L1phl, NfA
Electric Start Optloo
OptiOO
Seal
Optloo
Optloo
e R"k Optloo
I Tow H,"h Optloo
1.29
Indy lite GT Indy lite Star Lite
Lite Deluxe
0923133 0923033 0923027
0923231
Foo Cool'" Twlo I Twlo Foo I I
339 339 244
72.60
COl
t2V 15()W t2V 15()W 12V 15()W
1151292 103126' 103126'
48/121.8 461116.7
15138. 1 15/38. 1 15/38.1
7.7/6.4129 7.7/6.4129
, Mlo. , Mlo. , Mlo.
_
I I
iii o IFS iii olFS
I Disc I Disc 101"
Reacof Se" Rea, of Seal Reacof Seal

NfA NfA NfA
Optloo
NfA NlA NfA
O,tloo
6:f"e
NfA
O,tloo
?'IIoO L1le I
Optloo
NlA NfA
O,tloo NlA NfA
NfA NfA
Optloo O,tloo
8194
RIDE RED
The machine serial number may be used as an aid in identifying machine model year. Refer to the lirst digits in the serial number
FIBST DIGITS
12
13
14
15
16
17
18
19
20
MOOELYEAA
1985
1986
1987
1988
1989
1990
1991
1992
1993
YEAR DESIGNATIONI-------r=::;;=", " r,.r:=;----- ENGINE DESIGNATION
1093127 10
MODEl DESIGNATION _________ --==rl---'
1993
MODEL DESIGNATION
NUMBERS (ChaSSiS)
04 - Indy Sport
1993
ENGINE DESIGNATION
NUMBERS
27 - EC25PS-Q7-Single Fe
33 - EC34-2PM-()4-Twin Fe
t993
ENGINE DESIGNATION
NUMBERS
64 - ECSOPL-{)4/06-Twin LC
65 - EC50PL'()5-Twin LC ES
67 - EC58PL .. 01 .. Triple LC 05 - 440,500 EFt . XLI. RXl (SKS)
06 - 500 EFt, XLT SP
07 -Indy Trail, 440, XLI. AXl
08 - Classic/Classic Touring
17-440XCA
43 - EC44-3PM-Ol-Twin Fe
60 - EC45PL-Ql /02-Twin LC
68 .. EC65PL'()!)" Triple LC (EFI)
70 - EC75PL..Ql .. Triple LC
61 - EC50PM-Ol-Twin Fe 74 - EC50PL..Q7-Twin LC (EFI)
20 - WideTrak
25 - Storm (SKS)
27 - Storm
31 - Indy Ute GT/StarUte GT
34 -Indy lite DeluxeJStarlite
MODEL NO.
SERIAL NO.
MAOE IN U. S.A.
THIS VEHICLE CONFORMS TO ALL APPUCABLE u. S.
FEOERAL ANO STATE REOUIREMENTS AND
CANADIAN FEDERAL MOTOR VEHICLE STANOARDS
IN EFFECT ON THE DATE Of MANUfACTURE.
MfD. DATE:
POLRRIS
PATENT NOTICE
MId. by "'*"' II"IduSII"itI L P.
cneor """. aI tI>e -..g paWII.:
u.s. P""'II 30606.511 3.m,6&! 3.613.811
3.st1O.64t 3.613.810 3.605.510
3.' 83.16& 3.525."2
Paten* CW1IIOa 882.' 91m 883.6901111
ean.r..n RO. 3<1.573171 3<I.5nnl
3.1167.991
4.793.950
5.008.8111
ae.t.39oIIJ'I
1.227.823187
7072133
permanently stamped i nto 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 oul. Laser
engraved model and serial numbers are located on the crankcase (intake side) .
8/94
1.30
AIDE RED
Storm
Storm SKS
0932770
0932570
Engine Model Number EC75PL-Ol
CarburelionfThrotlle Body 3 Mikuni
VM38SS Slide
Ignition COl
Alternator Output 12V t70W
Length (in.lcm.) 106.251269.9
113/267 SKS
Width {in.lcm.J 43.12/ 109.5
41.621105.7 SKS
Height (inJcm.) 38.5197.7
44/ 111 .7 SKS
Ski Siance (inJcm. ) 38196.4
36.5192.7 SKS
Track Width (inJcm. ) 15/38. 1
Track Lengl h Overall (in.lcm.) 121/307. 1
133.51338.9 SKS
Fuel Capacity (U.S. gal./ lmp. gal.lliters) 10.7/ 8.9/40.5
Recommended Fuel 90 Oclane Min.
Front Suspension Parallel Link
Trailing Arm IFS
Hydraulic Disc
Tachometer Standard
Accessory Lights OiUBrakelTempJAcc
IHi Beam
Electric Start NIA
HandwarmersIThumbwarmer SId/Sid
Two-Up Seal NIA
Backrest Option
Storage Rack Option
Tow Hitch Option
1.31
RXL XLT XLT SKS
RXLSKS XLTSP
0930768 0930767 0930567
0930568 0930667
LC Triple LC Triple LC Triple
EC65Pl-OS EC58PL-Ol EC58PL-Ol
648 579 579
67.72)( 60 64 x60 64.60
3 Throttle Body 3 Mikuni 3 Mikuni
46mm VM34SS Slide VM34SS Slide
Stanoard Standard Standard
COl COl COl
12V 1 BOW 12V tlOW 12V 170W
106.25/269.9 106.2Sf269.9 113/287
11 3/287 SKS
43.121109.5 43.121109.5 41 .62/105.7
41.62/105.7 SKS
38.5197.7 441111.7 44/ 1'1.7
44/ 111.7 SKS 38.5197.7
38/96.4 38/96.4 36.5192.7
36.5192.7 SKS
15/38. 1 15138.1 15138.1
121 /307.1 121 /307.1 133.51338.9
133.51338.9 SKS
11 .919.9/45 11.9/9.9/45 11.9/9.9/45
88 Oclane Min. 88 Octane Min. 88 Octane Min.
Parallel Link Parallel Link Parallel Link
Liquid Cooled Hydraulic Disc Hydraulic Disc
Hydraulic Disc
Rear of Seal Rear of Seat Rear of Seat
Oi UBrakelTemplAcc Oill BrakelTempi Oi UBrakelTempJ
/Hi Beam Ace/Hi Beam Ace/Hi Beam
NlA TBA TBA
Std/N/ A SId/Sid Std/Sld
8194
RIDE RED
Engioe Type
Engine Model Number
Displacement (cc)
Bore )( Stroke (mm)
GarburetioolThroltle Body
Injected
Ignition
Alternator Output
Length (inJcm.)
Width (in.fern.)
Height (inlcm.)
Ski Stance (inlcm.)
Track Width (inJem.)
Track length Overall (inJcm.)
Fuel Capacity (U.S. galJlmp. gal./lil&rs)
Aecorrwnended Fuel
Front Suspension
Brake Type
Storage
Speedometer
Tachometer
Trip Odometer
Accessory lights
Electric Start
HandwarmersfThumbwarmer
Two-Up Seat
Backrest
Stornge Rack
Tow Hitch
8/94
500 EFI
500 SKS EFI
0930674
0930574
lC Twin
ECSOPL.()7
488
72 x 60
2 Throttle Body
46mm
Standard
COl
12V 200W
106.25/269.9
113/287 SKS
43.121109.5
41.621105.7 SKS
441111.7
38196.4
36.5192.7 SKS
15138.1
1211307.1
133.5I338.9SKS
11.919.9/45
88 Octane Min.
Parallel link
Trailing Arm IFS
Hydraulic Disc
Rear 01 Seat
Standard
Standard
Standard
OiUBrakeITeffiIY
Acc/Ba\VHi Beam
Option
Std'Std
NI'
Option
Option
Option
1.32
Classi c
0930864
LC Twin
ECSOPL.Q4
488
72,60
2 Mikuni
VM38SS Slide
Standard
COl
12V2QOW
106.25/269.9
43. 121109.5
441111.7
38196.4
15138.1
121/307,1
11.9/9.9/45
88 Octane Min.
Parallel Link
Trailing Arm IFS
Hydraulic Disc
Rear of Seal
Standard
Standard
Standard
OiUBrakeITefTll!'
AccIHi Beam
Option
Std/Std
Option
Option
Option
Option
Classic WideTrak
Touring
0930865 0932064
LC Twin lC Twin
ECSOPl-05 ECSOPL-06
488 488
72 )(60 72)(60
2 Mikuni 2 Mikuni
Standard S","""d
COl COl
12V200W 12V2QOW
1131287 1281324.9
41.621105.7 41.621105.7
441111.7 49/124.4
36.5192.7 36.5192.7
15138.1 20150.8
133.51338.9 1561396
11.919.9/45 1018.3/38
ParaJlellink Parallel link
Hydraulic DIsc Mechanical Disc
Rear of Seat Under Seat
Storage Rack
Standard Standard
Standard Standard
Standard Standard
OiUBrakeITetTlll
AccIHi Beam Hi Beam
Standard Option
Std/Std Std/Option
Standard Standard
Standard Standard
Option Standard
Option Standard
RICEREC
440 XCR
0931760
Engine Type lC Twin
Engine Model Number EC45PL-Ol
Displacement Icc) 432
CarbureHonIThrottle Body 2 Mikuni
VM38SS Slide
Qillnjected Standard
Ignition COl
Allemal of Output 12V 200W
Length (inJcm.) 106.25/269.9
Width (in.lcm.) 43.12/109.5
Ski Stance (inlcm.) 38196.4
Track Width (inJcm.) 15/38.1
Track Length OJerall (in.lcm.) 1211307.1
Fuel Capacity (U.S. gaUlmp. gaLlliters) 7.3/6.1/28
Front Suspension Parallel Li nk
Trailing Arm IFS
Hydraulic Disc
Tachometer Standard
Accessory Lights BrakefTempiAcc
Hi Beam
HandwarmersfThumbwarmer Std/Std
Two-Up Seat Option
Backrest Option
Storage Rack Option
Tow Hitch Option
1.33
440 Trail Trail Deluxe
440SKS
0930760 0930761 0930243
0930560
LC Twin Fan Cooled Twin Fan Cooled Twin
EC45PL-Q2 ECSOPMQl EC44-3PM-OI
432 488 432
67.72 x 60 72x60 67.72 1160
COl COl COl
12V 200W 12V 200W 12V 200W
106.251269.9 106.25f269.9 1131287
11 31287 SKS
43. 12/109.5 43. 121109.5 41.621105.7
41 .621105.7 SKS
441111.7 441111.7 45/ 114.2
38196.4 38196.4 36.5192.7
36.5192.7 SKS
15/38.1 15/38.1 15/38.1
121/307.1 121/307.1 133.5/338.9
133.5/338.9 SKS
11.9/9.9/45 11.9/9.9/45 11.9/9.9/45
Rear of Seat Rear of Seat Rear of Seat
OilJBrakefTernpl OilJBrake/ OilJBrakef
AcclHi Beam Ace/Hi Beam Ace/Hi Beam
StdfStd SId/Option StdfOption
Opt ion Option Option
8/94
RIDE RED
Sport 440
0930443
Engine Type Fan Cooled Twin
Engine Model Number EC44-3PM-Ol
Displacemeni (cc) 432
Garburelion/Throttle Body 2 Mikunj
VM34SS Slide
Ignition COl
length (inJcm.) 106.251269.9
Width (inJcm.) 41.62/105.7
Height (in.fern.) 44/111.7
Ski Stance (in.lcrn.) 36.5/92.7
Track Width (i n.lcm.) 15138.1
Track Length Overall (in,{cm.J 121/307.1
Fuel Capacity (U.S. gaUlmp. gal.lliters) 11.919.9/45
Trailing Arm IFS
Slorage Rear 01 Seat
Tachometer Option
TripOdomeler Standard
Accessory Lights A",
Handwarmers/Thumbwarmer SId/Option
Two-Up Seat Option
Backrest Option
Storage Rack Optioo
Tow Hitch Option
8/94
1.34
Indy Llle GT
0933133
Fan Cooled Twin
EC34-2PM-04
339
62.3155.6
2 Mikuni
VM30SS Slide
Standard
COl
12V 150W
1151292
37.9/96.2
481121.8
36.5192.7
15/38.1
133.51338.9
816.7130
88 Octane Min.
ParallelUnk
Trailing Arm IFS
Mechanical Disc
Rear 01 Seat
Standard
NtA
Standard
NtA
Option
Option/Option
Standard
Option
Standard
Standard
Lite Deluxe Indy Lite
0933431 0933433
Fan Cooled Twin Fan Cooled Twin
EC34-2PM-02 EC34-2PM-04
339 339
62.3155.6 62.3/55.6
2 Mikuni 2 Mikuni
Standard Standard
COl COl
12V 150W 12V 150W
1051267 1051267
37.9/96.2 37.9/96.2
461116.7 461116.7
36.5192.7 36.5192.7
15138.1 15138.1
121/307.1 1211307.1
816.7130 816.7/30
ParallelUnk ParallelUnk
Standard Standard
NIA NIA
Standard Standard
NIA NIA
Standard Oplion
SId/Option Option/Option
NIA NIA
NIA NIA
TSA TSA
Option Option
RIDE RED
Indy Starlite GT
0933127
Engine Type Fan Cooled Single
Engine Model Number EC25P$-07
Displacement (cc)
24'
SoJe l( Stroke (mm) 72)1.60
CarburelionfThrottle Body 1 Mikuni
VM30SS Slide
Qlllnjec1ed Slandrud
Ignition COl
Alternator Output 12V 1S0W
Length (in.lcm.) 1151292
Width (inJcm.) 37.9/96.2
Height (inJcm.) 481121 .8
Track Length Overall (in./cm.) 133.51338.9
Fuel Capacity (U.S. galJlmp. gal.lliters) 816.7130
Recommended Fuel 88 Octane Mm.
Trailing Arm IFS
Brake Type Mechanical Disc
Storage Rear 01 Seal
Speedometer Option
Tachometer NlA
Trip Odometer Op<oon
AccesSOfy Lights NlA
Electric Starl NlA
Handwarmers/Thurrbwarmer Option/Option
Two-Up Seat Standard
Backrest Option
Storage Rack Standard
Tow Hitch OptIOn
1.35
Indy StarLite
0933427
Fan Cooled Single
EC25PS{)7
244
72x60
1 Mikuni
VM30SS Slide
Stanc1ard
COl
12V 1SOW
1051267
37.9/96.2
46/116.7
36.5192.7
15138.1
121/307.1
8/6.7/30
88 Octane Mm.
Parallel Link
Trailing Arm IFS
Mechanical Disc
Rear of Seat
0_
NJA
Option
NlA
N' A
Option/Option
N' A
N'A
TBA
Option
AICERED
8194
-
The machine serial number maybe used asan aid in identifying machine model year. Aelerle the firstdigils in the serial number
fiRST DIGITS
'2
'3
14
'5
'6
17
'8
'9
20
22
MODEL YEAR
'985
'986
1987
1988
1989
1990
1991
'992
1993
1994
YEAR DESIGNATIONI-------r=::;c:h
ENGINE DESIGNATION
MODEL DESIGNATION _________ ----=::::J---'
'99'
MODEL DESIGNATION
NUMBERS (Chassis)
02 Sport SKS. Trail Deluxe
04 - Spon
1994
ENGINE DESIGNATION
NUMBERS
27 - EC25PS-07-Single Fe
31 - EC34-2PM-Q2-Twin Fe (ES)
33 - EC34-2PM-04-Twin FC
1994
ENGINE DESIGNATION
NUMBERS
65 - EC5QPL.Q5-Twin LC
67 - EC58PL-01-Triple LC 05 XLI SKS, Storm SKS
06 - XLI SP 43 - EC44-3PM-Ol-Twin FC 68 EC65PL-05-Triple LC (EFI)
07 - Super Sport, Trail, RXl, XLI, Storm
08 - RXL Touring
17 - 440 XeR
60 - EC45PL-OlI02- Twin LC (A)
61 - ECSOPM.Q1f03-Twin FC (B)
62 - EC50PM-02-Twin FC (ES)
69 - EC65PL-06-Triple LC (EFI ES)
74 - EC50PL-07-Twin LC (EF1)
75 - EC50Pl-08-Twin LC (EFI ES)
82 - ECBOPL-01 Triple LC 20 - WideTrak GT/LX
25 - 440 Indy SKS, 500 EFI SKS
27 - 440 Indy, 500 EFI
28 - Classic, Classic Touring
31 - Indy Lite Gr, StarLite Gt
34 - Indy Lile, lite Deluxe, Slarlile
KEY:
(Al '"' Carb 38 mm vs 34 mm
(B) = Jetting - Ti ming - Piston Length
(ES) Electric Start
(EFI) '"' Electronic Fuel Injection
(EFI ES) '" Electronic Fuel Injection with Electric Start
MODEL NO.
SERIAL NO.
MAOE IN U.S.A.
THIS VEHICLE CONFOfIMS TO All APPLICABLE U.S.
MFD.OATE:
POLRRIS
PATENT NOTICE
MId. Cy PolInIlndustriel LP
MN __ Of
u.s. "-*"" 3.6(1).511 3.533.662 3.613.811
3.seo.St7 3.613.810 3.605.510
3.483.766 3.5<15.821 3.525."2
p-*,*, c.n.o. 882,'91fl1 88l.69ml
c...- ReI. 3<1,573171 3<1,572171
These numbers should be relerred to in any correspondence regarding warranty, service or replacement parts.
3.1167.991
' .793.950
5.038.881
864.390&171
1.227.en'87
7072133
The machine model and serial number identilication decal is located on the right Iront side of the tunnel. The serial number is
Whenever corresponding about an engine it is important that the engine model and serial numbers be calied out. Laser
Bl94
1-36
AIDE RED
Engine Type
Engine Model Number
Displacement (eel
Bore x Stroke (mm)
Carburelion/Throttle Body
Qillnjected
Ignition
Alternator Output
Length (inJcm.)
Width (in.lcm.)
Height (inJcm.)
Ski Stance {in.lcm. )
Track Wklth {inJcm.)
Track Length Overall
{inJcm.)
Fuel Capacity (U.S. gaL/Imp. gal.l1iters)
Recommended Fuel
Front Suspension
Brake Type
Storage
Speedometer
Tachometer
Electric Fuel Gauge
Aceessory lights
Electric Start
Handwarmers/Thumbwarmer
Two-Up Seat
Backrest
Storage Rack
Tow Hitch
Storm
Storm SKS
0940782
0940582
LC Triple
EC80PL-Ol
794
72 x 65
RXL XLT XLT SKS
RXL Touring XLTSP
0940768 0940767 0940567
0940869 0940667
LC Triple lC Triple LC Triple
EC65PL-05/06 EC58PL-Ol EC58PL-Ol
648 579 579
67.72)( 60 64 x 60 64,60
3 Mikuni 3 Throttle Body 46mm 3 Mikuni 3 Mikuni
Standard Standard Standard Standard
COl COl COl COl
12V!BOW 12V!BOW 12V 170W 12V 170W
106.251269.9 106.251269.9 106.25/269.9 113/287
1131287 SKS 113/287 Touring
45.51115.6 45.5f 115.6 45.51115.6 43.5/ 110.5
43.5Il10.5SKS
38.5197.8 38.5197.8 44/ 111.6 44/ 111.8
44/111.8 SKS 44/ 111.8 Touring 38.5197.8 SP
40/ 101.6 401101.6 40/ 101.6 38/96.5
38/96.5 SKS
15/38.1 15/38. 1 15/38.1 15/38.1
121/307.3 1211307.3 121/307.3 133.51339. 1
133.51339.1 SKS 133.51339.1 Touring
10.7/8.9/40.5 10.7/8.9/ 40.5 10.7/8.9/40.5 10.7/8.9/40.5
90 Octane Min. 87 Octane Min. 87 Octane Min. 87 Octane Min.
Parallel Link Parallel Link Parallel Link Parallel Link
Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS
Liquid Cooled Liquid Cooled Hydraulic Disc Hydraulic Disc
Rear 01 Seat Rear 01 Seat Rear of Seat Rear of Seat
Option Standard Option Optioo
Oi l/Brake Oi l/Brake Oil/Brake Oil/Brake
Temp/Ace Temp/Ace Temp/Ace Temp/Ace
High Beam High Beam High Beam High Beam
NIA Touring Option Option
Hi-LoIStd HiLoINA Hi-LoIStd Hi-LoIStd
NIA Option Option Option
Option Opt ion Option Option
Option Option Option Option
1.37
8194
RIDE RED
XLT Special
XTRA
0946767
Engine Model Nurrt>er
EC58PL-03
Oisplacement (ee) 596
Bore x Stroke (mm) 6511'.60
Camuretion'Throttle BOOy 3 Mikuni
VM34SS Slide
Ignilion COl
Alternator Output 12V HOW
Length (inJcm.) 106.251269.9
Width (inJcm.) 49/124.5
Height (inJcm.) 47/ 119.4
Ski Stance (inJcm.) 38/96.5
Track Width (inJcm.) 15138. \
Track length Overall 121/307.3
(inJcm.)
Fuel Capacity (U.S. gasJlmp. gaJ./liters) 10.7/8.9/40.5
Rec:orrwnended Fuel 87 Octane Min.
Front Suspension Parallel link
Trailing Arm IFS
Storage Rear 01 Seat
Tachometer Standard
Electric Fuel Gauge Option
Ace::essory Lights Oil/Brake
TemptAce::
High Beam
HandWarmersfThumbwarmer Hi-La/SId
Two-Up Seat
0_
Backrest Option
StCH'8ge Rack Option
Tow Hitch Option
8194
500 EFI
500 EFI SKS
0942774
0942574
LC Twin
ECSOPL.(l7
488
7211'.60
2 Throtlle Body
46mm
Standard
COl
12V250W
107/271.8
11 31287 SKS
45.51115.6
43.51110.5SKS
461116.8
40/101 .6
38196.5 SKS
15/38.1
1211307.3
133.51339.1 SKS
10.7/8.9/40.5
87 Octane Min.
Parallel UNt
Trailing Arm IFS
Hydraulic Disc
Rear of Seat
Standard
Standard
Option
OilfBrakefTemp
AcclBalt
High8eam
Option
Hj.LoIStd
Option
Oplion
Option
Option
1.38
Classic Classic
Touring
0942865 0942875
LCTwin lC Twin
EC50PL-05 ECSOPl-08
488 488
72x60 72)(60
2 Mikuni 2 Mikunl
Standard Standard
COl COl
12V 200W 12V25QW
107f271.8 1131287
45.51115.6 45.51115.6
461116.8 461116.8
401101.6 40/101.6
15/38.1 15138.1
121 /307.3 133.51339.1
10.7/8.9/40.5 10.7/8.9f40.5
Parallellir* Parallel liNt
Standard Standard
Standard Standard
Standard Standard
OiVBrake OiVBrakefTemp
TemplAce:: Acc/Balt
High Beam High Beam
Option Standa<d
Hi LoISld Hi--LoISld
0pIi0" S"-d
Option S"-d
Oplion Option
Option Option
RIDE RED
WideTrak LX WldeTrak GT
0942064 0942061
Engine Type LC Twin Fan Twin
Engine Model Number
ECSOPM-03
Displ acement (cc) 488 488
CarburehonIThrottle Body 2 Mikuni 2 Mikuni
Ignition COl COl
Alternator Output 12V200W 12V 200W
Length (in.fcm.) 128/325.1 121.51308.6
Width (in./cm.) 43.51110.5 43.51110.5
Height (inJcm,) 49/124.5 49/124.5
Ski Stance (i nJcm.) 38/96.5 38/96.5
Track Width (in./cm.) 20150.8 20/50.8
Track Length Overall 1561396.2 141/358.1
(in.lcm.)
Fuel Capacity (U.S. gas.llmp. 10/8.3/38 10/8.3137.8
gaLll iters)
Recommended Fuel 87 Octane Min. 87 Oclane Min.
Front Suspension Parallel Link ParaUel Link
Trailing Arm IFS Traili ng Arm IFS
Brake Type Mechanical Disc Mechanical Disc
Storage Under Seat Under Seat
Storage Rack
Speedometer Standard Slaildard
Tachometer Standard Option
Electric Fuel Gauge NfA NfA
Aceessory Lights OiVTemp Rev/Ace
R"
Oil
High 8eam High Beam
Electric Start Option Option
Handwarmers/Thumbwarmer Single Heat/SId Single Heat/SId
Two-Up Seat Standard Staildard
Backrest Standard Slaildard
Storage Rack Standard Staildard
Tow Hitch Standard Slaildard
1.39
600 XCR 440 XCR
0941667 0941760
lC Twin l CTwin
EC58PL-02 EC45Pl-Ol
596 432
65x 60 67.72x60
3 Mikuni 2 Mi kuni
Standard Standard
COl COl
12V t70W 12V200W
106.251269.9 106.25/269.9
45.51115.6 45.51115.6
38.5197.8 38.5/97.8
411104.1 401101.6
15/38.1 15138.1
121/307.3 121/307.3
10.7/8.9/40.5 10.718.9/40.5
ParaUel Link Parallel Link
Liquid Cooled Liquid Cooled
Standard Standard
Standard Standard
Option Option
Oil/Brake Oil/Brake
Temp/Ace Temp/Ace
High Beam High Beam
Option Option
HiLoIStd Hi-La/Std
NfA Option
NfA Option
NfA Option
NfA Option
8/94
RIDE RED
440 XCR SP
0941660
Engine Type LeTwin
Engine Model Number
EC45PL-OO
Oisplacement (oe) 43.
Bofe J. Stroke (mm) 68.25 J. 60
CafburetiOfllThro"le Body 2 Mikuni
VM38S5 Slide
Ignition COl
Alternator Outpul 12V2OQW
length (inJcm.) 106.251269.9
Width On.fcm.) 45.51115.6
Ski Stance (i nJcm.) 411104. 1
Traclo; Width (inJcm.) 15138.1
Track Length Overall 121/307.3
(inJcm.)
Fuel Capacity (U.S. gasJlmp. gaL/lil ers) 10.7/8.9/40.5
Front Suspension Parallel lit<
T r a i ~ n g Arm IFS
Brake Type liquid Cooled
Hydraulic DIsc
Tachometer Standard
Etectric Fuet Gauge OpIioo
Accessory Lights OiVBrake
TempiAce
High Beam
Electric Stan Option
HandwarmerslThumbwarmer Hi-Lo/Std
Two-Up Seat NlA
Backrest NlA
Storage Ractl NlA
Tow Hitch N/A
8/94
1.40
440 Indy
440 Indy SKS
0942760
0942560
lC Twin
EC45PL-()2
432
67.72 .. 60
2 Mikuni
VM34SS Slide
Standard
COl
12V2OQW
1071271.8
1\31287 SKS
45.51115.6
43.5/110.5 SKS
461116.8
40/101.6
38196.5SKS
15138.1
1211307.3
133.51339. 1 SKS
10.7/8.9/40.5
87 Octane Min.
Parallel lit<
T r a ~ i n g Arm IFS
Hydraulic Disc
Rear 01 Seat
Standard
Standard
0pIi00
OiVBrake
TemplAce
High Beam
Option
Hi-LoiStd
0pIi00
0pIi00
0pIi00
0pIi00
Trail Deluxe Trail
0940262 0940761
Fan Twin Fan Twin
ECSOPM-02 EC50PM-Q1
488 488
72 .. 60 72x60
2 Mikuni 2 Mikuni
VM34SSSlide VM34SS Slide
Standard Standard
COl COl
12V200W 12V200w
1131287 106.251269.9
45.51115.6 45.51115.6
45/114.3 44/111.8
401101.6 40/101.6
15138.1 15138.1
133.51339. 1 1211307.3
10.7/8.9/ 40.5 to.7f8.9/40.5
Parallel lit< Parallel Link
Rear 01 Seat Rear 01 Seal
Standard Standard
Option Standard
Op"""
Option
OillBrake OiVSrake
Ace Ace
High Beam High Beam
Standard Option
Single Heat/Std Single Heat/Std
Standard Option
Standard Standard
Option Option
Option Option
RICEREC
Super Sport
0940743
Eogine Type Fan Twin
Engine Model Number EC44-3PM-Ol
Displacement {ee)
43'
BOfe x Stroke (mm) 67.72 x 60
Carburet ionIThrottle Body 2 Mikuni
VM34SS Slide
Oillnjecled Standard
Ignition COl
Alternator Output 12V200W
length (in.lcm.) 106.251269.9
Width (inJcm.) 45.51115.6
Track Width (in.lcm.) 15138. 1
Track Length Overall (in.lcm. ) 1211307.3
Fuel Capacity (U.S. gas.l lmp. gaLliiters) 10.7f8.9140.5
Trailing Arm IFS
Tachometer Standard
Accessory Lights Oi L/Brake
A",
High Beam
HandwarmersfThumbwarmer Single HeatfStd
Two-Up Seal Option
Backrest Standard
StOl'age Rack Option
Tow Hitch Option

1.41
Sport Indy Lite Indy Lite GT
Sport SKS Deluxe
0940443 0943431 0943133
0940243
Fan Twin Fan Twin Fan Twin
EC44-3PM-Ol EC34-2PM-02 EC34-2PM-04
432 339 339
67.72 x 60 62.3 x 55.6 62.3 x 55.6
VM34SSSlide VM305S Slide VM30SS Slide
COl COl COl
12V2QOW 12V 1 SOW 12V 1 SOW
106.25/269.9 105/266.7 115/292.1
1131287 SKS
43.51110.5 42.51108 42.51108
44/ 111.8 44/ 111 .8 481121.9
451 114.3SKS
38196.5 37/94 37194
15/38,1 15/ 38.1 15/38.1
1211307.3 121 / 307.3 133.51339.1
133.5/339.1 SKS
10.7f8.9f40.5 816.7130.3 8f6.7/ 3O.3
Hydraulic Disc Mechanical Disc Mechanical Disc
Rear 01 Seat Rear 01 Seat Rear 01 Seat
Option NlA N/A
Option NlA NlA
OiL/Brake OiL/Acc Oi L/Ace
Ae<
High Beam
Single Heat Std Single HeatfStd Single HeatfStd
Option NlA Standard
Standard SKS
Option NlA Standard
Standard SKS
8194
RIDE RED
Engine Type
Engine Model Number
Displacement (cc)
Bore x Stroke (mm)
Cart:>uretionIThrotile Body
Oilln)ecled
Ignition
Alternator Output
length (in.lcm.)
Width (inJcm.)
Height (in.fern.)
Ski Stance (inJcm.)
Track Width (inlcm.)
Track length Overall (in.fern.)
Fuel Capacity (U.S. gasJI"ll_ gal./Iilers)
Recommended Fuel
Front Suspension
Brake Type
Storage
Speedometer
Tachometer
Electric Fuel Gauge
Accessory lights
Electric Start
HandwarmersfThumbwarmer
Two-Up Seat
Backrest
Storage Rack
Tow Hitch
8/94
Starlite GT
0943127
Fan Single
EC25PS07
24'
72 )(60
1 Mikuni
VM30SS Shde
Standard
COl
12V 150W
1151292.1
42.51108
48/121 .9
37/94
15/38.1
133.51339.1
816.7130.3
87 Octane Min.
Paranel Link
Trailing Arm IFS
Mechanical Disc
Rear of Seat
Top of Hood
Option
N/A
N/A
N/A
N/A
Option/Option
Standard
Standard
Standard
Standard
1.42
-
StarLite Indy Lite
0943427 0943433
Fan Single Fan Twin
EC25PS-07 EC34-2PM-04
24' 339
72)( 60 62.3)( 55.6
1 Mikuni 2 Mikuni
VM30SS Slide VM3QSS Slide
Standard Standard
COl COl
12V 1 SOW 12V 1 SOW
1051266.7 1051266.7
42.51108 42.51108
44/111.8 441111.8
37/94 37/94
15/38. 1 15/38.1
121/307.3 121/307.3
816.7130.3 8/6.7/30.3
Paranel Link Parallel Link
Rearol Seat Rear of Seat
Top of Hood Topol Hood
Option Standard
N/A N/A
N/A N/A
N/A N/A
N/A Option
OptionfOption Option/Option
N/A N/A
N/A N/A
Option Option
Option Option
RIDE RED
The machine serial number may be used as an aid in identifying machine model year. Belerla the first digits in the serial number
fIRST DIGITS MODEL YEAR
12 1985
fiRST DIGITS
18
MOOELYEAR
1991
13 1986 19 1992
14 1987 20 1993
15 1988 22 1994
16 1989 23 1995
17 1990
YEAR r---- ENGINE DESIGNATION

MODEL DESIGNATION
1995
MODEL DESIGNATION
NUMBERS (ChaSSiS)
02 - Sport Touring
04 Sport
05 - XLI SKS. Storm SKS
07 - Super Sport, XLI, Storm
08 - AXl Touring
20 - WideTrak GI/LX
25 - 440 Indy SKS, 500 EEl SKS
27 - 440 Indy. SOD EEl, Indy Trail, Indy 500
28 - Classic, XLI Touring
31 - Indy Lite GT
34 - Indy Lile, lite Deluxe, Starlite
16 -Indy 440 XeR, Indy 600 XeR
29 - Indy 500 EEl SKS (paddle track)
67 -Indy XLT Special, RXL
1995
ENGINE DESIGNATION
NUMBERS
27 - EC25PS07
33 - EC342PM02JE02
43 - EC44-3PM01/02
60 - EC45PL02I03
61 - EC50PM03lE04/04
62 - EC50PME04/04
56 - EC58PL03
09 -Indy XLT SKS (paddle track), Storm SKS (paddle track)
MADE IN U.S.A.
PDLRRIS
Refer to Engine Section for
more detailed information
1995
ENGINE DESIGNATION
65 - EC50PL05/E04/04
67 - EC58PLOI E04
68 - EC65PL05/ E05
69 - EC65PLQ5/E05
74 - EC50PL07 ,
76 - EC58PL02
82 - EC80PLOI
PATENT NOTI CE M::>OEl NO.
SERIAL NO.
Mtd. bW p".rt. Indu._ LP. In R ........ MN un"-...... or
mar. oIlIIe following
THIS VEHICLE CONFORMS TO All APPLICASlE
U.S. FEDERAL AND STATE REOUIREIoIENTS AND
CANADIAN FEDERAL MOTOR VEHICLE STAN
DARDS IN EFFECT ON THE DATE OF MANUFAC
TURE.
1dF0. DATE:
U.S. "ltenlS
3.605.511
3.580.11(7
3 . .a3,7M
3.533.1162
3.5"5,821
3._.510
3.525.412
3,813,810
3.867,"1
",783,'50
5.038,881
5,ln.675
5,090,386
5,050,5&4
5,050,5511
5,048,503
5,056,"82
5.0IIII,813
5.07",271
5.1'1,531
3,813,811
Pltenll<1 Can.t<lol
882,",,1171
883.6t4171
IIIW,3t4171
c.n.dI ... Ad.
301.573171
301.572171
1.227,823187
70721:\3
Whenever corresponding about an engine it is important Ihatthe engine model and serial numbers be called out. Laser
1.43 8194
RIDE RED
Storm
Storm SKS/PT
0950782
0950582
0950982
Engine Model Number
EC80PLOI
Bore x StroKe (mm) 72 x 65
CarburetionlThrottle Body 3 Mikuni
VM38SS Slide
Ignition COl
Alternator Output 12V ll0W
Length (inJcm.) 106.251269.9
1131287SKS
Width (inJcm.) 45. 51115.6
43.5/110.5 SKS
Height (in./cm.) 38.5197.8
44/111.8SKS
38/96.5 SKS
Track Length Overall 1211307.3
(inJcm.)
133.51339.1 SKS
Fuel Capacity (U.S. galJlmp. galJliters) 10.7/8.9/40.5
Trailing Arm IFS
Hydraulic Disc
Toolbox Footrest
Tachometer Standard
Accessory Lights Oil/Brake
Temp/Acc
H ~ h Beam
Electric Start N/A
Hai"ldwarmersiThumbwarmer Hi-LoJStd
Two-Up Seat Option
Backrest Option
Storage Rack Option
Tow Hitch Option
8/94
RXL Touring
0950869
LC Triple
EC65PLE05
548
67.72 x 60
3 Throttle Body
4 6 ~
Standard
COl
12V 180W
11 31287
45.51115.6
451114.3
401101.6
15/38.1
133.51339.1
10.718.9/40.5
87 Octane Min.
Parallel Link
Trailing Arm IFS
Liquid Cooled
Hydraulic Disc
Rear 01 Seat
Toolbox Footrest
Standard
Standard
Standard
Oil/Brake
TefTlllAce
High Beam
Standard
HiLoIOption
Standard
Standard
Option
Option
1.44
RXL XLT
XLTSP
0956768 0950756
0956756
LC Triple LC Triple
EC65PL05 EC58Pl03
648 597
67.72 x 60 65 x60
3 Throttle Body 3 Mikuni
4 6 ~ VM34SS Slide
Standard Standard
COl COl
12V t80W 12V 170W
106.251269.9 106.25/269.9
49/124.46 45.51115.6
49/124.46 SP
43/109.22 44/111.8
431109.22 SP
43.51110.49 401101.6
43.51110.49 SP
15138.1 15138.1
1211307.3 1211307.3
10.7/8.9140.5 10.718.9140.5
Non-Parallel Link Parallel Link
Non-Parallel
LinkTrailing Arm
IFSSP
Liquid Cooled Hydraulic Disc
Hydraulic Oisc
Rear 01 Seat Rear 01 Seat
Toolbox Footrest Toolbox Footrest
Standard Standard
Standard Standard
Standard Option
Oil/Brake Oil/Brake
Temp/Acc Temp/Ace
High Beam High Beam
Option Option
Hi-LoJOption Hi-LoJStd
Option Option
Option Option
Option Option
TSA Option
TBASP
RIDE RED
Engine Type
Engine Model Number
Displacement (ee)
BOfe )( Stroke (mm)
CarburefionlThrottle Body
Oil Injected
Ignition
Alternator Output
Length (inl cm.)
Width (in'/cm.J
Height (inJcm.J
Ski Slance (inJcm. )
Track Width (in.lcm.)
Track Length Overall
(in.lcm.)
Fuel Capacity (U.S. gas.llmp. gal Jl ilers)
Recommended Fuel
Front Suspension
Brake Type
Storage
Speedometer
Tachometer
Electric Fuel Gauge
Accessory Lights
Electric Start
HandwarmersIThumbwarmer
Two-Up Seat
Backrest
Storage Rack
Tow HItch
XLT SKSIPT
095()556
0950956
LC Triple
EC58PlO3
597
65)( 60
3 Mikuni
VM34SS Slide
Standard
COl
12V 170W
113/287
43.51110.5
441111.8
38196.5
15138.1
133.51339.1
10.7/8.9/40. 5
87 Octane Min.
Parallel Link
Trailing Arm IFS
Hydraulic Disc
Rear 01 Seat
XLT Touring 600 XCR 500
0952857 0951676 0952764
LC Triple lC Triple LC Twin
EC58PLE04 EC58PL02 ECSOPL04
597 597 488
65 x 60 65)( 60 72)(60
VM34SS Slide VM38AL Slide VM38SS Slide
COl COl COl
12V t70W 12V t70W 12V 200W
1131287 106.25.1269.87 1071271.8
45.51115.57 45.51115.57 45.51115.6
46/116.84 40/101.6 401101.6
401101.6 40/101.6 401101.6
15/38. 1 15138.1 15/38. 1
133.51339. 1 1211307.3 121/307.3
10.7/8.9140.5 9.5/ 8.9/40.5 10.7/8.9/40.5
Parallel Link Parallel Link Parallel Unk
w/shock w/shock
Hydraulic Disc Liquid Cooled Hydraul ic Disc
Hydraulic Disc
Aearol Seat Rear 01 Seat Rear 01 Seat
Toolbox Footrest Toolbox Under Hood Toolbox
Opt ion Standard NfA Option
OiVBrake OiVBrake OiVSrake Oi VBrake
TempiAcc Temp/Ace Temp/Acc Temp/Ace
High Beam High Beam High Beam High Beam
Option Standard NfA Option
Hi-Lo/Std Hi-LoIStd Hi-Lo/Std Hi-Lo/Std
Option Standard Option Opt ion
Option Standard Option Option
1.45
8/94
RIDE RED
Classic
0952865
Engine Type LC Twin
Engine Model Number
EC50PLE04
Bore x Stroke (mrn) 72x60
CarburetionlThrotUe Body 2 Mikuni
VM38SS Slide
Ignition COl
Length (inl cm. ) 1071271.8
Width (in.lcm.) 45.51115.6
Height (inl cm. ) 44/111 .76
Ski Stance (inJcm.) 4D1101.6
Track Width (in.lcm. ) 15/38. 1
Track Length Ollerall 121/307.3
(inJcm.)
Fuel Capacity (U.S. gas.llmp. 10.7/8.9/40.5
gal Jliters)
Trailing Arm IFS
Toolbox Under Hood
Tachometer Standard
Electric Fuel Gauge Standard
Aceessory Lights Oil/Brake
Temp/Ace
High Beam
Electric Start Standard
HandwarmersfThumbwarmer HiLoIStd
Two-Up Seat Option
Backresl Option
Storage Rack Option
Tow Hitch Option
8194
500 EFI
500 EFI SKSIPT
0952774
0952574
0952974
lCTwin
EC50PL07
488
72 x 60
2 Throttle Body
46mm
Standard
COl
12V250W
107/271 .8
113/287 SKS
45.51115.6
43.51110.5 SKS
44/111 .76
40/101.6
38/96.5 SKS
15/38.1
121/307.3
133.5I339. 1SKS
10.7/8.9/40.5
87 Octane Min.
Parallel Unk
Trailing Arm IFS
Hydraulic Disc
Rear of Seat
Toolbox Under Hood
Standard
Siandard
Option
Oil/8rakefTemp
Ace/Ball
High Beam
Option
Hi-LoIStd
Option
Option
Option
Option
1.46
WideTrak LX WideTrak GT
0952064 0952061
LCTwin Fan Twin
EC50PL06 EC50PM03
488 488
72 x60 72x60
2 Mikuni 2 Mikuni
Standard Standard
COl COl
12V200W 12V 200W
1281325.1 121.51308.6
43.51110.5 43.51110.5
49/ 124.5 49/124.5
38/96.5 38196.5
20150.8 20150.8
156/396.2 141/358.1
10/8.3138 1018.3137.8
Mechanical Mechanical
Under Seal Under Seat
Storage Rack
Standard Standard
Standard Option
NJA NfA
OHrremp Rell/Ace
R"
Oil
High Beam High Beam
Option Oplion
Single Heal/Std Single Heat/Std
Siandard Standard
Standard Siandard
Standard Siandard
Standard Standard
RIDE RED
440 XCR
0951660
Engine Type LCTwin
Engine Mode! Number
EC45PL05
Bore x Stroke (mm) 68.25)( 60
Carburelion/Throttle Body 2 Mikuni
VM34SS Slide
Qillnjected Standard
Ignition COl
Length (inJcm.) 106.251269.9
Height (inJcm.) 38.5/97.8
Ski Stance (inlcm.) 41 /104.14
Track length Overall 1211307.3
(inJcm.)
Fuel Capacity (U,S. gas.llmp. gal.lliters) 9.518.9140.5
Trailing Arm IFS
wlshock
Hydraulic Disc
StOfage Rear of Seat
Tachometer Standard
Electric Fuel Gauge NfA
Accessory Lights Oil/Brake
Temp/Acc
High Beam
Electric Start NfA
Handwarmers/Thurrbwarrner Hilo/Sld
Two-Up Seat Option
Backrest Option
Storage Rack Option
Tow Hitch Oplion
1.47
440 Indy Trail Deluxe Trail
440 Indy SKS
0952760 0952262 0952761
0952560
LCTwin Fan Twin Fan Twin
EC45PL02 EC50PME04 ECSOPM04
432 488 488
67.72 x 60 72 x 60 72 x 60
COl COl COl
12V 200W 12V200W 12V200W
1071271,8 113/287 1071271.78
1131287 SKS
45.51115.6 45.51115.6 45.51115.6
43.5/1 10.5SKS
44/111 .76 46/116.84 44/111.8
401101.6 40/101.6 40/101.6
38196.5SKS
15138.1 15138.1 15138.1
1211307.3 133.Sf339.t 1211307.3
133.51339.1 SKS
10.7f8.9/40,S 10.7f8.9f40.S to.7/8.9/40,S
87 Oclane Min. 87 Oclane Min. 87 Octane Min.
Parallel Link Parallel link Parallel Link
Trailing Arm iFS Trailing Arm IFS Trailing Arm JFS
Rear 01 Seal Rear of Seat Rear Of Seal
Toolbox Toolbox Toolbox
Oil/Brake Oil/Brake Oil/Brake
Temp/Acc Aco A",
High Beam High Beam High Beam
Hi-lolStd Hi-lolStd Hi-loIStd
Opt ion Standard Option
8/94
RIDE RED
Super Sport
0950743
Engine Type Fan Twin
Engine Model Number
EC44-3PM02
GarburetiorVThrottle Body 2 Mikuni
VM34SS Slide
Oillnjec1ed Standard
Ignition COl
Alternator OUtput 12V200W
Length (inJcm.) 106.251269.9
Ski Stance (InJcm.) 41/104.14
Track Width (inJcm.J 15138.1
Track Length Overall (inJcm.) 1211307.3
fuel Capacity (U.S. gasJlmp. gal}litersj 10.7/8.9140.5
RecommencJed F usl 87 Octane Min.
Trailing Arm IFS
TooIbo:o: Footrest
Tachometer Standard
Accessory Lighls OillBrake
A=
High Beam
ElectrIC Start Option
HandwarmerslThumbwarmer Single Heat/Std
Two-Up Seat Option
Backrest Option
Storage Rack Option
Tow Hitch Option
8/94
Sport
Sport Touring
0950443
0950243
Fan Twin
EC44-3PMOI
432
67.72 x 60
2 Mikuni
VM34SS Slide
Standard
COl
12V 'l.fJ(JoN
106.251269.9
1131287 Touring
43.51110.5
44/111.8
451114.3 Touring
38/96.5
15138.1
121/307.3
133.51339.1 Touring
10.7/8.9/40.5
87 Octane Min.
Parallel Link
Trailing Arm IFS
Hydraulic Disc
Rear of Seat
Toolbox Footrest
Standard
Option
Option
OillBrake
A
High Beam
Option
SlOgle Heat/SId
Single Heat/Acc
Touring
Option
Standard Touring
0ptJ",
Standard Touring
Option
Option
1.48
Indy Lite Indy lite GT
Deluxe
095343\ 0953133
Fan Twin Fan Twin
EC34-2PME02 EC34-2PM02
339 33.
62.3 x 55.6 62.3 x 55.6
2 Mikuni 2 Mikuni
VM3O$S Slide VM3O$S Slide
Standard Standard
COl COl
12V lSOW 12V l50W
1051266.7 1151292.1
42.51108 42.51108
44/111.8 481121.9
37194 37194
15138.1 15138.1
121/307.3 133.51339.1
816.7/30.3 816.7130.3
Aearol Seat Aearol Seal
Standard Standard
NlA NlA
NlA NlA
OIVAce OillAce
S""",,,d Option
Single Heat/SId Single Heat/Std
NlA Standard
N/A Standard
Option Standard
Option Standard
AIDE RED
Indy lite
0953433
Engine Type Fan Twin
Engine Model Number
EC342PMQ2
Displacement (ee)
33'
Bore x Stroke (mm) 62.3)[ 55.6
CarburelionIThronle Body 2 Mikuni
VM30SS Slide
Oil I njected Standard
Ignition COl
Alternator Output 12V 15fJW
Length (inJcm.) 1051266.7
Width (in.lcm.) 42.51108
Heighl (inJcm.) 441111 .8
Ski Stance (inJcm.) 37194
Track Width (in.lcm.) 15138.1
Track Length Overall (in. /em.) 121/307.3
Fuel Capacity (U.S. gas.llmp. gaLlliters) 816.7/30.3
TrailillQ Arm IFS
Brake Type , Mechanical Disc
Topol Hood
Tachometer NIA
Electric Fuel Gauge NIA
AccessQ()' Lights NIA
HandwarmerslThumbwarmer Option/Option
Two-Up Seat NIA
Backrest NIA
Storage Rack Option
Tow Hitch Option
1.49
StarLite
0953427
Fan Single
EC25PS07
244
72 x 60
1 Mikuni
VM30SS Slide
Standard
CDI
12V 150W
1051266.7
42.51108
441111.8
37/94
15/38. 1
121/307.3
8/6.7/30.3
87 Octane Min.
Parallel Link
Trailing Arm IFS
Mechanical Disc
Rear 01 Seat
Top 01 Hood
Option
NIA
NIA
NIA
NtA
Option/Option
NIA
NIA
Option
Option
8/94
RIDE RED
,
CHAPTER 2
BODY AND STEERING
Summer Storage .................................. . . ................ 2.1-2.2d
Gas Tank and Seat Removal - Cutlass 58 ................. ...... ....... . .... 2.3
Gas Tank and Seat Removal- Indy Models ........... . .. . . ... ... .. ......... 2.4
Seat Cover Replacement (Plastic Base) ................ ... ...... .. ...... 2.5-2.7
Decal Removal and Installation .................... . ......... . ............ 2.8
ASS Nosepan - Care. Cleaning and Repair ....................... . ....... 2.9-2.10
Nosepan Replacement Procedure
(1994 Indy 440/SKS, 500 EFI/SKS, Classic/Touring) . .
RIM Metton
TW
Part Repair ..................... .
Fiberglass Repair ... . ........................ .
Hood and Nosepan Adjustment
(1994 Indy 440/SKS, 500 EFI/SKS, Classic/Touring) ..
2.11
2.12
2.13
2.13
Steering - Conventional Front Suspension .................................... 2.14
Steering - IFS - Independent Front Suspension - 1985 to Current ................ 2.15
IFS Adjustable Torsion Bar ......... .
1994 Shock and Spring Chart .
2.16
2.17
1995 Shock and Spring Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
IFS Torsion Bar Removal and Installation.................... . .. .. . 2.19
IFS Toe and Camber Adjustment .................. . ......... . ............ 2.20-2.22
XTRA Camber Adjustment ............................... ... .. . ............. 2.23
XTRA Ski Alignment ................................................. .. .... .
Ski Spindle Bushing Replacement - Handlebar Torque and Sequence
2.24
2.25
Ski Skag Removal - ConventionatType . . ......... .............. . . ......... 2.26
Ski Skag Removal- IFS and EZ Steer Type ........ . ............ . .. .. . ....... 2.27
1994 Model Seat Lengths ............. . .. ................ ..... .
1 995 Model Seat Lengths ........ . .. . . ....... . ....... . . ........ . .....
1993 Paint Codes ....... .. . ................... ...... . ....... . ...... ... .
1994 Paint Codes . . . . .............. . .. .. ... ... .. ...... .. ....... .
1995 Paint Codes . ..... ..... .... ...... . . . ........ ... .... . . . . ......
RIDE RED
2.28
2.29
2.30
2.31
2.32
11195
Cleaning And Preservation Of Hood, Chassis And Trim
BODY AND STEERING
Summer Storage
Properslorage starts bycleaning. 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 sail and acids are removed from
surfaces before beginning preservation with waxes and rust inhibitors (grease, oil, or paint).
If the machine is equipped with electric start, disconnect the battery cables and clean the cables and battery posts.
Fill battery to proper level 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 clutch and cable lubricant (PN 2870510). Force a small amount of
lubricant down cables.
Electrical Connections
Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector
blocks with petroleum jelly or dielectric grease and reconnect. Replace worn or frayed electrical wire and
connectors.
Clutch And Drive System
Remove drive belt and store in a cool dry location. Lubricate surface faces, shaft and ramps of drive and driven
clutches with light oil. This oil must be cleaned off before installing belt for service. A generous amount of
lubrication, such as Polaris clutch and cable lubricant should be applied onto the rollers and weight pins. Replace
chaincase lubricant with new oil. Apply lubricant to steel drive shafts, etc., to reduce rusting.
Track And Suspension
To prevent corrosion which will destroy the bearings,
always grease jackshaft and drive shaft clutch side
bearings with a high quality bearing grease. (This
includes fittings added to late modellndys.) Loosen
dri ven clutch retaining bol t and pull clutch outward to
expose bearing. Use a pOint type grease gun fitting to
inject grease through hole in flangette into bearing
until grease purges out inside or outside bearing seal.
Push clutch back on shaft and replace clutch retaining
bolt. Inject grease into fitting on speedometer drive
adaptor until grease purges out inside or outside
bearing seal. Lubricate both front ski pivots at
bushings and spindles. See 111.1 and 2.
Use Polaris Fogging Oil (PN 2870791) on shock
absorber shafts to help prevent corrosion.
Under normal conditions moderate track tension
should be maintained during summer storage.
Rubber track tension should be maintained at the
prescribed normal operati ng tension specified in this
manual. The rear of the machine should be supported
off the ground to allow free hanging of track.
2.1
Ski Spindle
a n d ~ /
Ings ~
III. 1
Jackshaft
Bearing
Driveshaft
Bearing
Grease
~
Grease
W
r
0
J)
o
Located on left side
III. 2 '---_o_' _m_a_c_h_ in_e..:lc _I_"I_C_h_s_id_e;...J 1
8194
RIDE RED
BODY AND STEERING
Summer Storage
Engine And Carburetor
The fuel lank, fuel lines and carburetor should be
completely drained of gasoline. To eliminate any fuel
remaining in the carburetor, run the engine until it stops.
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 mil Polaris
oil into the cylinder. NOTE: Allow ample time for oillo 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.
Fog engine with Polaris Fogging Oil (PN 2870791)
according to directions on can.
Add 10 ounces (80 ml) of fuel conditioner/stabilizer such
as Gold Eagle brand STA-BIL (Polaris PN 2870652) to fuel
tank and top off the tank with fresh fuel.
EFI Storage Considerations
Add fuel conditioner/stabili zer and fill tank as described above. Fog engine. If machine is to be stored for one
month or longer, fill and charge battery monthly using Polari s Battery Tender (PN 2871076), or a 1 amp trickle
charger to maintain at 1.270 specific gravity. Disconnect ground cable. Cover and store machine out of direct
sunlight. If machine is to be stored more than four months, start and run engine for at least 15 minutes and re-fog
with fuel stabilizer added to 1he fuel.
Standard Torque Specifications
Refer to pages 10.4-10.5 for a complete list of standard torque speci fications, and torque deviations.
8/94
2.2
RIDE RED
BODY AND STEERING
Off Season Storage
When the snowmobile will not be operated for periods exceeding 30 days, the following maintenance items should
be performed.
Fuel System Storage
Top off the fuel tank with fresh fuel and add fuel conditioner/stabilizer. It is recommended that the snowmobile
be operated for approximately 10-15 minutes after stabilizing fuel to ensure trealed fuel reaches the entire fuel
system and all components. Follow the directions on the container for recommended amount to add for long term
storage.
Polaris Premium Carbon Clean
Fuel System AddItive
PN 287t328
NOTE: Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system.
Engine Fogging Procedure
CAUTION: I
Failure to perform the following preventive maintenance can result in serious engine corrosion during off season
storage. In order to prevent rust and corrosion on internal engine parts (Le. crankshaft, bearings, pistons, rings
cylinder walls), Polaris highly recommends the use of Polaris fogging oil as a recommended storage procedure.
The engine should be operated for 1 0-15 minutes prior to fogging (see fuel system storage above). Awarm engine
will remove moisture from the engine and exhaust and fogging oil will disperse readily.
When properly applied, fogging oil coats all internal engine parts forprevenlion of rust and corrosion, which in turn
will extend the service life of the engine. Follow directions on can and engine/carburetor storage procedures
below.
Poiarls Premium Fogging 011
and Corrosion Inhibitor
PN 2870791
Engine And Carburetor
Perform fuel stabilization and initial fogging procedure above. To eliminate any fuel remaining in the carburetor(s),
shut fuel valve off and run engine until it stops while simultaneously spraying fogging oil alternately into each
carburetor or throttle body. Lift choke lever on carbureted models to clear enricher fuel passages. Remove water
trap drain plug to completely drain carburetors. Support front of snowmobile so engine is level or tilted slightly
rearward. Remove spark plug(s). Rotate piston to Bottom Dead Center (BDC) and pour approximately two
ounces (60cc) Polaris Premium 2-Cycle lubricant 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 ensure coverage of piston rings, cylinder walls and crankshaft bearings.
Lubrication
Lubricate all grease fittings with Polaris Premium all season grease. Remove the weight of the vehicle from the
component being lubricated to ensure proper cleansing of the joint and complete grease penetration. Compo-
nents thaI do not have a grease fitting should be disassembled, cleaned, and re-Iubricated at least once per year.
Premium All Season Grease
PN 2871322 (30:' Tube)
PN 2871423 (14 oz. Tube)
2.2a
RICERED
11/95
BODY AND STEERING
Off Season Storage
Chaincase
Drain and re-fill chaincase with Polaris Chaincase Lubricant. The chaincase cover should be removed every 2
years for thorough cleaning of the chaincase cavity. Refer to Section 8 for cover removal.
Premium Chalnease Lubricant
PN 2871280 (1 U.S. qt.)
Cooling System
1. Test coolant strength with an anti-freeze hydrometer.
2. Add Polaris Premium 60/40 coolant to proper level in reservoir.
3. Drain and re-fill cooling system every two years following procedure outlined in the engine section.
Premium 60140 AntlFreeze/Coolant
PN 2871323
Cleaning
I CAUTION: I
Never clean the snowmobile with strong detergents, abrasives, de-greasers, paint thinner, acetone, window
cleaners, ammonia or products containing alcohol. They can damage finishes, decals, vinyl. and plastics, and can
accelerate UV breakdown which could cause color change and premature deterioration of parts. Use only mild
detergent and warm water. Do not use high pressure washers.
1. After cleaning, protect and shine watercraft using a regular furniture polish or nonabrasive silicone wax.
Protect seat and handlebar unit with a vinyl protector.
2. Coat all external metal surfaces with T-9 Metal protectanl.
T .. 9 Metal Protectant
PN 2871064
Replenishing Battery Fluid
The fluid level should be kept between the upper and tow-
er level marks.
To refi1l use only distilled water. Tap water contai ns miner-
als which are harmful to a battery.
11/95
2.2b
" " ' " ' ~ " ~ ~
Maintain ~ l aw I
~ ~ ~ ; ~ n n d ! ~ I
l ower l evel
Marks
RIDE RED
Battery Connections
Battery terminals and connections should be kept free of
corrosion. If cleaning is necessary, remove the corrosion
with a stiff wire brush. Wash thoroughly with a solution
of baking soda and water (one tablespoon of baking soda
to one cup of water) . Rinse well with tap water and dry
off with clean shop cloths. Coat the terminals and termi-
nal bolts with dielectric grease.
Corrosion Resistant Dielectric Grease
Battery Charging
I CAUTION: I
PN 2871027
The battery must be removed from the snowmobile for
maintenance and charging. Battery electrolyte may spill
and damage the machine.
BODY AND STEERING
Off Season Storage
Top View of Battery
o

Black I-I
Vent
Tube
Red 1+1
Always disoonnect the black (negative) cable first. Electrolyte or fuel vapors may be present in the engine compart-
ment and a spark could ignite them which could cause personal injury. When r&-instatling battery connect black (nega-
tive) cable last.
A WARNING
Keep the battery away from sparks and open flames during charging because the battery gives off gases which
are explosive. If you smell fuel do not attempt to charge the battery. When using a battery charger connect the
battery to the charger before turning on the charger. This prevents the possibility of sparks at the terminals which
could ignite the battery gases. Do not connect charger cables to the battery unless the charger is unplugged.
1. Remove caps from cells. Add distilled water if necessary to bring electrolyte up to proper level.
2. Connect battery to a charger. Set charging rate at 1 to 1.9 amps (maximum) and charge battery for ten hours.
I CAUTION: I
During charging, if the electrolyte temperature rises above 115F (45C) or if battery feels hot when touched, re-
duce the charging rate to lower the temperature and increase the charging time.
3. After battery is charged, check fluid level. If it has dropped add distilled water to bring electrolyte up to proper
level.
4. Check results of charging. The specific gravity of each cell must be 1.270 at room temperature. The voltage
should be 14.5 - 15.5 V during charging; 12.2 - , 2.8 V after charging.
Specific Gravity
1.270 or greater each cell
Battery Tender
TW
Battery Charger
PN 2871076
2.2c
RIDERED
11 /95
BODY AND STEERING
Off Season Storage
Drive Belt
Remove drive belt from machine. Wipe drive and driven clutch sheaves with T-9 Metal Protectant to prevent cor-
rosion. Attach a note to the belt as a reminder to wipe clutch sheaves with lacquer thinner prior to belt installation
when machine is removed from storage.
Drive Track
Elevate rear of machine to keep track off ground.
Cover Machine
Cover snowmobile with a Polaris cover and store in a clean, dry place. Do not use plastic or coated materials
as condensation and corrosion may occur.
11 /95
2.2d
RIDE RED
BODY AND STEERING
Gas Tank and Seat Removal -Cutlass SS
Be sure the fuel tank is emptied before beginning the removal procedure.
A WARNING
Gasoline is extremely flammable and explosive under certain conditions.
ADO not smoke or allow open flames or sparks in or near the area where refueling is performed or where
gasoline is stored .
.&. 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.
&'lfyoU spill gasollne on yourskin orclothing, immediately wash it off with soap and water and change clothing.
A Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and death in a short lime.
Removal
1. Remove the two 1/4 x 1 ~ screws from the rear
underside of the tunnel.
2. Disconnect the seat wire harness at the tank and
remove the seat.
3. Remove the six 10-24 x S/S'" bolts (A) securing the
console to the chassis. See photo at right.
4. Remove the fuel line from the fuel pump.
5. Locate tank vent line on upper left front side of tank.
Cut line from its fiMing. CAUTION: Do not attempt to
pull the line off as damage to the vent fitting may
result.
6. Roll the front and rear tank hold-<:lown springs off the
tank.
7. Disconnect the fuel gauge sight line, both top and
bottom, from the right front side of the tank.
S. Remove the fuel cap.
9. Lift the console slightly and remove the tank.
10. Reverse procedure for reinstallation.
2.3
8/94
RICE RED
BODY AND STEERING
Gas Tank and Seat Removal - Indy Models
1. Remove tank cover by disconnecting snaps.
2. Remove venlline 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 at
right.
WARNING: Gasoline Is extremely flammable and
explosive under certain conditions. 00 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 cloth
lng, Immediately wash If off with soap and water
and change clothing. Prolonged exposure to pe-
troleum based products may cause paint failures.
Always protect finished surfaces and wipe up any
spills immediately,
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.
, O. Fuel tank can now be removed from chassis by
disconnecting two springs at center of fuel tank.
One Piece Fuel Tank/Seat Removal Proce-
dure (1994 440/SKS, 500 EFIISKS, Classici
Touring)
,. Remove seat cover by disconnecting snaps at
front of tunnel.
2. Remove front tank retaining spring located
behind driven clutch area.
3. Remove fuel cap and grommet.
4. Remove fuel lines.
5. If machine is equipped with gauges, unplug
gauge wires.
6. Remove two bolts in tool box.
7. Disconnect taillight wiring.
8. Remove two console bolts attaching console to
tunnel.
9. Remove two console bolts located under hood.
, O. Remove fuel cap and lift console up. Replace fuel
cap.
10. Lift up at rear of seat and slide oul.
11195
2.4
RIDE RED
1 . Remove seat cushion assembly as oullined on
page 2.4.
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 UO" ring buckle which
secures the center hold down strap. Push the UO"
ring through the sial 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 Itt. 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.
2.5
BODY AND STEERING
Seat Cover Replacement (Plastic Base)
SEAT FOAM
FOR USE WITH
STANDARD
LENGTH SEAT
ILl. 1
RIDE RED
SEAT BUCKET
HOLD DOWN
STRAP
FOR USE WI TH
LONG SEAT
STORAGE
BOX AREA
PLASTIC SEAT
BASE
8/94
BODY AND STEERING
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 III. IA.
CAUTION: Apply stapl es in the stapling channel only. See 1111. 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 afthe 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 seal cover with the two back corners of the seat base. See
III. 1. Pull the vinyl tight and tack the seat cover to the plastic seat base in each corner. Use two or three
staples per corner.
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 .
BonOM VIEW OF SEAT ASSEMBLY STAPLES
STAPLING
CHANNEL
TACK COVER
HERE FIRST
LOCATION
INDICATORS
ILL 1
11 . Staple the remainder of the unattached seat cover 10
Ihe plastic seat base as shown in III. 1. HINT: Always
staple between two existing staples and follow this
procedure until the seat cover is completely stapled
to the seat base. See III. 2.
12. Turn the seat cushion assembly over and inspect for
wrinkles or imperfections. If imperfections are
visible, remove the staples in the affected area and
staple correctly.
8194
2.6
___ SEWN SEAMS
"" TACK COVER
HERE SECOND
VINYL SEAT FLAPS
STAPLI NG CHANNEL
STAPLE HERE FIRST
STAPLE
HERE SECOND
STAPLE HERE THIRD
STAPLE SEQUENCE ILL.2
RIDE RED
BODY AND STEERING
1995 Models With Grommets In Tool Flap
, 3. Close 1001 flap cover, making sure it is aligned properly, and mark grommet holes.
14. Align twist lock with mark from step 13. Verify alignment with grommet in tool ftap.
15. Using twist lock as a template, drill two . 1 6 0 ~ to .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 afthe seal area only after a satisfactory fit is obtained. See
III. 1, page 2.6.
18. Reinstall seal by reversing disassembly steps as they apply to your particular model.
Seat Covering Instructions
OnefTwo Piece Seal and Tank PN 9912521
1994-1995 XCA 440 SP, XCA 600 PN 9912842
Taillight Assembly Replacement
1. After removal of seal cover, drill out three rivets
from the top of the taill ight.
2. Remove the 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 the seat cover tightly and evenly into position
and restaple to the seat pan.
6. Inspect cover for a wrinkle--free finish before
reinstalling on the snowmobile.
2.7
RIDE RED
8194
BODY AND STEERING
Decal Removal and Installation
Decal Removal
1. Before removing old decal, it is import ant to nole its
position by mar1<ing it in several locations.
2. Remove old decal completely. NOTE: A small
amount of solvent wi ll aid in removing the old decaL
3. Depending on year and model, the decals may be
UV based or solvent based. If heat will nol remove
decal, gently buff area with a mild abrasive. Use
3M Scotch Brite
n
.. Graphics Removal Discs (3M
PN 048011-16855), with a NO. 1 Aoloc and holder
(3M PN 048011-15408), or an equivalent low RPM
buffing disc. CAUTION: Maintain 2500-3500 RPM
to prevent damage to hood caused by excessive
heat.
4. Remove any remaining decal adhesive with a citrus
based cleaner or equivalent non-solvent based
cleaner.
5. Thoroughly clean area where the new decal wi ll be
installed using a solution of mild soap (such as
dishwashing liquid) and clean water. NOTE: Use
approximately four ounces soap to one gallon
water.
Decal Installation
1. Apply a solution of mild soap mixed with clean
water to the area where the new decal is to be
applied. 00 not wipe off.
2. Carefully remove decal backing and apply new
decal.
3. If decal does not have a premask, 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 sol ution 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.
8/94
2.8
RIDE RED
BODY AND STEERING
ABS Nosepan - Care, Cleaning, and Repair
Care and Cleaning
ASS nosepans will retain their original finish with reasonable care and handling. The following care and cleaning
tips will help them keep the original luster.
Do:
Dust and clean with a soft, damp cloth or chamois. wipi ng the surfaces gently.
Use mild soap (such as dishwashing detergent) and lukewarm water.
Dry the surfaces after washing and rinsing by blotting with a damp cloth or chamois.
Wax the surfaces sparingly for protection and the highest degree of polish. Apply house
hold or commercial type wax sparingly in a thin, even film with a soft clean cloth.
Polish waxed surfaces lightly with a clean cotton flannel or jersey cloth. After polishing,
wipe gently with a damp cloth to ground any electrostatic charges which may attract dust
particles.
Do Not:
Use cloths containing grit or abrasive particles or kitchen scouring compounds to clean or
dust. Light scratches may be rubbed out with wax.
Use boiling water or strong solvents to clean, as they will soften the plastic.
Use strong soaps or abrasives.
Special Cleaning Problems
Dlrtand Grease: Normal liquid cleaners or soap and water may not always remove grimy dirt. Janitor in a Drum
and Cascade have been found to be the best cleaners for removing dirty, ground in grease.
Stains: Stains such as iodine may be safely removed with 45% isopropyl (rubbing alcohol). Higher concentration
commercial grades will remove the stain, but wi ll dull the film surface. The gloss can be returned with Simoniz
paste wax.
Surface Scratches and Abrasions: Light scratches can be removed by waxing with Simoniz paste wax. Deeper
scratches may be removed by fightlybuffing with a fine grade of rubbing compound.
Repair of Cracks and Fractures
Either hot air plastic welding, or the method described below may be used to repair cracks and fractures. Materials
required include: Fiberglass cloth; ABS pipe cement (NOTE: Several types of plumbing cement are available. Be
sure to use one which is for either ABS or PVC and ABS material. Do not use cement labeled "for PVC only");
Polaris blue ASS touch up pai nt (PN 2870423) (NOTE: Do not use standard Polaris touch up paint, since it is not
adaptable to ASS); squeegee; rubber gloves.
Procedure
1. Using household detergent, clean all dirt, grease, etc., from the area around the crack. The crack itself should
be as clean as possible. Thoroughly dry nosepan.
2. Cut a piece of fiberglass cloth approximately 3'" (76 mm) wide and long enough to extend 1" to 2'" (25 to 50 mm)
past the ends of the fracture.
3. Separate edges of crack slightly and fill void with cement. Press edges together, clamp in place, and wipe
excess cement from outside of pan.
4. Liberally coat inside surface of pan with cement, covering approximately 1 1/2'" (38 mm) on either side of the
fracture.
5. Lay fiberglass cloth over fracture.
6. Wearing rubber gloves, work cloth into pan using a squeegee or your fingers. NOTE: ASS cement is a solvenl
cement which dissolves the outer surface of the nosepan. The cement and cloth will change color as this
happens.
2.9
8/94
RIDE RED
BODY AND STEERING
ABS Nosepan - Care, Cleaning, and Repair
7. When fiberglass cloth is well worked in, wipe off excess cement and let dry. Drying time will depend on the
brand of cement used. Refer to manufacturer's instructions.
8. Ughtlysand the outside of the pan and paint. The results will be more professional looking if the repaired area
on the inside of the pan is also painted.
Replacement Nosepan Installation
When installing a replacement ASS nosepan, the following procedures must be closely observed to ensure
correct fit to the frame and maximum strength. ABS malerial is not rigid. Consequently, it must be installed in such
a manner thai it can expand or contract with temperature changes.
1. Remove damaged nosepan by drilling out rivet heads. Engine mountings and other mounlingsattached to the
forward part of the machine should be removed for ease of installation.
2. The following aluminum rivets must be used to attach nosepan:
PN 7621448. 3/16 x .652. Quantity required 7
PN 7621403, 3/16 x .527. Quantity required 39
All holes are to be drilled into the nosepan using a 7/32" drill bit (.218'"). NOTE: This will be larger than the
diameter of the 3/16'" rivet.
3. Position new nosepan in place and attach to bulkhead at the top using (7) 3/16 x .652'" rivets (PN 7621 448).
See illustration below. All remaining holes require 3/16 x .527'" rivets (PN 7621403).
4. Make sure there is 1/4'" (. 6 cm) clearance around the exhaust outlet.
5. Install foil (PN 5810108) in the same location as the original part.
Rivet PN 7621448
6 4 2 1 3 5 7
o o
@ @
8 9
Rivet PN 7621403
11
8/94
2.10
RIDE RED
BODY AND STEERING
Nosepan Replacement Procedure (1994/1995 Indy 440/SKS, 500 EFI/SKS,
ClassiclTouring, Trail/Deluxe, XLT Touring)
IMPORTANT: When installing a replacement nosepan, this rivet sequence must be followed correctly in order to
ensure proper nose pan and body panel fit.
NOTE: The rivet for polyethylene nosepans is PN 7621467.
NOTE: Rivet holes 14 through 19 may require drilling into the bulkhead. Circled rivet numbers 1,2, 5 and 6 are
locating holes used for proper alignment.
o
NOTE:
31
33
-
1
. .
Front of
Nosepan
9
8
. . 7
4 3
.= ___ 12 11
15
17
19
---L----' 29
21
23
+
22 ___
'24
26 '--'-,
30
32
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.
2.11
RIDE RED
8/94
BODY AND STEERING
RIM Metton ~ Part Repair
Polaris has approved the use of Evercoat Plastik Works'" as a repair for the RIM Metton'" Type Materials. This
two part repair system is number coded for different types of plastic material. See example below.
The patch kit can be obtained from your local automotive parts house. It is suitable for repair 01 small cracks,
gouges and holes. NOTE: Major damage will require replacement of the part.
Reaction Injection Molding (RIM) is a thermoset type plastic which can only be repaired using this two part system
(1988 to current hoods).
CAUTION: Heal , such as hot air welding, cannot be used because it will cause the hood material to bubble and
char, becoming irreversibly brittle.
Sheet Molded Compound (SMel, another thermoset type plastic which is very similar to fiberglass has been used
on a few Polaris hoods. A two part repair system will work well for any repairs required. Structural adhesive is
acceptable for SMC type hoods. Follow directions on container.
Nosecones and new style Indy removable front and side panels are constructed of Thermoplastic Olefin (TPO),
which is a flexible thermoplastic requiring a flexible two part repair kit. The example shown above is No.3. An
adhesion additive must be used in addition to the kit. If deformed, flexible thermoplastic can quite often be
reshaped with the aid of a heat gun.
Nosepans are constructed of polyethylene, another flexible thermoplastic, which can be repaired either with a two
part repair kit or by hot air type plastic welding.
8/94
2.12
AIDE RED
Fiberglass Repair
Damaged fiberglass can be easily repaired by
following a few basic steps.
1 . Remove all damaged material with a sabre saw or
grinder.
2. Using a disc grinder or die grinder, taper
fiberglass 1" (2.5 em) back from patch area on
inside of part.
3. Apply masking tape to outside of part to form a
mold.
4. Mix enough polyester resin and catalyst to
complete the repair, following instructions for
resin being used.
5. Apply resin to inside of patch area using a
disposable paint brush.
6. Lay in small pieces of shredded fiberglass matt.
Use the paint brush to force ai r bubbles out. Add
more resin and move man around. NOTE:
Pieces of matt between , ~ to 2" (2.5 to 5 em)
square work best.
7. Keep adding mall and resin until patch area is
filled up to the original thickness.
8. Let resin cure thoroughly.
9. Remove masking tape from outside of repair.
10. Remove any high spots from outside with a disc
grinder.
11. Fill and smooth any defects with polyester auto
body filler.
12. Sand smooth and feather with 360 to 400 grit
sandpaper.
13. Paint outside of repair following instructions on
paint container.
Hood Adjustment Sequence (New Style
1994 to Current)
BODY AND STEERING
Fiberglass Repair and Hood Adjustment
,- ---------..,
/ 1 ~ I
/I
Hood
~ I
/ I I
/ I I
r-------I I Upper 0"- I
I I I Hinge I
I I L _________ ~
I A ~ 1 Hood and Hinge
I J, I need not be flush
I - -- I
I I
I I
I I
I I
L __ _
B
III. 1
23/8" (6em)
III. 2
1. Check to see that hood and upper hood hinge are properly aligned. To adjust , loosen nuts (A) and align
properly. lighten nuts. See III. 1.
2. With hood open, loosen nut (B). See III . 1.
3. Close hood and remove both rubber plugs. Then, using a 7/16" (.4 cm) socket with an 8" (20 cm) extension,
loosen nut (C). Adjust hood to pan gap. Tighten nuts.
4. Check outer perimeter alignment and front and rear alignment of hood, side bumpers and side panels. There
should be 3/ 16"(.5cm) + 1/8"(.3cm) -0 clearance between hood to side panels and side bumpers. If
adjustment is required, open hood and loosen nuts (D). Adjust and re-Ughten one nut per hinge. Close hood
and recheck alignment.
5. After correct alignment is achieved, tighten all nuts.
Nosepan, Front Bumper and Side Bumper Adjustment (New Style 1994 to Current)
If the nosepan, front bumper or side bumper are removed and reinstalled, it is imperative that these components
be properly adjusted before hood installation. See ill ustration. The distance from the front surface of the bumper
support bracket to the front point of the side bumper must be 2 3/8" (6 cm). To adjust, loosen front bumper
mounting bolts and move bumper until proper distance is achieved. Make sure side bumper fits evenly into front
bumper all the way around before re-tightening mounting bolts. NOTE: While adjusting, be sure to move bumper
in or out in line with support bracket mounting holes. Any undue pressure either upward or downward on the front
bumper will result in improper adjustment. See III. 2.
2.1 3 8/94
RIDE RED
BODY AND STEERING
Steering Conventional Front Suspension
Steering
1. With the handlebars in Ihe straight ahead
position, skis should be parallel at points A and B.
Skis must not toe in.
CAUTION: The steering assembly should be
checked whenever a machine comes in for tuneup or
repair.
Steering Removal
NOTE: To retain proper ski alignment, the spindle
and steering arm should be marked.
1. Remove steering arm boll (A) .
2. Adjust tie rod end (8) by turning clockwise or
counterclockwise until skis are parallel with each
other and with vehicle track and frame when
handlebars are in straight ahead position.
CAUTION: If there is evidence of wear or stress on
the tie rods or lie rod end bearings, they should be r&-
placed as a complete unit.

3. Remove spindle from body.
CAUTION: If spindles are cracked or bent they must
be replaced.
NOTE: Spindles should be lubricated annually to in-
sure proper steering.
8/94
2. 14
A
RIDE RED
BODY AND STEERING
Steering, I.F.S. - Independent Front Suspension 1985 to Current
Specifications
Ski Spindle Center Distance:
Ski Width:
Ski Length:
Independent Ski
37' (94 em) Lite Series
38" (97 em) Standard Front End
40" (102 em) approximate Wide Front End
NOTE: This dimension is set at the factory.
No adjustment necessary.
5.25" (13 em)
5.5" (14 em) 1995 Models
40" (102 em)
Vertical Travel: r (18 em)
Caster:
Camber:
7.25" (18.4 em) Standard Front End
8" (20 em) Wide Fronl End
10" (25.4 em) Long Travel Front End
Fixed
Adjustable for Positive/Negative
Toe-infToe-oul: Adjustable
Dampening: Coil Spring With Five Position Spring Rate Adjustment Cam Over
Oil-filled Shock Absorber
Torsion Bar
1994-1995 - All Indy models with tracks longer than 121" have the 38" standard width front end, except Trail
Deluxe, Classic Touring, XLT Touring, and RXL Touring, which are equipped with the 40" wide front end.
Standard Indy Models ...... ................. 40" wide front end
1994-1995 XCR 440 SP, XCR 600 ............ 41" wide front end
1995 XLT SP, RXL. ......................... 43.5" wide front end
NOTE: Width on standard Indy and wide models (Non-XTRA) is adjusted with suspension compressed until
radius rods are parallel with the ground.
Inspection
Pri or to performing any alignment procedures, the suspension should be inspected for damage or wear and
replacement parts installed as required. The following are components which must be inspected at this time:
1. Tie rods and ends
2. Radius rods and ends
3. Torsion bar
4. Handlebars and steering post assembly
5. Spindles and bushings
6. Trai ling arms and bushings
Alignment Bar Specifications
Material : C-1018
Diameter:
Length:
.623"-.625" (15.82-15.87 mm)
48" (122 em)
Not available through Polaris
2.15
8194
RIDE RED
BODY AND STEERING
Steering - IFS Adjustable Torsion Bar
Adjustabl e Torsion Bar
Operation: For high performance applications the tor-
sion bar can be adjusted for any number of varying
conditions.
Adj ustment: Each side is individually adjustable.
there should be some free play in rod ends when the
rider is in position on the machine.
Maintenance: Periodic inspection of the support
area, set screw and bar arm bolts is recommended to
prevent arm to spline loosening. Periodic lubrication
of the bushi ngs is required using Polaris Low Temp
grease (PN 2870577).
NOTE: Adjustable Torsion Bar Kit PN 2871035
440 XCR SP Adjustabl e Torsion Bar
Parts for new style liquid twin models.
Operation: Provides Increased stability in high performance applications.
Adj ustment: Adjusts for bias to either side. There should be some freeplay in rod ends when the rider is in posi-
lion on the machine. Hole #2 (see illuslration) provides a stiffer rate.
Maintenance: Periodic inspection of the support area, set screw and bar arm bolts is recommended to prevent
arm to spline loosening. Periodic lubrication of the bushings is requi red using Polaris Low Temp grease (PN
2870577).
Set Screws
Torsion Bar Support
Torsion Bar Housing
Torsion Bar Bushing
Torsion Bar Arm
Bar Arm Bolt
Rod End
Torsion Bar
Bar Arm Bolt
Rod End
Torsion Bar Bracket
8/94
2. 16
AIDE RED
BODY AND STEERING
Shock and Spring Chart 1994 Models
The following chart lists all currently available shock types, spring rates and descriptions.
1994 Independent Front Suspension (IFS)
Model Description Model PN Shock PN Shock
Description
StarLite 0943427 7041284 Hyd
SlarLile GT 0943127 7041284 Hyd
Indy Lite 0943433 7041284 Hyd
Indy lite Deluxe 0943431 7041264 Hyd
Indy LileGT 0943133 7041284 Hyd
Sport 0940443 7041284 Hyd
Trail 0940761 7041284 Hyd
Trail Deluxe 0940262 7041284 Hyd
440 liquid Indy 0940760 7041288 Gas/Cam
440 liquid Indy SKS 0940560 7041282 G.B. Cam
440 XCR 0941760 7041291 Gas IFP
Classic 0942865 7041288 Gas/Cam
Classic Touring 0942875 7041288 Gas/Cam
WideTrak LX 0942064 7041284 Hyd
500 EFI 0942774 7041288 Gas/Cam
500 EFI SKS 0942574 7041282 G.B. Cam
XLT 0940767 7041285 Gas-Bag
XlT SKS 0940567 7041285 Gas-Bag
XlT SP 0940667 7041292 Gas IFP
RXL 0940768 7041 282 G.B. Cam
RXl SKS 0940869 7041292 Gas IFP
Storm 0940782 7041288 Gas/Cam
Storm SKS 0940582 7041251 Gas/Cam
Super Sport 0940743 7041288 Gas/Cam
WideTrak GT 0942061 7041284 Hyd
KEY: Hyd - Hydraulic Standard Shock
Gas/Cam - Gas Filled Cam Adjustable Shock
G.B. Cam - Gas Filled Bag, Cam Adjustable Shock, Separate Oil Cavity
Gas IFP - Gas Charged Internal Floating Piston, Fox Shock
2. 17
Spring PN
7041261
7041261
7041261
7041261
7041261
7041261
7041261
7041261
7041334
7041334
7041252
7041334
7041334
7041261
7041334
7041334
7041261
7041261
7041252
7041261
7041252
7041287
7041287
7041261
7041261
RIDE RED
Spring
Description
105#lin
105#/i n
105#li n
105#lin
105#lin
105#/in
lD5#/i n
105#lin
120#/in
120#lin
120#lin
120#I1n
120#lin
105#lin
120#/i n
120#lin
105#lin
1000lin
120#li n
105#lin
120#lin
160#lin
160#lin
105#lin
105#lin
8/94
BODY AND STEERING
Shock and Spring Chart 1995 Models
1995 INDEPENDENT FRONT SUSPENSION (IFS) SHOCK
Model Model No. Shock PN Shock Shock Maker Spring Spring PN
Description Description Description
StarLite 0953427 7041284 Hyd Gabriel 105#fin 7041261
Indy Lite 0953433 7041284 Hyd Gabriel 105#fin 7041261
Indy Lite Deluxe 0953431 7041284 Hyd Gabriel 1000/in 7041261
Indy Lite GT 0953133 7041284 Hyd Gabriel 105#lin 7041261
Sport 0950443 7041264 Hyd Gabriel 1000/in 7041261
Super Sport 0950743 7041388 G. B. Cam Gabriel l QS#li n 7041261
Sport Touring 0950243 7041284 Hyd Gabriel 1000lin 7041261
Trail 0952761 7041288 G. B. Cam Gabriel 105#lin 7041261
Trail Deluxe 0952262 7041288 G.B. Cam Gabriel 12O#fin 7041344
440 0952760 7041288 G.B. Cam Gabriel 105#fin 7041261
440 SKS 0952560 7041282 G.B. Cam Gabriel 120#lin 7041334
440 XCR 0951660 7041346 Gas IFP Fo' 120#fin 7041252
600 XCR 0951676 7041346 Gas IFP Fo, 120#lin 7041252
Classic 0952865 7041288 G. B. Cam Gabriel 120#lin 7041334
500 Carb 0952764 7041288 G. B. Cam Gabriel 120#lin 7041334
WideTrak GT 0952061 7041264 Hyd Gabriel 105#lin 7041261
WideTrak LX 0952064 7041264 Hyd Gabriel 105#fin 7041261
500 EFt 0952774 7041288 G.B.lCam Gabriel 120#lin 7041261
500 EFI SKS 0952574 7041282 G.B. Cam Gabriel 120#/in 7041334
500 EFt SKS PT 0952974 7041282 G.B. Cam Gabriel 120#/in 7041334
XLT 0950756 7041285 Gas-Bag Gabriel 105#lin 7041261
XLT SKS 0950556 7041285 Gas-Bag Gabriel 105#lin 704 1261
XLT SKS PT 0950956 7041285 G.B. Cam Gabriel 105#lin 7041261
XLT SP 0956756 7041385 Gas IFP Fo, 50#lin 7041396
XLT Touring 0952657 7041288 G.B. Cam Gabriel 120#lin 7041334
AXL 0956768 7041385 Gas IFP Fo' 75#/in 7041398
AXL Touring 0950869 7041282 G.B. Cam Gabriel 120#lin 7041261
Storm 0950782 7041390 G. B. Cam Gabriel-Select 160#lin 7041287
Storm SKS 0950582 7041393 G.B. Cam Gabriel-Select 16O#lin 7041287
Storm SKS PT 0950982 7041393 G. B. Cam Gabriel-Select 16O#lin 7041287
KEY: Hyd - Hydraulic Standard Shock Gas IFP - Gas Charged Internal Floating Piston, Fox Shock Select
Gabriel Select Adjustable Shock NOTE: AU pounds referred to in the spring description column are 10%
8194
2. 18
RIDE RED
The IFS introduced on 1984 Indy models incorporated
the following components improvements, making it
lighter and more responsive.
A SIS'" heavy duty torsion bar is standard equipment on
XLT SP, RXL and Storm Models. The Indy Storm ra-
dius rods incorporate bushings into the ends.
One piece lorsion bar
Redesigned trailing arm
Torsion Bar Removal
4. Remove trailing arm assembly.
5. Using a small pin punch, lap out the rivet mandrels
in the center of the torsion bar support rivets.
6. Using a 1/4'" bi t, drill out the center portion of the
rivets.
7. Punch out the rivet body.
8. Remove support and torsion bar.
9. Repeat procedure for second torsion bar.
Torsion Bar Reinstallation
1. Rivet support in place using Polaris PN 7621449
rivets. NOTE: These high strength "0" rivets are
the only replacement rivets recommended for this
application.
2. Reinstall torsion bar.
3. Reinstall trailing arm assembly.
4. Check camber and toe adjustments.
2.19
BODY AND STEERING
Independent Front Suspension (IFS)

8194
RIDE RED
\
BODY AND STEERING
Steering - Independent Front Suspension
Checking Toe and Camber Adjustment
5. Make sure the track is properly aligned. This will be used as a reference point for toe out measurement.
6. Support the front of the machine 1-2" (2.5-5.1 em) off the floor.
7. Remove skis and pivot bushings.
8. Disconnect torsion bar linkage.
9. Insert alignment bar through both spindles.
NOTE: If camber and toe adjustments are correct, the bar will slide freely through the spindles. Horizontal mis-
alignment indicates toe adjustment is required. Vertical misalignment indicates camber adjustment is required.
If the alignment bar does not enter the oPPosite spindle freely:
1. Measure spindle to chassis centering. Both
spindles should be an equal distance +/- 1/8'"
(.3 em) from the center of the chassis. This
measurement is controlled by adjusting radius
rod length.
2. Measure spindle to spindle center distance.
Correct center distance on standard front ends
is approximately 36 112" (93 cm) +/- 1/4" (.6
cm). Correct center distance on wide front ends
is approximately 38" (96.5 cm), 40" (1 02 cm), or
41 '" (104 cm). XTRA Models are approximately
43.5" (110 em). This measurement is also
controlled by adjusting radius rod length.
Toe Adjustment, Preliminary-Standard IFS
1 . Loosen jam nuts (A) on each end of both tie
rods.
2. Change toe adjustment as required for a free
sliding fit of the al ignment bat.::;.through the
spindles.
3. Tighten jam nuts.
NOTE: If the alignment bar still will not slide through
the spindles after toe adjustment is completed, it will
be necessary to adjust camber.
8/94
2.20
RIDE RED
J
BODY AND STEERING
Steering - Independent Front Suspension, 1985-Current
Camber AdjustmentStandard IFS
NOTE: Camber is not adjustable on Indy Lites
through 1993 models.
1. Correct camber adjustment is with both spindles
in a true vertical or 00 position. Determine which
spindle requires the greatest amount of correction
by installing the alignment barthrough 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 jam nul and
remove the lower radius rod bolt from the spindle
requiring the most camber correction. Adjust the
opposite side next.
3. To adjust camber, change radius rod length until
alignment bar slides through both spindles with
radius rod installed.
CAUTION: Radius rod ends must remain parallel to
the mounting brackets after the rod end jam nuts are
tightened to the specified torque.
4. With alignment bar installed through spindles,
center handlebars by adjusting drag link length
(A) . The steering arm (B) should be centered
also. The steering arms on each spindle should
be parallel to slightly inward in relation to each
trailing arm. <
,
2.21
(
Mounting
Bracket
~
Rod End
. L-________________ ~
AIDE RED
8/94

BODY AND STEERING
Steering - Independent Front Suspension, 1985 - Current
5. Remove alignment bar from spindles. Turn
handlebars fully to right. Loosen upper radius rod
bolt (el and adjust steering stop so it contacts
steering arm. Ae-lighten bolt. Repeat this
procedure on left side.
6. Tighten all jam nuts. Torque radius rod attaching
bolts to 25 ft. Ibs. (3.45 kglm) .
7. Reinstall torsion bar linkage. Torque attaching
bol ts to 15 ft.lbs. (2.07 kglm).
8. Lubricate ski pivot bushings using suspension
lube (PN 2870511). Install skis. Torque pivot
bushing bolts to 25-3Q ft.lbs. (3.45-4. 14 kglm).
9. Final toe-oul should be 1/8"- 1/4" (.3-.6 em)
measured with a straight edge along each side of
the track and skis.
NOTE: The radius rods on the XTRA suspension
models are non-parallel. The distance between the
radius rods is wider at the trai ling arm mounting
bracket and narrower as it runs toward. the pan.
CAUTION: XTRA Suspension Models Radius rod
ends will be wider (non-parallel) at the trailing arm
mounting bracket. It is important that a true vertical or
0
0
position is maintained at the camber.
SERVICE HINT: Before final measurement is taken,
hook a rubber strap between the ski loops to help pull
them together at the front. This removes any play in
the steering components and helps achieve an accu-
rate measurement figure .
8194
2.22
Standard IFS - Front View
Front
Spindle
Parallel
'-... Radius Rod
XTRA Models - Front View
Front
Spindle
Non-
Parallel
_ _ Rod
RIDE RED
Front Shock Spring Preload Adjustment
BODY AND STEERING
Camber Adjustment-XTRA
The XTRA suspension system on the 1995 RXL and XLT SP has been designed to provide the rider with a wide
range of adjustment.
Generally, the softest spring and spring preload adjustment give the best ride and also the best traction. Front
shock spring preload will affect the ride height of the machine, the amount of rear suspension sag. and ski
pressure or steering effort.
Spring preload should be adjusted equally on both sides of the machine. Ski pressure must be equal to prevent
undesirable handling characteristi cs. The front shock spring preload can be adjusted by grasping the spring and
turning in a clockwise direction, (as viewed from the top), to increase preload.
Camber Adjustment
As with our standard IFS. the XTRA suspension camber adjustment is 0
0
Both spindles should be in a true
vertical or 0
0
position.
1. To determine proper camber. elevate the front end of the machine so that the suspension is fully extended.
2. Determine which spindle requires the greatest amount of correction by insta(ting the alignment bar through
one side to the opposite spindle. Remove the bar and install it through the other side to the opposite spindle.
Tools Required:
3/8" (1 cm) Drive
1 I I I 6" (1 .7 cm) Crowfoot Wrench
20" (51 cm) 3/8" (1 cm) Drive Extension
3. Loosen the radius rod jam nut and removelhe lower radius rod bolt from the spindle requiring the most camber
adjustment. Torque radius rod end jam nut 10 25 ft. Ibs. (3.45 kg/m). Repeat for opposite side.
4. To adjust camber. change radius rod length until alignment bar slides through both spindles with radius rod
installed.
5. With alignment bar installed through spindles, center
handlebars by adjusting drag link length (A). The
steering bell crank arm (B) should be centered also.
The steering arms on each spindle should be parallel
to each trailing arm.
6. Remove alignment bar and turn handlebars fully to
the right Loosen upper radius rod bolt (A) and adjust
steering stop so it contacts steering arm. Tighten
bolt (C, photo 21. Torque to 25 ft. lb,. (3.45 kg/mi.
Repeat procedure on left side.
NOTE: Lubricate ski pivot bushings with Polaris
Suspension Lube PN 287051 1.
Torque Specifications:
Radius Rod End Jam Nut25 ft. Ibs. (3.45
kg/m)
Radius Rod Attaching Bolts 25 ft. tbs. (3.45
kg/ml
Torsion Bar Linkage Bolts 15 ft.lbs. (2.07
kg/m)
Ski Pivot Bushing Bolts 25-30 ft. Ibs.
(3.45,4.14 kg/m)
2.23
8194
RIDE RED
BODY AND STEERING
Ski Alignment-XTRA
Ski Alignment
CAUTION: Improper ski alignment on XTRA models will
cause extreme difficulty when steering. Ensure unit is
correctly aligned during set up and pre-delivery.
A
I
There is no toe in or toe out on the XTRA front ski
assembly. With the machine at normal ride weight, the
position of the skis should be parallel at points A and B,
measured with a straight edge along the track and skis.
~ \ . \ . ~ ' ' ' ' - - r - _r:
B
t
NOTE: Normal ride weight is the weight of the machine S
traight ./
with no rider on the unit. E
dge
1. To obtain normal ride weight of the front suspension,
lift the front end up off the ground 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.
Lift 3-5-
(7.6-12.7 em)
NOTE: To prevent carbide skags from grabbing, make
sure the surfice under the skis will allow full side-la-side
movement. Avoid rough concrete, asphalt. or carpet
which may cause carbide skags to grab or catch and
restrict movement.
8194
1
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2.24
RIDE RED
I
:(2W)
I
BODY AND STEERING
Ski Spindle Bushing Replacement - Handlebar Torque and Sequence
Ski Spindle Bushing Replacement
1. With a scribe. mark the steering arm to spindle for
reference in reassembly. Remove steering arm
bolt and spindle.
2. With a drift punch, remove old bushings and
install new bushings, tapered end first.
3. Some models require bushings to be reamed
before attempting to install the ski spindle.
Upper Bushing - Reamer Size: . 7 5 0 ~ (1,9 em)
Lower Bushing - Reamer Size: .875" (2.2 em)
Handlebar Torque And Sequence
Torque handlebar adjuster block to "-'3 fl. Ibs. as
shown. The gap should remain rearward.
IMPORTANT: When adjusting the handlebar, be sure
the serrations in handlebar and adjuster block match
before torquing.
NOTE: Handlebar adjustment on 440/SKS, 500 EFI!
SKS and ClassicfTouring models requires removal of
two plastic fasteners located below handlebar cover
holding console cover.
WARNING: Improper adjustment of the handlebars,
or incorrect torquing of the adjuster block tightening
bolts can cause timited steering or loosening of the
handlebars which could result in loss of cootrol.
2.25
8/94
RIDE RED
BODY AND STEERING
Ski Skag Removal Conventional Type
Each time a machine comes in for repair 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.
Check alt ski saddle bolts. If they are loose or worn,
replace with new bolts and nuts.
1. Remove retai ning nuts as shown.
2. Push bolt down through ski.
3. Pull rearot skag from ski as shown. This frees the
skag for removal from the ski.
Ski Skag Reinstaliation Conventional Type
1. Insert skag into the front hole.
2. Insert skag into rear hole.
3. Tap on the rear of the skag untillhe stud lines up
with the hole in the ski.
4. Reinstall retaining nut and torque to 15 ft. tbs. (2.1
kglml
8194
2.26
RIDE RED
BODY AND STEERING
Ski Skag Removal - IFS
Each time a machine comes in for repair 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.
Check all ski saddle botls. If they are loose or worn, replace with new bolts and nuts.
5. Remove the three nuts from the skag.
6. Pull down and rearward to remove the skag.
Ski Skag Instailation - IFS
1. Push skag forward, then up into position.
2. Reinstall nuts and torque to 15 ft. Ibs. (2.1 kglm) .
Ski Skag Removal - EZ Steer
1. Remove the three nuts from the skag.
2. Pull down and rearward to remove the skag.
Ski Skag Instailation - EZ Steer
1. Install flat bar as shown.
2. InslaJlI FS carbide skag.
3. Reinstall nuts and torque to 15 ft . lbs. (2.1 kglm).
2.27
8194
RICERED
BODY AND STEERING
Seats
1994 Model Seat Lengths
The following chart lists models according to seal length. Arrcms indicate interchangeability to match colO(.
Standard Two-Up "lile" Standard " I n d y ~ Long "Indy" Two-Up "Indyn Length
"Ute" Length Length Length Length
StarUte StarUte GT Sport
.. Sport SKS
Ule Lite GT Trail ... .. Trail Deluxe
Ute Deluxe
Indy 440 " Indy 440 SKS
XCR WideTrak GT
WideTrak LX
Classic Classic Touring
500 EFI SKS " 500 EFI
Super Sport }
XLT SKS .-. XLT
XLT SP
RXL
Storm SKS ",

Storm
8194
2.28
RICE RED
1995 Model Seat Lengths
BODY AND STEERING
Seats
The following chart lists models according to seat length. Arrows indicate interchangeability to match color.
Standard Two-Up "Lite" Standard ~ I n d y " Long "Indy" Two-Up "Indy" Length
"Lite" Length Length Length Length
Star Ute Sport
..
iii- Sport Touring
Lite Lile GT Trai l 4l1li .... Trai l Deluxe
Lite Deluxe
Indy 440 " ~ Indy 440 SKS
440 XCR WideTrak GT
600 XCR WideTrak LX
500 Classic
500 EFI SKS " ~ 500 EFI
Super Sport }
XLTSKS .-. XLT SKS
XLT XLT SP XLT Touring
RXL RXL Touring
Storm SKS ",
~
Storm
2.29
8/94
RIDE RED
BODY AND STEERING
1993 Polaris Snowmobile Paint Codes
MODEL MODEL NO. COLOR DESCRIPTION POLARIS PPG/Dltzler
"P" NO. Division
Auto Paint
Code No.
440 0930760 Porsche Red PI36 72060
Sport 0930443 Claret Burgundy - Melallic' PI72 4052
Classic 0930064 Midnight Blue Metallic P145 3216
Trail Deluxe 0930243 Dar!< Teal- Metallic' PISS 4300
Classic Touring 0930865 Midnight Blue Metallic P145 3216
Indy Ute 0933433 Porsche Red PI3S 72060
500 EFt 0930674 Black POlO 9000
Indy lite GT 0933133 Porsche Red PI36 72060
Indy Ute Deluxe 0933431 Porsche Red ?1 36 72060
440 SKS 0930560 Porsche Red ?136 72060
Trail 0930761 Dan.: Teal - Metallic' ?168 4300
Starlite 0933427 Star Blue ?150 12375
Slani!e GT 0933127 Star Blue ?1 50 12375
Widelrak 0932064 Porsche Red PI 3S 72060
650 AXL 0930768 Midnight Bl ue Metallic P145 3216
500 EFt SKS 0930574 Black P070 9000
XLT 0930767 Black Sapphire - Metallic' P173 3885
650 AXl SKS 0930568 Midnight Blue Metallic P145 3216
XlTSP 0930667 Black Sapphire - Metallic' P173 3885
XLT SKS 0930567 Black Sapphire - Metallic' P173 3885
Storm SKS 0932570 Black - Metallic' PI77 9000
440 XCA 0931760 Porsche Red P136 72060
Storm 0932770 Black - Metallic' PI77 9000
Clear Topcoat All Models Clear Topcoat NlA DAU82
Metallic Topcoat' All Models Clear Topcoal with Sparkle Metallic NlA DAU82
powder added. Order Polaris PN
8520109. Use one each per quart
of DAU82.
8/94
2.30
AIDE RED
MODEL MODEL NO.
440 0942760
Sport 0940443
Super Sport 0940743
Sport SKS 0940243
Classic 0942865
Trail Deluxe 0940262
Classic Touring 0942875
Indy Lile 0943433
500 EFI 0942774
Indy Lile GT 0943133
Indy Lite Deluxe 0943431
440 SKS 0942560
Trail 0940761
Starlile 0943427
Starlite GT 0943127
Widetrak LX 0942064
Widelrak GT 0942061
500 EFI SKS 0942574
XLT 0940767
RXL 0940768
RXL Touring 0940869
XLT SP 0940667
XLT SKS 0940567
Storm SKS 0940582
440 XCR 0941760
Storm 0940782
Clear Topcoat All Models
"Metallic Topcoal All Models
BODY AND STEERING
COLOR DESCRIPTION POLARIS PPGJDitzier
"P" NO. Division Auto
Paint Code No.
Porsche Red P136 72060
Black Sparkle Melallic' Pl77 9000
Bright White P133 2185
Black Sparkle Metallic' PI 77 9000
Bahama Blue P183 4307
Teal Melallic' P168 4300
Bahama Blue PI83 4307
Black P070 9000
Black Sparkle Metallic' Pl77 9000
Teal Metallic' P168 4300
Star Blue P150 12375
Star Blue P150 12375
Black Sparkle Metallic' P177 9000
Black Sapphire Metallic' P173 3885
Black Sparkle Metallic' PI77 9000
Bright White P133 2185
Black Sparkle Metallic' P177 9000
Clear Topcoat N/A DAU82
Clear Topcoat with Sparkle N/A DAU82
Metallic powder. Order direct
from Midwest Industrial Coatings
(612-934-8252). Mi x.s
directed.
CAUTION: (4401SKS, 500 EFIISKS, ClassicITouring models) Prolooged exposure to petroleum based products may cause
paint lailure. II the machine must be tipped on its side lor service work l or a period 0115 minutes or more, the painted body side
panels must be removed prior to tipping machine in order to prevent possible damage due to Ituid leakage.
2.31
8194
RIDERED
BODY AND STEERING
MODEL MODEL NO. COLOR DESCRIPTION POLARIS RAW MATERIAL NO.
P" NO.
Ute 0953433 Black Sparkle Metallic P177 8520044
Lite Deluxe 0953431 Teal Metallic P1 68 8520096
Lite GT 0953133 Porsche Red P136 8520066
StarLite 0953427 Bahama Blue P183 852011 9
Sport 0950443 Black Sparkle Metallic P177 8520044
Super Sport 0950743 Bright White P133 8520079
Sport SKS 0950243 Black Sparkle Metallic P177 8520044
Trail 0952761 Teal Metall ic P168 8520096
Trail Deluxe 0952262 Teal Metall ic P1 68 8520096
440 LC 0952760 Porsche Red P1 36 8520066
440SKS 0952560 Porsche Red P1 36 8520066
500 Carb 0952764 Black Sparkle Metallic P1 77 8520044
Classic 0952865 Bahama Blue P1 83 8520119
XLT Touring 0952857 Black Violet Metallic P200 8520136
500 EFI 0952774 Black Sparkle Metallic P177 8520044
500SKS 0952574 Black Sparkle Metallic P1 77 8520044
XLT 0950756 Black Violet Metall ic P200 8520136
XLT SKS 0950556 Black Violet Metallic P200 8520136
XLTSP 0956767 Black Violet Metallic P200 8520136
WideTrak LX 0952064 Porsche Red P1 36 8520066
WideTrakGT 0952061 Porsche Red P136 8520066
RXL Touring 0950869 Black Sparkle Metallic P1 77 8520044
RXL 0956768 Black Sparkle Metallic P1 77 8520044
Storm 0950782 Black Sparkle Metallic P1 77 8520044
Storm SKS 0950582 Btack Sparkle Metallic P1 77 8520044

440XCR 0951660 Bright While P1 33 8520079
600XCR 0951856 Bright While P133 8520079
Clear Topcoat All Models Clear Topcoat N/A 8520069
-Metallic Topcoat All Models Clear Topcoat with N/A 8520106
Sparkle Metallic powder.
Order direct from Midwest
Industrial Coatings
(612-934-8252). Mix as
directed.
CAUTION: (Trail, Trail Deluxe. 440, 440 SKS, 500, Classic XLT Touring, 500 EFt, 500 EFt SKS models) Prolonged exposure to
petroleum based products may cause paint failure. If the machine must be tipped 00 its side for service wori< lor a period 0115
minutes or more, the painted body side panels must be remo ....ed prior to tipping machine in order to prevent possible damage
due to lIuid leakage.
8/94
2.32
AICERED
CHAPTER 3
BODY ELECTRICAL
Headlight Adjustment, Bulb Replacement .. . . ... .. ......... ........ 3.1-3.3
Electrical Test Equipment, Digital Multitester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.3
Headlight Bulb Test ................................ . .. ... . . . .. .. ..... 3.4
lighting System Test, Unregulated and Regulated. . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.4
Seat Harness Troubleshooting ..... ......... ........ .. . .. . .. . .. .......... 3.5
Hi/Low Switch Testing ............. . .. . . .. .. . . ........... ... .........
Ignition Switch Testing
Non Battery Models ............... . ...................
Electric Start and Fuel Injected ............ ........... .. ..
3.5
3.5
3.6
Speed Control Assurance Testing ............. . .. ... ... .. . .. .... ..... 3.7-3.8
Coolant Temperature Hot Light .... .. . ... . . . .. . . .. .... . ...... .. . .. 3.9
Handlebar/Thumbwarmers ......... . . . . .. ........................ 3.10-3.11
Wiring Diagram/Schematics
1985 - Star - 100 Watt Alternator .......... .
1985 - SS, Long Track - 120 Watt Alternator ... .
1985 - Indy Trail- 120 Watt Alternator
1985 - Indy 440 - 120 Watt Alternator ....
3.12
3.13
3.14
3.15
1985 - Indy 600, Indy 600 SE - 120 Watt Alternator ............. ......... ....... 3.16
1986 - Star - 100 Watt Alternator ...................... ..............
1986 - Sprint. SS, Long Track - 120 Watt Alternator .........
3.17
3.18
3.19 1986 - Indy Trail - 120 Watt Alternator
1986 - Indy 400 - 120 Watt Alternator ... 3.20
1986 - Indy 600, Indy 600 SE - 120 Watt Alternator ...... . . . . .. . . ...... 3.21
1987 - Star, StarTrak -100 Watt Alternator ............... .. ........ .... ... .. .. 3.22
1987 - Sprint, LongTrack (RLR) - 120 Watt Alternator ........ . ...... .. . . ..... 3.23
1988 -Indy Sport, Indy Trail (133 SKS) -120 Watt Alternator ..... . ...... ....... .
1988 . Indy 400 (133 SKS). Indy 600 . 120 Wan Allernalor . ... ..... .... .......
3.24
3.25
1988 - Star, StarTrak - 100 Watt Alternator ....................... .. .. . ...... 3.26
a
RIDE RED
8/94
8194
1988 - Sprint, LongTrak (RLR) -120 Watt Alternator .. .. .............. .. ..... 3.27
1988 - Indy Sport, Indy Trail (All Excepl ES) - 120 WaH Allernalor ........ . .. .... 3.28
1988 - Indy 400 Classic - 120 Watt Alternator .................................. 3.29
1988 - Indy 400 (SKS), Indy 650 (SKS) - 120 WaH Allernalor ...... .... .. , ... .. 3.30
1989 - Star, StarTrak - 100 Watt Alternator ..................... . . .. .. . . . . ... .. 3.31
1989 - Sprint ES, LongTrak (LTR) - 120 Watt Alternator .... .. . .. . . . ..... 3.32
1989 - Sport, Sport GT - 120 Watt Alternator ........ . .... .. . . . . .. . . . . . . ..... 3.33
1989 - Indy 400, 500, 500 SP - 120 WaH Allernalor ......... .. . .. ........ .. ..... 3.34
1989 - Indy 500 Classic - 120 Watt Alternator .................................. 3.35
1989 - Indy Trail ES. SP, SKS, Deluxe, SuperTrak - 120 Watt Alternator .... . ...... 3.36
1989 - Indy 650 (SKS) - 120 WaH Allernal or ........... .... ... . ................ 3.37
1990 - Star, StarTrak - 150 Watt Alternator ...... . . . .. . . . . . .. .. ......... 3.38
1990 - Sprint ES - 150 Watt Alternator .... ..... . . ... ........ .. .. .. .. . .. .... . .. 3.39
1990 - Indy Sport, Sport GT - 150 Watt Alternator 3.40
1990 - Indy WideTrak - 200 Watt Alternator .. .. .. ... .. . . . .. ... . . .... . _ .. . ..... . 3.41
1990 - Indy Trail , Deluxe - 200 Watt Alternator ............. .... .. . . . . .. ........ 3.42
1990 - Indy 400, 500, 500 SP, SKS - 200 Watt Alternator .. .. ...... . ... .. ........ 3.43
1990 - Indy 500 Classic - 200 Watt Alternator .............. . .. ... .. .. .... . ..... 3.44
1990 - Indy 650, SKS - 120 Watt Alternator . . ..... . .. . _ . . . . .. .... ... .. ........ 3.45
1991 - StarUte. Indy Lite - 150 Watt Alternator
1991 - Indy Sport, Sport GT - 200 Watt Alternator
1991 - Indy WideTrak - 200 Watt Alternator .......... .
3.46
3.47
3.48
1991 -Indy Trail , Deluxe, SuperTrak - 200 Watt Alternator ...................... 3.49
1991 - Indy 400, 500, 500 SP, SKS - 200 Wan Allernal0r .. . ..................... 3.50
1991 -Indy 500 Classic - 200 Watt Alternator ....... . .... ....... . .. .......... .. 3.51
1990-1991 - Indy RXL .. .......................... .. ...... . ................. 3.52
1991 - Indy 650 - 180 Watt Alternator ...................... . ... . .. ..... .. ... .. 3.53
1992 - StarUte, Indy Ute, Lite GT - 150 Watt Alternator .......... . . ............. 3.54
1992 - Lite Deluxe - 150 Watt Alternator ................... _ .. . ... . _ ...... 3.55
1992 -Indy Sport, Sport GT - 200 Watt Alternator............ . . . .... . ..... 3.56
1992 -Indy Trail , Trail Deluxe, SuperTrak - 200 Walt Alternator .... . .. . . .. ....... 3.57
1992 - Indy 440, 500 - 200 Watt Alternator ............................. _ ...... 3.58
1992 - Indy 440 XCR - 200 Walt Alternator .......... .. ... .. .... . ....... . ...... 3.59
1992 - Indy 500 SP, SKS - 200 Watt Alternator .... . .. . ...... .. .. . ......... . . . 3.60
b
RIDE RED
1992 -Indy 500 Classic - 200 Watt Alternator ..... .... . ...... .. ........... 3.61
1992 -Indy WideTrak - 200 Watt Alternator .......... . . . . .... . .. . . . ...... ...... 3.62
1992 - Indy 650 - 180 Watt Alternator. . . . . . . ....... . . .... . ... . ......... .... 3.63
1992 - Indy RXL, SKS - 180 Watt Alternator
1993 - Indy StarLite/GT, Lite/GT - 150 Wall Alternator .............. ...........
3.64
3.65
1993 - Indy Lite Deluxe - 150 Watt Alternator ................. . . ............... 3.66
1993 - Indy Sport - 200 Watt Alternator .......................... .. ........... 3.67
1993 - Indy Trail , Trail Deluxe - 200 Watt Alternator ..... . ........ . . . .. . .. . ...... 3.68
1993 - Indy 440, SKS - 200 Watt Alternator .................. . .. . .... ......... . 3.69
1993 - Indy 440 XCR - 200 Watt Alternator ............ . ....................... 3.70
1993 - Indy 500 EFI, SKS - 200 Watt Alternator 3.71
1993 - Indy Classic - 200 Watt Alternator ........................ 3.72
1993 - Indy Classic Touring - 200 Watt Alternator ........................... 3.73
1993 - Indy WideTrak - 200 Watt Alternator .................................... 3.74
1993 - Indy XLT, SP, SKS - 170 Watt Alternator ................... . .. . ........ .
1993 - Indy RXL, SKS - 180 Watt Alternator ..... . . .. ......... ....... ... ...... .
1993 - Indy Storm, SKS - 180 Watt Alternator ..... . .. ..... ........... . ........ .
1994 - Indy StarLite/GT, Lite/GT - 150 Watt Alternator ..... .
1994 - Indy Lite Deluxe -150 Watt Alternator ............................
1994 - Indy Sport, SKS, Super Sport - 200 Watt Alternator .......... ......
1994 - Indy Trail - 200 Watt Alternator ................................. .
1994 - Indy Trail Deluxe - 200 Watt Alternator .......... .. ...... .. ...........
1994 - Indy 440, SKS -200 Watt Alternator ............ . ..... ...........
1994 - Indy 600 XCR ............. . . ... . . ... . . .. . ...... .........
1994 - Indy 440 XCR - 200 Watt Alternator ............. .... .. .. . ..... ... . .... .
1994 - Indy 440 XCR SP ........................... . . . . . .. . . .. . .. .
1994 - Indy 500 EFI, SKS - 250 Watt Alternator .......... .. . . .. .... ...
1994 - Indy Classic - 200 Watt Alternator ................. . .... . .............. .
1994 - Indy Classic Touring - 250 Watt Alternator ..
1994 -Indy WideTrak GT - 200 Watt Alternator ...
1994 -Indy WideTrak LX - 200 Wall Alternator ................... .
3.75
3.76
3.77
3.78
3.79
3.80
3.81
3.82
3.83
3.84
3.85
3.86
3.87
3.88
3.89
3.90
3.91
1994 - Indy XLT, SP, SKS, Special XTRA - 170 Watt Alternator ...... ........... 3.92
1994 - Indy RXL - 180 Watt Alternator .. . .................................. 3.93
1994 - Indy RXL Touring - 180 Watt Alternator .. 3.94
c
RIDE RED
8/94
1994 . Indy Storm, SKS 180 Watt Alternator . ......... . ............ . .. . ...... 3.95
1995 . Indy StarLite/Lite/Lite GT ............. . ...................... . .. . ..... 3.96
1995 . Indy Ute Deluxe ............... . ............................... . ..... 3.97
1995 - Indy Sport/Super Sport/Sport Touring .. . ... . ............................ 3.98
1995 . Indy Trait ..................... . .. . ...... . . .. .. . .. , . .. . . . ... .. . ...... 3.99
'995 . Indy Trail Deluxe . .............................................. . .... 3.'00
1995 -Indy 440/SKS ....... ............. ........ .. ...................... . . 3.101
1995 -Indy 440 XCR ....................... .. ............................. 3.102
1995 - lndy600XCR .................. .. .. . ....... ... ..................... 3.103
1995 -Indy 500 EFI/SKSJPT ................. .. . ...................... 3.104-3.105
1995 -Indy 500 ........... . . . .. . ... .... ........ .. .... . .... .. .............. 3. 106
1995 . Indy Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.107
1995lndyWideTrakGT ....... .. . .. .. ... ..... ..... . ... .. ... .. . . . .. ....... 3.108
, 995 Indy WideTrak LX .............. . . .. ... .... .. ......... ... ............ 3.' 09
1995 - l ndyXLTIXLTSP/SKSJPT ...... .. ............... . .. .. ...... .. ........ 3.110
1995 - lndyXLTTouring ... . ......... . . . . .... . . .. . .. . . . .. ..... . .... . ........ 3.111
1995-lndyRXL ... . ............... _ ............. .. . .... ........ .. ... ..... 3.112
1995 . Indy RXL Touring ........ .. ......... . .. . .... . .............. . ........ 3.1 I 3
1995 -Indy StormlSKSJPT ................................................. 3.114
8194 d
AIDE RED
Headlight Adjustment
Headlights may be adjusted for both horizontal and
vertical aim using the following procedure.
1 . Place the snowmobile on a level surface with the
headlight approximately 25' (7.6 m) from a wall.
2. Measure the distance from the fl oor to the center
of the headlight and make a marl< 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 four headlight mounting screws either
in or out as needed for proper aim.
1994 and Newer Liquid Twins
Headlight Adjustment
1. If necessary, the headlight vertical 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.
3, 1

BODY ELECTRICAL
Standard Indy Models
25' (7.6 m)
Lamp Center
Height

)11" ilJJ i";
V
~ t d u
~ -
Headlight Adjustment Knob
RICEREC
8194
BODY ELECTRICAL
Headlight Bulb Removal (Models with Metal Retaining Ring)
1. Pull rubber boot back.
2. Release the retaining ring by depressing and rotating it
counter clockwise.
3. Grasp the plastic harness connector and carefull y
remove the harness, retaining ring and bulb assembly
from the reflector assembly.
4. Grasp the bulb by its metal base and carefully
disconnect the bulb from the harness.
Headlight Bulb Installation (Models with Metal Retaining Ring)
1. While holding the metal base of the bulb, connect it to the
wi re harness. Make sure the bulb blades are properly
positioned in the socket.
2. While holding the plastic harness connector, align the
bulb tabs with the slots in the socket. Slide the bulb into
the reflector assembly.
3. Reinstall the bulb retaining ring with the word "TOP"
toward the top of the reflector.
4. Al ign the retaining ring mounting tabs. Push the ring in.
compressing the spring, and rotate the ring clockwise to
lock it in place.
5. Reinstall the rubber boot.
NOTE: Due to possible differences in bulbs, re-check head-
light aim whenever a bulb or reflector is replaced.
1994 and Newer Liquid Twins
Removing the Center Bulb
1. Push down on spring until it releases from spring
retainer.
2. With wire harness attached to bulb, withdraw bulb from
housing.
3. Grasp bulb by metal base and carefully separate bulb
from harness.
Installing the Center Bulb
NOTE: Do not touch a halogen bulb with bare fingers. Oil
from skin leaves a residue, causing a hot spot which will
shorten the life of the lamp.
1 . Hold bulb by metal base and install j n ~ o wire harness.
2. Insert bulb into housing.
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 118 turn to left and withdraw from
housing. ,
8194
3.2
Wire .Bf!
Harness ~ / ~ I
>r Bulb
Spring
RIDE RED
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 1/81urn to right losecure in housing.
4. Verify headlight operation.
Headlight Bulb Removal
(Models with Wire Bulb Retainer)
1. Push down on left side of spring until it releases from
spring retainer.
2. Lift spring carefu1ly around wire harness and fl ip 10
outside of housing.
3. With wire harness attached to bulb, withdraw bulb from
housing.
4. Grasp bulb by metal base and carefully separate bulb
from harness.
Headlight Bulb Installation
(Models with Wire Bulb Retainer)
1. Hold bulb by metal base and install into wire harness.
2. Insert bulb into housing.
3. Carefully flip spring back into housing placing it around
wire harness.
4. Push spring down until it is secured by spring retainer.
5. Verify headlight aim.
Electrical Testing
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 Model 73
(PN 2870659). See photo at right. This instrument will pro-
vide 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
V - :: Volts AC - measuring alternator output
V :-:-:- = Volts DC - measuring battery voltage, volt drop, etc.
300mv :-:-:- = Milli Volts DC - measuring small DC voltages
RED I ",m "";
FOR VOLTS AND
RED LEAD HERE
FOAAMPS
COMMON
(BlACK LEAD)
BODY ELECTRICAL
Q = Ohms, resistance - measuring component resistance values - testing coils, wiring, etc .
........ := Diode check - checking the condition of rectifier diodes, cannot be used for testing except when the diodes
are out of circuit
A- = Amps AC - not used for snowmobile service
A :-:-:- = Amps DC - used to check battery charge rate, system draws, etc.
NOTE: When using the Amp settings, the red test lead must be moved to the 10A (unfused) socket on the front
of the instrument.
3.3
RIDE RED
8194
BODY 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. Viewi ng 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.
Lighting System Test (Unregulated Voltage)
1. Turn the multitester dial to the Volts AC (V ........ ) position.
2. Disconnecllhe alternator to main harness connector at
engine.
3. Connect one of the tester leads to the yellow alternator
wire and the other lead to the brown alternator wi re.
NOTE: On floating alternators, the yellow/red stator
wi re should connect to the brown stator wire. If it does
not, the system wi ll not have a ground and will not
operate.
4. Start the engine. While observing the voltage reading,
increase the engine speed to about 3000 RPM.
Readings of between 15 and 45 VAG are considered
normal. If there is no output, refer to the Stator Testing
section under Section 4, Engine Electrical .
Regul ated Voltage:
1. Reconnect 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. NOTE: Do not disconnect the regulator from
the system.
3. Ground the other tester lead.
4. Start the engine. While observing the voltage reading,
increase the engine speed to about 3000 RPM. An
acceptable reading will be between 10 and 15 VAG.
Voltages lower than 10 VAG may indicate an excessive
system load, poor flywheel magnets, lighting coil
problems, wiring problems or a bad voltage regulator.
Voltage readings higher than 15 VAG indicate a voltage
regulator problem or a poor ground at the regulator heat
sink.
NOTE: Fuel injected models have two regulators; one for
lighting and one for charging the battery. Battery charging
is discussed in Section 4, Engine Electrical.
NOTE: Regulator PN 4060090 (10 mark LR 11) should not
be used on machines with halogen headlamps.
8194
3.4
"
RIDE RED
Seat Harness Troubleshooti ng
I. Remove the taillight lens.
2. Remove the two taillighl bulbs and the brakelight bulb.
3. Separate the seat harness from the main harness by
unplugging Ihe connector at the right rear of the tank.
4. With the multitester dial set on ohms (Q) connect either
meter tesllead to the brown seat harness wi re.
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 seal.
7. Tip the seat over and remove the right side seat cover
staples. Locate and repair Ihe harness problem.
S. Reinstall the staples and re-check the seat harness.
Hilla Beam Switch Testing
I . Set the multitester dial to the ohms (Q) position.
2. If the Hil la switch has not been removed from the
machine. disconnect the switch to harness plug in
connector.
3. With the Hil la switch in the Lobeamposition, check the
resistance between the yellow and the green switch
wires. The reading should be less than .4 ohms.
4. Turn the HilLa 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/La Switch back to the Lo beam position and
the meter should again read an open circuit (Ol).
Ignition Switch Testing (Non-Electric Starter)
1. Set the multitester dial to the ohms (Q) position. Connect
one of the tester leads to either of the switch terminals
and the other tester lead to the other switch terminal.
2. With the switch off, the reading should be less than .4
ohms. With the switch on, the reading must be an open
circuit (Ol).
3. Check the resistance between each of the switch
terminals and the switch body. With the switch still in the
on position, there must be an open circuit (OL) reading.
Readings other than those listed indicate a defective
switch.
3.5
BODY ELECTRICAL
Electrical Testing
Low H h
"or
Gm
Yel
Yel/ Ad
High/low Switch
Off
I ::: I
!
Ignition Switch
8/94
RIDE RED
BODY ELECTRICAL
Ignition Switch Testing
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. Sellhe multitester dial to the ohms
(0) position.
2. With the key in the off position, check the resistance
between the G (Ground, brown) terminal and the M
(Mag, black) terminal. Thi s reading must be less than .4
ohms.
3. Turn the key to the on position. The multitester should
now read an open circuit (Ol).
4. Move the tester lead from the G terminal to the switch
housing and re-check the reading. It should also be an
open ci rcuit (OL).
5. Place one of the tester leads on the 8 (Battery, red)
terminal and the other tester lead on the S (Starter, blue)
terminal. With the key in the on position, there must be
an open circuit (Ol) reading.
6. Turn the key to the start position. The reading should be
less than .4 ohms. Readings other than the ones listed
indicate a defective switch.
Ignition Switch Testing (Fuel Injected Models)
1. Disconnect wires. Set the multitester dial to the ohms
(0) position.
2. With the key in the off position, connect one of the tester
leads to the G terminal.
3. Randomly connect the other tester lead to the other
terminals. The only terminal that should show other
than an open circuit (Ol) is the M terminal. The M
terminal should read less than .4 ohms.
4. Turn the key switch to the run position. Check the
resistance between the M terminal and each of the other
terminals, and the M terminal and the switch housing.
All of these readings must be an open circui l (Ol).
5. Return the key to the off position.
6. Connect a tester lead to the B terminal. Randomly
connect the other tester lead to each terminal. The
readings must be an open circuit (Ol).
7. Turn the key to the run position and repeat the test. All of
the readings must be an open circuit (Ol), except
between the Band L terminals. This reading must be
less than .4 ohms.
8. With one tester lead connected to the B terminal and the
other to the S terminal and with the switch in any position
except start, the reading should be an open circuit (Ol).
In the start position, the reading must be less than .4
ohms.
8/94
3.6
RIDE RED
Auxil iary Kill
Switch Contacts
Ignition Primary
Engine Ground
B
Throttle Control
Cutaway
A
BODY ELECTRICAL
Speed Control Assurance Operation
Off Idle Switch
Plungers
Outward
~ - - ~
Idle Switch
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 circui t 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 .010-.030"
(.25-.8 mm) clearance between throttle lever (A) and
throttle block (8). This clearance is controlled by the throttle
cable sleeve{s) and the idle speed screw(s).
If the idle speed screw(s) is adjusted inward and the cable
sleeve(s) is nol adjusted to take up the throttle leller to
throttle block clearance, the engine may misfire or kill upon
initial throttle opening.
CAUTION: After any idle speed adjustments are made, the
throttle lever 10 Ihrottle block clearance must be checked
and adjusted.
NOTE: When adjustments are made on models which
have more than one carburetor, refer to Section 6, Carbure-
lion, for proper carburetor synchronization adjustments.
3.7
8/94
RIDE RED
BODY ELECTRICAL
Speed Control Assurance Testing
1. Set the mullitester in the ohms (Q) position.
2. Disconnect the switch harness from the main wire harness.
3. Connect the two multitester lest leads to the two switch wires.
Test 1 - Open Circuit - Run
With the auxiliary shut-off switch in the on position, the
multilesler should read an open circuit (OL). As the
throttle lever is moved from idle to off idle, the tester
should conti nue to read an open circuit. If the tester
fluctuates and the throttle lever 10 throttle block clearance
is adjusted properly, the switch assembly needs to be
replaced.
Test 2 - Closed Circuit Kill
The two speed control switches must make a complete cir-
cuit to kililhe 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
or the switch assembly needs to be replaced.
Test 3 - Auxiliary Shut-Off
The mullitester should read less than .4 ohms in the off posi-
tion and an open circuit in the the on position. If not, the
switch assembly needs replacement.
Speed Control Assurance Testing
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 out 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.
8/94
3.8
AIDE RED
BODY ELECTRICAL
Coolant High Temperature Indicator Testing
Circuit
Power
In -
II Temp II
Ground the BlackIWhile wire here
(with the engine running) to test
the light.
Engine
Ground
The indicator light is controlled by a temperaturelwarning switch installed into the engine cooling system. When
engine coolant temperature reaches approximately 205
0
F, the switch closes, completing the circuit through the
indicator light to ground. the system should be tested periodically for proper operation.
Lamp Circuit Test
1. Remove wi re 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 ci rcuit.
Temp Light Temperature Sensor Test
The temperature/warning switch is normally open.
1. Set the multitester on the ohms (n) scale.
2. Disconnect the lamp wi re.
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
0
F, the
contact in the switch would close and the reading would be less than .4 ohms.
CAUTION: 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.
Handlebar Warmer Testing
Polaris has used four different types of handlebar warmers. They are all similar in that when on Hi, they are each
15 watt warmers. Each type must be wired differently from one another due to internal resistance difference.
Use the wiring diagrams on the foll owing pages whenever troubleshooti ng, repairing or replacing any handlebar
warmer.
The warmers are broken down into the following types:
Type I - Single element, stick on grid
Type II - Dual element (Hill a) stick on grid with diode
Type tll- Dual element (Hill a) stick on grid
Type IV - Polaris Hot Grips''''
3.9
8/94
RIDE RED
BODY ELECTRICAL
Type I
The Type I warmer grid is used as standard equipment
on single heat units such as the Trail. Individual grid re-
sistance is approximately 10 ohms when measured be
tween the two element leads (1 or 2). There must also
be an open circuit (Ol) between either lead and ground
with the element totally disconnected.
Type I System Check
1. Remove the yellow power in wi re from the toggle
switch.
2. Read the resistance between the switch terminal
and ground. The resistance with the switch on
should be about 5 ohms. With the switch off it should
be an open circuit.
NOTE: Individual grid resistance may vary slighlly (1 0%)
due to temperature and element manufacturing differ-
ences.
Type II
The Type II warmer grid was used as standard equip-
ment on the t989 dual heat units such as the Classic and
650 Indy. Individual grid resistance between the com-
mon lead (1), and either of the two grid leads, (2 and 3),
is approximately 20 ohms. These grids must be wired
with the 2 and 3 leads connected together and mounted
on the middle switch terminal.
The diode kit (PN 2200315) must be installed as ajumper
between the upper and lower switch terminal. Refer to
Service Bulletin S-89-01. The common grid connection
1 must be grounded.
Type II System Check
1. Remove the yellow power in wire (switch center).
2. Measurethe resistance in the Hi position (switch up).
The resistance will be approximately 5 ohms with all
grids connected parallel. See illustration at right.
Type III
The Type III warmer grid is used as standard equipment
on 1990 and newer dual heat units such as the Classic
and 650. Individual grid resistance between the common
lead (1), and either of the two grid leads (2 and 3), is
approximately 10 ohms.
These grids are wired parallel between the left and right
handlebar, and are wired in series for low heat on an indi-
vidual grid. Example: Low heat on each grip would have
the power in to wire 2. Wi re 3 would be the ground. Re-
sistance between 2 and 3 is 20 ohms.
Type III System Check
1. Remove the yellow power in wire from the center of
the toggle.
2. Measure the resistance between the switch terminal
and ground. With the switch in the Hi position the
resistance should be approximately 5 ohms. In
the La position the resistance should be
approximately 10 ohms.
8/94 3_10
GRID IOENTlFICATON NUMBER: 2536C
POWER IN (YELLOW)
,
GRID IDENTIFICATION NUMBER: 3866B
-- ."
GROUND
DIODE KIT
PIN 2200315
.:,?W 2r:??) I
1
POWER IN (YEllOW)
1
2
3
GRID IDENTIFICATION NUMBER: 4010A
_____ --,
POWER IN (YEllOW)
RIDE RED
TYPE IV
The Type IV handlebar warmer is a complete grip
assembly mounted on the end of each handlebar.
The dual heal version is a series connected circuit
between the grips. It has an additional ballast resistor
added in series to provide tow heat. The resistance of
each grip is approximately 2.5 ohms. The combined
series resistance is 5 ohms in the high position.
CAUTION: The grip kit must be properly installed and
wired as shown or electrical system overloading will
result.
SYSTEM CHECK
Remove switch center connection. With a digital
multitester set in the ohms (Q) position, measure
resistance between switch center terminal and
ground. In the off (center) position, meter should
indicate an open circuit (Ol). In the high position,
meter should read approximately 5 ohms. In the low
position, meter should read approximately 7.4 ohms.
With ground terminal lifted, meter should indicate an
open circuit (Ol).
HIGH-LOW HANDWARMER TOGGLE SWITCH
Below are the correct wire to PIN numbers:
I. Blue - High Circuit
2. Yellow - Regulated Power (A.C.)
3. Blue/Red - low Circuit
4. Blank
5. Blank
6. Blank
7. Brown - Ground Circuit
8. Blank
THUMBWARMER TOGGLE SWITCH
Below are the correct wire to PIN numbers:
1. Blank
2. Yellow - Regulated Power (A.C.)
3. White/Gray - To Thumbwarmer
4. Blank
5. Blank
6. Blank
7. Brown - Ground Circuit
8. Blank
3.11
Ground
2.4 ohm
BODY ELECTRICAL
Power in
Yellow
HANDLEBAR HARNESS WIRE CONN.
BLUE

YELLOW
BLUE/ RED
3
,

BROWN
1994
BROWN
1995
SWITCH - HANDWARMER
HI - LOW
BROWN
YELLOW

7
~
, ,
tb=
,
F,=

WHITE/G RA/
SWITCH - THUMBWAAMEA
8/94
RIDE RED
BODY ELECTRICAL
1985 Wiring Di agram/Schematic - Star
WIRING DIAGRAM
1985 Star EC25PS-06
SCHEMATIC DIAGRAM
.. -
1985 STAR EC25P$- 06 (100 WATT ALTERNATOR)
..... :
tClIo"S4I ontIno
_ ... ,-......
-
" . ........ Tt
",'<1- Si mi
__ "" 1IIIrnT UfllI

ill II /
.. J. SIll w, EJ- "
SWIIU
. 8/94
Ullua, SWIIOI
ss
3.1 2
AIDE RED
WIRING DI AGRAM
SS EC44- 2PM-3100
Long Track EC44- 2PM-5000
BODY ELECTRICAL
1985 Wiring Diagram/Schematic - 55, Long Track
"':t:" _ ..
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......... -
--
SCHEMATIC DIAGRAM
SS EC44- 2PM-3100 !12Q WAn ALTERNATOR)
LONG TRACK EC44- lPM5000 (120 WATT ALTERNATOR)
..... ,
lC2PS-OI .".1 ..
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8/94
RICE RED
BODY ELECTRICAL
1985 Wiring Diagram/Schematic - Indy Trail
WIRING DIAGRAM
1985 INOV TRAI L
EC44- 2PM- 2tOO
SCHEMATIC DIAGRAM
1985 INDY TRAil
EC44-2PM- 2100
(120 WATT ALTERNATORl
8/94
' 1 ~ I T l I
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3.14
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RIDE RED
WIRING OIAGRAM
1985 INDY 400 EC40f'L-02
BODY ELECTRICAL
1985 Wiring Diagram/Schematic - Indy 400
l
SCHEMATIC DIAGRAM
1985 INDY 400 EC40f'L - 02
( 120 WATT ALTERNATOR)
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3.15
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8/94
RIDE RED
BODY ELECTRICAL
1985 Wiring Diagram/Schematic - Indy 600, Indy 600 SE
WIRING DIAGRAM
1985 INDY 600, INDY 600 SE
ECSOPL- 02
SCHEMATI C DIAGRAM
1985 INDY 600, INDY 600 SE
EC6OPL -02
(120 WATT ALTERNATOR!
_,_, .... "_ ......
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8/94
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WIRING DIAGRAM
1986 SIM EC25PS- 06
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1986 Wiring DiagramJSchematic - Star
.. -
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1986 STAR EC25PS- 06 ( 100 WATT ALTERNATOR)
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8/94
BODY ELECTRICAL
1986 Wiring Diagram/Schematic - Sprint, 55, Long Track
- _.'
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8194
WIRING DIAGRAM
Spr;,,1 ECJ.4- 2PM- Ol
Loog T,ack EC44- 2f'M- Sl00
SCHEMATIC DIAGRAM
SPRINT EC34- 2PM- Ol ( 120 WATT ALTERNATOR)
LONG TRACK EC44-2PM- SOOO (120 WATT ALTERNATOR I
&GlIlIUT I.l.f
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3.18
AIDE RED
WIRING DIAGRAM
1986 INDV TRAil
ECSOf'M- Ol
BODY ELECTRICAL
1986 Wiring DiagramiSchemalic - Indy Trail
@_ ... _--
SCHEMATIC DIAGRA M
1986 INDV TRAIL
ECSOPM- Ol
(12Q WATT ALTERNATOR)
3.19
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8/94
AIDE RED
BODY ELECTRICAL
1986 Wiring DiagramiSchematic - Indy 400
WIRING DIAGRAM
1986 INDV 400 EC40f'l - 02
8/94
15--
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SCHEMATIC DIAGRAM
1986 INDY 400 EC4OPL- 02
(120 WATT ALTERNATOR)
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3.20
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AIDE RED
BODY ELECTRICAL
1986 Wiring Diagram/Schematic " Indy 600, Indy 600 SE
WIRING DIAGRAM
1986 INDY 600, INDY 600 lE
EC6Of'L- 02
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SCHEMATIC DIAGRAM
INDY 600. INDY 600 lE
EC60PL- 02
( 120 WATT ALTERNATOR)
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8/94
BODY ELECTRICAL
1987 Wiring Diagram/Schematic Star, Star Trak
1987 WIRING DIAGRAM
STAR, STAR TRAK EC25PS- 06
LONG TRACI( (RLR)
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8/94
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1987 SCHEMATIC DIAGRAM
STAR. STAR TRAK EC25PS- 06 (100WATT ALTERNATOR)
3.22
RIDERED
BODY ELECTRICAL
1987 Wiring Diagram/Schematic - Sprint, Long Track (RLR)
1987 WIRING DIAGRAM
STAR, STAR TAAK EC2SPS- 06
SPRINT EC34- 2PM_ Ol
LONG TRACK ! RLR) EC44- 2PM- 5100
LONG TRACK (ALR)
,<:.:J:',"Tt' " iL

SPRINT EC34-ZPM- Ol ( 120 WATT ALTERNATOA)
LONG TRACK (ALA) EC44- 2PM-5100 fl20 WATT ALTERNATOR)
Refer to page ZOIc for Sprint Electric Starl Schemat ic Diagrwn

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AIDE RED
8/94
BODY ELECTRICAL
1987 Wiring Diagram/Schematic - Indy Sport, Indy Trail (133 SKS)
1981 WIRING DIAGRAM
INDY SPORT EC34- 2PM- 03
INDY TRAIL 1133 SKS) EC50- PM-Ol
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INDY TRAIL ( 133SKS) EC50- PM- Ol (120 WATT ALTERNATOR)
Indy Tlail ElK!riC SlM1 !khemalic , e' e,_ page 201c
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BODY ELECTRICAL
1987 Wiring Diagram/Schematic -Indy 400 (133 SKS), Indy 600
1987 WIRING DIAGRAM
INDY 400 EC4OPL- 02
INDY 600 EC6OPl-02
,oG'"
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INDY 600 EC60PL - OZ ( 120 WATT ALTERNATOR)
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1988 Wiring Diagram/Schematic - Star, Star Trak
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1988 Wiring Diagram/Schematic - Sprint. Long Trak RLR
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8/94
BODY ELECTRICAL
1988 Wiring Diagram/Schematic -Indy Sport, Indy Trail (All Except ES)
1988 WIRING DIAGRAM
INDY SPORT EC34- 2f'M- OJ
INDY TRAil (All EllCtpl ES) EC50_PM_ Ol
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INDY TRAIL (All beepl ESI EC5OPM- Ol ( l :roWATT ALTERNATOR)
Indy f il Electric Slarl Schemat ic IH1I8 20k
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1988 Wiring Diagram/Schematic - Indy 400 Classic
1988 WIRING DIAGRAM
INDY 400ClA$SIC EC4OPl - OJ
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INDY 650 (SKS) EC65PL- 01 ( 120 WATT ALTERNATOR)
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1989 Wiring Diagram . Indy 400, 500, 500 SP

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1990 Wiring Diagram - Indy Sport, Sport GT

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1990 Wiring Diagram
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1991 Wiring Diagram Starlite, Indy Lite
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1991 Wiring Diagram - Indy 400, 500, 500 SP, SKS
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CHAPTER 4
ENGINE ELECTRICAL
Ignition and Alternator Data
1985 ............... . ........ . . . . .. . .... . .. . . . ............... . . . .. . ..... 4.1
1986 .................. . ...... ....... . ...... . .. . . .... ....... . ........ 4.2
1987 ... . . ... . ......... . ....... ............. .............. . ........ 4.3
1988 ..... . .. . ......... . . ... . .. . . .. . . . . ... .. . . ... . . . . . . . . . . . . ....... 4.4
1989 ..... ........... .............. . ....... . .................. .. . ... 4.5
1990 ..... . .. . . ... . . ... . . . . .. . ..... . . . ....... . . . . . . . ..... . .. ..... 4.6
1991 ....... .. ................................................. .. ....... 4.7
1992 ..... . . .. . ... .. ..... .. . . . . .. . .. . . ... . ... . . ... .......... 4.8
1993 ....... . .... ......... .. . .... .... . .... . .... . .. ..... ........... 4.9
1994 ..... . . .. .... . . . . . . ... ... .. . ......... . . . ... . . . ........... . ........ 4.10
1995 ....... . ..... .. ....... .. ...................... .. ... . .............. 4.11
Ignition Systems
Typical 19S5 - Current Timing Advance Curves .................. . .. ..... 4.12
Conversion Chart - Degrees to Piston Position B.T.D.C ....... . . .. . . .. ..... 4.13
Timing
Single Cylinder CDl lgnilion - Exploded View - Ti ming .............. . ..... 4.14
Twi n Cylinder Fan COl Ignition (Fixed) - Exploded View - Timing .... . .. . ...... 4.15
Twin Cylinder Fan CDllgnilion (Adjustable) - Exploded View - Timing ......... 4.16
Twin Cylinder Liquid COl Ignition (Pul se, Pulseless) - Exploded View Timing .. 4.17
Three Cylinder COl Ignition (Pulse, Trigger) Expl oded View - Timing . . ..... . . 4.18
Three Cyli nder COl Ignition (Storm and XLT) - Exploded View - Timing ........ 4.19
Operating RPM Timing Check All Model s .......... .. ..................... 4.20
a
AIDE RED
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Ignition System Testing .. ....... ............... ...... .. ............ 4.21
Ignition/Charging System Testing ...... ...... ...... .............. 4.22-4.25
Alternator
Ignition System Troubleshooting ............................ ........ 4.26
Alternator Output Test Open Circuit ................................... 4.27
Typical Exciter, Pulser or Ughting Coil Replacement ..... . ............ .. 4.28
Battery Service ......... . .... . .......... .............................. 4.29-4.30
ElectriC Starter System
Electric Starter System Testing .... . ........ ... .... .. . .............. .. 4.31
Electric Starter System Testing (Static) ................ ........ ........ 4.32
Electric Starter Reassembly and Reinstallation . ................ ........ 4.33
Electronic Fuel Injection
EFt Introduction and Operation .............. ...... ........ . ..... .. 4.35
EFI Data ........................................ ................ 4.36
Battery Maintenance and Testing ....... .. ..... ..... .... . ... . . . .. . . ....... 4.37
Power Up Testing .................................... ......... 4.38-4.41
Alternator Controlled Switch ~ A C S " ............................ ........... 4.42
Basic Operation - System II ............... ................ . ....... ...... 4.43
Fuel Handling System
Tank. Hose and Filters .......... .. . ...... ........... .... .... ..... 4.44
Fuel Pump ............... . . .. . . ........ . ..... 4.44
Fuel Rail ........... ........... ...... . . .... .. ................... 4.45
Return Hose ........... . .. . .... . . . .... . ... . . ........... 4.45
Pressure Regulator .... . .................................. . ............. 4.45
Injector (Mechanical) ..................... ......... ...................... 4.46
EFI Fuel System Maintenance and Testing ............... . .... . .... . ....... 4.47
Throttle Body .......................................................... 4.48
b
RIDERED
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ElectroniC Control System
System III - ElectroniCS Operation . . .................. .... .......... 4.49-4.50
System 111 - Electronics Testing ........ ....... . .. . . .......... 4.51-4.56
Select Monitor/RPM Sensor .................................. . ..... 4.54
Throttle Posi tion Sensor .. . ......................... . . . ......... .. ... 4.55
Intake Air Temperature Sensor ...... . . .. . .. . . . ................. . ......... 4.56
Crankcase Temperature Sensor ........ ....... ...... .............. 4.56
Barometric Pressure Sensor ........................ . ... .. ............. 4.57
MR Adjustments ........ .. ............... . . .... . .. ..... 4.58
Type II System - 1991 to Current EFI 's .......... . ....... .. ...... . ......... 4.59
Fuel Injectors ............. . .................... . . . ... . . .. . ..... 4.60
Dropping Resistor .............................................. 4.60
ECU Diagnostics ... . .......... . ... .......... . . . ... . .. . ..... 4.61
Select Moni tor Readings ............. ....... .. .................... 4.61
. Mode Description Chart ............. . ....... . .... .. . . . ..... . . .. .. . ...... 4.61
Memory Fai l Code Descri ption ..... .. ....................... .. ........... 4.61
EFI Electronics ................. . ... . ..... . ...... . .. ...... 4.62
1994-1995 Wiring Diagram, RXL ............... . ......................... 4.63
1994-1995 Wiring Diagram, 500 EFI .................. . .. . .. . ......... 4.64-4.65
c
AICERED
'*e_
8194
1985 Models
Machi ne Engine
Model Model
SIa< EC25P8-06
SS EC44-2PM-JIOO
Indy Trail EC44-2PM-2100
'"",400 EG40PL-Q2
'"",600 EC60PL.02
Long Track EC44-2PM-SOOO
Engine MM Inches
Model BTDC BlOC
EC25PS-OO 4 . 19 .165
EC44-2PM-3100 3.93 .155
EC44-2PM-21()() 3.93 .155
EC4OPL-02 5. 19 .204
EC6OPL-Q2 4. 10 .162
EC44-2PM-5000 3.93 .155
ENGINE ELECTRICAL
Ignition Data
Spark Plug
Ignition Type
Alternator Output NGK Champion
Plug Gap
Inches
COI- l00Walt BRaES AN-3C .020
COI- l20Walt BR9ES AN-2C .020
COI- I20Wan SR9ES RN-2C .020
CDI-I20Watt SMES RN-2C .020
COI-I20Watt SR9ES RN-2C .020
C0I-120 Watt SR9ES RN-2C .020
Running Ignition Timing at 3000 RPM
Derees Acceptable Variances
B DC
MM Inches Degrees
21.5 3.35-5. 12 ,132-.202 24.5-30.5
26.'
3.39-4.56 . 133-. 179 24.5-28.5
26.'
3.39-4.56 .133-.179 24.5-28.5
30.'
4.55-5.85 .17&.230 28.5-32.5
27.0 3.81-4.40 .15()..173
,.."
26.' 3.36-4.56 .133-.179 24 .5-28.5
.&. All above engines requi re a minimum of 88 (R+M)/2 octane fuel. If fuels of a lesser octane number are
used or engines are subjected to frequent overheated situations, the timing must be adjusted to the low side
of the accepted variance.
R.F.I. spark plug cap resistance: 3,700 to 6,300 ohms.
4. 1
8/94
AIDE RED
ENGINE ELECTRICAL
Ignition Data
1986 Models
Machine
Model

Sprint (ES)
SS
Indy Trail
'''''' <00
Indy 600 (LE)
LongT_
Engine
Model
EC25P5-06
EC34-2PM-OlI02
EC44-2PM-3100
ECSOPM-Ol
EC40PL-02
EC60PL-02
EC44-2PM-5100
Engine
Model
EC25P5-06
E(;34.2PM-Ol/Q2
EC44-2PM-3loo
EC5OPM.(),
EC4OPl-<l2
EC60Pl-Q2
EC44-2PM-5HXl
MM Inches
.TOC .TOC
4.19 . 165
3.41 .'34
3.93
.'"
3.26 . 128
5.19 .20<
4. 10 . 162
3.40 . '34
---
Spark Plug
Ignition Type Plug Gap
Alternator Output NGK Champion Inches
COI l00Watt BRSES RN-OC .020
CDI- I2QWatt BA9ES RN-2C .020
COI-I20Wan BA9ES RN-2C .020
COI-l20Wan SR9ES RN-2C .020
COI- I20Wan BR9ES RN2C .020
COI -120 Watt BR9ES RN2C .020
CDI 12QWatt BR9ES AN 2C .020
Runni ng Ignilion TIming at 3000 RPM

DC
Acceptabl e Variances
MM Inchos
27.5::1:3 3.35-6. 12 . 132-202 2O.5@6(X)()
25,5::1:2 2.90-3.94 .114-. 160 IS.S" @7000
26.5:t2 3.39-4.56 . 133-. 179 \4.5" @6500
24.02 2.75-3.53 ,106-.150 16"@6500
3O.52 4.55-5.85 . 179-.230 IS" @7500
27.0::1: 1 3.8\-4.40 . ISO-. 173 2O"@75OO
24.5:2 2.87-3.93 .113-. 155 12.se@6500
& All above engines require a minimum of 88 (R+M)/2 octane fuel. If fuels of a lesser octane number are
used or engines are subjected to frequent overheated si tuations, the timing must be adjusted to the low side
R. F.1. spark plug cap resistance: 3,700 to 6,300 ohms.
8194
4.2
RICE RED
1987 Models
Machine Engine
Model Model
Star, SlarTrak EC25PS.oo
Sprint (ES) EC34-2PM-Ol102
''''''-
EC34-2PM-03
Indy Trail (All) ECSOPM-Oll02
Indy 400 EC40PL-Q2
'''''' 600
EC60Pl-Q2
long Track (ALA) EC44-2PM-5100
Engine MM InChes
Model BlOC BlOC
EC25PS-OS , 4, 19 .165
EC34-2PM-Oll02 3.41
.'"
EC34-2PM-03 3.41
.'"
ECSOPM-o 1/02 3.26 .126
EC4QPL-02 5.19 .2""
eC60PL-Q2 4.10 .162
EC44-2PM-51(Xl 3.40
.'"
ENGINE ELECTRICAL
Ignition Data
Spal1t Plug
Ignition Type
Alternator Output NGK Champion
Plug Gap
Inches
COI-l00Wan BABES RN-3C
.02'
COI-l20Watt BRSES RN-2C .02'
COI-l20 Watt BR9ES RN-2C
.02'
COI-l20 Watt BR9ES RN-2C
.02'
CDI-120Wan BR9ES RN-2G
.02'
CDI-l20Watl BRSES RN-2C
.02'
CDI-I20 Watt BR9ES RN-2C
.02'
D8rees
B DC
Acceptable Variances
MM Inches Degrees
27.53 3.35-5.12 ,132-.202 2O.5@6000
25.52 2.90-3.94 .114-. 160 15.5@7000
25,52 2.90-3.94 .11 4-. 160 lS.so@7ooo
24.0 2 2,75-3.53 .108-. 150 16@6500
3O.S2 4,55-5.65 .179-.230 15"@75OO
27.0:t 1 3.61-4.40 .150-. 173 2O"@75OO
24.5:t2 2.87-3.93 .113-. 155 12.5"@6500
A All above engines require a minimum of 88 (R+M)/2 octane fuel. If fuels of a lesser octane number are
used or engines are subjected to frequent overheated situations, the timing must be adjusted to the low side
R.F.1. spark plug cap resistance: 3,700 to 6,300 ohms.
4.3
8194
RIDE RED

ENGINE ELECTRICAL
Ignition Data
1988 Models
Machine Engine
Model Model
Star, Star Trak EC25PS-OS
Sprint (ES) EC34-2PM-02
I"., Sport EC34-2PM-03
Indy Trail (All) ECSOPM-Ol102
Indy 400 (All) EC40PL -Cl2JOJ
Indy 650 EC65PL-Ql
Long Trak (RLA) EC44-2PM-4100
Engine MM
Model BTOC
EC25P5-06 4.19
EC34-2PM-Q2 3.41
EC34-2PM-03 3.41
EC50PM-Ol102 3.26
EC40PL -<l2J1)3 5.19
EC85PL{)1 4.10
EC44-2PM-4100 3.76
Spark Plug
IgnItion Type Pl ug Gap COIBol.
Alternator Output NGK Champion InChes Identification
Number
CDI-l 00 Wan BRaES RN-3C .025 CU6204
CDI-I20Watt BR9ES RN-2C .025 CU6409
CDIl20Watl BR9ES RN2C .025 CU6410
CDI l2QWalt BR9ES RN-2C .025 CU6408
CDI-I20Watt BASES AN-2C .025 CUI559
Inches D;rees Acceptable Variances
BTDC DC
MM Inches Oegrees
. 165 27.53 3.35-5. 12 .132-.202 2O.S@6000
.,,,
25.52 2.90-3.94 .114-.160 15.S @7ooo
.,,,
25.52 2.90-3.94 .114-.160 15.so@7ooo
. 126 24.02 2.75-3.53 .106-. 150 16@6500
.204 30.52 4.55-5.85 .179-230 15@75OO
.,,,
27.01 3.81-4.40 .150-. 173 2{)O@75OO
. 148 26.52 3.23-4.29 . 127-. 169 14.5 @65OO
A All above engines require a minimum of 88 (R+M)f2 octane fuel. If fuels of a lesser octane number are
used or engines are subjected to frequent overheated si tuations, the timing must be adjusted to the low side
R.EI. spark plug cap resistance: 3,700 to 6,300 ohms.
8/94
4.4
RIDE RED
1989 Models
Machine Engine
Model Model
Star, Slar rrak EC25P5-06
Sprint (ES) EC342PM-<l2
'''''' """

Indy Trail (All) ECSOPM-Ol102103
Indy 400 (All) EC4{JPI.Al2
Indy 500 (AU) EC50PL{lIfQ2
'''''' 65<l
EC65PL-ol
l ong Trak (ALA) EC442PM-4t OO
Engi ne MM
Mode' BlOC
EC25P5-06 4.19
EC34-2PM-Q2 3.41
EC34-2PM-Cl3 3.41
EC50PM.{)Ii02 326
EC50PM-OO 5.03
EC40PL-l2 5.19
ECSOPL.(Ili02 5. 19
EC65Pl-QI 4. 10
EC44-2PM-4100 3.16
Spark Plug
Ignition Type
ENGINE ELECTRICAL
Ignition Data
Plug Gap COl Box
Alternator Output NGK Champion Inches IdentUication
Number
COI-lCXI Watt BRSES RN-3C .025 CU6204
COI-t20Wa" BR9ES RN-2C .025 CU6409
CDI-I20Wan BR9ES RN2C .025 CU6409
CDl-120Walt BA9ES RN-2C .025
CU64"
CDl-l20Walt BR9ES RN-2C .025 CU6<08
COI-I20Watt BR9ES RN-2C .025 CUS<08
CDI-I20Wan BR9ES RN-2C .025 CUl559
CDI-I2tJ Wan BR9ES RN-2C .025 CU6405
Running Ignition TIming 813000 RPM
Inches

BlOC B OC
MM Inches Degrees
.'65 27.5:1:3 3.35.-5.12 . 132-.202 2O.S @6000
.'34 25.5:2 2.90-3.94 . 114-,160 15.S@7OOO
.'34
25,51:2 2.90-3.94 . 114-. 160 15.S"@7OOO
.128 24.02 2.75-3.53 .1 oe-. 150 16"@6500
.198 3O.02 4.40-5.59 . 173-.224 22'@6500
.204 3O.S2 4.55-5.85 .179-.230 lS"@75OO
.204 3O.S2 4.55-5.65 .119-.230 IS" @7500
. ''''
27.01 3.81-4.40 . 15C).. 173 2o-@75OO
., .. 26.S2 3.23-4.29 .127. 169 14.S @6500
.&. All above engines require a minimum of BB (R+M)/2 octane fuel. If fuels of a lesser octane number are
used or engines are subjected to frequent overheated si tuati ons, the timing must be adjusted to the tow side
R.F.I. spark plug cap resistance: 3,700 to 6,300 ohms.
4.5
8/94
AICERED
ENGINE ELECTRICAL
Ignition Data
1990 Models
Machine Engine
Model Model
Star, Star Trak EC25P$.06
Sprint (ES) EC342PM-02
,,,,,,- EC34-2PM-03
Indy Trail (All) ECSOPM-(lII02!03
Indy 400 EC4OPL-02
':::l' 500

1 . Wide rak
'W."O
EC65PL-QI
AX
-(13
Engine MM
BTOC
EC25PS-06 4.19
EC342PM{)2 3.41
EC34-2PM-03 3.41
ECSOPM-(llfQ2 3.26
ECSOPM-03 4,71
EC4OPL-m 5.36
ECSOPL-{)1102 5.36
ECSOPL.{)3 5.36
EC65PL-Q1 4. 10
EC65PL-Q3 5.02
8194
Spark Plug
Ignition Type Plug Gap COl Box
Alternator Output NGK Champion Inches Identification
Number
CDI-l50Watt BABES AN-3C .025 CU2167
CDI-I50Watl SR9ES AN-2C .025 CU6409
CDI-I50Wan SR9ES AN-2C .025 CU6409
COI-200Wan BR9ES RN-2C .025 CU6413
COI-200 Watt BReES AN-3C .025 CU6412
CDI-200Watt BASES AN-3C .025 CU6412
COI-l20Watt SR9ES RN-2C .025 CU1559
-180 Watt CU217B
Running Ignition TIming al 3000 RPM
Inches

BlOC B DC
MM Inche. Degrees
. 165 27.53 3.35-5. 12 . 132-.202 2O.s
o
@6000
.'"
25.5::1:2 2.90-3.94 .11 4-.160 15.so@7000
.'"
25.52 2.90-3.94 .114-. 160 15.5@7ooo
.128 24.0:i:2 2.75-3.53 , 108-,1SO 16 @6500
.'85 29.0 = 2 4.10-5.35 . 162.210 21 @S500
210 31.0 = 2 .185-.238 15 @7500
21. 31.0 = 2 .185-.238 15 @7500
21. 31.0=2 .185-.238 15.5 @7ooo
. '62 27.0 1 3.61-4.40 .150-. 173 2{)0@7500
., .. 3O.01 1.65-2.06 .065-.081 lSO@7500
4.6
RIDERED
1991 Models
Machine Engine
M"el Model
S""""
EC25P$-{)7
Indy lila EC34-2f'M.03
Indy Sport/GT
Indy Trail (All) ECSOPM-{) I/02103
'"",400 EC40PL.Q2
EC40PL-G4

EC50PL..ol102/03
I . Wide rak
Indy 650IRXL EC65PL .Q2/03
Engine MM
Model BlOC
EC25PS-07 4.1 9
EC34-2PM.oo 3 .41
EC44-3PMoOl
32'
EC50F'tMlli02 3.26
ECSOPM-03 4.71
EC4OPL-02 5.36
-0< 3.93
ECSOPL-ol/02 5.36
""""
3."
ECSOPL-06
3."
EC65PL-()2J03 3.26
Sp8rW. Plug
Ignition Type
ENGINE ELECTRICAL
Ignition Data
C0180.
Alternator Output NGK Champi on
PIUp' Gap
MMJ nchas Identl flcatlon
Number
CDI-I50Wan BReES RN-3C 0.71028 CU"""'
COI-I50Wan BASES AN-2C 0.71028 CU6409
CDI-200Wan BABES AN-2C 0.71028 CU6418
CDI200Wan BRaES RN2C 0.7/028 CU6413
CDI-200Wan BReES RN-3C 0.71028 CU641 2
CU6415
COI-200Wan BReES RN-3C 0.71028 GU6412
GU6415
COl-ISO Wan SR9ES AN2C 0.7/028 CU2178
Inche.
D&rees
Acceptabla Variances
BToC B DC
MM Inch.s Degrees
.165 27.S3 3.35-5. 12 .132-.202 20.S@6000
.,,,
2S.S2 2.90-3.94 .114-. 155 16@7ooo
.128 24.02 2.75-3.811 . 108-.150 16@6500
.128 24.0:*:2 2.7fN.811 . 108-.150 J60@6500
.185 29.0:*:2 4.10-5.35 .162-.210 21@6500
.210 31 .0:*:2 4.71-6.04 .185-.238 16@75OO
.155 26.5:*:2 3.4Q-4.55 .133-. 179
.210 31 .0:*: 2 4.71-6.04 .185-.238 W@7500
.155 26.5:*:2 3.4Q-4.55 . 133-. 179
. 155 26.5:*:2 3.4Q-4.55 . 133-. 179 16@7500
. 126 24.0:*:1 3.00-3.53 .118-. 139 18"@75OO
4.7
8/94
RICEREC
ENGINE ELECTRICAL
Ignition Data
1992 Models
Machine Engine
Model Model
Starlite EC25P5-07
Indy UleJGT IOLX EC34-2PM-02J03I04
Indy SporVGT EC44-3PtM)1
Indy Trail (All) ECSOl'tMll/02103
Indy 440 EC45PL-Q2
Indy XCR EC45PL-Ql
I ~ 500, Classic EC50PL-04I05I
Wi eTrak, SOOSP ,.",7
Indy 650, AXL eC65PL-Q2/00
Onglnal Equipment
Engine MM
Model BlOC
EC25P5-07 '.05
EC34-2PM-Q2J03I04 3.28
EC44-3PM-Ol 3.81
ECSOPM-Ol102 3.Bl
ECSOPM-03 4.71
EC45PL-Q2Itll 4.40
ECSOPL-(}4f05l06 4.40
ECSOPL-{)1 4.71
EC65PL-D2 3.26
-03 3.53
8194
Spar1t Plug
Ignition Type PIUPr Gap COl Box
Alternator Output NGK Champion MMf nches Identification
Number
CDI-l50Wan BRaES' AN-3C 0.7/028 CUS204
CDIl50Wan BRBES' AN-3C 0.7/028 CU6409
CDI-200Wan BRBES' RN-3C 0.7/028 CU641S
CDI200Wan BRaES' RN-;lC 0.7/026 GU6413
CDI-200Wan BRBES RN-3C- 0.7/028 CU641S
BR9ES RN-2C-
COI-200 Watt BAaES RN-3C- 0.7/028 CU641S
COI-I80Watt BR9ES AN-2C' 0.71028 CU2178
Inches
D8rees
BlOC B DC
MM Inches Oegrees
.159 273 3.22-4.96 .127-. 195 2O.S@6000
.129 25 1.5 2.90-3.67 .114-.144 16"@7000
.150 26 1.5 3.39-4.25 .133-. 161 16"@65OO
.150 26::1: 1.5 3.39-4.25 .133-. 167 16"@6500
.185 291.5 4.25-5.20 .167-.204 19@6500
.173 28 1.5 3.91-4.87 .156-.191 16@7500
.173 28::1: 1.5 3.91-4.87 .156-.191 16@75OO
.185 29::1: 1.5 4.25-5.20 .167'.204 17@75OO
.128 24::1: 1.5 2.87-3.67 .113-.144 ,,0:1: 7500
. 139 25::1: 1.5 3.13-4.01 .123-.156 19" 7500
4.8
RIDE RED
1993 Models
Machine Engine
Model Model
StarUleJGT
IndyUtelGTIDLX
IndySpMlGT EC44-3PM-Ol
Indy Trail (All) ECSOPM-Ol
Indy 440
Indy XCR
eg45PL-02
E 45PL-Ol
C"""
ECSOPL-04
W!deTrak 05I06I07
500 EFt
XLT EC58PLoOl
Indy RXl EC65PL.oS
Indy Storm EC75PL.1
.
..
Onglnal Equipment
Spark Plug
Ignition
Al ternator utput NGK Champion
CDI-l50Watl BRBES' RN-3C
CDI-I50Watt BRBES' AN-3C
CDI-200Watt BRBES' AN-3C
CDI-200Wan BASES' AN-X
COI2OQWatt BABES RN-3C-
BA9ES RN-2C'
CDI-200Wan BRBES RN-3C-
CDIt7QWatt BA9ES RN-2C'
CDII80Watt BA9ES RN-2C'
COI-t70Watt BR9ES' RN-2C
ENGINE ELECTRICAL
Ignition Data
Gap COIBol(
MMI nches Identification
Number
0.71.026 CU6204
0,71.028 CU6409
0,71.028 CU6416
0.71.028 CU6413
0.71.028 CU6415
0.7/.028 CU6415
0.71.028 CU2194
0.1/.028 CU2193
0.7/.026 CU2196
Runni ng Ignition Timing 813000 RPM Operating
l lmln!U'nd
Engine MM Inches
o:vr&elJ
RP
Model BlOC BlOC DC
MM Inches
EC25Ps.<l7 4.05 .159 27%3 3.22-4.96 .127 . 195 2O.5" @6OOO
EC34-2PM.o2/04 3.28 .129 25J:1.5 2.903.67 .114'. 144 16"@7000
EC44-3PM.ol 3.81 .150 26J: 1.5 3.39-4.25 .133-.1 67 16" @6500
ECSOPM.ol 3.61 .150 26J: 1.5 3.39-4.25 .133-.167 W@6500
EC45PL.olI02 4.40 .173 28J: 1.5 3.91-4.87 . 156-.191 W@7SOO
ECSOPL.()4105I06 4.40 .173 28;1:1.5 3.91-4.87 .15&-.191 16" @75OO
ECSOPL.o7 4.71 .185 29J: 1.5 4.25-5.20 .167-.204 17'@75OO
EC58PL.ol 4.40 .173 26J:1.5 3.91-4.87 .1 5&-.1 91 2O"@75OO
EC65PL.o5 3.53 .139 25,il.5 3.13-4.01 .123-.156 19'@75OO
EC75PL.ol 4.74 .187 28J: 1.5 4.30-5.28 .188-.206 12"@8OOO
4.9
11195
AICERED
ENGINE ELECTRICAL
Ignition Data
1994 Models
Machine Engine
Model MOdel
StarLitaIGT EC25Ps.o7
Indy1.JteIGTIDLX EC34-2PM-02/04
Indy SportISuper Sport EC44..:]PM{)1

ECSOPM-Ol/02J03
Wi Trak G
Indy 440 EC45Pl-02
Indy XCR EC45PL-Ql
Indy XCR 440 SP EC45Pl-05
Classic ECSOPL
WldeTrak 05106/07108
500 EFt
XLT(AII) EC58PL-Ql
Indy RXL EC65Pl-05lO6
Irdy Slorm ECSOPL..()1
Original Equipment
Ignition Rpe Spark Pl ug P1Ur. Gap
COl Bolt Fly-
Alternator utput MMJ nches Identi fication wheel
NGK Champion Number 10 .
CDl-l50Wan BABeS' RN3C 0.71.028 CU6204 FP5355
CDI-l50Wan BRBes' RN-3C 0.71.028
CU"'"'
FP5439
CDI-200 Watt BABES' RN-3C 0.71.028 CU64Hi FP5446
CDI-200Wan BABES' RN-3C 0.7/.028 CU6413 FP544\
CDI2OQWatt BRBES RN-3C' 0.7/.028 CU6415 FP5445
BRSES RN-2e'
CDI-200Watt BRSES RN2C 0.71.028 CU6417 FP5510
COI200 Wan 05106 BRBES AN-3C' 0.71.028 CU6415 FP5445
COt 250 Watt 07108
CDI-170Watt BRBES RN3C' 0.7/. 028 CU2194 FP8312
CDI- l80 Wan BASES RN2C 0.71.028 CU2193 FP6392
CDI170Wan BR9ES RN2C 0.7/.028 CU2196 FP6369
Running Ignl tl on l iming at 3000 RPM Operat ing
Eng ine MM Inches
Model BlOC BlOC
O:,""S
B DC
l lmlnij,.and
RP
MM Inches
EC25PS..()7 ' .05 .1 59
",3
3.22-4.96 .127.195 2O.5"@6000
EC34-2PM..Q2/04 3.28
.'29
25.t;1.5 2.9Q..3.87 .11 4.144 18"@7ooo
EC44..JPM..Ql 3.81 .'SO 28.:tl.5 3.39-4.25 .133-.1 67 16"@6500
EC5QPM..()1102103 3.81 .'SO 28.:tl.5 3.39-4.25 .133-.1 67 18@6500
EC45PL"() 1102 ... 0 .173 28.:tl.5 3.91-4.87 .1 56.191 16"@7500
EC45PL"()5 4.40 .173 28.:tl .5 3.91-4.87 .156' .191 16"@75OO
EC50PL"()5IOe 4.40 .173 28.:t1.5 3.91-4.87 . 156.191 16" @7500
EC5QPL..()7108 4.71 ., BS 29.:tl.5 4.25-5.20 .167.204 17"@75OO
EC56PL..()1 4.40 .173 28.11.5 3.91-4.87 .156-.191 20@7500
EC65PL"()5I06 3.53 .139 25.t;1.5 3.13-4.01 .123-.156 19" @7500
ECSOPL..()l 2.96 .116 22.1.5 2.58-3.10 .102-.133 11'@8000
,
11195
4.10
AIDE RED
1995 Models
Machine
Model
StarUte
Indyl.ite Models
Indy Spor1 ModelS
Indy Trail Models
WideTrak GT
Indy 440 LCiSKS
Indy XCR
Indy XCR 440 SP
Indy 500ICIasslc
WIdeTrak l.)(
500 EFI
XLTIXLT SPIXLT SKS
Indy XCR 600
XlT Touring
Indy RXUTouring
lndy Slorm
Englna
MOdal
EC2SPS07
EC342PM02fE02
EC443PMQ1102
EC50PM04IE04
ECSOPM03
EC4SPl02lO3
EC45PL07
ECSOPlO4/E04I06
ECSOPL07
EC58PlO2lO3fE04
ECSSPLOSfE05
EC80PLOI
ENGINE ELECTRICAL
Ignition Data
Engine
Model
Alternator Spark Plug
P1Ur. Gap COl Box Fly-
Wattage MMI nches Identification wheel
NGK Champion Number
'D.
EC25PS07 150 BASES RN-3G 0.71.028 CU62Q.4 FPS355
EC34-2PM02JE02 150 BRSES RN-3C 0.1/.026 CU6409 FPS439
EC44-3PMQII02 200 BRSES RN-3C 0.7/.028 CU6416 FP5446
EC5QPMQ4/E04 200 BRSES RN-3C 0.7/.028 CUS413 FP5441
ECSOPM03 200 BRSES RN-3C 0.7/.0:26 CU6413 FP5441
EC4SPL02 200 BRSES RN-3C 0.7/.026 CU6415 FP5445
EC45PLOJ 200 SA9ES RN2C 0.71.028 ClI6417 FP5510
EC45PL07 200 BA9ES RN2G 0.71.028 CU6417 FP5510
EC50Pl04lE04 200 BRSES AN3G 0.7/.028 CU641S FP5445
ECSOPL06 200 BASES RN-3C 0.71.028 CU6415 FP544S
ECSOPL07 250 BRBES RN3C 0.7/.028 CU6415 FPS508
EC56PL03 170 BRSES RN-3G 0.71.028 CU2194 FP8312
EC5802 110 BR9ES AN-2C 0.71.028 CU2194 FP8312
EC58PLE04 110 BR8ES AN-3C D.7/.028 CU2194 FP8312
EC65PlD5IEOS 180 BR9ES AN-2C 0.7/.028 CU2178 FP6392
EC80PLOI 180 BA8ES AN-3C 0.71.028 CU2521 FP6320
Running Ignition Timing al3000 APM

MM Inches
Bfr&es
C
BToC BToC B DC
MM Inc hes
4.05 .159 27%3 322-4.96 .127-.195 2O.S @6000
3.67 .145 26.5%1 .5 3.28-4.08 .129-.1 61 IS.S@7000
3.81 .150 26%1 .5 3.39-4.25 .133-.167 W 1016500
3.81 .150 26.11.5 3.39-4.25 .133-.167 16@6500
4.71 .185 29%1.5 4.25-S.2O .167-.204 19"@75OO
4.40 .173 28%I.S 3.91-4.87 .156-.191 16' @75OO
4.40 .173 28%1.5 3.91-4.87 .156-. 191 16'@75OO
, ... 0 .173 28%I.S 3.91-4.87 .156-.191 W@75OO
4.71 .165 29%1.5 4.25-S.2O .1 67-.204 17@75OO
4.40 .173 28%1.5 3.91-4.87 . 156-.191 2O @7500
3.53 .139 2S%I .S 3.13-4.01 . 123-.156 19 @75OO
2.96 .116 22. I.S 2.58-3. 10 .102-.133 11 @8000
4. 11
11/95
RICEREC
ENGINE ELECTRICAL
Typical 1985 - Current Timing Advance Curves
Ignition Timing

&1
o
w
()
z
"
51
Cl
z
"
F
tODD
..
2000 3000 4000
RPM
-
, .
MAXIMUM ADVANCE
5000 6000

RPM
(DEPENDIN
ON ENGINE)
SEE DATA
7000 8000
..
NOTE: Always verify timing of engine at room temperature only (68
0
F/20C).
The ignition maximum advance is at or near 3000 RPM on all current style ignition systems. Verify the ignition
position at maximum advance when checking the liming.
If engine damage has occurred due to a suspected ignilion related problem. check the ignition timing at the
specified operating RPM.
Due to differences between engines, it is necessary to dial indicate the timing marks on all engines before
attempting to adjust the ignition timing. To indicate the marks:
1. Remove the mag 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 SlOps 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 Ihe bezel until the 0 on the
dial and the pOinter align.
4. Rotate the crankshaft opposite the direction of rotalion 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: 1993 EC50PM-01 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 slops 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, determine which of the rotating and
stationary timing lines align. Mark these lines with
chalk or a marker to make them easier to identify
when you are doing the running timing.
t 1/95
4.12
RIDE RED
ENGINE ELECTRICAL
Conversion Chart - Degrees to Piston Position - B.T.D.C.
II the ignition timing specification is listed in degrees only, convert to either inches or mm BTOC and use a dial
indicator to verity timing marks. NOTE: Due to differing rod lengths and engine strokes, consult the engine model
list for correct engine.
EngIne ECiOPL EC35PL EC75PL EC34-2PM EC25PF
Model EC442PM eceoPL EC25PS
EC44-3PM EC44PT
EC45PL ECSOPM EC44PQ
ECSOPL EC50PL EC44PM
EC58PL EC65PL
CEG. 112 MM ROD 130 MM ROD 125 MM ROD 103 MM ROD 120 MM ROO
BTDC 50 MM STROKE 70 MM STROKE 155 MM STROKE 55.& MM STROKE 60 MM STROKE
""
INCHES
""
INCHES
""
INCHES
""
INCHES
""
INCHES
1 0.0058 0.0002 0.0068 0.0003 0.0062 0.0002 0.0054 0.0002 0.0057 0.0002
2 0.0232 0.0009 0.0271 0.0011 0.0249 0.0010 0.0215 0.0006 0.0228 0.0009
3 0.0521 0.0021 0.0609 0.0024 0.0561 0.0022 0.0484 0.0019 0.0514 0.0020
4 0.0926 0.0036 0.1082 0.0043 0.0997 0.0039 0.0860 0.0034 0.0913 0.0036
5 0.1 447 0.0057 0.1690 0.0067 0.1558 0.0061 0.1343 0.0053 0.1426 0.0056
,
0.2083 0.0082 0.2432 0.0096 0.2242 0.0088 0.1933 0.0076 0.2053 0.0081
7 0.2833 0.0112 0.3309 0.0130 0.3050 0.0120 0.2630 0.0104 0.2793 0.0110
8 0.3698 0.01 46 0.4319 0.0170 0.3981 0.0157 0.3432 0.0135 0.3646 0.0144
,
0.4677 0.0184 0.5463 0.0215 0.5036 0.0198 0.4341 0.0171 0.4612 0.0182
10 0.5770 0.0227 0.6739 0.0265 0.6212 0.0245 0.5355 0.0211 0.5689 0.0224
11 0.6976 0.0275 0.81 47 0.0321 0.7510 0.0296 0.6474 0.0255 0.6878 0.0271
12 0.8294 0.0327 0.9687 0.0381 0.8930 0.0352 0.7698 0.0303 0.8178 0.0322
13 0.9724 0.0383 1.1357 0.0447 1.0470 0.0412 0.9025 0.0355 0.9588 0.0377
14 1.1265 0.0444 1.3157 0.0518 1.2129 0.0478 1.0456 0.0412 1.1108 0.0437
15 1.291 7 0.0609 1.5086 0.0594 1.3908 0.0548 1.1989 0.0472 1.2737 0.0501
"
1. 4678 0.0578 \.7143 0.0675 1.5804 0.0622 1.3624 0.0536 1.4474 0.0570
17 1.6548 0.0652 1.9327 0.0761 1.7818 0.0701 1.5359 0.0605 1.6318 0.0642
18 1.8526 0.0729 2.1637 0.0852 1.9948 0.0785 1.7195 0.0677 1.8269 0.0719
19 2.0611 0.0811 2.4072 0.0948 2.2193 0.0874 1.9130 0.0753 2.0326 0.0800
20 2.2802 0.0898 2.6631 0.1048 2.4552 0.0967 2.1163 0.0833 2.2487 0.0885
21 2.5098 0.0988 2.9312 0.1154 2.7024 0.1064 2.3294 0.0917 2.4752 0.0974
22 2.7497 0.1083 3.211 4 0.1264 2.9608 0.1166 2.5521 0.1005 2.7119 0.1068
23 3.0000 0.1181 3.5036 0.1379 3.2303 0.1272 2.7843 0.1096 2.9587 0.1165
24 3.2603 0.1264 3.8077 0.1499 3.5107 0.1382 3.0260 0.1191 3.2156 0.1266
25 3.5307 0.1390 4.1235 0.1623 3.8019 0.1497 3.2769 0.1290 3.4824 0.1371
2'
3.8110 0.1500 4.4508 0.1752 4.1038 0.1616 3.5370 0.1393 3.7590 0.1480
27 4.1010 0.1615 4.7895 0.1886 4.4161 0.1739 3.8062 0.1498 4.0452 0.1593
28 4.4007 0.1733 5.1395 0.2023 4.7389 0.1866 4.0843 0.1608 4.3410 0.1709
29 4.7098 0.1854 5.5005 0.2166 5.0719 0.1997 4.3712 0.1721 4.6461 0.1829
30 5.0282 0.1980 5.8724 0.2312 5.4149 0.2132 4.6667 0.1837 4.9604 0.1953
31 5.3559 0.2109 6.2550 0.2463 5.7679 0.2271 4.9708 0.1957 5.2839 0.2080
32 5.6926 0.2241 6.6482 0.2617 6.1306 0.2414 5.2832 0.2080 5.6163 0.2211
33 6.0381 0.2377 7.0517 0.2776 6.5028 0.2560 5.6039 0.2206 5.9575 0.2345
34 6.3924 0.2517 7.4654 0.2939 6.8845 0.2710 5.9326 0.2336 6.3073 0.2483
35 6.7552 0.2660 7.8891 0.3106 7.2754 0.2864 6.2693 0.2468 6.6656 0.2624
36 7.1263 0.2806 8.3225 0.3277 7.6753 0.3022 6.6138 0.2604 7.0322 0.2769
37 7.5057 0.2955 8.7655 0.3451 8.0840 0.3183 6.9658 0.2742 7.4069 0.2916
38 7.8931 0.3108 9.2179 0.3629 8.5015 0.3347 7.3253 0.2884 7.7896 0.3067
3'
8.2883 0.3263 9.6795 0.3811 8.9274 0.3515 7.6920 0.3028 8.1801 0.3221
40 8.6912 0.3422 10.1499 0.3996 9.3616 0.3686 8.0659 0.3176 8.5782 0.3377
4.13
11/95
RIDE RED
y:
-
ENGINE ELECTRICAL
Single Cylinder CDllgnllion - Exploded View - Timing
Timing Procedure - Single Cylinder Models
STATOR PLUG
cp
VIBRATION
OAMPNER
Single Cylinder Capacitor Ignition System
STATOR PLATE
LIGHTING COIL

"", , ',>\J
EXCITER COIL (a -;;.
COl CONTROL UNIT / STATOR PLUGS
COUPLERS b#!
,

"0- TOROUE TO 8 TO 10 IN. LBS. FAN
0
F/20C).
7. Verify and mark which flywheel timing line corresponds with the listed ignition timing from the chart at the
beginning of this unit. Refer to the method of using a dial indicator for verifying the timing marks, shown on
page 4.12.
8. Connect an accurate tach and a good quality timing light to the engine.
9. With the engine running at 3000 RPM, point the timing light at the timing hole.
NOTE: Your sight line during the timing mark verification (dial indicator check) and the actual running timing light
check, must be the same.
FLYWHEEL
ROTATION

FLYWHEEL LINES
;df\ __ STATIONARY
POINTER
10. Position your head so there is a straight line between your eye, the static timing pointers, and the crankshaft
center line. Note the relative position between the flywheel mark and the stationary pointer. If the flywheel
mark is within the acceptable +I-variance, the timing is correct. If the mark is outside the variance, then the
stator will have to be rotated either with crankshaft rotati on to retard timing, or against rotation to advance it.
NOTE: The recoil and recoil cup must be removed to loosen stator bolts and change the timing.
11 . Make sure all nuts and bolts are properly tightened after making adjustments.
8194
4.14
RIDE RED
.,.
ENGINE ELECTRICAL
Twin Cylinder Fan COl Ignition (Fixed) - Exploded View - Timing
Timing Procedure
NON ADJUSTABLE SYSTEM
"", ... "" - I
I
I
I
,.... r-
CO'L"'''''
...
'-'_'00'''''"' .
NOTE: Always verify timing of engine al room temperature only (68
0
F/20 C).
12. Verify and mark which flywheel timing line corresponds with the listed ignition timing from the chart althe
beginning of this unit. Refer to the method of using a dial indicator for verifying liming marks described on
page 4.12.
Blower Housing
Stationary
Lines
Flywheel
Mark
NOTE: Acceptable variance
is usually one line on either
side of the dial indicated
blower housing stationary
line.
14. With the engine running at 3000 RPM, point the timing light at the blower housing stationary lines. If the
flywheel mark aligns with the correct stationary line or anywhere in the acceptable +/- variance, the timing is
correct. If the timing is not correct, follow steps 4 through 7, re-checking the timing after each step.
15. Disconnect the ignition kill circuit by disconnecting the black wire at the COl module.
16. Check the exciter coil resistance and replace if necessary.
17. Replace the COl module.
18. Replace the flywheel.
4.15
8194
RIDE RED
..
ENGINE ELECTRICAL
Twin Cylinder Fan COl Ignition (Adjustable) - Exploded View - Timing
Timing Procedure
LI GHTING COil
EXCITER
. .. ..... ,
=i'
o .' ....
o ,

,,-
120 Watt Pulse Type 150 and 200 Watt Pulseless
0
F/20 C).
19. Verify and mark which blower housi'ng liming line corresponds with the listed ignition liming from the charts at
the beginning of this unit. Refer to the method of using a dial indicalorfor verifying timing marks described on
page 4.12.
Blower Housing
Stationary
Lines
Flywheel
Mark
NOTE: Acceptable variance
is usually one line on either
side of the dial indicated
blower housing stationary
line.
21. With the engine running at 3000 RPM, point the timing light at the blower housing stationary lines. If the
flywheel mark aligns with the correct stationary line or anywhere in the acceptable +/. variance, the timing is
correct.
22. If the mark is outside the acceptable variance, the stator must be either rotated with crankshaft rotation to
retard the timing, or against rotation to advance it. NOTE: The recoil and recoil cup must be removed to
loosen the stator bolts and change the timing.
23. Make sure all nuts and bolts are properly tightened after making adjustments.
8/94 4. 16
RIDE RED
ENGINE ELECTRICAL
Twin Cylinder Liquid CDllgnition (Pulse, Pulseless) - Exploded View - Timing
Timing Procedure
n AlOR'LAH
HC,TROOll
PLATE

"'(f LIGHTING COIL

/'
... ""'" "0
flVWHUL
120 Watt Pulse
Type COl
'" ""b.tW
EXCITER

200 Watt
Pulseless eDt
NOTE: Always verify timing of engine at room temperature only (6S
0
F/2Do C).
beginning of this unit. Refer to the method of using a dial indicator for verifying timing marks described on
page 4.12.
26. With the engine running al 3000 RPM point the
timing light at the timing hole.
27. Position your head so there is a straight line
between your eye, the stationary timing pointer,
and the crankshaft center line. Note the relative
posilion belween the flywheel mark and the
stationary pointer. If the flywheel mark is within
the acceptable +1- variance, the timing is correct.
If the mark is outside the variance, the stator will
have to be rotated either with crankshaft rotation
to retard timing, or against rotation to advance it.
NOTE: The recoil and recoil cup must be
removed to loosen stator bolts and change the
timing.
28. Make sure all nuts and bolts are properly
tightened after making adjustments.
4.17
Acceptab e Variance
FlyYJheel
Rotation
j
,..---..-. Flywheel Unes
Stationary
Pointers
NOTE: Acceptable variance is usually
one line on either side of the dial indicated
timing mark.
RIDE RED
8/94
ENGINE ELECTRICAL
Three Cylinder COl Ignition (Pulse, Trigger) Timing - Exploded View
Stator
"'"
RFI
Sparkplug
c a ~ e
Exciter Coil
lighting Coil
1985 - 1990
3 Cylinders (Except RXL)
Timing Procedure: Three Cylinder Models
Ughting
"'"
Charging Coil (RXlJ
Lighting Coil (650, Storm)
All RXL's, 1991 and Later 650's,
1993 to Current Storms 180 Watt
C
C/68F) .
beginning of this section. Refer to the method of dial indicator use for verifying timing marks described on
page 4.12.
3. With the engine running at 3000 RPM, point the
4. 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
stationary pointer. If the stationary pointer is
within the acceptable variance, the timing is
correct. If the pointer is outside the variance, the
stator will have to be rotated either with
crankshaft rotation to retard the timing, or against
rotation to advance it. NOTE: The recoil and
recoil cup must be removed to loosen Ihe stator
bolls and change the timing.
Acceptab e Variance
Flywheel
Rotation
j
____ ....... Flywheel Unes
Stationary
Pointers
timing mark.
5. Make sure all nuts and bolls are properly tightened after making adjustments.
8/94
4.18
AIDE RED
ENGINE ELECTRICAL
Three Cylinder COl Ignition (StormlXLTj Timing - Exploded View
Coils
Pulser Coil
'.,,*,"IlI Stator Plate
__ -' Lighting/Exciter
Secondary
Cable
Flywheel
COl Control Box
JO--'t:)---J7"'-- RFI Spark Plug Cap
170 Watt
1993 to current XLT Secondary
The Exciter Coil can be identified by
wire color, and smaller windings.
Timing Procedure: Three Cylinder Models
NOTE: Always verify timing of engine at room temperature only (20"C/68" F).
1. Verify and mark which flywheel liming line corresponds with the listed ignition timing from the chart al the
beginning of this section. Refer to the method of dial indicator use for verifying liming marks described on
page 4.12.
3. With the engine running at 3000 RPM, point the
4. 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 tine and the
stationary pointer. If the stationary painter is
within the acceptable variance, the timing is
correct. If the pointer is outside the variance, the
stator will have to be rotated either with
crankshaft rotation to retard the timing, or against
rotation to advance it. NOTE: The recoil and
recoil cup must be removed to loosen the stator
bolts and change the timing.
Flywheel
Rotation
j
Flywheel lines
Stationary
Pointers
timing mark.
5. Make sure all nuts and bolts are properly tightened after making adjustments.
4.19
RIDE RED
8194
ENGINE ELECTRI CAL
Operating RPM Timing Check - All Model s
CAUTION: I
Due to the high RPM necessary and the possible danger involved, special care must be observed whenever
performing an operating RPM timing check to avoid serious personal injury.
This check need nol 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 whi le performing this lest.
Perform the test as quickly as possible. Avoid prolonged periods of engine free-rev.
Operating RPM Timing Test Procedure
29. Using the charts at the beginning of this unit, determine the ignition advance BlOC at the operating RPM.
30. Remove the mag side spark plug and install a dial indicator in that cylinder.
31. Zero the dial indicator as explained on page 4.12.
32. Turn the crankshaft in the opposite direction of rotation to a point approximately .100'" (2.5 mm) before the
operating ignition timing point.
33. 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 4.13. Example: The operating timing and RPM for a 1993 EC45PL-02
engine is l6
e
at 7500 RPM. Using the chart, t 6on 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.
34. While holding the crankshaft at the operating RPM ignition timing point, make some timing marks on the
flywheel or blower housing using a piece of chalk or marker.
35. Remove the dial indicator and reinstall spark plug.
36. Start the engine. Advance and hold the throttle at the operating RPM specified on the charts. View the timing
mark with the timing light. The marks should be between the allowable +/- variance indicated on the operating
RPM timing specification.
37. If the operating RPM timing greatly varies from the specification, but the 3000 RPM ignition is correct, refer 10
the ignition troubleshooting section in this unit for corrective action.
8194
4.20
RIDE RED
ENGINE ELECTRICAL
Ignition System Testing
Ignition system components can be individually tested by measuring their internal resistance and insulation to
ground. These checks must be done with a digital volUohm meter. Compare the readings obtained to the values
listed on the chart. Actual values may vary up to 10% between like components. Any readings outside the span
should be considered Questionable.
NOTE: The stator coils can be checked without removing them from the engine. Simply disconnect the connector
plug in the stator-to-COl wire and check the resistance values between the wire colors listed below. Consult the
stator schematics shown on the next pages .
Indicates a system that incorporates a white CDI-Ie-slalor ground wire. These systems will indicate continuity
between the exciter/pulser wires and ground.
EXCITER COIL PULSER COIL
Check Wi res Value Check Wires
,
Value
SINGLE CYLINDER MODELS BrownI'Nhite 123 Ohms Not Applicable
t985-Current Star/Star LT to BlackfRed
StarLite
TWIN CYLINDER MOOELS BrowrvWhite 164 Ohms Not Applicable
AI EC342PM (Pulseless) to Black/Red
AI EC4O--PUSOPL thru 1989 BrowrvWhite
'" ""'"'
BrOWli"While
I 45 Ohms
AI EC442PM
.
to While toBladURed
AI EC40PUSOPL 1990 to current BrownlWhite
'" ""'"'
NOI Applicable
EC4SPL (Pulseless) 10 Black/Red
AI ECSOPM 199010 current
All EC44-3PM (Pulseless)
AO ECSOPM thru 1989 BrownI'Nhile 164 Ohms Brownl'Nhite
I 17 Ohms
to White to Black/Red
Indicates a system that incorporates a white COIle-stator ground wi re. These systems will indicate continuity
between the exciterlputser wi res and ground.
EXCITER COIL PULSER COIL CONTROL COIL TRI GGER COIL
THREE e_ Val ... e_ Value Chock Value Chock Value
CYLINDER Wires Wires Wires Wires
MODELS
All ECS8PL-Ql BlacI<IRed 4.6 White to
"Xl
to Red Ohms White/Red Ohms
AH EC60Pl and Black to White 261 Red to White 20 Ohms Green to 29.4
EC6SPL..(l1
Oh""
Blue Ohms
Ai BlacI<IRed to 248 Red 10 Green 20 Ohms White to 96 0_
EC65PL--02/03IOS Green
""""
White/Red
All EC75PL..(l1 and Black/Red 248 Red 10 Green 20 White to 96 0_
EC80PL..(l1 10 Green
on"" ""m.
White/Red
Three Cyli nder Models: ECSSPL..(l 1 ECSOPL ECS5PL EC75PL..(l 1
Secondary Ignition Coli ECS5PL--Ol 02103105 ECBOPL-Ol
Prima, Resistance .4 Ohms .1060hms .4 Ohms .4 Ohms
Tablo ab 15% 15% 15% 15%
Secondary Resislance 4 KOhm 2K Ohm 7.5 K Ohm 7.5 KOhm
Tab to Plug Wire End
.,"" .,""
.-
.20%
(Cap Removed)
S p a ~ Plug Cap 3.7106.3 3.710 S.3 3.7 to 6.3 3.7 to 6.3
KOhm KOhm KOhm KOhm
Secondary coils can also be dynamically lested with a coil power tester such as the Graham Lee Model 31.
Consult Ihe tester operation manual for specific operating instructions.
4.21
8194
RIDE RED
ENGINE ELECTRICAL
Ignition I Charging System Testing
Stator Schematics
STATOR
o
BRN/W BlK/A
W
STATOR
VEL
EXCITER
0
VELJA
BRN!W
8194
Single Cylinders
Exciter Coil:
Wire Color
BrnlW to BlklR
Twin Cylinders
EXCiter Coil:
Wire Color
Srn/W to Blk/R
Twin Cylinder
Pulse Type
EXCiter Coil:
Wire Golor
BrnlW to W
lighting Coil:
Wire Color
Yel to 8rn or W
Exciter Coil:
Wire Golor
Brn/Wto W
Lighting Coil :
Wire Color
Vel to 8rn or W
Twin Cylinder
EXCiter Coil:
Wire CQIQ(
Brn/W 10 BlklR
4.22
EC-25-PS
lighting Coil:
llaI!.Ie Wjre CQIQ[ llaI!.Ie
123 ohms Yel to W or 8rn .3 to.6 ohms
Lighting Coil :
llaI!.Ie Wire CQIQ[ llaI!.Ie
164 ohms Yel to W or 8rn .3 to .6 ohms
EC40/50 PL through 1989 120 Watt
EC44-2PM 120 Watt
Pulser Coil:
llaI!.Ie
Wiu:! CoIQ[ llaI!.Ie
164 ohms BrnN-l to BlklR 45 ohms
llaI!.Ie
.310.6 ohms
EC50PM through 1989 120 Watt
Pulser Coi l:
llaI!.Ie
Wj[e CO!Qr llaI!.Ie
164 ohms BrnlW to BlklR 17 ohms
llaI!.Ie
.3 to .6 ohms
EC44-3PM 200 Watt
EC50-PM 200 Watt
EC40/45/40 PL 200 Watt
Lighting Coit
llaI!.Ie WiU:l; CQIQ[ llaI!.Ie
164 ohms Yel to Yel/R .2 to.S ohms
RIDE RED
Stator Schematics
Ughting Y to Brn
Charge
Gry to GryfW
Brn/W to BlkJR
Engine h ~ { : ; ; ; ; ; ; ; ; ; ; : : ~ (
Gnd.
Exciter
BlkJR to R
Pulser
W to ''' 'D'-I=I
199211993
ENGINE ELECTRICAL
2 Cylinder
Exciter Coil:
ECSOPL07 All SOO EEl Pulseless 200 Watt
Battery Charge Coil:
Wi re Color .'ial.u..e Wire Color Ya!..u..e
Brn/W to BlkJR 164 ohms Gry to GryfIN .2 to.4 ohms
Ughting Coit:
Wire Color .'ial.u..e
Y to Brn .2 to.4 ohms
1994 to Current
2 Cyljnder ECSOpLOZ/08 500 EEl Pulse less 250 Watt
EXCiter Coil: Battery Charge Coil:
Wire Color
Brn/W to BlkJR
Lighting Coil:
Wire Color
Y to Brn
1993 to Current
Ya1ue Wjre Color Ya!..u..e
164 ohms Gry to GryfIN .4 to.8 ohms
YlIIull
BrnfIN to GryM/ .2 to .4 ohms
Open to Ground
.2 to.4 ohms
3 Cylinder ECS8PL 170 Watt
Exciter Coil:
Wire Color
BlkJR to R
Lighting Coil:
Wire Color
Y to VIR
4.23
~ Wi re Color
YlIIull
4.6 ohms W to WIR 100 ohms
YlIIull
.2 to.4 ohms
8/94
RIDE RED
.
-
q .......
ENGINE ELECTRICAL
Stator Schematics
Stator
__
Grn
I
Y
Exciter
8194
I I
W/R
Blk!
Stator ___ v
Brn
Gry
Battery
Charge
Grn
Lighting
Brn
Gry
BralW
GryfW
Battery
Charge
Grn R
---- --
1983-1992
3 Cylinder EC60PL and EC65PL-OlI02
Exciter Coil: Pulser Coil:
Wire Color
'laIw
Wire Color
'laIw
Blk lOW 261 ohms RloW 20 ohms
Ughting Coil: Control Coil:
Wire Cala[ 'laIw Wire Calor 'laIw
Y to Brn .3 to.5 ohms Grn to Blu 29.4 ohms
or Ground
NOTE: All Values are 10%
1900-1991
3 Cylinde( I SO Wan
Wire Qalc[ 'laIw Win:: Qolar 'laIw
SlivA to Grn 248 ohms R to Grn 20 ohms
Ughtiog Coil: Trigger Coil:
Wire Cclc[ 'laIw Wire Ccl!:u 'laIw
Y to 8m .2 to.4 ohms WloW/R 96 ohms
Open to Ground
Wire Colo[ 'laIw
Gry 10 GryfW .3 to.S ohms
Open to Ground
1992 to Current
J Cylioder EC6seL lao Watt
Wire Qalcr 'laIw Wiu:: Qolo[ 'laIw
BlklR to Grn 248 ohms A to Grn 20 ohms
Lighting Coil : Trigger Coil:
Wice Qolo( 'laIw WiUl QoIQ( 'laIw
Y to Brn .2 to.4 ohms WloW/R 96 ohms
Wire QQlo( 'laIw
Gry 10 GryfW
.410.8 ohms
BrnIW 10 Gryrw
.310.5 ohms
Open 10 Ground
4.24
AIDE RED
Stator Schematics
Trigger
W
W/R
BlklR
Grn Red
y
B
Lighting
-
Blk
Brn
ENGINE ELECTRICAL
Ignition / Charging System Testing
1993 to Current
3 Cylinder ECZf2EI.-Ql StQ[OJ 1 ao Watt
ECSOPL-Ql Storm
EXCiter Coil: Pulser Coil :
WjU:I Color llaI!Je Wirfl Color llaI!Je
BlklR to Grn 248 ohms Grn to Red 20 ohms
Lighting Coil: Trigger Coil:
Wire; Color llaI!Je ~ i [ f I Color llaI!Je
Y to 8rn .2 to.4 ohms W to W/R 96 ohms
4.25
AICERED
11195
ENGINE ELECTRICAL
Ignition System Troubleshooting
Condition: No Spark
isconnecllhe single black (biackJwhite) wire Irom the COl Module to Check the ignition switch, wire harness, thronle safety switches
the ignition kill cirCliit. Does it have a spark? and kill switch for proper adjustment Or short to ground. Repair
yes ..... or replace as necessary.
No!
isconnect the stator to COl module wires. Test the resistance values All except 3 cylinders: If the parts 01 the ignition system under
of the nywheel coils as per the charts on page 4.21 . Are the resis- the ftywheel check OK, the only remaining component is the
lance values within specs?
coiVeOI module asserrbly. Replace the module with another
with the same CU number. (See ignition data)
II 3 cylinders: Disconnect and check the secondary ignition coil
resistances. Refer to the resistance values listed on IVa-1 O. If
yes .....
the coil reSistance values are within specs. replace the COl
No! module.
Isolate which component's resistance is not within specs. Aemove
the ffywheel and slalor. Recheck the resistances; look for pinched Of
bare harness wires; or replace the coil. Refer to page 4.28 for coil
replacement procedures.
Condition' Incorrect Advance/Retard .
Follow the engine timing procedure for checking running timing at Adjust the ignilion timing by rotating the stator plate to correct the
3000 RPM. Is the timing within limits? timing. After adjusting the 3000 RPM timing, continue with
No_ operating RPM timing if poor performance exists . (Continue on
Ves 1 w ~ h left column.) See ignition timing page 4.20.
ollow the engine timing procedure for checking operating RPM timing If the 3000 and operating RPM timing are within limits, no other
from page 4.20. Is the timing within limits? testing is necessary.
Ves .....
No!
Remove the ignition kill circuit by disconnecting the singte black wire Check the ignition switch, throttle safety switches, kill switch and
~ t w e e n the COl module and the machine harness. Is the timing now harness for damage which can cause intermittent shorting
correct? problems. Correct the problem.
Ves .....
No!
Verify the correct COl 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 ffywheel. Compare these Check the wiring connecting the coils and/or replace the coils as
values to the charts on page 4.21. Are they within limits? necessary.
No-.
Vest
I the 3000 RPM timing is within limits but the operating RPM timing is
oot acceptable, replace the COl module.
NOTE: 3 cyli nder engines fire three limes per revol uti on. 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 timi ng light PN 2870630 or equivalent.
8/94
4.26
RIDE RED
ENGINE ELECTRICAL
Alternator Output Test - Open Circuit
CAUTION: Perform this test with a digital volt/ohm
meter such as the Fluke 73 (PN 2870659). or
equivalent. Set meier to AC valis (V....-v) when
performing the test.
1. Di sconnect alternator connector from engine.
2. Insert red test lead into yellow wire coming from
engine alternator.
3. Black tester lead must be grounded to either the
engine, a brown wi re at the connector, or the
yellow/red wire at the plug. See plug wi re
identification for proper hook-up.
4. Start engine and observe AC voltage reading on multitester. Slowly increase RPM to 3000 and note voltage.
The reading should be approximately 20 volts. Readings of 1510 45 VAC are considered normal. If readings
are low, remove flywheel and look for damaged magnets, shorted or damaged lead wires or damaged lighting
coils. Repai r or replace problem component and recheck.
5. On EFI models AC amos can be checked between Gray and GrayJINhite. At 5,000 RPM reading should be 7
amps.
lighting System Identification - Test between labeled wires.
Used On:
100 Watt Singles
120 Watt Twins
180 Watt 3 Cyl . (Carb.)
170 Watt 3 Cyl . (Carb.)
250 Watt Twin - 500 EFI
Brown
Brown
150 Watt Singles and Twins
200 Watt Twins
1990, 1991 RXL
1992, 1993 500 EFI
GraylWhite
Check Lighting Coil Between
Yellow and Brown.
Check Battery Charging
Between Gray and GrayMhite.
120 Watt 3 Cylinder
180 Watt
1992 to Current 650 EFt
Brown
" " " ~ Grayl
White
Gray
Brown/While
Check Lighting Coit Between
Yellow and Brown.
Check Battery Charging
Between Gray and Brown/White
and GraylVVhite and BrownlWhite.
Yellow
NOTE: Gray, GraylVVhite, Brown/White are Bullet Type Connectors
4.27
RICEREC
8/94

ENGINE 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 (6) on the replacement coil
and re-solderto their proper wires. NOTE: Always
position with numbers towards the outside.
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 coit leads to prevent
possible contact with the flywheel.
8/94
4.28
RIDERED
Preparing a New Battery for Service
ENGINE ELECTRICAL
Battery Service
To assure 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 itwiJl be pul 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/ 1 a 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 assure 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.
Leadacid 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 requi re further
battery testing and charging.
Specific Gravity Test
A tool such as the battery hydrometer (PN 2870836)
can be used to measure electrolyte strength or
specific gravity. As the battery goes through the
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.
4.29
State Of Conventional Yumacron
Charge 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 Conventional Yumacron
Charge lead-aci d Type
1 00% 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 40F and compare these values to the
chart.
- : ; : : ; u , , ~
Delai!A I:
"
'"
'"
, ,
RIDE RED
8/94
ENGINE ELECTRICAL
Battery Service
Load Test
NOTE: This test can only be performed on machines equipped with electric start. This lest 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 Ihiscranking period, the observed vollage should not drop below
9.5 volts. If Ihe beginning voltage is 12.6 or higher and Ihe cranking voltage drops below 9.5 volts during the lesl,
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 componenls of water. Because of the loss of these gases and Ihe 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).
011 Season Storage
To prevent battery damage during extended periods of nonuse, 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 lois 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 termi nals.
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 unlillhe electrolyte's specific gravity
reaches 1.270 or greater.
5. The battery may be slored either in the machine
with the cables disconnecled, or on a piece of
wood in a cool place. NOTE: SIored batteries
lose their charge at the rate of 1 % per day. They
should be fully recharged every 30 to 60 days
during a nonuse period. If slored during winter
months, the electrolyte will freeze al higher
temperatures as the battery discharges. The
chart indicates freezing points by specific gravity.
Charging Procedure
Charge battery with a r.harger no larger than 1/10 of
the battery's amplhr rating for as many hours as
needed to raise the specific gravity to 1.270 or greater.
WARNING: The gases given off by a battery are
explosive. Any spark or open flame near a battery can
cause an explosion which will spray battery acid on
anyone close to it. If battery acid gets on anyone,
wash the affected area with large quantities of cool
water and seek immed:ate medical attention.
8/94
4.30
SpecifiC Gravity of Electrolyte Freezing Point
1.265 .75
0
F
1.225 -35
0
F
1.200 _17F
1.150 +5F
1.100 +18
0
F
1.050 +270 F
Battery electrolyte is poisonous. It contains acid!
Serious burns can result from contact with the skin,
eyes, or clothing.
ANTIDOTE:
EXTERNAL: Flush with water.
INTERNAl: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or vegeta-
ble oiL Call physician immediately.
EYES: Flush with water for 15 minutes and get prompl
medical attention.
Batteries produce explosive gases. Keep sparks.
flame, cigarettes, elc. away. Ventilate when charging
or using in closed space. Always shield eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
RIDE RED
ENGINE ELECTRICAL
Dynamic Testing of Electric Starter System
Condition: Starter fails to lurn molor or molor turns slowly.
NOTE: Assure thai engine crankshaft is free to turn before proceeding. For this test a digital multilesler must
be used.
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 bal- charged shop battery to conti nue the test.
tery positive (+) terminal. Reading should be 12.6V
or greater. Is it? (Continue with left column)
No_
Yesl
(A) Page 4.32
Disconnect red engagement coi l wire from start sole- With black tester lead on ground, check for voltage
noid. Connect black tester wire to an appropriate allarge relay in terminal" circuit breaker in and out
ground and red lead to red harness wi re at solenoid. terminals, and across both sides (red and red/white)
Rotate igni tion key to the start position. Meter of the ignition switch with switch on start. Repair or
should read battery vol tage. Does it? replace any defective parts.
No_
Yesl
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. Turn key to
start position. The reading must be less than .1 V
DC. Is it?
No_
Yesl
(B) Page 4.32
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. Turn key to start posi-
tion. The reading must be less than .1 V DC. Is it?
No_
Yesl
(C) Page 4.32
Connect black tester lead to solenoid end of solenoid Clean solenoid to starter cable ends or replace
to starter cable and red tester lead to starter end of cable.
same cable. Turn key to start position. The reading
must be less than .1V DC. Is it?
No_
Yes!
(D) Page 4.32
Connect black tester lead to starter frame. Connect Clean ends of engine to battery negative cable or
red tester lead to battery negative (-) terminal. Turn replace cable.
key to start position. The reading should be less
than .1 V DC. Is it?
No_
Yes!
(E) Page 4.32
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.
4.31
8194
AIDE RED
ENGINE ELECTRICAL
Electric Starter System Testing (Static)
Starter Motor Static Testing
IGNITION . IRE
G . 6ROWN - GROUND
TEfWJNIIL - REO - 511TTEFIY
... TEm<INAI.- - BLACK - IGNITION
5 TERMINAL - REO/WHJTE - STNHf;A
: Ral SURf :
, ,
,
IGNITION S"lTCH
COLOR COOE
R ' RED
!lRN ' I\A()lIIN
i!lLACI(
Y YELLOW
R/'OI ' RED WITH 'fI'HlTE TRACER
RECTIFIER
,
: -= l!iA TTERY
IGNITION
SWITCH
SYSTEM

0. IGNlTlCI'I
- - KILL
, '---
R (C)
-- -- - (D)
L __ : STARTER
CIRCUIT SREIII<ER
19......"
-------- -(8)
--
,.
,
STARTER RELAY
cw.SS1S G/,(J
,
r- -- ----- - - (E) - - ----- -- !_
; ENG I NE: c;r.o 7='
,
,
I "";" ,
_______ J
See page 4.31
6. Remove starter molor and disassemble. Mark end covers and housing for proper reassembly.
7. Remove pi nion retaining snap ring, spring and pinion gear.
8. Remove brush end bushing dust cover.
9. Remove housing through bolts.
10. Slide brush end frame off end of starter. NOTE: The electrical input post must stay with the field coi l housing.
11 . Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate.
12. 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 cleani ng, use only an electrical contact cleaner and/or a non-metallic
grit sandpaper. Replace brush assembly when worn to (.8 cm) or less.
Starter Housing and Fi eld 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 wi re 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 infi nity.
3. Place armature in a growler. With the growler on, position a hacksaw blade lengthwise 1/8" (.03 cm) above
armature coi l laminates. Rotate armature 360. If hacksaw blade is drawn to the armature on any pole, the
armature is shorted and must be replaced.
8/94
4.32
RIDE RED
-
ENGINE ELECTRICAL
Electric Starter Reassembly and Reinstallation
Starter Reassembly
1 Field C<>I Housing
2 Amalu,," "-en1b1y
3 W .. "'" Kit
4 Filtid C<>I
5 . PcM Core Set Sc"M
o . I!rus/I 1+)
7 BNSh Holder
8 BtusI1 H
9 BtusI1 B!><'ng
10 Brush End Fr""",
1 1 Brush EIICI BusIIing
12 Plrrion "-en1b1y
13 SI_, Se!
14 Throogh Bot!
15 [Nol Cove,
16 DrIw End FratrIfI
\7. DrIw EIICI B<JsI1fr1g
leSe,_
19 . Spring WlISI>.,.
20 Engine Mounting B,acket
21 Stud
22 Nut
23 Spring Wuh.,.
241'1'_
25 Aing GH!
26 . SoIeftOid
27 Nut
28 S"';ng Washer
29 Wuhe<
31 Engine Mounting B,"ckl!'1
"'"
3J . N..-t
1. Slide armature into field coil housing.

..@ .., Ci1 'r It
" .
......
"
"
... 0
z, I . ' t C!. e
cr "
"
,>
.. ..
..

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.
S. 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 lighten all screws.
9. Lightly grease pinion shaft and install pinion, spring stopper
and snap ring.
Starter Solenoid Bench Test
It is difficult to test the high amp side of the solenoid accurately
on the bench. The only test which can be done on the bench is
the pull in coil resistance, which should read 3.4 ohms.
Starter Reinstallation
1 . Position starter motor so there is no less than .100"
clearance between the ring gear and the starter motor pinion
gear.
2. Torque 8mm drive end mount bolts to 15 ft .lbs. (2.07 kg/m).
3. Torque 6mm brush end mount bracket to engine bolts to 5 ft.lbs.
(.69 kg/mi.
4. Torque through bolt mount bracket nuts to 30-42 in. Ibs.
4.33
Ring Gear
RIDE RED
.100
Starter Pinion
Gear
8/94
-
ROM Identification f Charge Coli Test Specifications
Model
Sfstem ROM 10 ROM PN
ypo
1990 RXL I 1990 V2 Contact Service
Oept.
1991 RXL I FSM 582 4040032
1991500
"
FSM 752 4040033
1992 AXL I FSM 582 4040032
1992500
"
FSM 752 4040033
1993 RXL I FSM 583 4040036
1993500
"
FSM 762 4040037
19941995 RXL I FSM 581 4040044
1994500
"
FSM 782 4040043
1995500
"
1995500 VI 4040051
1993-1995 RXL I 1995650 VI 4040057
Optional ROMs for special applications
ROMID Part Number Application
1992 SOO V2 4040038 199H992500
1994650 HE1 4040042 1993-1994 RXl
ENGINE ELECTRICAL
EFllntroductlon and Operation
B a t t e ~ Charge Colt Tesl
Pos lion/Resistance
G to GNoI .3 to .5 ohms
G to GNJ .3 to .5 ohms
G to GfW .3 to .5 ohms
G to BNV .2 to .4 ohms
BfW to GfW .2 to .4 ohms
G to G/IN .3 to .5 ohms
G to BIW .2 to .4 ooms
B!W to G/W .2 to .4 ohms
G to GfW .2 to .4 ohms
G to B/V'J .2 to .4 ohms
BfW to GfW .2 to .4 ohms
G to 8JW .2 to .4 ohms
8m to G!W .2 to .4 ohms
G to Bf\N .2 to .4 ohms
em to G/W .2 to .4 ohms
G to B!W .2 to .4 ohms
8No1 to G/W .2 to .4 ohms
Description
For repeated lean failures and
lean starts.
For high elevation lean drive
away. Calibrated for ethanol.
NOTE: FSM 58 1 and 1994 650 HE1 can be used for 1991- 1992 RXLs, but may experience rich mid-range and
reduced fuel economy.
The machines equipped with Polaris Electronic Fuel Injection (EFI) have many advantages over the normal
carburetor equipped models. The most noticeable improvements will be ease of throttle operation, better cold
weather starting and improved cold engine drive away. The EFI system also compensates for temperature and
altitude, and with minor adjustments will perform well over a wide range of temperatures and altitudes.
To assist technicians in troubleshooting and understanding the EFI , we have divided it into three separate
systems. The following is a short description of these three systems:
System I is battery, battery charging, and how the EFI is powered up or energized.
System II is fuel handling, fuel filtering, and fuel pressure regulations.
System III is electronics control, which includes the Electronic Control Unit (ECU), ECU inputs from
various sensors, and control of fuel to the cylinders by injector operation.
The following information is a more detailed explanation of the three systems. It's very important during diagnosis
that each of these systems be checked. Failure to do so may result in a reoccurrence of that particular problem.
Basic Operation System I
Battery, Battery Charging and Powering Up
The battery is the heart of the EFI system, its condition is critical to all EFI funct ions. Long off-season storage
periods, the high vibrations and extreme temperature variations which are encountered in snowmobile
applications make periodic battery inspection and service essential.
Some Polaris EFI systems have an alternator or charging system which will produce just enough output to
maintain the EFI system (1990- 1991 RXL). If the battery is partially shorted, or if connections offer any high
resistance, the resul t might be a lean fuel condition.
4.35
11/95
RICEREC
ENGINE ELECTRICAL
Electronic Fuel Injection Data
EFt models have two separate alternators or charging systems. One is used for lighting and accessories, the
other for battery charging and EFt operation. The battery size and alternator size have been designed to provide
adequate output forthe EFt system. If your sled is equipped with electric start, a larger battery will be required to
provide adequate cold cranking amperage.
CAUTION: At no time should any accessories be added to the battery or battery side of the charging system. To
do so may overload the system, discharge the battery and cause substandard EFt operation.
To power up or turn on the EFt system, we have utilized different methods. To explain properly, we have to talk
about the two basic EFt types:
TYPE I The Type I system is used on all AXLs. To power up requires both key and auxiliary switches to be in the
"Run" position. At that time, a circuit is completed between the battery positive terminal and the brown relay which
passes through the switches and the circuit breaker. The brown relay then connects the battery directly to the
ECU via the fuse link, causing the ECU to begin to function. The ECU connects itself to the battery via the self
shut-off relay, which serves to maintain power to the ECU for approximately ten minutes after power is cut off by
the key or auxiliary switches. The ECU is kept on for a short time in order to help prevent flooding of the engine
during a restart a short time after the engine has been shut off.
When the ECU is first powered up, the fuel pump will run for approximately five seconds in order to build up fuel
pressure in the rail. If the engine is Slapped by the switches and then reslarted within the ten minute period, the
fuel pump will not repeat the five second run, since the ECU was kept powered up by the self shut-off relay.
If the engine is stopped or dies with the switches in the "Run" poSition, the ECU will remain powered up until the
battery is drained.
TYPE 11 - The Type II system is used on all 500 EFI model s. The t991 and 1992 models power up differently than
the 1993 and later models. The Type II system is similar to the Type I system in the way that it maintains power to
the ECU after the engine stops, but is different in the way that it powers down. The Type I system depends on the
operator to turn off at least one of the switches before the ECU will power down. The Type II system will power
down regardless of the position of the switches in the event that the engine stops unexpectedly. This preserves
battery power.
1991 And 1992 Model Type II Systems
These systems use a "READY" light on the dash panel to indicate that the ECU is powered up and "ready" to go.
Power to the system does not pass through the auxiliary swi tch as it does on the Type I system. This switch only
grounds the ignition system like those on carbureted engines. Power to the system is supplied primarily through
the self shut-off relay and the key switch.
The key switch has three positions: OFF, RUN, and SYSTEM RESET/START. In the OFF position, the ignition is
grounded. In the run position, the switch does nothing. It is not connected to any wire in this position. The
SYSTEM RESET/START position is spring loaded, so the switch returns to the RUN position when the operator
releases it. In the SYSTEM RESET/START position battery power is connected to the ECU via the fuse link,
allowing the ECU to initialize and connect itself to the battery using the self shut-off relay. When the key switch is
allowed to return to the RUN position, the ECU is powered only by the self shut-off relay.
If the engine is stopped the ECU will remain powered by the self shut-off relay for a period which varies with engine
temperature. lithe engine is warm the ECU will power down almost immediately. If the engine is cold it may stay
powered up for as long as five minutes. The key only needs to be turned to the SYSTEM RESET/START position
if the "READY" light is not on.
1993 And Later Type II Systems
These systems are similartothe earlier Type II systems in function, but do not have a "READY"light or a SYSTEM
RESET/START position on the key switch. The key switch on these models only grounds the ignition in order to
stop the engine. There is no battery power connected to the switch in these models, unless electric start is used.
This system uses and Alternator Controlled Switch (ACS) to power up the system. It is mounted on the battery box
and also houses the voltage regulator/rectifier. This device senses the rotation of the crankshaft by recognizing
output from the engine's alternator. It then connects power to the ECU just as the earlier Type II system does when
the operator turns the key switch to the SYSTEM RESET/START position. This system eliminates the need for a
"READY" light and a complicated key switch. The operator simply pulls on the rope and the system powers up
automatically.
8194
4.36
RIDERED
-
Battery Maintenance And Testing
Batt ery maintenance is of the utmost importance to
ensure satisfactory EFI operation. Partially shorted
batteries can cause an additional load on the charging
system and in turn leave the EFI system with too little
to supply the relays, ECU, fuel pump, injectors, etc.
When this type of machine enters your service area,
be sure to thoroughly clean, inspect and test the
battery.
ENGINE ELECTRICAL
Battery Maintenance and Testing
CAUTION: It is extremely important that the battery condition and state-of-charge be maintained at the highest
level possible or serious performance and driveability problems will arise. Battery testing procedures are covered
below.
Off season storage for snowmobiles, especially EFI equipped machines, requires the battery to be removed. In
the summer months we find higher temperatures and higher levels of humi dity. These conditions. along with a
small drain applied from the EFI system will in a very short lime discharge the battery. Once the battery is
discharged. the plates will become sulfated (turn white), and the battery will no longer accept a charge. Batteries
which are not disconnected. removed and kept charged will need to be replaced at the beginning of each season.
Never sUbstitute any battery of lesser quality when replacement is required. Batteries may be
maintained by using the Polaris Battery Tender PN 2871076.
Battery Service
Conventional battery service techniques apply to this battery. Maintain the specific gravity of the electrolyte to
between 1.270 and 1.300. The open ci rcuit voltage must be maintained to between 12.7 and 12.9 volts QC (at
room temperature). at lower lemperalureslower values may be OK. Voltage readings should always be taken
with a fluke meter. The select monitor will place a load on the battery and on Type I units the monitor will incorrectly
read the low volts (less than 10).
Battery Charging System Testing
1. Adjust digital meter to DC volts and check battery voltage. Remove the battery. Service and test as outlined earlier
Must be 12.4 volts or more (no load). 11 the select monitor is In the engine electrical section. Before continuing, the
bein9 used. the battery has been placed in a load and battery must be in iood serviceable condition and full
6 readIngs will be approximately .2 volts lower. Also. the select charged. IMPORT NT: Replace battery il questiona Ie.
monitor on some models wi ll not read accurate voltaPte below Yes - See Block 2
12.0 and therelOfe should not be used. Does DC vo ta98
read correctly?
No-
Yes!
2. Start engine and increase to at least 4000 RPM. Battery Check battery charging coil. Disconnect coil leads.
voltage should increase to 13.6 to 14.6 volts. NOTE: If Reference specifications for ohms values and
battery is low on charge, the reading wi!! be low. A fully connections. NOTE: These coils are open to ground,
charged battery will reach the higher number more quickly. Is between any wire and ground should show open circuit.
voltage reading correct? AC amperage testing will show ar-rroximately 7 amps at
No- 4000 to 6000 RPM. Are tests OK
Yes! Yes - See Block 3
NOI
3. Charging system is test ing OK. Check for any ~ S S i b l e Replace lighting coil andlor flywheel. Rs-test system.
loose connections between rectifier. regulator an battery. See Block t.
Are there any loose connections?
NOl
4. Replace regulator rectifier and fe-test system.
5. Relet'ence Alternator ConIlOl Switch Testing 1993 To Curr&nl500 EFt
4.37
RIDE RED
11/95
\
ENGINE ELECTRICAL
Power Up Testing - Type I RXLs
Reference correct wiring diagram in chapter 3.
1. Check battery voltage. Must be 12.2 or higher. Use digital
fluke meier. Does it read correctly?
Charge, service, test and/or replace battery.
No--
Yesj
2. Check EFt brown relay. YIBK wire should read 12.2 volts
or more with switches turned on. Does it read correctly?
No--
Check circuit breaker. key switch, kill switch, connections
and wires. Check relay ground black wire.
Vest
3. Check brown relay. Retar should connect RIY from fuse
link to RISK (ECU) and RIB U (select monitor). Does it?
Replace relay and repeal tests.
No--
Vesl
4. Check self shut-off relay and wires from relays to ECU.
Are tests OK?
No_
Replace wires and/or relays.
may affect ECU operation.
Nole: Non-resistor caps
Yesl
5. Replace ECU.
11 /95
4.38
RIDERED
ENGINE ELECTRICAL
Power Up Testing Early Type II, 19911992 500's
1. Check battery vollage. Must be 12.2 or higher.
digital fluke meter. Is vollage OK?
No--
Usea Charge, service and test battery; or replace battery.
Yesl
2. Check voltage between ECU Orange wire and Check fuse link, key switch RlGR to A/IN, and all wires and
wound, and between Y/Blk and ground. With switch connections between battery to fuse link; fuse link to key
In the spring loaded voltage should rea 12.2 or switch, key switch to ECU. Are connections and components
higher. Is voltage 0 ? OK?
No-- Yes - See Block 3
Yes! Noj
3. Test self shut-off relay and circuits to relay. Are
circuits and relay OK?
Repair andlor replace components or wires as needed and
retest. Nole: Non-resistOf caps may affect ECU operation.
No--
Yesl
4. Replace ECU and retest system.
4.39
11 /95
RIDE RED
ENGINE ELECTRICAL
Power Up Testing Late Type II, 1993 to Current 500's
1 . Check battery voltage usin digital fluke meier. Must read
12.2 or higher. II voltage OK
No-
Charge, service, and test battery; or replace battery.
Continue lesting if needed. See battery service.
Yesl
2. Check voltage to ECU R/GN Pin #106. Should be 12.2 or
higher. Is voltage OK?
No-
Yesl
Check circuit from battery Ihrout circuit breaker and to
ECU. Repair and/or replace lau ty wiring or
components. Continue to slep 3.
3. Check to ECU OIBK wire Pin #11. Should be 12.2
volls while is being turned over. Is voltage OK?
Check lor signal from battery charRa ccilla ACS G GW
wires. Is signal OK? Repalr cireUi If necessary.
Yes! See Also Block 5 No See Block 4
Yesl
4. Check battery charge coil and connecting wires.
coil and/or repair wires. Continue tests.
Replace Check for from batterx to ACS.
Is circuit OK? epair circuit If needed.
Yesl
Replace ACS. Is system now OK?
No!
Replace ECU and retest.
5. Check self-shut-off relay and circuit, OK?
No-
Yes!
Rer:lr relay circuit
No e: Non-resistor caps may affect ECU operation.
6. Replace ECU and retest.
11 /95
4.40
RIDE RED
Fuse Link
The fuse link is the circuit protection device in Type I
and 1991-1992 Type II electrical system. Should a
system overload such as a dead short occur, the fuse
wire will open the circuit preventing further damage. If
this link should open, find and correct the problem and
then replace the fuse link. Never attempt to replace
the fuse link with a conventional fuse. Use only an
2EM-fusa lin!<-
Service of the fuse link is limited to verification of
whether or not the wi re is continuous. Remove fuse
link from machine and use an ohmmeter to determine
resistance value of wire between plugs. Resistance
values of less than .5 ohms indicate a good wire.
Values greater than that will necessitate link
replacement. Current models will use a self setting
circuit breaker.
Relay COils
The system relay coils are mounted on the front side
of the right footrest assembly on Type I and
1991-1992 Type II systems. The relays for later
model Type II systems are mounted on the ECU.
Their function is to control a major current carrying
circuit with a smaller, low current carrying control
circuit. When the ECU or ignition switch closes the
low current coil circuit within the relay, the magnetism
in the coi l closes the contact points, allowing current to
pass through the relay and power up to the ECU, fuel
pump, etc. Both system types incorporate two blue
relays, onecontrolling the fuel pump and the other the
self shut-off time delay relay. The Type I system also
uses a brown relay to control the main power input to
the ECU. On 1993 and later model Type II systems,
the relays are black.
Service to relays is limited to measuring pull-in coil
resistance and measuring volt drop across contacts.
The coil resistance should be between 65 and 70
ohms measured between the two pins marked coil on
relay base. When relay is energized, volt drop across
relay contacts should be less than .1 vDC, measured
in parallel with relay. On the bench, the relay can be
checked by hooking the marked relay coil terminals to
a 12v battery and checking resistance of relay
contacts. The resistance must be less than .2 ohms.
1993 and later Type II style EFI relays are tested by
placing 12 volts to contact left side as shown in the
diagram to the right. Measuring volt drop across
contacts .1 vDC. Measure resistance of right side
contact. This should be 100 ohms 10%.
4.41
Left
ENGINE EL1:CTRICAL
Power Up Component Testing
BL.UE BROWN
TOp
~
~
. ~ .
100
ohms
t ,
10%
Right
Bottom
8/94
RIDE RED
-
ENGINE ELECTRICAL
Alternator Controlled Switch" ACS"
Shown is the (ACS) for the 1993 to current 500 EFI
systems. The ACS controls voltage from the
alternator by rectifying from AC to DC voltage current
to charge the battery. It also supplies the ECU with a
12vOC battery voltage signal to indicate that the
engine's crankshaft is turning. The ACS eliminates
the need for the "Ready" light system reset as used on
previous 500 EFI models. NOTE: Even if the key
switch and kill switch are in the waff' position, the ACS
will power up the system if the crankshaft is turned.
(See also page 4.40, Power up testing.)
Test Procedure
With ignition in the on or run position, crank engine over slowly. You will hear the fuel pump run for approximately
five seconds. This tells you the ACS is working. If the fuel pump doesn't work when cranking, disconnect Eeu
wire harness and reconnect to reset ECU. Crank engine again. If fuel pump won't start working, unplug the
harness at Ihe ECU and check Orange/Black wire PIN #11 on the ECU harness. Battery voltage should be
present when cranking engine. NOTE: You can also use the select monitor to determine if the ECU is getting
power. If the setect monitor display lights up, then the ECU is getting power, check the ACS wire at the ECU plug.
CAUTION: Take care not to distort the pin with your tester lead. If no voltage is present, reset ECU and check
Orange/Black lead at ACS unit. If no vottage is present, check for alternator output or loose connections. If
alternator output is OK, replace ACS. Note:The ACS switch must also cut out battery voltage to ECU when engine
is not running. A voltage reading at the O/Blk wi re will cause battery to drain.
NOTE: 1994 to current 500's will use a five wire ACS LR36. The extra wire is for a center tap alternator.
Cold Starting
Whenever the engine is being cold started, the ECU will select a special "start-up" mode. This will occur any time
the engine is being cold started; for example, any Type I system which has been Wkey off' long enough for the self
shul-off limer to power down the system, or a Type II system which has had the engine stopped long enough for
the ready light to go off. After turning on the ignition key to reset the system, the fuel pump wi1l run from three 10 five
seconds to pressurize the system. When the ECU sees the first ignition pulse it provides a longer than normal
Wprime" pulse to the injectors to inject enough fuel into the engine for starting. On , 993 and later Type 11 systems,
there is no ready light or ignition key reset. The pump mayor may not run forthe 3-5 second period depending on
how long the engine has been off. In all systems, the "prime" pulse only occurs if the pump runs forthe 3-5 second
period.
Once the engine is running the ECU provides a rich cold engine mixture while the engine is warming up. It uses the
engine temperature sensors as an indicator of when the engine is warm enough to start decreasing the fuel to air
ratio. If the key is turned off, the ECU provides power to the self shut-off relay for from ten seconds to ten minutes,
depending upon the system type, and will not repeat the fuel system pressurizing and prime pulse during that time.
Once the self shut-off sequence has expired, the engine will have had sufficient lime to cool and the ECU will again
repeat the cold start sequence.
In Type I systems only, during times of severely hard running or in very warm weather if the engine crankcase
should approach a temperature which might result in engine damage the ECU will provide additional fuel to the
engine for cooling. When the crankcase temperature sensor indicates a temperature of approximately 100C, the
ECU will lengthen the pulse time and cause an over-rich condition which will cool the engine. As soon as the
engine temperature returns to normal, the EeU will return to the original map.
If the engine should become flooded during starting, it can be cleaned out by holding the throttle wide open while
turning the engine over. If the engine is not running, and the throttle is open more than 60, no fuel will be injected.
The engine will start and will begin receiving fuel from injection when the engine exceeds 800 RPM, or when the
throttle position goes under 60. The engine should then clean out and run normally.
In Type II systems, the engine is protected against overheating by the engine coolant sensor. If the engine coolant
reaches a threshold (85C' 993 and later, else 100C) the "temp" light on the dastlwill begin to flash. If the engine
coolant temperature continues to increase, the light will begin to blink faster. When the light bl inks fast, the ECU
adds fuel to enrich the mixture andto help prevent engine damage. Thefuel wilt continue to be added until the light
stops blinking.
" /95 4.42
RIDE RED
ENGINE ELECTRICAL
Basic Operation - System II
The fuel system consists of aillha parts responsible for storing, cleaning, delivering, pressurizing and injecting fuel
into the engine. They are: fuel lank, fuel pick-up, fuel hose, primary filler, fuel pump, secondary filter, fuel rail.
injectors, throttle bodies, pressure regulator and fuel return hose. Traci ng the path oftuel through the system, fuel
is pi cked up from the bottom of the fuel tank by the fuel pick-up hose and filter. It then travels through a hose to the
primary 75 micron fitler, located under the carb air box. Once leaving the primary fitter, it travels to the electric fuel
pump, located under the mag end Ihrotlle body. The electric fuel pump is responsible for the movement of the fuel
in the entire system. The fuel pump is connected to the banery by a relay. The pump runs conlinuouslywhenever
the engine is started. Atso located at the outlet end of the pump is a check valve. This valve holds pressure in the
system when the pump has stopped.
Vent Line
Fuel Tank
Weighted Pickup
and Screen
Fuel Filter
75 micron
Screen on
Inlet End
Injector - Side View Cross Section
Injectors,
Screen on:-_1'
inlet
Return Line
Fuel Filter
10 mienon
Check
Valve
Oullet End
Pressure
Throttl e Bodies
After leaving the pump, the fuel goes through the secondary 10 micron filter for further purification. The secondary
fiNer is.located under the mag-end thronle body. As you can see, cleanliness is essential to the 01 the
system, and its importance cannot be overstressed. The fuel is then stored under pressure in the fuel rait, ready
for discharge into the thronle bores. It is necessary to provide consistent pressure and to maintain a specific
pressure in the rail. This is accomplished by the pressure regulator. The pressure regulator is pre-set to maintain
rai l pressure at a desired or specific pressure. Any pressure greater than the set pressure is relieved or returned to
the tank by a return line.
4.43
AICERED
8194
ENGINE ELECTRICAL
EFI Fuel System Maintenance and Testing
Tank, Hose And Filters
The fuel tank is the reservoir for the fuel. II contains a
flexible hose with a weighted pickup and a course
screen which drops to the lowest part of the tank
regardless of machine attitude. Fuel travels through
the urethane fuel hose to the primary 75 micron filter
located under the airbox and then to the fuel pump.
From the pump the fuel hose changes to a reinforced
rubber hose which carries fuel to the secondary 10
micron filter located under the throttle bodies, and
then to the fuel rail.
STANDARD FUEL HOSE
SECONDARY FILTER
REINFORCED
PRIMARY FILTER
The fuel tank, hoses and filters require little, jf any. service. Periodically inspect lank and hose condition. Assure
that the pickup is clean and properly positioned and vent tube is properly routed and not kinked or pinched.
Replace any hose showing signs of deterioration. Replace primary and secondary filters at 5000 mile (SODa km)
intervals, every two years, or more often if contamination of any kind is present in the system. Use OEM parts only.
If for any reason, at any engine RPM, the fuel system should fail to deliver a sufficient quantity of fuel to meet
engine requirements and have some fuel returning to the tank, the fuel hoses must be checked for obstructions
and/or the fuel filters replaced. If the problem does not rectify itself, proceed to fuel pump testing.
CAUTION: Whenever inspection reveals worn, damaged or defective parts, replacement is necessary in order to
avoid serious damage to the machine or injury to the operator.
Fuel Pump
The electric fuel pump is located on the bulkhead
underneath the mag end throttle bore. The 12v pump
receives fuel from the fuel tank, then sends ilthrough
the small strainer in the pump inlel nozzle, through the
roller vane type pump, through the outlet check valve
and on to the injector rail. The pump is completely
filled with fuel during operation. This providescooling,
corrosion protection and lubrication.
CAUTION: Never run the pump without a sufficient
supply of fuel or pump damage will result. The pump
is cooled and lubricated by fuel.
Outlet
I
Armature
The pump outlet pressure can reach as much as 70 psi. It is regulated however to 35 to 37 psi by the fuel rail
pressure regulator. Located near the outlet end of the pump is a check valve. The pressure regulator also acts as
a check valve. There will be high pressure fuel between these two valves.
The fuel pump is a sealed unit. No internal repair of the pump components can be performed. Pump condition can
be verified by an amp draw test, an output volume test and an output pressure test.
Amp Draw Test: Install a DC ammeter in series with the purple pump power feed wire. The draw should be 2.5
amps. A draw at or slightly less than that value indicates the pump is electrically sound. No draw indicates either
no power present or an open circuit in either the pump or its ground. A draw greater than that value indicates either
a stuck or defective pump. A pump which is stuck due to long periods of non-use can occasionally be freed by
striking with a soft face hammer. If this does not free the pump, it must be replaced.
Output Volume Test: The output volume of the fuel pump and delivery system can be verified with an output
volume test. To perform test, start machine and make sure delivery side of system is filled and pressurized to the
pressure regulator. With machine turned off, disconnect fuel return hose and place it into a 200 milliliter graduated
container. Activate ECU to cycle pump for approximately five seconds. The measured output during this time
period should not be less than 9010100 milliliters. NOTE: Battery voltage less than 12.6vDC or restrictions in the
fuel lines or fillers will cause output to be less than recommended amount.
8/94
4.44
RIDE RED
Output Pressure Test: Install EFI fuel System
pressure tester (PN 2870982) in fuel line on PTO end
of rail. NOTE: Use caution when removing hose. The
rail may contain pressurized gas if engine has been
recently run. Activate dealer mode using select
monitor service harness plug, by connecting gray and
black test loads together or by jumping gray and black
wire terminals at diagnostic plug, then turning on
ignition switch. With pump running, system pressure
should be between 35 and 37 psi. A pressure reading
of higher than normal indicates a faulty pressure
regulator or an obstructed fuel return hose. A
pressure reading lower than normal indicates a fautly
pressure regulator, a bad pump, or a restriction in fuel
hoses or filters between tank and rail. If pressure
starts out normal and then gradually lowers, suspect
the fuel tank vent and/or any of the fuel filters or hoses
which may restrict fuel delivery to the pump.
Fuel pressure can also be checked with the gauge in
place and with the engine running. Pressure should
be checked at both idle and at operating RPM. A
plugged filter may show good pressure at idle but
restrict flow at operating RPM.
Fuel Rail
The fuel rail is the fuel distribution manifold for the
injectors. The injectors slip into fittings on the
underside of the rail which are sealed with O-Rings
around the injectors. The rail stores fuel under
pressure so that simply opening the injectors wi l l allow
fuel to pass from the fuel rail through the injectors and
into the throttle body. Pressure in the fuel rail is
controlled by the pressure regulator.
The fuel rail requires little if any service. Periodically
inspect seal between rail and injectors and rail and
regulator. If any leakage exists, replace O-Rings and
recheck for leaks.
Return Hose
The return hose runs between the bottom of the
pressure regulator and the top of the fuel lank. II
provides a path for excess fuel from the fuel rail to
relurn to the fuel tank. If this hose should become
obstructed in any way, the excessive fuel pressure in
the rai l will cause a rich operating condition.
Pressure Regulator
The fuel pressure regulator is mounted on the
opposite end of the fuel rail from where the fuel enters.
Its function is to maintain a consistent fuel pressure
within the rai l by allowing pressure above the desired
level to bleed off the rai l, through the regulator, and
back to the tank by way of the return hose. When the
fuel pressure on the bottom of the regulator
diaphragm reaches between 35 and 37 psi , it
overcomes the spring on the other side of the
diaphragm and pushes it up. This opens the valve to
the return hose, allowing fuel to escape and
maintaining a specific pressure.
4.45
ENGINE ELECTRICAL
Fuel System Maintenance and Testing
RICEREC
ENGINE ELECTRICAL
The regulator can also vary pressure consistent with
engine load, atmospheric pressure, etc. A manifold
pressure tube runs between the mag end throttle body
and the top of the diaphragm. As the throttle is
opened, the pressure in the throttle bore rises. This
additional pressure enters the cavity above the
diaphragm, assisting the regulator spring and raising
the pressure in the rail, anowing more fuel through the
injectors while they are open due to the higher
pressure. The opposite is true during deceleration.
High engine vacuum whi le the butterflies are closed is
applied to the top of the diaphragm, allowing the fuel to
compress the spring and open the regulator valve at a
lower pressure. These pressure changes are very
small and tend only to maintain a specific pressure
differential between the throttle bores and the fuel rai l,
and not to vary mixture ratios while driving.
In addition to checks made under fuel pump service,
the pressure regulator span can also be checked.
With a fuel pressure gauge on the fuel line and a
pump (PN 2870975) installed on the
regulator, activate the system the same as was done
for the fuel pump check. The fuel pressure at
atmospheric pressure should read between 35 and 37
psi; with five inches of vacuum it should be between
33 and 35 psi; with ten inches of vacuum it should read
between 30 and 32 psi; and with five pounds of
pressure it should be between 42 and 44 psi.
Consistent readings outside the span indicate a bad
regulator, bad hoses or filter, bad fuel pump, or an
inaccurate test gauge. Verify the problem and correct
it before any additional work is done to the system.
Injector
The injector is an extremely close tolerance solenoid
type valve which opens and closes electrically. It
allows fuel to pass from the fuel rail through the
injector body and into the throttle body. The quantity
of fuel is controlled by the length of time each injector
is open, and constant fuel rai l pressure.
8/94
4.46
Fuel

RIDE RED
1. Check battery voltage. Must be 12.2 or
higher and be capable of handling pump
load. If not, the fuel rail pressure lest will
below.
No_
Yes!
Connect fuel pressure gauge and test as
earlier outlined. Must read 35 to 37 psi.
Pressure reading high __
Pressure reading low 1
Inspect pump pickup lines, fillers and
volume test pump. Is volume OK?
No_
Yes!
Replace pump.
ENGINE ELECTRICAL
Charge, service, test andlor replace
battery. See battery service section.
Check for pinched Of kinked
pressure regulator return line.
OK?
Is line
Clean Of replace relurn tine.
No -
Yesl
Replace pressure regulator.
NOTE: It is very important to inspect fuel tank pick up screen and tank for floating plastic particles. It's possible to
have particles collect around screen as pump is running and float away after pump has stopped running.
4.47
AICERED
8/94
ENGINE ELECTRICAL
EFI Fuel System Test ing
Injectors cannot be disassembled for service or Cleaning. If a cylinder is not functioning properly and fuel supply is
suspected as the cause, determine if an injector problem exists and whether it is mechanical or electrical. Switch
the harness leads from the injector in Question with an adjacent injector. If the problem moves to the adjacent
injector, then it is electrical (see injector electrical service). If the problem stays with the same injector, then the
problem is mechanical and injector replacement is necessary. If one of the cylinders fi ll s with fuel after shutdown
and the rail empties, remove airbox, open throttles, install a 1" (2.S em) wide strip of cardboard above butterfly and
close throttles. Turn on ignition to pressurize rail. Wait two minutes and remove cardboard. Some wetting is OK.
but a soaked cardboard indicates a defective injector. Some of Ihe mechanical problems which will necessitate
injector replacement are inlernal and external leakage. partial or lotal fuel blockage. open injector coil, and
physical damage to the pintle and pintle case.
Throttl e Body
The throttle body assembly replaces carburetors in a
fuel injected type engine. It consists of one throttle
bore unit for each cylinder which has the air flow
controlled by a butterfly type throttle shutter. On top of
each unit one injector is held in place by the fuel rai l.
The throttle position sensor is mounted on the mag
end of the throttle body assembly. Engine idle RPM is
controlled by the throttle stop screw mounted
between the mag and center throttle bore units.
Synchronization of the throttle assembly is
accomplished by synchronizing adjuster between
each pair 01 throttle bore units.
THROTTLE STOP REGULATOR
Since each cylinder and throttle bore operates independently and the only common factor is that they all get the
same quantity of fuel . it may be necessary to periodically synchronize the throttle butterflies to coordinate the
fuellair quantities. This is best accomplished by removing the throttle body and visually synchronizing the
butterflies on the bench.
Procedure
Loosen synchronizer jam nut between mag and center cylinder. Turn adjuster until center and PTO butterflies are
farther open than mag side. While shining a flashlight into bore on engine side. view through air box side of mag
throttle bore. Back out throttle stop screw until butterfly just closes al topol bore (no light shining through) . Moving
flashlight to center bore. adjust synchronizer until center butterfly just closes at top of bore. NOTE: Make sure the
PTO butterfly does not hold the center open whi le adjusting.
Once center and mag butterflies are set to a just closed position, synchronize PTO butterfly the same way by
adjusting synchronizer between center and PTO throttle bores until PTO butterfly is just closed. Open and close
throttle three or four times by pulling up on cable attaching point on throttle shaft. Recheck all three butterflies to
verify synchronization and readjust if necessary. Make sure that all synchronizer jam nuts are tight. Reinstall
throttle body assembly on engine. The method for adjusting the throttle position sensor will be discussed under
TPS.
NOTE: The same procedure can be used on twin cylinder engines.
Bl94
4.48
RIDE RED
-
ENGINE ELECTRICAL
System III - Electronics Operation
The Electronic Control System is the mixture control part of the system. It uses sensor inputs to control the fueVair
ratio. The illustration shows the components of the basic ElectroniC Control System.
Sensors (Inputs)
rps
ECU
(Type II Systems Only)
(Three Cylinder System Shown)
Twins have 2 injectors
Injectors (Outputs)
Drop ResistOl'
In From
Battery
~ " ' - - - l D
O"'put DO
DO
Select
Monitor
The electronic control unit delivers a low voltage signal to each sensor. Depending on variations in air
temperature, throttle position, etc., each sensor will vary the amount of that signal passing through it to ground
depending on its position and temperature. The ECU reads the information and from that determines what the
actual air temperature, throttle position, etc. is. This information is then plotted on a map which is
pre-programmed on the PROM (Programmable Read Only Memory) or "chip". Based on the two primary inputs;
RPM (x) and throttle position (y), the ECU can select a specific injector open time (z). This value is the distance
between the base plane and the map at the point where x and y cross. The value is converted to milliseconds and
referred to as pulse width.
Simu-
lated
prom
map
RP
M
(x)
4.49
Throttle Posi-
lion
(y)
RIDE RED
Pulse Width
(in milliseconds)
(z)
8194
ENGINE ELECTRICAL
Syst em 111 - Electronics Operation
Input from the other sensors either adds to or subtracts a percentage from the pulse width to lailor the fueVai r ratio
for the specific altitude, air temperature and engine temperature. See illustration.
]
Richer for low attitude.
cold engine. cold inlet
air, etc.
Leaner for warm air [1
temps, high altitude elc. Pulse Width Z
RPMX
,,/
,.
" "-
" "-
Throttle Position Y
The illustration below depicts pulse widths in milliseconds output by the ECU. Figure A shows a situation where
the air temperature Is low, the machine is at low altitude with a cold engine, wide open throttle and high RPM.
The ECU determines the engine's fuel requirements and selects a relatively long pulse width which allows more
injector open time for fuel to enter the engine.
ON ,----_-,
Figure A I
OFF
Long Pulse Width (i.e. High RPM, Cold Temps., Low Altitude, etc.)
Figure B ON n n
OFF L ____ -'
Short Pul se Width (i.e. Idling, Warm Temps . High Altitude, etc.)
If the same engine were at high altitude on a warm day at low RPM and throttle settings, the ECU would select a
pulse width closer to Figure B, indicating a shorter injector open time and less fuel entering the engine. In this way
the system can ultimately vary the mixture for all temperatures, loads and altitudes by varying the amount of time
the injectors are open per revolution.
8/94
4.50
AIDE RED
Select Monitor
The select monitor (PN 2870969) is designed to
provide easy, accurate diagnostic and service
information to the technician. When installed on the
machine it will provide both dynamic and static
displays of the function of critical fuel system control
components. It also has the ability to display the
contents of the ECU memory. With this tool, electrical
service of the EFt system should be Quick and easy.
Remove protective plug from diagnostic plug in
machine harness next to ECU. Connect select
moni tor to instrument harness, to service harness,
and to diagnostic plug in. Install program cartridge
into select monitor. Turn on ignition switch and place
handlebar kill switch into run position. Turn on select
monitor switch. On most models the monitor display
will now light up.
NOTE: On 1993 500 models, it is necessary to
connect the RedlYeliow and Yellow/Green wire in the
5 pin electric start coupler with a jumper wire to
maintain power to the ECU and select monitor. Type I
models will stay powered up with switches on. On
Type II systems, the time will be limited unless the
engine is running. On 1994 and later models, the ECU
will remain powered for approximately one minute at
room temperature and above.
There are two ways to search for information with the
monitor. You can scroll through the different modes in
order until the correct information is found, or you can
select the specifi c mode letter and number and
advance to the specific information that you want.
Electronic Control Unit
The Electronic Control Unit (ECU) is the brain of the
EFI system. It is a digital computer which holds the
memory chip for the read out of basic injector opening
duration on a three dimensional map. There are two
ECU systems used, Type 1 for the RXL and Type 2 for
the 500 EFI snowmobiles. Each system receives the
same type of information from the sensors. The ECU
incorporates a number of special features. Some of
these features are: adjustable low speed mixture
control, automatic cold engine stan up enrichment,
engine over temperature protection, flooded engine
cleanout mode, failsafe feature and LED self
diagnostic system. In the event that any sensor
should give inaccurate or no information, the EGU will
then flash a coded light sequence to identify the
affected sensor. NOTE: It is imponantto note that the
EGU will not identify mechanical problems. Only
sensor inputs are monitored. For example, low fuel
pressure or lack of fuel will not be diagnosed.
The EGU can only tell if a sensor reading is within a
specifIC range. For example, a failure code will not be
indicated if throttle position shows 3.9
0
when the
throttle is actually wide open. Use display of throttle
position to ensure the readings reflect actual
conditions. Thi s same concepl applies to the
temperature sensors and the barometric sensor.
4.51
ENGINE ELECTRICAL
System III - Electronics Testing
SERVICE HARNESS
PRESSURE
SENSOR
ECU Part Numbers
Type I wlo chip
Type I w/o Chip Elect. Start
Type II w/o chip
RICEREC
LE
2410028
2410029
2410030
8/94
ENGINE ELECTRICAL
ROM Chip Removal and Installation
The chip can be removed and replaced wi th the
appropriate chip puller and installation tool. You will
need to supply ROM Removal Tool (Digi-Key PN
KI5S-NO; Calil-SDO-344-4539); and Nyogel (Polaris
PN 2871 044). Note the location of the indicator notch
when replacing the chip (see photo). The system will
not function with the chip in backwards or with the chip
pins not properly in their sockets. See the
specification section in this chapter for chip
information.
CAUTION: The computer chip and the ECU are
extremely sensitive to static electricity. The handling
of either component in a static electricity environment
will cause irreversible damage. Work on a metal
bench or other static dissipating surface. It is very
important that you ground yourself by touching the
crystal inside the ECU before any internal service
work begins on the ECU assembly. See the
Illustrations 1 and 2. If the ECU has not been removed
from the machine, be sure to unplug it before
proceeding.
1. Disconnect main harness connector from ECU.
Remove phillips head cover screws and cover.
2. Touch the crystal located inside the ECU box to
ground yourself before proceeding. See
Illustrations 1 and 2. CAUTION: The chip and the
ECU are very sensitive to static electricity.
Working inside the ECU without grounding
yourself may cause irreversible damage to either
or both components.
3. In the event you are removing an old chip for
replacement, place ROM removal tool (Dig i-Key
PN KI58-ND) over ROM chip. Pull up on triggers
to securely grasp Chip and pull chip oul.
4. Check charts on page 4.35 to be sure you are
installing the correct ROM.
5. Coat the pins of the ROM with a light coating of
Nyogel (Polaris PN 2871044).
6. Carefully insert the ROM, making sure the notch
on the end of the ROM matches the notch
indication mark drawn in white on the circuit
board. See illustrations 1 and2. CAUTION: lithe
chip is installed with the notch incorrectly
positioned the chip will be ruined and the machine
will lail to run.
7. Align cover gasket, positioning cover rubber
bumper above chip. Reinstall cover screws and
FSM5631
Connector J
White tine on board
IIi. I
e sure notch on ROM is
positioned here
Crystal - touch before
performing service to

RXLECU Box A

II",

Cryslal- ___ IX
touch before . \.
performing
White line
service to
on board
ground your-
self Be sure notch on ROM
chip is positioned here

Connector 1
A>
500 ECU Box
reconnect wire harness. Install select monitor III. 2
and check functions.
8/94 4.52
RIDE RED
Troubleshooting EFI System
ENGINE ELECTRICAL
When key switch is turned to the on position, voltage is supplied to ECU and the select monitor. NOTE: Some
models will require the engine to be turned over.
As explained on page 4.36, after the ECU is powered up, it will run the fuel pump for five seconds, read the sensors
and do a self diagnosis afthe complete system. The ECU does not check the Air Temperature Sensor (ATS) until
the engine RPM is above 1000.
With a good understanding of how each component functions, the test procedures given in this manual, and the
use afthe select monitor, you will be able to service and diagnose the Polari s fuel injection system. All information
and specifications are on the latest product information available.
Select Monitor Scrolling
With the ignition on and the monitor hooked up and turned on as described earli er, the display should show the
year and the mode (FOO). By pressing the " key, the display wilt proceed to (FOt ) which is the model. Press the ",
again and the (F02) will appear, which is battery vol tage. By pressing the ", or T keys, you can either scroll
forward or backwards through the modes.
If you know the mode you want, service time can be saved by pressing "PO followed by the two digit number, and
enter. The monitor will display the mode number and the registered information.
The following chart shows the modes, what the readings are for, and what an approximate reading should be.
Mode Description Normal Reading
FOO Model Year Year of machine (not always correct)
FOl Engine Code Polaris code number 30 for Triples; 20 for Twins
F02 Battery Voltage 12.2 or above at room temperature
F03 Engine RPM Idle: 2000 to 2200 3 Cylinder; 1600 Twins
F04 Throttle Valve Angle (Whole Range) 0to 7]0 large steps
F05 Intake Air Temp in Cc Room temperature (engine cold)
F06 Intake Air Temp in P Room temperature (engine cold)
F07 Crankcase Temp in Co Room temperature (engine cold)
F08 Crankcase Temp in FO Room temperature (engine cold)
F09 Barometric Sensor Barometric pressure in millimeters of mercury
F14" Throttle Valve Angle (Low End) 0to 35.9
0
small steps
F21 MR (Idle Mixture) Position 2.5 or more than 4.0 for All. See page 4.58.
F22 Water Temp Sensor in Cc Same as ATS or CTS Cold or 30to 90running
FAD Ignition Key Diagnostic KY + NO. 3 LED (with key on)
FAl Dealer Mode OM + NO. 5 LED (with OM activated)
FA2 Relay Check FP,SO,SS + NO.1 ,2, and 3 LED when operating
FBO EXisting Trouble Codes Faults presentty existing
FBl Memory Trouble Codes Faults that are intermittent
FCO Memory Clear -
"Not used on 1990 Type I systems
4.53
8/94
RIDE RED
ENGINE ELECTRICAL
The ECU determines the amount of fuel to be injected by accurately calculating the engine's needs for fuel
delivery. In order to do this, the ECU is loaded with a memory chip for the read oul of the three dimensional map
which reads the throttle sensor and engine speed. Various sensors such as air temperature sensor, coolant
temperature sensor, barometric pressure sensor, battery voltage and the MR setting in the ECU are also inputs to
control fuel delivery.
Select Monitor Readings
Mode Description Nonnal Reading
F100 Model Year Year of machine
F01 Engine Code Polaris cOOe number 30 for Triples
Polaris code number 20 lor Twins
F02 Battery Voltage 122 or above
NOTE: Type I system will indicate a high battery vottage on the select monitor if the actual voltage is below
approximately lOvOC. If you suspect a low battery, use a Fluke meter to directly measure the battery voltage.
Type II systems do not have this problem. The select monitor accurately reads battery voltage.
RPM Sensor
The Electronic Control Unit receives an engine RPM
signal from the COl box. This signal is oneo! the main
inputs and is very critical to proper operation. If the
ECU does not see this signal, the injectors will not
open and the fuel pump will only cycle for the initial five
seconds when the ECU is powered up. (See page
4.36).
The ignition switch and auxiliary kill switch are
connected in series with the ECU COl signal. If these
switches are leaking partial voltages to ground, the
ECU will not function properly. Whenever COlor
intermittent running problems are occurri ng, the
switches should be suspect for potential problems.
These switches will also fail more oft en when humidity
is high. To troubleshoot the switches, disconnect or
isolate them from the circuit.
Mode Descri ption
F03 Engine RPM
8/94
"""'RPM OUTPUT
Nonnal Reading
Cranking 300-500
4.54
RICE RED
Throttle Position Sensor (TPS)
Throttle position is one of the two main inputs used to
calculate fuellair ratio. The throttle position sensor is
a rheostat type variable resistor which is mounted on
the end of the throttle shaft. The resistance value of
the sensor is relatively low al idle. As the throttle is
opened, the resistance goes up proportionately to the
butterfly angle. The ECU passes a specifIc current
through the sensor and experiences more current
flow al idle. This fJow lessens as the throttle is
opened. From this information, the ECU can
determine butterfly angle and control fuel delivery
accordingly.
ENGINE ELECTRICAL
The throttle position sensor can be checked on the bench with an ohmmeter. With the butterflies closed, the
resistance between the black and white wire, measured at the plug, should be between 400 and 700 ohms. With
the throttle wide open, the resistance should be approximately 4.5 k ohms. Some minor variations in resistance
values will be experienced due to throttle position sensor location; but radical differences or failure to see a
consistent progressive increase or decrease in the resistance as the throttle is opened and closed indicate a
defective position sensor. The sensor can also be checked with the select monitor using mode F04. It should read
between 3- 4when the throttle is closed and consistently. progressively increase with throttle openi ng to more
than 74at WOT. The throttle position sensor can be replaced by removing the two mounting screws and gently
prying it off the end of the throttle shaft.
During periodiC inspection, or when replacing the TPS, it must be synchronized to the throttle butterflies. The
sensor must be positioned to the positive side of 0 with the butterflies totally closed. To adjust the sensor,
disconnect the throttle cable from the throttle flipper and back out the throttle stop screw until the butterflies are
1Q1atJ closed. Connect the select monitor to the system diagnostic plug. Turn on the ignition switch and the
moni tor on/off switch. Scroll the monitor to mode F04 or F14 and verify the sensor positioning. NOTE: F14 is a
low end scale for sensor adjustment. This is the desirable scale, but because of programming may not work on all
models. Loosen the sensor mounting screws and rotate the sensor until the reading on the monitor is .1 on F14,
or the point where the reading "breaks over" between 0and a positive number on F04. Tighten the mounting
screws, open and close the throttle a few times and recheck the reading. Readjust if necessary.
Mode Descripti on Normal Readi ng
F04 Throttle Valve Angle-Range 0to 7]0 large Steps
See TPS Adjustment
F14 Throttle Valve Angle Low End 0to 35Small Steps
Not Used on All Systems Depending on Position
4.55
8/94
RICEREC
ENGINE ELECTRICAL
Intake Air Temperature Sensor (ATS)
The air temperature sensor is mounted in the air box.
lis function is similar to the crankcase temperature
sensor in that its temperature will vary the resistance
across the sensor. It has a reduced thermal capacity
for quicker response.
Cold air will cause high resistance and warmer ai r will
lower the resistance. The ECU sends current to the
sensor and, depending on its temperature, a certain
amount will pass through to ground. By measuring
how much passes through, the ECU can calculate air
inlet temperature and vary fueVai r ralio accordingly.
The intake air temperature sensor can be tested in a manner similar to the crankcase temperature sensor.
Determine the approximate temperature of the sensor, measure the resistance between the two lead ends at the
plug and compare the reading to the graph shown on the bottom of page 4.59. An easier and more accurate
method is to use the select monitor to indicate what air temperature reading the ECU receives from the sensor. If
the air box and underhood area have not been warmed due to recent running of the engine, the air temperature
sensor should read room temperature on the select monitor. Radical differences between room temperature and
the indicated reading indicate a problem with the sensor, wiring, battery, or ECU. Verify and repair any problem
before attempting to operate the machine.
Select Monitor Readi ngs
Mode Descr ipti on
F05 Intake Air Temp C
F06 Intake Air Temp OF
Crankcase Temperature Sensor (CTS)
The crankcase temperature sensor is screwed into
the upper crankcase half below the mag throttle bore.
This thermi stor type semi conductor varies in
resistance depending on its temperature. The ECU
delivers an electrical current to the sensor. When the
sensor is col d, its resistance is high and not much
current passes through the sensor to the engine
ground. As the sensor heats up its resistance lowers,
allowing more current to pass through. The ECU
measures the current flow through the sensor and
knows the temperature of the engine crankcase and
can vary fuel ratio according to case temperature.
The CTS is used on all Type I systems and on 1991
and 1992 model Type II systems. 1993 and later Type
II systems do not use crankcase temperature sensor.
Mode Descr i pti on
F07 Crankcase Temp C
F08 Crankcase Temp OF
8/94
4.56
Nonnal Reading
Room Temp Cold"
Room Temp YEngine
Normal Reading
Room Temp "Engine
Room Temp "Engine Cold"
RIDE RED
Barometric Pressure Sensor (BPS)
The barometric pressure sensor is located inside the
ECU. Its function is to read atmospheric pressure.
This information is then used by the ECU to determine
fueVair ratio, depending on pressure changes during a
given day, or for any altitude change. The barometric
pressure sensor is an integral part of the ECU and
cannot be replaced separately.
No service can be performed on the barometric
pressure sensor. However, the barometric sensor
reading can be checked with the select monitor. The
monitor reads in millimeters of mercury. To gel air
pressure in inches of mercury, divide this number by
25.4. Compare the reading to an accurate barometer.
NOTE: Readings reported by the radio or television
are corrected to sea level. The select monitor is an
actual reading. Any changes to the stock machine
which affect the air pressure around the ECU will
cause the barometric sensor reading to be inaccurate.
Mode Description
F09 Barometric Sensor
4.57
ENGINE ELECTRICAL
System III - Electronics
Normal Reading
Barometric Pressure in Millimeters of
Mercury
8/94
RIDE RED
ENGINE ELECTRICAL
System III Electronics
MR Adjustments
Fuel/air ralio al engine RPMs below 3500 can be adjusted slightty richer or leaner from the standard program
mixture by adjusting the MR control. This adjustment is to compensate for individual engine differences on Type I
and 1991 and 1992 Type II systems. This adjustment affects the same area as an ai r screw on a carbo
To adjust the MR control, remove the rubber plug. Install the select monitor, power up the system and press
buttons F21. A correct reading on the monitor is between 2 and 3, with 2.5 being the most desirable. NOTE: At
high altitudes, a higher number will result in earl ier drive-away after startup. Turning the MR screw clockwise will
increase the observed number and richen the mixture. Turning the screw counterclockwise will lower the number
and lean the mixture. The leanest setting will be 0 and the richest will approach 5.
Type II System 1993 To Current
The production setting is 2.5. Adjusting the MR control screw on 1993 to current model 500s will only affect cold
starts and cold drive-away. (It is designed to assist the driver when using poor or summer grade fuels.) If a lean
condition is suspected, change the number to a higher value. If a rich condition is suspected, change to a lower
number. Approximately two minutes aft er starti ng, this adjustment has little effect; aft er 10 minutes it has no
effect.
Mode Description Normal Reading
F21 Mixture Enrichment 2.5
MR Adjustments For Altitude And Temperature
The following tables list MR screw settings for various temperatures and altitudes. Whenever performing MR
adjustments, take the operator's riding location and weather conditions into account before making an
adjustment. Numbers anywhere wi thin the ranges listed should provide acceptable operation.
Type I Systems 1990 Through Current Rxls
Production Settings 2.5
Ambient Temperature Below +20F (_6C) +20 to +50F (_6to 10C)
0-3000 Flo or 2.5 3.0-3.5
0-900 m
3000-6000 Flo or 3.0-3.5 3.5-4.0
900-1800 m
6000-9000 Ft. or 3.5-4.5 4.0-4.5
1800-2700 m
9000-12000 Ft. or 3.5-4.5 4.0-4.5
2700-3700 m
Type II Systems 1991 1992 500 EFls
Production Settings 2 5 .
Ambient Temperature Below +20F (_6C) +20 to +sooF (_6to 10C)
0-3000 Ft. or 2.5 2.S.3.5
0-900 m
3000-6000 Ft. or 2.5 3.0-4.0
900-1800 m
6000-9000 Ft. or 2.5-3.5 3.0-4.0
1800-2700 m
9000-12000 Ft. or 2.5-3.5 3.0-4.0
2700-3700 m
8194
4.58
Above +SOF (10C)
3.5-4.5
3.5-4.5
4.5
4.5
Above +SOF (10C)
3.0-4.0
3.5-4.5
3.5-4.5
3.5-4.5
RICE RED
Type II System. 1991 To Current EFls
Type II EFI systems incorporate an engine coolant
temperature sensor. This sensor is positioned in the
engine water jacket where it is able to receive and relay
reliable engine top end temperature to the ECU. This
sensor also controls the temperature light and a fait safe
mode. The "TEMP" dash light will come on and begin to
blink slowly when the coolant reaches an unsafe
temperature. If the temperature continues to increase, the
light will begin to blink faster; at this time the EFt system
will increase the fuel being supplied 10 the engine.
ENGINE ELECTRICAL
EFI Electronics
This increase in fuel will be noticed by a decrease in engine performance which is designed to protect the engine in
an overheat condition. The increased fuel will continue until the engine coolant reaches a safe temperature and
the light goes out. Correcting thi s problem may be as simple as driving the machi ne slower and/or driving in a snow
condition which allows for more snow to be thrown onto the heat exchangers. If this condition continues, check the
cooli ng system, coolant level, water pump belt tension, etc.
To check sensor function, connect a select monitor and advance to mode F22. With engine cold, observe reading.
It should be near the readings of the ATS and CTS in degrees centigrade. Start engine and observe temperature
increase as engine warms up. If readings vary greatty or fluctuate from other sensor readings, check harness and
connectors for condition and repair as necessary. If no other problems can be found, and incorrect readings
continue, replace sensor.
Mode Descri pti on Normal Reading
F22 Water Temp Co Cold Engine Room Temp
Bench testing of a temperature sensor can be accomplished by measuring resistance between sensor wire
terminal and sensor shell; then comparing reading to graph shown. An easier and more accurate method is to use
the select monitor to indicate what temperature reading the ECU receives from the sensor. If the engine has not
recently run, the sensor should read at or near room temperature. A radically different reading from room
temperature could indicate a problem with sensor, wire to sensor, any of sensor connections, battery, or ECU.
Verify and repair any problem before attempting to operate machine.
The sensor's resistance curve is
shown at right. Resistance of the
sensor is high when it is cold, and
lowers as its temperature increases.
This creates low current flow through
the sensor at low temperatures and
high current flow as the temperature
increases. NOTE: The formula for
converting OF to C is (OF = C x 1'.8
+ 32)
80
40
20
10
6
4
Resistance (kQ)
2 ------
1
0.6
0.4
0.2
-20 o
4.59
2.5kQ /20
0
C
20 40 60 80 100 120
RICEREC
8/94
ENGINE ELECTRICAL
EFI El ectronics
Fuel Injectors
Variation in the amount of fuel delivered per stroke to
suit varying load and speed conditions can be
obtained by controlling the discharge duration 01 the
injector.
The injector is a solenoid-actuated constant stroke
plunger consisting of a solenoid, plunger. needle
valve and housing. The ECU will determine the
duration time the injector is energized to deliver fuel.
The resistance between the two pins on the injector
(isolated) should be 2 to 2.5 ohms. There should be
no continuity to ground. CAUTION: Since the
operating voltage is approximately 5 volts DC on the
injectors, never attempt to lest them with any higher
voltage or the injector will be destroyed.
Mode Description
FB0-21 Type One System AXL
Type Two System 500 EFI
FB0-22 Type One System
Type Two System
FBO-23 Type One System
Dropping Resi stor
The dropping resistor is mounted on the engi ne side of
the battery box. The three cylinder system consists of
four individual resistors (only three are used) wired in
parallel with a common voltage feed. The twin
cylinder has two resistors wired parallel, also with a
common voltage feed. They are used to drop or
reduce the voltage going to the injectors to
approximately 5 volts. Voltage from the battery
travels through one of the reSistors, through an
injector and into the ECU. A failure of any injector or
resistor will cause one cylinder to quit operating. The
ECU will then flash the trouble code for that injector.
NOTE: The ECU can only determine electrical failure.
If an injector failure code is flashing, the problem could
be anywhere in the electrical circuit for that injector.
The ECU will not find a plugged or leaky injector.
PinUe
Normat Reading
Mag Side Injector
Center of PTO Injector on Twin Cylinders
PTO Injector
The dropping resistor may be tested with an ohmmeter between the white terminal and each of the black terminals
at the resistor plug. The resistance is 6 ohms 1 0%. Replace the resistor if any of the readings are outside of the
spec. Clean the termi nals if they become corroded. NOTE: The injector's operating power comes through these
resistors. Any suspected injector electrical problem must first be traced through the dropping resistor.
8194
4.60
RIDE RED
-
ECU Diagnostics
ENGINE ELECTRICAL
EFI Electronics
If any of the main sensors should malfunction while the machine is being driven, the ECU will sense a problem and
proceed to an over-rich "fail-safe" mode. An open or shorted circuil in any of the sensor Circuits will show the ECU
a reading outside of what it normall y sees and the ECU will determine that a problem exists. Without this feature,
certain kinds of failures could cause the mixture to be leaner than the required ratio and cause engine damage.
This feature is important for engine protection. Once the sensor problem is determined and corrected, the ECU
will return to the original map.
If any althe injectors or sensors should malfunction during operation, the ECU will record this information and start
fl ashing a Ugh! Emitting Diode (LED) code informing the mechanic/ownerwhich component failed. The LED is on
the right of the ECU, in front of the main plug. See ECU photo. If the problem still exists and is ongoing, the LED
will continuously flash the code. I' the problem occurred but the machine is now operating properly (intermittent), it
will be stored in the memory and can be drawn out of the ECU by connecting the gray and black wires together at
the diagnostic plug. The LED will then begin blinking long followed by short light pulses; then a pause and the long
and short pulses again. The long pulses are the first digit in the code and the short pulses are the second digit.
Ihe code to the following trouble code chart to determine the problem. Rememberthat the problem can
exist in the sensor, the power feed to the sensor, the sensor ground, connectors, or the part of the injector or
sensor ci rcuit inside the ECU.
Mode FBa is for existi ng problem diagnosis. Press
buttons F, S, 0 and enter. If there is an existing
problem, a code number and the abbreviation of the
problem component will appear. See the chart for an
explanation of the code numbers. The LED will also
display this code. Example: Code 12- the light will
display one long and two short pulses.
Mode FBI is for retrievi ng trouble codes from the ECU
memory. If a problem happened sometime during the
machine's operation, but everything is operating
properly at the present time, the ECU memory will
verify which component was at fault. This is good for
finding intermittent problems such as a wiring open or
short. Press the F, B, I and enter buttons. If the
display shows one of the above codes, check that
component and its circuit. If nothing appears, there is
nothing in memory. NOTE: If the ECU power is
disconnected at any lime, this memory will be erased.
Mode FCa is used for erasing problem codes which
are stored in the ECU's memory. To erase the
problem codes, certain steps must be followed in
order. First select the mode for the component which
indicated a failure. Next, press F, C, 0 and enter on the
monitor. The display will ask "Memory clear? o-yes
and I-no". By pressing a and enter the memory will be
erased. Indication of the memory being cleared will be
a display of "Please key off'.
Mode Desc ri ption Normal Reading
FBO E)(isting Trouble
Codes
Faults Presently E)(isting
FB1 Memory Trouble Faults Which Are
Codes Intermittent
FCO Memory Clear Used to Remove Stored
Information
4.61
...
-
Monitor
Syst em
and LED
Code Type
11
12
13
14
14
15
21
22
23
31
32
33
One
X
X
X
X
X
X
X
CHIP
PRESSURE
SENSOR
Type Abb.
Two
X THV
X T
Case
X T Air
ALT
X TW
X ALT
X Inp
X Inj 2
Inj 3
X VB
X VB
X CDt
RICE RED
Component
Throttle Position
Sensor
Crankcase
Temperature Sensor
Intake Air
Temperature Sensor
Barometric Pressure
Sensor
Water Temperature
Sensor
Barometric Pressure
Sensor
Mag Side Injector
Center or
PTO on wins
PTO Injector
Low Battery Voltage
low Charging
System Output
COl Output
CONTROL.
8194
-
ENGINE ELECTRICAL
EFI Electronics
The FA modes are for testing the input and output functions from the ignition switch and the relays.
Type I System
With the select monitor on mode FAD, the display should show KY. Whenever the ignition switch and the
handlebar kill switch are in the run position. the number 3 LED should also light. Cycle the switches a few times
and observe that the LED goes off when the switches are turned off and re-lights when the switches are returned to
the run position.
Advance the monitor to mode FA 1 and connect the gray and black dealer mode wires together on the monitor's
service harness. The monitor display should read OM (Dealer Mode), and the number 5 LED should be lit. During
dealer mode operation, the fuel pump will cycle on and off in one second intervals and any stored problem code will
flash on the ECU's LED.
Advance the monitor to mode FA2 and the leHers FP (fuel pump), SO (self diagnostics) and SS (self shut-off) will
appear on the display. Whenever the EFI system is in the normal run mode the number 1 LED will be lit when the
fuel pump is required to run. This will be for five seconds when the key is initially turned on, and whenever the ECU
senses engine ignition pulses. The number 3 LED will be lit when the key is turned on and will go out ten minutes
atter the switch is turned off. When the dealer mode wires are connected together at the service harness, the
ignition key is cycled off and back on, and the select monitor returned to mode FA2. the number 3 LED will not be lit.
The number 2 LED will flash any problem codes which are in memory in the ECU and the number 1 LED will flash
off and on in one second intervals.
Type II System
With the select monitor on mode FAO.the monitor should show an ST and OM on the left. and a KY on the right of
the display. The number 1 and 5 LEOs will light when the key is rotated to the start/reset position. The number 6
LED will light when the gray and black dealer mode wires are connected together on the service harness. The fuel
pump relay will only cycle on and off for three one second runs each time the system is reset whi le in dealer mode.
Due to the different operational method used in the Type Two system, there is not an FA 1 or FA2.
8194
4.62
RIDERED
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4.63
ENGINE ELECTRICAL
1994-1995 Wiring Diagram RXL

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8/94
ENGINE ELECTRICAL
1994-1995 Wiring Diagram - 500 EFI (Page 1 of 2)
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8/94
4_64
AIDE RED
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ECU
PIN
& WIRE COLOR
PIN f
&. WI RE COLOR
1 P/BLU 101 LG
3 W 102 LG/BLK
.. 6LU/ W 105 GRN/ W
5 BLU/GRN 106 R/GRN
8 GRN/R ! 11 BAN
]0 eLK 112 BRN/R
11 OR/BLK 113 P
11 Y/BL.J 114 BAN/Y
15 115 BAN/Y
16 GRN/Y 116 R/BLK
17 BLK/Y 12\ BRN
122 eRN/A
123 BLlVR
124 euvIII
125 BRN/Y
126 R/BU<
-
POLARIS TO FUJI
HARNESS INTERCONNECTION
V ! EW FROM THE BACK Of"
THE POLARIS PLUG
ITEWPt euc;'JI
TEMP/BATTERY
WARN ING LIGHTS
""'fi!.i:'"1'
SEE POL .... R I 5 W! RING Hi\RNESS I
__ __ ...
RELAY REL'" Y
(BLACK I (BLACK I
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POSITION
SENSOR
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. FU-.j-I--H"RNESS- - _. -- -r -r
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L..... R/GRIJ P eRN
eLK BLACK
BLU BLUE
BRN BROwN
GAY GRAY
GRN GREEN
PUR PURPLE
LG LIGHT GREEN
OR ORANGE
P PINK L
Y YELLOW
\II WH ITE DAI&.K
R AEO
TWO COLOR WIRES ARt SHOWN
WITH MAIN/TRACE COLORS .
EXAMPLE :
BLU/R < BLUE WITH RED TRACER .
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POLARIS ELECTROINC FUEL
CONTROL UNIT
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ENGINE
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Engi ne Speci ficati ons
CHAPTER 5
ENGINES
1985 ..................... . .. .... ........... . ...... .... . .. . ......... 5.1
1986 ....... . . .... .. . .... .. . . . . . ...... . ........ ...... . . . . .. ......... 5.2
1987 ............... . ... . .. . . . .. . . . . . . . ......... .. . . ....... .. .... 5.3
1988 ........ .......... . .. . ... .. .... . ............. . ........ . ....... 5.4
1989 ...... . .. . . . . .... .... .. ... .... ......... . .... . ............. ..... 5.5
1990 ............... .. ... ....... . ............ . ..... . . . .. . . ... . ........ 5.6
1991 ....... . . ... . ... . . . ................ . ................. ........ 5.7
1992 ................... . ........ ... ....... . .. . ...... . .. . . . . . ..... 5.8
1993 ...... . ... . .. .. .... . ..... . ...................................... 5.9
1994 ......... ......................... . .. . ............ . . .. . ..... 5.10
1995 ................ ... ......................... .................... 5.11
Piston Identification ............. . . .. ... ........ . .. . . . . ..... 5. 125.13
Metric Conversion Factors ..... . .. .. .......... . ................ ....... 5.14
Two Cycle Operation ... . .. ...... ... . . .. _ . .... . ... . . ..... 5. 15
Troubl eshooti ng . ... ... . . . ................ .. . ...... .. ... . . . .......... 5.16
Spark Plug Information ..... ... . ,' .. .. ... ... .. ..... .. .. . .. 5 . 1 7 - ~ . 1 8
Lubricants ................. .. ............. ........... . .... .. . ....... 5.1 S.S. 19
Fuel Mixtures ............. .. .... .... ................................ 5.19
Torque Specifications ................. ..................... ............. 5.20-5.21
Disassembly and Reassembly Procedures - PS - Single Cylinder Series ...... 5.22-5.29
Disassembly and Reassembly Procedures - Pl - Three Cylinder Series ....... S.3Q--S.36iM
Disassembly and Reassembly Procedures - Pl Series - Reed Valve .......... "5.37-5.42
Di sassembl y and Reassembl y Procedures - MonobJock ..................... 5.43-5.46
Disassembly and Reassembly Procedures - PL - Twin Cylinder Series ....... . 5.47-5.53
a
RIDERED
8/94
8194
Disassembly and Reassembly Procedures - PM - Twin Cylinder Series ....... 5.54-5.55
Crankshaft Truing and Crankcase Bearing Fit .............................. 5.56-5.57
Cylinder Service ............................... . . . .. . . . .. . ........... 5.58
Cylinder Service - Piston Identification ................................ _ . .. 5.59
Cylinder Service - Piston/Cylinder Clearance .......... ................... 5.60
Cylinder Service - Oversize Pistons and Rings .. . . . . . . .. . .. .. .. .. .. . . . . . . . . .. 5.61
Cylinder Hone Selection and Honing ................ . ........ .... ...... 5.62-5.63
Recoil Starter Rope/Spring Replacement ..................... ........... 5.64-5.67
Cooling System - EC60PL with Recovery System ........ . ... . . ........... 5.68
Cooling System - EC65PL-05 .... . ........................................... 5.69
Cooli ng System- EC75PL-Ol . EC80PL-Ql .............. . .. . ... . .. ............ 5.70
Cooling System - EC80PL-02 ................................................ 5.71
Cooling System - EC4OJ45/50160/65PL with Positive Bleed Recovery System ... . .. 5.72
Oil Pump Bleeding and Adjustment - All Models ......................... . ...... 5.73
Oil Pump Operation and Troubleshooting ..................................... 5.74
b
AIDE RED

1985 Models
Machine Model Engine Model Cyl. Disp. Bore
CC's MM
Star EC25P506 244 72
SS EC44-2PM-3100 432 67.72
Indy Trail EC44-2PM-2100 432 67.72
Indy 400 EC40PL..()2 398 65
''''' 600
EC60Pl-02 597 65
Long Track EC44-2PM-5000 432 67.72
Engine Model Cyl. Head Cyl. Head Piston
ec's ec's Rings
Un Installed Installed
EC25PS-06 26.5 23.7 '(2) 2.0 mm
Plain
EC442PM3100 22.6 21.0 '(1) I .Smm
Keystone
EC44-2PM-2100 22.6 21.0 '(1) 1.5mm
Keystone
EC44-2PM-5000 26. 1 24.5 ' (2) l.Smm
Keystone
EC40PL.02 19.0 19.0 '(1) 1.2mrn
Keystone
EC60PL-02 19.2 19.2 '(I) 1.2mm
Con1>ressed Gasket
Keystone
Thickness' .4Smm
ENGINES
Engine Specifications
Bore Stroke Stroke No. of Type of
Inches MM Inches Cyl. Cooling
2.8346 60 2.362 1 Fao
2.6557 60 2.362 2 Fao
2.6557 60 2.362 2 Fan
2.559 60 2.362 2 Liquid
2.559 60 2.362 3 Liquid
2.6557 60 2.362 2 Fan
Piston/Cylinder - Engine Recommended
Bore Ciearance Operating RP Idle RPM
+.002" +200 RPM
.006 6300 2100
.006 6000 2300
.
.006 6800 2300
.006 6300 2300
.005 7600 1900
+.002
-.001
.0055 7800 1900
. 002
-.001
-Piston ring end gap all engines .20 mm .45 mrn (.008" - .018")
5. 1
8/94
AICERED
ENGINES
1986 Models
Machine Model Engine Model Cyl. Disp. Bore Bore Stroke Stroke No. of Type of
CC's MM Inches MM Inches Cyt. Cooling
Slat, StarTrak EC25P5-06 244 72 2.8346 60 2.362 1 Foe
Sprint (ES) EC34-2PM-Ql /02 339 62 2.4410 55.6 2.1866 2 F,n
SS EC44 2PM3IOQ 432 67.72 2.6557 60 2.362 2
F""
Indy T r a ~ ECSOPM-Ol 488 72 2.8346 60 2.362 2
F""
Indy 400 EC40Pl-02 398 65 2.559 60 2.362 2 liquid
Indy 600 (lEI EC60Pl-02 597 65 2.559 60 2.362 3 Liquid
Long Trak EC442PM-5100 432 67.72 2.6557 60 2.362 2 F,n
Engine Model Cyl. Head Cyl. Head Piston Piston/Cylinder Engine Recommended
CC's CC's Rings Bore Clearance Operating RP Idle RPM
Unlnstalled Installed +.002" +200 RPM
EC25P$-06 26.5 23.7 ' (2) 2.0 mm .006 6300 2100
Plain
EC34-2PM-Oll02 21.0 17.2 ' (I) 1.5mm .005 6500 2100
Keystone
EC442PM-3I00 22.6 21.0 '(I) 1.5 mm .006 6000 2300
Keystone
EC44-2PM-5100 26.1 24.5 '(2) I .Smm .006 6300 2300
Keystone
EC5QPM-01 26.6 24.0 ' (2) 1.5 mm .0055 7000 1900
Keystone
EC4OPl-02 19.0 19.0 '(1) 1.2 mm .005 7600 1900
Keystone +.002
-.001
EC6QPL.()2 19.2 19.2 (1)1 .2mm .0055 7600 1900
Compressed Gasket
Keystone
+.002
Thickness 1.45mm
-.001
'Piston ring end gap all engines .20 mm - .45 mm (.OOS" - .01S")
8194
5.2
AIDE RED
1987 Models
Machine Model Engine Model Cyl. Oi sp. Bore
ce's MM
Star, SlarTrak EC25PS06 244 72
Sprint (ES) EC342PMQlf02 339 62
Indy Sport EC34-2PM-03 339 62
Indy TraH (AI) EC50PM.ol J02 488 72
Indy 400 EC40Pl-02 398 65
'"", 600 EC60Pl-02 597 65
long Trak (ALA) EC44-2PM-5100 432 67.72
Engine Model Cyl. Head Cyl. Head Pi ston
ce's ce's Rings
Un installed Installed
EC25P5-06 26.5 23.7 '(212.0 mm
Plain
EC34-2PM-O 1 f02 21.0 17.2 '(1) 1.5mm
Keystone
EC342PM-Q3 21.0 17.2 '(I) 1.5mm
Keystone
EC44-2PM-51OQ 26.1 24.5 -(2) I .Smm
Keystone
ECSOPM-Ol102 26.6 24.0 '(2) 1.5mm
Keyslone
EC40Pl-02 20.85 22.05 '(1) 1.2mm
Keystone
EC60Pl-02 19.5 19.5 '(2) 1.2mm
Compressed Gasket
Keyslone
Thickness 1.45mm
ENGINES
2.8346 60 2.362
,
Foe
2.4410 55.6 2.1886 2 Foe
2.4410 55.6 2.1886 2 Foe
2.8346 60 2.362 2 Foe
2.559 60 2.362 2 UqOO
2.559 60 2.362 3 UqOO
2.6557 60 2.362 2
F"
Piston/Cylinder Engine Recommended
Bore Clearance Operating RP Idle RPM
+.002" +200 RPM
.006 6300 2100
.005 6500 2100
.005 6500 2100
.006 6300 2300
.0055 7000
'900
.005 7800
'900
. 002
-.lXll
.0055 7800
'900
.... 002
-.001
'Piston ring end gap all engines .20 mm -.45 mm (.008" - .018")
5.3
AICERED
8194
ENGINES
1988 Models
Machine Model Engine Mode.l Cyl. Disp. Bore Bore Stroke Stroke No. of Type of
CC's MM inches MM Inches Cyl. Cooling
Star, StarTrak EC25PS-06 244 72 2.8346 60 2.362 1 FM
Sprint (ES) EC34-2PM-Q2 339 62.3 2.4546 55.6 2.1886 2 FM
Indy Sport EC342PM-03 339 62.3 2.4546 55.6 2.1886 2 FM
Indy Trail (All) EC50PM-O, /02 488 72 2.8346 60 2.362 2 FM
Indy 400 (All) EC40PL-02J03 398 65 2.559 60 2.362 2 Liquid
Indy 650 (All) EC65PLOl 648 67.72 2.668 60 2.302 3 Liquid
Long Trak (ALA) EC44-2PM-4100 432 67.72 2.6557 60 2.362 2 FM
ec's ec's Rings Bore Clearance Operating RP Idle RPM
Un Installed Installed +.002" +200 RPM
EC25P$-06 26.5 23.7 ' (2) 2.0 mm .006 6300 2100
Plain
EC34-2PM-02 21.0 17.2 '(I) 1.5mm .005 6500 2100
Keystone
EC34-2PM-03 21.0 17.2 ' (I) 1.5 mm .005 6500 2100
Keystone
EC44-2PM-4100 22.6 21.8 '(2) 1.5mm .006 6300 2300
Keystone
EC50PM-Ol/02 26.6 24.0 '(2) 1.5mm .0055 7000 1900
Keystone
.
EC40PL-02I03 19.5 20.7 '(1) 1.2 mm .0060 8000 1900
Keystone +.002
-.001
EC65PL-Ol 21.5 21.0 '(2) 1.2 mm .0055 7800 1900
Compressed Gasket
Keystone
. +.002
Thickness 1.45mm -.001
Piston ring end gap all engines .20 mm - .45 mm (.008" - .018")
8194
'.
5.4
RIDE RED
1989 Models
Machine Model Engine Model Cyl. Disp. Bore
ce's MM
Star, StarTrak EC25PS.()6
'"
72
Sprint (ES) EC34-2PM-02
33'
62.3
Indy Sport EC342PM-(l3
33'
62.3
Indy Trail (AU) EC50PM01/02J03
, ..
72
Indy 400 (AI) EC40PL-02 398 65
Indy 500 (AI) EC50PL-Olf02
, ..
72
Indy 650 (AM) EC65PL-{)1 648 67.72
long Trak (RLA) EC44-2PM-4100 432 67.72
Engine Model Cyl. Head Cyl . Head Piston
ce's ec's Rings
Unlnstalled InstalJed
EC25P5-06 2.' 23.7 (2) 2.0mm
Plain
EC342PM-Q2 21 .0 17.2 (1) 1.5 mm
Keystone
EC342PM-03 21 .0 17.2 '(I) 1.5mm
Keystone
EC44-2PM-4100 22.6 21.8 (2) 1.Smm
Keystone
ECSOPM-Olf02 26.6 24.0 ' (2) 1.5mm
Keystone
ECSOPM-OO 31.2 28.6 "(2) I .Smm
Keystone
EC40PL-02 19.5 20.7 '(1) 1.2mm
Keystone
ECSOPl-Ol/02 23.4 23.5 '(2) 1.5mm
Keystone
EC65PL-Ol 21.5 21.0 "(2) 1.2 mm
Keystone
ENGINES
2.8346 60 2.362 1 Fao
2.4546 55.6 2.1886 2 Fao
2.4546 55.6 2. 1886 2 Fao
2.8346 60 2.362 2 Fao
2.559 60 2.362 2 UquKl
2.8346 60 2.362 2 Uquid
2.668 60 2.362 3 Liquid
2.6557 60 2.362 2 Fao
Piston/Cylinder Engine Recommended
+.002" +200 RPM
.006 6300 2HlO
.005 6500 2HlO
.00' 6500 2HlO
.00' 6300 2300
.0055 7000 1600
.0055 6600 1600
.0050 8000 1900
+.002
-.001
.0042 7800 1900
7000
.0055 7800 1900
'Piston ring end gap all engines .20 mm .45 mm (.008" - ,018")
5.5
AICERED
8/94
ENGINES
1990 Models
Machine Model Engine Model Cy!. Disp. Bore Bore Stroke Stroke No. of Type of
CC's MM Inches MM Inches Cyl. Cooling
Star,StarTrak EC25PS-06 244 72 2.8346 60 2.362 1 Fao
Sprint (ES) EC342PM-{)2 339 62.3 2.4546 55.6 2.1886 2 Fao
Indy Sport EC342PM-03 339 62.3 2.4546 55.6 2.1886 2 Fao
Indy Trail (All) ECSOPM-Ol102J03
, ..
72 2.8346 60 2.362 2 Fao
Indy 400 (All) EC4QPL-{)2 396 65 2.559 60 2.362 2 liquid
Indy 500 (All) ECSOPL-Olf02I03
, ..
72 2.8346 60 2.362 2 liquid
Indy 650 (AU) EC65PL-Ol 646 67.72 2.588 60 2.362 3 liquid
ec's ec's Rings Bore Clearance Operating RP Idle RPM
Un Installed Installed +.002" +200 RPM
EC25P&-Q6 26.5 23.7 ' (2) 2.0 mm .0040-.0065 6300 2100
Plain
EC34-2PM-02 21.0 17.2 ' (I) 1.5 mm .0035-.0055 6500 2100
Keystone
EC442PM..Q3 21.0 17.2 '(I) 1.Smm .0035-.0055 6500 2100
Keystone
ECSOPM-OlI02 26.6 24.0 '(2) 1.5 mm .0040-.0065 7000 1600
Keystorle
ECSOPM-03 3t .2 28.6 '(2) t.5mm .0040-.0065 6600 1600
Keystorle
EC4QPl-02 19.5 20.7 '(I)I.2mm .0050-.0055 8000 1900
KeystOrle
ECSOPl-{)lf02 23.4 23.5 '(2) 1.5 mm .0025-.0045 7800 1900
ECSOPl-{)3 Keystorle 7000
EC65Pl-{)1 21.5 21.0 '(2)1 .2 mm .0035-.0060 7800 1900
Keystorle
'Piston ring end gap all engines .20 mm -.45 mm (.008" - . 0 1 8 ~ )
8194
5.6
RIDE RED
1991 Models
Machine Model Engine Model Cyl. Ol sp. Bore
CC's MM
StarUte EC25PS-07 244 72
Indy Ute EC342PM-03 339 62.3
Indy Sport/GT EC44-3PM-01 432 67.72
Indy Trait (AN) ECSOPM-Ol/02I03 488 72
Indy 400 (All) EC40PL-02 398 65
Indy 500 (AU) ECSOPl-Ol102J03 488 72
Indy 650 (AI) EC65PL-02J03 648 67.72
Engine Model Cyl. Head Cyt. Head Piston
CC' s CC' s Rings
Unlnstalled Installed
EC25PS-07 26.5 23.7 ' (2)2.0 mm
Plain
EC342PM'()3 21.0 17.2 '(I) 1.5 mm
Keystone
EG443PM-Ol 28.6 23.0 ' (2) 1.5 mm
Keystone
ECSOPM-Ol/02 26.6 24.0 ' (2) 1.Smm
Keystone
ECSOPM-03 31.2 28.6 ' (2) 1.Smm
Keystone
EC40PL.()2 19.5 20.7 (1 ) 1.2mm
Keystone
ECSOPL-Ol102 23.4 23.5 (2) 1.5 mm
ECSOPL-03 Keystone
EC65Pl-01J03 21.5 21 (2) 1.2 mm
Keystone
ENGINES
2.8346 60 2.362
,
'.n
2.4546 55.6 2.1886 2
'on
2.668 60 2.362 2
'on
2.8346 60 2.362 2
'on
2.559 60 2.362 2 Liquid
2.8346 60 2.362 2 liquid
2.668 60 2.362 3 Uq.;d
Piston/Cylinder Engi ne Recommended
+.002" +200 RPM
.0040-.0065 6300 '200
.0035-.0055 6500 2100
.0035-.0055 6500 2100
.0040-.0065 7000
'600
.0040-.0065 6600
'600
.005-.0055 6000
'900
.0025-. 0045 7800 1900
7000
.0035-.0060 7800
'900
Piston ring end gap all engines .20 mm -.45 mm (.008" - . 0 1 8 ~ )
\
,

5.7
RICEREC
6/94
ENGINES
1992 Models
Machine Model Engine Model Cyl. Olsp. Bore Bore Stroke Stroke No. of Type of
ce's MM Inches MM Inches Cyl. Cootlng
Starlite l- EC25PS07 244 72 2.8346 60 2.362 1
,,,
Indy liteIGTI D e l u ~ e EC34-2PM.Q2/03/04 339 62.3 2.4546 55.6 2.1886 2
,,,
Indy SportlGT EC44-3PM-Ql 432 67.72 2.668 60 2.362 2
,,,
Indy Trail (All) ECSOPM-QlI02J03 488 72 2.8346 60 2.362 2
,,,
Indy 440 XCR/440 EC45PL-oI /02 432 61.72 2.668 60 2.362 2 Uquid
Indy 500 (All) ECSOPL-041051(l6107 488 72 2.8346 60 2.362 2 Uquid
Indy 850 (All) EC65PL-02/03 648 67.72 2.668 60 2.362 3 Uquid
Engine Model Cyl. Head Cyl. Head Piston PlstonfCylinder Engine Recommended
ee's ce's Rings Bore Clearance Operating RP Idle RPM
Unlnstalled Installed +.002" .200 RPM
EC25PS-07 26.5 23.7 '(2) 2.0 mm .0040-.0065 6300 1200
Plain
EC342PM-02J03IO 21.1 17.3 '(I) 1.5 mm .0035-.0055 6500 2100
4 Keystone
EC44-3PM-OI 28.6 23.0 '(2) 1.5 mm .0035-.0055 6500 2100
Keystone
EC50PM.(I l102 26.6 24.0 '(2) 1.5 mm .0040-.0065 7000 1600
Keystone
ECSOPM-03 31.2 28.6 '(2) 1.5 mm .0040-.0065 6600 1600
Keyslone
EC45Pl-Ol102 26.4 21.0 "(1) 1.2mm .0035-.0055 6000 1900
Keyslone
ECSOPl-04105107 23.5 23.5 "(2) 1.2 mm .0035-.005 7800 1900
ECSOPl-06 "(2) 1.5 mm .0025-.004 7000
Keyslone
EC65Pl-Ol103 21.4 20.4 "(2) 1.2 mm .CJ050..0070 7800 1900
Keystone
'Piston ring end gap all engines .20 mm - .45 mm (.008"' .018")
8/94
5.8
RICERED
.,.(

1993 Models
Machi ne Model Engine Model Cyl. Disp. Bore
ee's MM
Slarlite EC25PS-07 244 72
Indy LiteJGTI Deluxe 339 62.3
Indy SportlTr3il Deluxe EC44-3PM-ol 432 67.72
Indy Trail ECSOPMOlf03 488 72
(AU)M'ideTrak
Indy 440 XCR/440 EC45Pl-Ql102 432 67.72
Indy 500 (AU) ECSOPl.Q4J05lO6lO7 488 72
Indy XlT (All) EC58-Pl-Ol 579 64
Indy 650 (All) EC65PL-05 648 67.72
Indy Storm EC75PL-Ol 744 69.72
Engine Model Cyl. Head Cyl. Head Piston
ee's ce's Rings
Uninstalled Installed
EC25PS07 26.5 23.7 '(Z)2.0mm
Plain
EC34-2PM.Q2I04 21.1 17.3 '(1) 1.5 mm
Keystone
EC44-3PM-Ol 28.6 23.0 (2) 1.5 mm
Keystone
ECSOPM-Ol103 31.2 28.6 (2) 1.5mm
Keystone
EC45PL-Ol/02 26.4 21.0 (2) 1.2 mm
Keystooe
ECSOPL-()4f05/07 23.5 23.5 (2) 1.2mm
EC50PL-C16 (2) 1.5mm
Keystone
EC58PL-Ol 23.5 25.4 (2) 1.2 mm
Keystone
EC65PL-05 21.4 20.4 (2) 1.2 mm
Keystone
EC75PL-Ol 30.5 24.8 0(2} 1.2 mm
Keystone
ENGINES
2.8346 60 2.362
,
F,n
2.4546 55.6 2.1886 2 F,n
2.668 60 2.362 2
F"
2.8346 60 2.362 2 F,n
2.668 60 2.362 2 liquid
2.8346 60 2.362 2 Uqu;d
2.519 60 2.362 3 liquid
2.668 60 2.362 3 Liquid
2.744 65 2.559 3 Liquid
Piston/Cyl inder Engine Recommended
+.002" 200 RPM
.OQ4()'.0065 6300 '200
.0035-.0055 6500 2100
.0035-.0055 6500 2'00
.004()'.0065 6600 '600
.0035-.0055 8000
'900
.0035-.005 7800 ,900
.0025-.004 7000
.0035-.0055 8000
'900
.00SQ...0070 7800 '900
.0045-.0055
'900
Piston ring end gap all engines .20 mm -.45 mm (.008" - .0181
5.9
RICEREC
8/94
ENGINES
1994 Models
Machine Model Engine Model Cyl. Bore Bore Stroke Stroke
Disp. MM Inches MM Inches
ec's
StarLite/GT EC25PS07 244 72 2.8346 60 2.362
Incty Ute/GTI Delu)(e EC342PM-02I04
33'
62.3 2.4546 55.6 2.1886
Indy Super Sport EC44-3PM-Ot!02 432 67.72 2.668 60 2.362
Indy Spoft/SKS
Indy Trail (Aa)/'NideTrak ECSOPM..()l102103 488 72 2.8346 60 2.362
Indy 440/SKS EC4SPl-Ol102 432 67.72 2.668 60 2.362
XCRl440
Indy 500 (All) ECSOPL-05/06I07fQ8 488 72 2.6346 60 2.362
Indy XLT/5P/SKS EC58PL-Ol 579 64 2.521 60 2.362
Indy RXUTouring EC65PL-05l06 648 67.72 2.668 60 2.362
Indy StormlSKS EC80PL-Ol 794 72 2.8346 65 2.561
Engine Model Cyl . Head Cyl. Head Piston Pi ston/Cylinder Engine
CC's ec's Rings Bore Clearance Operating
Unlnstalled Installed +.002" RPM 200
RPM
EC25PS-07 26.5 23.7 (2) 2.0mm .cM)4G-.OO65 6300
Keystone
EC34-2PM-02J04 21.1 17.3 (2) 1.5mm .0035-.0055 7000
Keystone
EC44-3PM-OlI02 28.6 23.0 (2) 1.5mm .0035--.0055 6800
Keystone
ECSOPM-Olf02/03 312 (02) 28.6 (02) (2) 1.5 mrn .0040-.0065 6600
26.7(01103) 24.1(01103) Keystone
EC45PL-Ol102 26.4 21.0 (2) 1.2 mrn .0035-.0055 6000
Keystone
ECSOPL-Osr06l07i08 23.6 23.6 (2) 1.2/'1.5 .0035-:005 8000/07
Keystone '.0025-.004 77500'05108
7000l06
EC58PL-Ol 23.5 25.4 (2) 1.2mrn .0035-.0055 8000
Keystone
EC65PL-05 21.4 20.4 (2) 1.2 mrn .005Q-.0070 6000
Keystone
EC80PL-Ol 28.1 26.6 (2) 1.2mm .0045-.0065 8250
Keystone
Piston ring end gap all engines except EC80PL-Ol .20 mm - .5 mm (.008" - .020")
Piston ring end gap EC80PL-Ol engi nes .36 mm - .62 mm
8194
5.10
RICERED
No. Type ot
01 Cooling
Cyl.
1 Fao
2 Fao
2 Fao
2 Fao
2 Liquid
2 liquid
3 liquid
3 Liquid
3 Liquid
Recommended
Idle RPM
1200
2100
2100
1600
1900
1900
1900
1900
1900
1995 Models
Machine Model Engine Model Cyl.
Clsp.
ec's
Slarlite EC25PS07
24'
Indy UteiGTI Deluxe EC34 2PM02JE02 339
Indy Super Sport EC44-3PM01102
'32
Indy SporVSKS
Indy Trait (AIQM'"tdeTrak ECSOPM03I04/E04
'88
Indy 4401SKS EC45PL02 432
XCRl44Q 03 439
Indy 500 (All) ECSOPl04/E04/06f07
'88
Indy XLT/SP/SKS EC58PL02/03l04 596
XCR600
Indy RXUTouring EC65PlO5lE05 646
Indy SlormlSKS ECSOPl
79'
Engine Model Cy!. Head ec's Cy!. Head
Un Installed ee's
Installed
EC25PS07 26.5 23.7
EC34-2PM02E02 21.1 17.3
EC44-3PM01102 28.6 23.0
EC50PM03I04E04 31.2 (03) 28.6 (03)
26.7(04) 24.1(04)
EC45PlOl /02-03 25.8 21.1
19.0
ECSOPlO4E04107 23.6 23.6
06
EC58Pl02 17. 1
03104 19.1
EC65Pl05 21.4 20.4
ECBOPl02 28.1 24.9
26.6 mag
Bore Bore Stroke
MM inches MM
72 2.8346 60
62.3 2.4546 55.6
67.72 2.668 60
72 2.8346 60
67.72 2.668 60
68.25 2.689
72 2.8346 60
65 2.561 60
67.72 2.668 60
72 2.8346 65
ENGINES
Stroke No. Type of
Inches Of Cooling
Cy!.
2.362 1 F,n
2.1886 2 F,n
2.362 2 F,n
2.362 2 F,n
2.362 2 Liquid
2.362 2 Liquid
2.362 3 Liquid
2.362 3 Liquid
2.561 3 Liquid
Piston Piston/Cylinder Engine Recommended
Rings Bore Clearance Operating Idl e RPM
+.002" RPM 200
RPM
(2) 2.0 mm .0040-.0065 6300 1200
Keyslone
(2) 1.5mm .0035-.0055 7000 1600
Keyslone
(2) 1.5 mm .0035-.0055 6800101 1600
Keystone 7000'02
(2) 1.5 mm .0040-.0065 6600103 1600
Keystone 7000/04
(2) 1.2mm .0035-.0055 6000 1900
Keystone
(2) 1.2mm .0035-.005 6000l07 1600
(2) 1.5mm .0025-.004 7750104
Keystone 7000l06
(2) 1.2mm .0035-.0055 6500 1900
Keystone 6250
(2) 1.2 mm .0050-.0070 6000 1900
Keystone
(2) 1.2mm .0045-.0065 6250 1900
Keystone
Piston ring end gap all engines except EC80PL-01 .20 mm - .45 mm (.008" - .020")
Piston ring end gap EC80PL01 engines .36 mm - .62 mm
5. 11
11/95
AIDE RED

ENGINES
Piston Identification
Piston Retainer Groove (Dimensions MM)
Usage Clarification
Model
EC44-2PM
EC44-3PM
EC5DPM
EC4DPL
EC45/5DPL
EC6DPL
EC58165175/BOPL
Spiral Clip Groove MM
., B r- 0.75-.85
1984/85
B
B
B
B
-
Spiral Style
Wrist Pin
II
-B--Y--It-
1985/86
B
B
B
B
-
C-Clip Groove MM
D
-I I- 0.75-.85
1986/81"
D
B,O
B,O
B,O
-
C-Cllp Style
Wrist Pin

0
0
0
0
0
0
0
45" -(II
E--8-
CAUTION: Do not use C-clip retai ners in spiral clip style pistons, or spiral Clip retainers in C-clip style pistons.
Severe cylinder damage will result .
CAUTION: Do not use C-clip style wrist pins (with 45 chamfer) with spiral style piston retainer groove. Severe
cylinder damage will result. Spiral style wrist pin may be used in either style piston.
8/94
5. 12
AICERED
Spiral Clip Pislons
Motor Model
EC44-2PM
1100,2100,4100
Piston Height.68 mm
EG44-2PM
3100,5000,5100
Piston Height.7Q nYl1
EC50PM
EG40Pl
ECSOPL
C-clip Pistons
Motor Model Standard
EC44-2PM 3083682
1100,2100,4100 3083680
Piston Height. S8
mm
EC44-2PM 3083789
3100.5000,5100
Piston Height. 70
mm
EC44-3PM-Ol 3084239
ECSOPM-Ol-02 3083841
EC50PM-03 3083954
EC40PL 3083a48
EC45PLQ1 /02J03 3084326
EC45PL05 TBA
EC50PL-ol-o2 3083901
ECSOPL-04-o5-07 3084339
ECSOPl-03-06 3083942
EC60Pl 3OB3883
EC58Pl-ol 3084449
ECS8Pl -02 3085018
EC58Pl -03
EC65Pl 3OB3857
EC75Pl-ol 3084575
EC80Pl-ol 3085030
-Ring face width in mm.
Standard
3083000
3083159
308354'
3083681
3083348
Piston .010"
ENGINES

Piston .010" Piston .020" Piston
Mark Oversize Mark Oversize Mark
Ml NlA 3063173 50Ml
M2 NlA - 3083174 50M2
M NlA 3083716 50M
4L 3083303 4l2' 3083720
4L'
6L 3083292 6l2' 3083293 6L5
Piston .020" Piston Mark C Clip
Mark Oversize Marl< Oversize
M3,Ml NfA 3083881 SOM3,SOM! 3083839
M5 NfA - 3083895 5OM5
M4,M2 NfA 3083791 5OM4,5OM2 3083839
M6 3084240 25M6 3084241 5OM6 3083839
Ml ,M 3083902 4W25 3063842 SOM1 ,SOM 3083839
M2 3063943 5W25 3083975 50M2 3083839
4A,4L 3083877 4A25, 3083878 4A5,4L5 3083839
4l2'
45A 3084327
45A2'
3084328 45ASO 3083839
455A TBA 455A2S TBA 455A50 3084167
1.S4W 3083902 1.5 4W2S 3083903 1.S 4WSO 3083839
1.2 SA/SB 3084340 1.2 SAlB2S 3084341 1.2 5AIBSO 3083839
5W 3083943 SW2S 3083944 5W50 3083839
6A,6L 3083a84 6A2S,6L2S 3083885 6AS.6lS 3083839
58B 3084450 S882S 30844S1 58B50 3084456
58E 3085019 S8E25 3085020 58E50 3084456
58E 58E25 58E50
65E 3063875 65E25 3083876 6SEC5O 3083839
75PL 3084576 75PL25 3084577 75PLSO 3083839
80B 3085027 8OB25 3085028 80BSO 3084167
CAUTION: Be sure to install the proper piston C Clip in the engine.
There are two types of 18mm C Clips. Some engines use an 18mm C Clip with a 1,2mm wire diameter (PN
3084167). Two examples are the EC80PLOl and the EC45PL05.
The maj ority of others use 18mm C Clip PN 3083839. This C Clip has a wire diameter of 1.4mm and mustnotbe
installed in engines requiring the l.2mm clip. Always refer to the appropriate parts manual or microfiche when
orderi ng C Clips and verify the proper diameter before installati on.
5.13
RIDE RED
8194

..

ENGINES
Metric Conversion Factors
Metric - Conversion
MM
1NC':i
MM IMM

o:ii6O
'"
-=-
"

"'32

53
,
0."75 0/32

,,-
,.",-, ,5/32 -
"
5

30

I'
-
55
--. i3iiO .".
--;-
0.35<3 11/32

"
-,_
11/32 - 59
10 0.3937 ,3/32 - 35 13780

60
o:5ii8
'"
--;-
36 Uii6> lln - 63
"
0.5512

-
39 153&1 , 17/32

"

, 9/16

65
"
o:66e3 2iI32
--;-
"
C6335 , 21/32
- 67
18 0.7087 23/32 -
"
16929

68

"
o:i268
"'"
--;-
4s UliiO - 71
22 0.866' 7/8
-
"

127/32

72
"
--.....-

Compari ng The Most Common Measurement Units
Approximate conversions from Customary to metric and vice versa
When you know: You can lind:
LENGTH inches millimeters
feel centimeters
yards meters
miles kilometers
millimeters inches
centimeters inches
meters yards
kilometers miles
AREA square inches square centimeters
square feet square meters
square yards square meters
square mile square kilometers
acres square hectometers (hectares)
square centimeters square inches
square meters square yards
square kilometers square miles
square hectometers (hectares) acres
MASS ounces grams
PO''''''
kilograms
"""""'"
megegrams (metric tons)
grams ounces
kilograms pounds
megegrams (metric tons) short tons
LIQUID ounces milliliters
VOLUME pinls liters
"",rt, lilers
gallons liters
milliliters ounces
liters pints
liters quart
liters gallons
TEMP degrees Fahrenheit degrees Celsius
degrees Celsius degrees Fahrenheit
8194
5.14
I

2._
2.'260 21/8

25/32

-
2.3228

2.3622 23/8 -
-
2.5197 217/32 I -
25591 29/16 I -
2.6772 211/16 1-

I 223/32 I -
"'953
2.83<6

I -
=ffi
If you multiply by:
2S
30
0.9
16
0.1>1
0.<
1.1
0.6
6.S
0.09
08
2.6
0.<
0.16
1.2
0.4
2.S
28
0.45
0.9
0.035
2.2
1.'
30
0.47
0.95
3.8
0.034
2.'
1.06
0.215
519 (after subtracting 32)
9/5 (then add 32)
IMM

79 3.1102 31/8 -
80 3."" 35/32 -
81

"
3.3071 3&16 -
"
3.""
3 11/32

86 3.3858

89 3.5039 31n

90

I 317/32 I
93 3.66" 321132 I
"
3.7008 311/16

97 3.8189
3.8583 I 327132
3.9370 3
To Detennlne
Metric Displacement
mmBore + 2.
x itself, or A squared
xpi3.1416_
x mm stroke .
+ 1000 _.-,_--,-
displacement
of one cylinder
incc
To Determine
Compression Ratio
Compression Ratio ..
Piston Displacement +
Installed Head Volume +
InstaJled Head Volume ..
: 1 Ratio

RIDE RED
Polaris snowmobiles are equipped with dependable, high-performance two
cycle engines. The first step in proper care of the two cycle engine is to have
a basic understanding of how it works.
Intake
The piston in a two-cycle engine acts as a valve. When the piston moves
upward in the cylinder (first stroke), the exhaust port is closed and the intake
port is opened. Air and fuel are drawn into the crankcase and the air/fuel
mixture is compressed in the combustion chamber. The spark plug ignites
the air/fuel mixture, which expands and forces the piston downward.
Power
After the piston starts downward, high pressure from the burning gases is
applied against the piston, driving it downward with maximum force. This
vertical motion is transmitted through the connecting rod into radial motion
by the crankshaft. The force of combustion continues until the piston is
further down in the cylinder when the exhaust port is opened.
Exhaust
Several functions take place simultaneously during the exhaust phase.
When the piston moves downward far enough to open the exhaust port, most
of the burned exhaust gases are expelled from the cylinder. Complete
exhaust takes place after the piston drops low enough to expose the transfer
ports.
Fuel Transfer
The transfer port connects the crankcase to the combustion chamber. The
air/fuel mixture pulled into the crankcase earlier during the intake phase is
now transferred into the combustion chamber. This fresh charge helps to
push out the remaining exhaust gases. The piston then moves upward and
the intake phase begins.
When you realize that at 6000 RPM this happens 1 00 times a second, you
can appreciate the importance of proper lubrication, fuel mixture, and
carburetor adjustments.
Oil provides the only lubrication the engine receives. Keep in mind the
manufacturer's recommendations:
Use a good grade of both
oil and gasoline.
Always mix them in proper
proportions, thoroughl y,
and in a clean container.
Keep surplus fuel tightly
capped to prevent
evaporation, loss of
volatility and power.
ENGINES
Two Cycle Operation
Exhaust
Port ff"o"9
l7
, Intake
Port
E ' h a ~
Port ::-...,Intake
o Port
Too little oil means inadequate lubrication; too much oil means spark plug fouling, rapid carbonization, and
ovemeated pistons, all of which may lead to engine damage and costly repairs. .
The carburetor feeds the gas/oil mixture to the engine, mixing fuel and air to obtain the correct volatile mixture,
thus providing fuel for combustion, lubrication, and as a coolant for internal surfaces.
5.15
RICEREC
8194
ENGINES
Troubleshooting
PROBLEM
PROBABLE CAUSE
Will not start -Check ignition switch for run position
-Check auxiliary shut-(lff switch
-Check fuel sUfrply
-Check wiring rom engine to coil(s) or spark plug(sJ
-Check sparl< plug(s)
-Disconnect engine connector \0 eliminate any shorts thai might be in the system
-If starter won't work (electric models), check wires from starter solenoid and batt ery or check battery and
battery cables
-Open or broken reed valves
No spark -Spark plug fouled
-Secondary coil bad or wires disconnected
-Primary coil shorted or open
-Ignition points pitted or dirty
-Ignition switch shorted
-Auxiliary switch
No compression -Crankcase plug is oul
-Head gasket is blown
-Bad rings or piston
Engine idles but -Restricted fuel flow
no acceleration -Clogged main jet
-liming
-Clutching
Engine runs but
fails to reach
-Clogged fuel filter
-Incorrect track tension
maximum RPM -Incorrect main jet
-Throttle slides not fully open
-Chain too tight
-Clutching
Engine runs but -Incorrect air mixture setting
fails to idle -Throttle stop screw incorrectly adjusted
Dirt in pilot jet
Engine runs, but -Chokes are not seating
overloads wi th -Fuel pump IS ruptured (caused by engine backfiring)
fuel -Carburetor sli es are not synchronized
-Too large main jet
-Needle and seat not seating p!'operly
Incorrect float level
-Check reed valve condition
Carburet ion and -If a lot of riding is on trails, and foul and get black when so, lower jet needle E clip in
plug fouling 2nd notch from top of needle. F oat arms should be level when hoi ing carburetor upside wn. A so, air set
screw settin8 should be checked, and slide valves must be synchronized again to raise and lower evenly.
Maintain a, 17 to .020 spark plug gap.
Engine runs but -Coolant level
overheats -Incorrect main jet
-Incorrect timing
-Incorrect spark plug
Battery will not -Check for bad connections
charge (electric -Check alternator output
models only) -Check diodes
Ughts don't work Engine must be running
-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 bell (center distance)
pel itself -Check torque-o-matic unit
-Check chain
-Check drive sprocket assembly
Track wears un- -Check tension
evenly -Check for proper alignment
Chaincase gets -Check oil level
hoI -Check chain tension
-Check track assembly
Unit hard to steer -Check lubrication on spindles
-Check ski alignment
-Check spindle bearings
8194
5.16
RIDE RED
ENGINES
Spark Plug Information
The spark plug and its condition is indicative of engine operati on. 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 wilt be a
few combustion deposits. The electrodes are not burned or
eroded. Thi s indicates the proper type and heat range for the
engine and the service.
NOTE: The tip should not be while. A white insulator tip f
indicates overheating, caused by use of an improper spark
plug or incorrect carburetion adjustments.
Worn Out
Corrosive gases formed by combustion and the high voltage
spark have eroded the electrodes. Spark plugs in this
condition require more voltage to fire, often more than the
ignition system can produce.
Wet Foul ed
The insulator tip is black. A damp oily film covers the firing
end. There may be a carbon layer over the entire nose.
Generally, the electrodes are not worn. General causes are
excessive oil, use of non recommended injection oil,
excessive idling, idle too low or too rich, or weak ignition
output.
5.17
8194
RICE RED
ENGINES
Spark Plug Information/Lubricants
Gap Bri dgi ng
Gap bridging: This is usually a "Whisker" or filament 01
lead-carbon compounds which completely short-circuits
the spark, making the spark plug inoperative.
Original equipment parts, or their equivalent, should
always be used. The heal range of spark plugs is of ulmost
importance. A spark plug with a heat range which is 100
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 spark plug with a heat range
which is 100 low will cause excessive fouling and
malfunction. It is extremely important when replacing the
spark plugs to install only those which are factory tested
and recommended. The correct plug for the engine will
improve both starting and all-around performance.
CAUTION: Spark plug failure may be the result of contributing factors such as wrong fuel-air mixture, available
ignition voltage, carburetion adjustment, etc. Do not experiment with different heat ranges of spark plugs.
Lubricants
A good two-cycle lubricant must provide anti-friction protection to pistons, cylinder walls and bearings, but with no
flushing action. The oil must therefore contain, or be provided with, an affinity for metal. It must burn cleanly with a
minimum of smoke. II must mix easily with gasoline and remain in suspension. It must inhibit the formation of
varnish, rust, or other engine deposits.
Base oils vary in their ability to meet these requirements. Most good two-cycle oils are blends with carefully
selected additives to provide the necessary operating characteristics.
Polaris snowmobile oil has been subjected to a series of severe tests covering a broad range of operating
conditions. It meets all requirements. Polaris has a TC-W3 premium oil available for use in all of our products. We
highly recommend its use. The only oil recommended for this fuel system is Polaris brand oil. Engine warranty
coverage may become voi d if other brands are substituted.
CAUTION: Excess oil will cause carbonization of pistons, spark plugs, ports and exhaust systems, causing loss
of power. Too little oil will cause a lean condition and may cause piston seizure, over heating and rod end bearing
failure. If oil brands are changed, it is advisable to clean excess carbon from pistons, heads and exhaust ports.
Blue Premium 2-cycle Lubri cant - TC-W3 Certifi ed, TC Certified
Polaris Premium 2-Cycle lubricant is the most advanced formulation of oil available for today's 2-cycle engines.
Over twenty months of lab and field tests have resulted in a new generation of 2-cycle lubricant. Polaris Premium
2-Cycle lubricant addresses the problem of lower quality fuel ; keeping ring grooves cleaner with less ring sticking
and providing improved overall engine cleanliness. With new generation lubricity technology, it excels in meeting
the lubricity demands of today's faster, more precisely engineered 2-cycle engines. It is the optimum oil
recommended for liquid cooled 2-cycle engines and performs well in all air cooled 2-cycle engines. TC-W3 is the
recommended oil for today's 2-cycle outboard engines. We believe this oil is the best product available in the
market today, and strongly recommend its use in our products.
Red Injector Oil - TC-WII Equivalent
Polari s Injector Oil is designed for 2-cycle liquid cooled engines and fan cooled engines operated in cool ambient
temperatures. This formulation of 2-cycle oil is recommended for injection or pre-mix application. It is a TC-WII
equivalent, -40C pour point oil and is a proven performer in Polaris liquid cooled and fan cooled engines. For
those who chose not to use Polaris Premium lubricant, we recommend the use of this high quality product.
8/94
5.18
AIDE RED
ENGINES
Lubricants/Fuel Mixtures
Green Extreme Temp Oil TC Equivalent
Polaris Extreme Temp Oil is a 2-cycle engine lubricant designed for air cooted. high ambient temperature
operation. This low ash formulation reduces deposits created by high internal engine temperature and high
engine RPM. Polaris Extreme Temp Oil is formulated to maintain lubricity required by high RPM operation under
high internal engine temperatures. It is specifically designed for Polaris ATV and snowmobile air cooled 2-cycle
engines, but also works well in Polaris liquid cooled engines. It is an excellent oil for chain saws, weed eal er, lawn
mowers and any other 2-cycle air cooled engine.
Oxygenated Fuels
Due to the increased emphasis on reducing aulo emissions, some areas of the U.S. are required to use
oxygenated fuels. Oxygenated fuels have oxygen carrying additives which improve the engine'S combustion
process by providing additional oxygen. The improved combustion results in lower tailpipe emissions. The
additional oxygen results in a ~ I e a n e r " air/fuel ratio which four-cycle automotive engines easily tolerate, but the
two-cycle engines used in our products do not.
Polaris fully supports any efforts to reduce emissions, and we feel that oxygenated fuels are certainly an effective
method to reduce emissions. However, our engines are designed for maximum performance and durability, which
requires us to operate with a richer ai r/fuel ratio. It is very import ant that the proper airlfuel ratio is maintained to
ensure the engine's durability. THIS SNOWMOBILE'S ENGINE IS NOT CALIBRATED TO USE
OXYGENATED FUELS. If the customer must use oxygenated fuel , you should make the necessary adjustments
to ensure that they can use these fuels without risking engine damage. These changes will cause some loss in
performance if they do not use oxygenated fuels. If they use oxygenated fuels with the engine modifications, they
will notice little or no performance loss.
Break in Fuel/Oil Ratios
Oil Injection Models:
Models equipped with oil injection are required to have the first tank of fuel pre-mixed at a 40: t ratio in addition to
the normal lubrication received from the injector system.
Pre-Mix Models:
The break-in fueVoil ratio for aU pre-mix engines is 20:1 for the first tank of fuel.
After Breaki n
All pre-mix engines are designed to operate at a 40:1 fuel mixture ratio after break-in.
Fuel System Deicers
If the customer is using non-oxygenated fuel , Polaris recommends the regular use of Isopropyl base fuel system
deicer (PN 2870505) at the rate of 1 to 2 ounces per gallon (8- 16 ml per liter) of gasoline to prevent engine damage
resulting from fuel system icing and lean mixtures.
If the oxygenated fuel contains an alcohol blend (ethanol) , they should not use addi tional alcohol deicers or water
absorbing additives. If water is present in the fuel tank prior to fueling, they should not use alcohol blended
gasoline until the water has been removed. In both cases, the additives and alcohol blended fuels will cause any
water present to separate from the fuel. resulting in poor engine performance and or engine damage.
&. CAUTtON: Never add fuel while snowmobile is running.
Never pour oit or gasoli ne into fuel tank unless mixed.
Never use low grade multi-viscosity oil.
5. 19
8/94
RICE RED
.
ENGINES
Torque Specifications
When tightening bolts, nuts, or screws, a torque pattern should be foHowed to insure 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 assures optimum performance from precision machined, close tolerance assemblies. On vital
engine parts, torquing negligence could be costly.
Torque is a force which tends to produce rotation. The
measurement of this force is expressed in units of
force and length. There afe at present two basic
systems of units used to express torque, English and
Metric. In the English system, the units of force are
the pound or ounce, and the length is the foot or inch.
In the Metric system, the unit of force is expressed in
grams (gm) or kilograms (kg), and length as
centimeters (cm) or meters (m). The most common
units of torque in the English system are ft. lb. and in.
lb. . In the Metric system, torque is commonly
expressed in unils of kg/m.
Engine Cylinder Head Crankcase
8 mm
EC25PS 17-18 ft.lbs. 17-18 ft.lbs.
2.3-2.5 kg/m 2.2-2.3 kglm
Air Cooled 17-18 ft.lbs. 17-18ft.lbs.
Twin Cylinder 2.3-2.5 kg/m 2.2-2.3 kg/m
EC34-2PM 18.5-19.5 ft. Ibs.
2.6-2.7 kg/m
,
EC34PL 8mm 17-18 ft. lbs.
EC40PL 17-18 ft.lbs. 2.2-2.3 kglm
EC45PL 2.2-2.3 kg/m
EC50PL
EC51 PL
10 mm
EC58PL
24-26 ft. Ibs.
EC60PL
3.6-4.0 kg/m
EC65PL
EC75PL
EC80PL
A WARNING
Multiply
in.lbs.
ft. Ibs.
kg/m
Crankcase
10mm
23-25 ft. Ibs.
3.2-3.5 kglm
23-25 ft. Ibs.
3.2-3.5 kg/m
23-25 ft. Ibs.
3.2-3.5 kglm
.
Gasoline is extremely flammable and explosive under certain conditions .

By To Obtain
. 0834 ft. Ibs .
1150 gm/cm
.01 150 kg/m
12 in.lbs.
13,800 gm/cm
.138 kglm
86.8 in.lbs.
7.24 ft. Ibs.
Flywheel Cylinder Base
Studs
60-65 ft. Ibs. 24-28 ft. Ibs.
8.3-9.0 kglm 3.3-3.9 kg/m
60-65 ft. Ibs. 24-28 ft. Ibs.
8.3-9.0 kg/m 3.3-3.9 kg/m
60-65 ft. Ibs. 24-28 ft. Ibs.
8.3-9.0 kg/m 3.3-3.9 kg/m
Always stop the engine and refuet outdoors or in a well ventilated area.
8/94

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 overflilthe tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change
clothing.
Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and death in a short time.
5.20
RIDE RED

0 8 0 0
PTD MAG
SIDE SIDE
8 0
0
PL TWIN BASE
o 0
000@
0
@80@
o
8
ENGINES
Torque Specifications .
@000
@
80
0
@080

EC40i50PL CYLINDER HEAD
0
0
8
0
0 0
8
8
TWIN CYLINDER CRANKCASE ALL CYLINDER BASE STUDS 6 STUD CYLINDER HEAD
(INDIVIDUAL)
@J CD t11' @
@ 00 00'0@
@@0G@0@@@@
3 CYLINDER CRANKCASE
@@J
CV
@D00@@
@@00
0
8@@@
EC58PL HEAD
808
o 0
000
3 CYLINDER HEAD
244 CRANKCASE
5 STUD CYLINDER HEAD
5.21
8/94
AICERED
ENGINES
Disassembly and Reassembly Procedures - PS - Single Cylinder Series
1. The photo at right shows a complete EC25PS
engine removed from chassis.
2. Remove carburetor intake rubber boot, fan housing
with recoil, fan shrouding and exhaust manifold.
3. Unhook COl coil pack from stator plale connector
plug.
4. Remove recoil rope starter cup.
5. Remove flywheel nut.
6. Install flywheel puller (PN 2870159) on flywheel.
Hold with your hand or an appropriate approved
strap wrench while pulling the flywheel.
7. Remove oil pump and oil pump drive gear. NOTE:
Make sure the small end bearing washer comes
with the gear assembly.
8/94
5.22
RIDE RED
ENGINES
8. Mark stator plate before removing hold down
screws. Using an impact screwdriver, remove
stator plale hold down screws and remove stator plate.
9. Remove head, head gasket, and cylinder base
nuts.
10. Remove cylinder. Secure piston with piston support
block.
11. Remove C-<:Iip retainers.
12. Use piston pin puller to remove wrist pin. Remove
piston.
5.23
RICE RED
ENGINES
13. Remove crankcase bolts.
14. With a propane torch, apply heat to the mag end of
the crankcase. Heat enough to see small tailings of
smoke.
15. Wearing glov8s. hold mag end of case and strike
end of crankshaft with a plastic hammer.
CAUTION: The case will be hot! Protect hands to
avoid serious burns.
16. Heat PTO end of crankcase until smoke tailings
appear again, then strike the PTO end of the shaft.
CAUTION: The case will be hot! Protect hands to
avoid seri ous burns.
17. Before reassembly, check crank end play. Proper
endplay is .008 - . 0 1 6 ~ . NOTE: The bearing on the
PTO end may move when disassembled. Make
sure bearings are properly positioned on shaft .
Also, check crankshaft runout and adjust if
necessary.
8194
5.24
RICERED

ENGINES
18. Measure and record mag side of crankcase.
Remember to subtract depth of straight edge.
, 9. Measure and record PTO side of crankcase.
Remember to subtract depth of straight edge.
Exampl e: Crankshaft .. 4.130
Mag side minus thickness of straight edge = 2.550
PTO side minus thickness of straight edge = 1.565
Add mag side measurement and PTO side measurement = 4.11 5
Subtract from Crankshaft measurement ... 015 (end play)
To control end play, use the following shims behind PTO bearings:
PN 3083630 . 004- (. lmm)
PN 3083629 . 008- (.2mm)
20. Check trueness of crankshaft . See page 5.33 .
5.25
AICERED
8/94

ENGINES
21. Heat crankcase as shown, PTO end first.
22. Let case half coo1. Add Locti!e 515.
23. Heat mag side of case and install over crankcase.
24. Install crankcase bolts and torque in a criss cross
pattern.
25. Grease and install crank end seals.
26. Align stator plate with marks and secure to case.
27. Check oil pump end play.
8194
5.26
RIDE RED
ENGINES
Disassembly and Reassembly Procedures " PS " Single Cylinder Series
28. Measure crankcase surface to gear drive bushing
and record measurement (A).
29. Measure from case mating surface to end of pump
body as shown and record (8).
30. Subtract measurement B from measurement A.
The difference is the end play.
31 . The photo at right shows oil pump drive assembly
sequence for EC25PS only.
Optional shims:
PN 3083671 . 006" (.15mm)
PN 3083672 . 012" (.3mm)
PN 3083673 . 024" (.6mm)
End play should be .008 to .016"' .
5.27
".

,.,-,. ..
I ,'"
'1
. --
-- ---
'. ,-- ,
- ,
- -
..
--p $' .. - .-
>
\ . i:-).."
.......... "
Ii" _" - "--
8/94
AICERED
ENGINES
32. Hone cylinder until a cross hatch pattern is
achie .... ed.
33. Chamfer ports so they are not sharp.
34. Check piston skirt to cyli nder clearance and ring end
gap prior to assembly. See pages 5.60-5.61.
35. Install piston wi the lOp' or arrow toward flywheel.
Always install new rod end bearings, C-clips and
new rings when rebuilding the motor.
36. Lightly oil the cylinder. Compress rings with a ring
compressor or with fingers.
37. Install cylinder. Torque base nuts to 24 - 28 ft . Ibs.
(3.3 - 3.86 kg/mi.
38. Install head gasket with large diameter of fire ring
toward cylinder.
8/94
5.28
RIDERED
ENGINES
39. Install head with exhaust side marking toward
exhaust port.
40. Torque head nuts to 17 18 ft. Ibs. (2.34 2.48
kg/m).
41. Install and torque flywheel nut to 60- 65 ft. Ibs. (8.28
- 8.97 kg/m). Hold flywheel with a strap wrench
while torquing.
42. Reinstall recoil cup, recDil fan housing, fan shroud,
rubber carburetor mount, carburetor and exhaust
manifold. Connect stator and CDI wire connector.
5.29
8/94
RIDE RED
ENGINES
Disassembly and Reassembly Procedures - PL - Three Cylinder Series
Take care to insure all parts are kept extremely clean.
1. Drain coolant from unit.
2. Disconnect necessary cooling system and
electrical components.
3. Remove drive clutch and exhaust system.
4. Remove carburetors and recoi l.
5. Mark cyli nders # 1 mag side, #2 center, #3 PTO side.
6. Remove inlet water manifold.
7. Remove oil pump lines and secondary coils.
8. Remove oil pump and drive gear.
9. Remove waler pump.
8/94
5.30
AIDE RED
--
ENGINES
Disassembly and Reassembly Procedures PL Three Cylinder Series
10. Remove outlet manifold.
11 . Remove heads either as a unit or individually.
12. Remove recoil starter cup and flywheel nut.
13. Using flywheel puller PN 2870384, remove
flywheel. Hold puller with your hand or a strap/chain
wrench.
14. Mark stator plate and case and remove attaching
screws.
15. Mark cylinders - mag, center, PTO.
I
5.31
RICE RED
ENGINES
16. Remove piston C-clips as shown.
17. Using wrist pi n puller, remove piston wrist pin and
mark pistons mag, center and PTO.
18. Remove seat plate and crankcase bolts.
19. Remove crankshaft from case.
20. Clean and check runout.
8194
5.32
RIDE RED
ENGINES
Crankshaft Truing
21. To correct a situation like that shown in III. 1, hit
crankshaft at pOint A. NOTE: The rod pin position in
relation to the dial indicator position lells you what
action is required to straighten the shaft.
22. To correct a situation like that shown in III. 2,
squeeze crankshaft at point A. NOTE: The rod pin
position in relation to the dial indicator position tells
you what action is required to straighten the shaft.

23. If the crank rod pin location is opposite the position
shown in III. 2, or at 180
0
from the dial indicator it will
be necessary to spread the crankshaft at point A as
shown. When rebuilding and straightening a
crankshaft, straightness is most important. As
close to zero runout as possible is also required.
24. Remove old crankcase sealer from case halves.
25. Grease mag end seal with new grease.
26. Grease labyrinth seal area.
27. Make sure bearing alignment anti-rotation pins are
in the straight up position.
5.33
r-
~ tHigh .004
A
High .004
r-

~
-
I
-
'--
-
'---
-
~
r- r- High .002
r- i--- + High .005
,- I--
l
-
~
J
'---
~ I - ~
--:- r7 High .002
r- A -- A ' High.OOS
,- .
I l
-
'--
i---
I J
L
L- i---L-
RIDE RED
8/94
ENGINES
28. Apply Loctite 515 Sealer to the bottom crankcase
half as shown.
29. Torque crankcase bolls as shown. Refer 10 torquing
pattern, page 5.21.
30. Install pistons with arrow toward flywheel side of
crankcase.
31. Install piston C-clips with C-clip installation tool.
32. Oil crankshaft bearings through access holes in the
case.
33. Install keystone rings onto piston with beveled side
up and flat side of ring down.
34. Secure wrist pi n into piston with C-clip tool , making
sure open end of C-clip is toward down side of
bevel.
8/94
5.34
RIDE RED
l
ENGINES
Disassembly and Reassembly Procedures" PL " Three Cylinder Series
35. Before install cylinder, refer to honing procedure on
pages 5.62-5.63 of this section.
36. Depress rings in alignment with anti -fotation pins on
piston using either a ring compressor or your
fingers. Carefully install the cylinder.
37. Oil gasket sides or paint using high temperature
aluminum paint. The large diameter side of the fire
ring should be installed toward the cylinder.
38. I nstall cylinder heads onto cylinder either as a unit or
individually.
39. Torque 10mm nuts to 24-26 ft. Ibs. (3.3-3.59 kg/m).
40. Torque 8mm nuts to 17-18 fl. Ibs. (2.35-2.48 kg/m).
".
41. Install exhaust manifold gaskets and water
manifold. Torque nuts to 6 ft. Ibs. (2.28 kg/m). Use
caution when torquing nuts so as not to damage
gasket.
5.35
8/94
RIDE RED
-
ENGINES
42. Install and align stator plate with previous marks.
43. Install flywheel and flywheel nut. Using a strap or
chain wrench to hold the flywheel, torque flywheel
nut to 60 ft. Ibs. (8.28 kg/mi.
44. lnslaH water pump and pump belt. Adjust belt
tension.
45. Install oi l pump and connect feed lines to cylinder.
46. Install secondary coils.
47. Install carburetors. recoil housing and water pump
belt guard.
48. Install exhaust manifold gaskets and exhaust
manifold.
50. fy1easure from case mating surface to end of pump
body as shown and record (B) .
51 . Subtract measurement B from measurement A.
Optional shims:
PN 3083671 = .006- (.15mm)
PN 3083672 . 012- (.3mm)
PN 3083673 . 024- (.6mm)
End play should be .008 to .016'",
8194
5.36
----
. If: '
..", . ,\
.-&1' . -....
. .. , .
. . , (! .. .,.
;;; , ., ...
. It.
.
-,
, .- . -'"
- \ .
' , -.." "
AIDE RED
ENGINES
Disassembly and Reassembly - PL Series Reed Valve
1. Disconnect electrical connectors, fuel lines, throttle
cable/oil pump cable.
2. Remove air box and exhaust system.
3. Remove drive clutch.
4. Unhook recoil handle. NOTE: Do not allow recoil
rope to retract into recoil housing.
5. Drain coolant from engine.
6. 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
sequence when reassembling.
7. Remove recoil housing, water pump belt guard,
water pump and flywheel nul.
8. Install flywheel puller and remove flywheel.
CAUTION: Do not lurn puller bolts too deeply into
Itywheel or coil damage will occur.
9. Mark stator plate at case parting line and remove
plate.
5.37

.lI, / ;, ,, "t

': ,.... . .
I ( ; ttt ' 'I
. . I' . ' 4. I
i.' "
. .
.. . . ,,' , '
.. .:A. ,"
. .
8194
RIDE RED
ENGINES
10. Remove remainder of head nuts and cylinder base
nuls.
11. Carefully remove cyl inders.
12. Remove C-clip retainers.
13. Use piston pin puller to remove wrist pins.
, 4. Remove crankcase bolts and split case.
15. Inspect crankshaft for trueness. See page 5.33.
8194
5.38
RIDE RED
ENGINES
Disassembly and Reassembly PL Series Reed Valve
16. Grease labyrinth.
17. Grease end seals and oil pump drive gear.
18. Position anlirotation pins with divot in case.
19. Apply a light film of Loetite 515 gasket eliminator to
crankcase and reassemble halves.
5.39
RIDE RED
8194
ENGINES
20. Inslall bolt and torque following torque pattern.
Torque 8mm bolts to 18 ft.lbs. (2.48 kg/m). Torque
10mm bolts to 26 ft.lbs. (3.59 kglm).
21. Inslall wrist pin bearings.
22. Install piston with arrow (lo- ) toward fl ywheel.
23. Install C--clip relainers using tool PN 2870773.
NOTE: The C-clip opening should be in the up or
down position.
24. Lightly oil rings and cylinder. NOTE: Keystone ring
bevel must be up.
25. Carefully compress rings and install cylinder over
piston. Torque cylinder base nuts 10 28 ft.lbs. (3.66
kglm).
8194
5.40
RIDERED
ENGINES
26. Position head gasket shoulder over outlet on head.
750 Storm head gasket should be installed
with tab (shoulder) located directly above
left exhaust stud, as viewed from intake
side.
800 Storm head gasket should be
positioned with Ihe words "Up" and "80"
directly over center of intake port. Raised
side of head gasket should face up (toward
head).
27. Install heads, positioning outlets as shown. Make
sure coils are in correct position and torque head
nuts to 18 ft. Ibs. (2.48 kg/mi.
800 Storm coolant outlet reslrictor plates
must be positioned as follows:
PTO 11 mm
Center 12 mm
Mag 13mm
28. Inspect reed pedals.
29. Install reed cages.
30. Install rubber mounts.
31. Position oil check valve as shown.
5.41
RIDE RED
-
ENGINES
32. Install oil pump drive gear in correct sequence.
33. Install oil pump.
34. Position stator plate at previously marked position
and secure in place.
35. Torque flywheel nul to 65 ft. Ibs. (B.9? kg/m).
36. Install water pump, recoil cup, and belt. Adjust bell
tension.
37. Install recoil housing and belt guard.
8/94
5.42
AIDE RED
....
EC58PL Engine
1 . Disconnect electrical connectors, fuel lines, throttle
cable/oil pump cable.
2. Remove air box and exhaust system.
3. Remove drive clutch.
4. Unhook recoil handle. NOTE: Do not allow recoil
rope to retract into recoil housi ng.
5. Drain coolant from engine.
6. Remove carburetors and secondary coils.
7. Remove recoil housing waler pump and belt.
8. Remove water jacket cover.
ENGINES
Disassembly and Reassembly - Monoblock
5.43
RICE RED
ENGINES
Disassembly and Reassembly Monoblock
9, Remove head. Mark PTO end of head to assure
correct reassembly.
10. Remove cylinder.
11. Refer to PL series three cylinder disassembly
beginning on page 5.30 for remainder of
disassembly and reassembly instructions.
12. Use piston support block on center piston as shown.
Apply a small amount of Loetite 515 gasket
eliminator to gasket ends.
13. Install pistons in the foll owing order:
mag
center
PTO
8/94 5.44
RIDE RED
14. Torque base bolls, starting in the middle, alternate
intake to exhaust side, moving from PTO end to
mag end.
15. Apply Loctite 515 around compression O-Ring in
cylinder. NOTE: Some models also use a
monotype gasket (single, one piece) for aU three
cylinders.
16. Install head, making sure it is in the correct position.
17. Inspect outer O-Ring seal.
18. Apply Loctite 515 to cover as shown.
19. Position shim and O-Ring as shown.
ENGINES
5.45
8/94
RIDE RED
-
ENGINES
20. Install stator in the previously marked position and
secure.
21. Install and torque flywheel nut.
22. Inslall waler pump and belt. Tighten belt.
23. Install oil pump and connect feed lines to rubber
mount.
24. Install recoil housing.
25. Install secondary coi ls and secure carburetors to
rubber mounts.
8/94
5.46
RIDE RED
..... r
ENGINES
Disassembly and Reassembly - PL Twin Cylinder Series
The photo al right shows a complete PL series twin
cylinder engine.
1. Remove carburetors or throttle bodies.
2. Remove recoil housing and exhaust manifold.
3. Remove water pump. starter rec6tl cup with water
pump drive pulley and flywheel nut.
4. Install flywheel puller. Secure puller with a holding
fixture tool , strap wrench, or chain wrench while
pulling flywheel.
5.47
8/94
RICE RED
------ ---
ENGINES
5. Mark stator plate for reference when reassembling
the engine.
6. Using an impact screwdriver, remove stator screws.
7. Remove oi l pump and oi l pump feed lines from
cylinder banjo bolls.
8. Remove cylinder head.
8194
5.48
RIDE RED
ENGINES
9. Remove head gasket. Note position of head gasket
inlet and outlet hole sizes for reference during
reassembly.
10. Remove cylinder.
11 . Remove C-clip retainer clips from piston as shown.
12. Using wrist pin tool, remove wrist pin from piston as
shown.
5.49
RIDE RED
ENGINES
13. Using the cylinder as a holding fixture, remove
crankcase bolls.
High 004
r-
'A
t
,-
High.

004
,--
-
I
~ -
J
L-
B
'- -
III. 1
14. To correct a situation like that shown in Ill. 1, hit
crankshaft at point A. NOTE: The rod pin position in
relation to the dial indicator position tell s you what
High 002
-
I--
-
+
-
High. 005
,----- r--
+
I
~
J
-
~ r - - ~
III. 2
15. To correct a situation like that shown in III. 2,
squeeze crankshaft al point A. NOTE: The rod pin
position in relation to the dial indicator position tells
High 002
'A
--
A

High .
,--
,+
005
r I I
L
r--
I J
L-
I--
'-
-
III. 3
16. If the crank rod pi n localion is opposite the position
in the second illustration, or at 180
0
from the dial
indicator it wilt be necessary to spread the
crankshaft at point A as shown.
17. Clean case halves and check crankshaft runout
before reassembly.
r 1.
8194
5.50
RIDE RED
... -
ENGINES
Prior to reassembly, refer to page 5.60 and check ring end gap and piston skirt to cylinder clearance.
18. When reassembling, grease crankshaft end seals
and labyrinth seal area as shown.
19. Turn bearing so anti-rotation pins are in the proper
groove.
20. Apply Loctite 515 to crankcase halves.
21. Torque crankcase following torquing specs and
sequence outlined on pages 5.20 and 5.21.
22. Install pistons with " F ~ mark or arrow (>-) toward
flywheel .
23. Install C-clip using installation tool PN 2870773.
24. Install base gasket.
25. Install keystone rings with beveled side up and flat
side down.
26. Oil crank bearings through access holes as
indicated.
5.51
RIDE RED
ENGINES
27. Install cylinder, being careful nol to damage rings.
28. Install head gasket. Note proper position of gasket,
~ V M notch forward, small intake hole on right (mag)
side, large hole on left (PTO) side.
29. Install cylinder head and torque cylinder head nuts
following torque specs and pattern sequence on
pages 5.20 and 5.21.
NOTE: Engine coolant may seep from the cylinder head
cover bolts on the 1994 XCR SP EC45PL-D3 engine.
Apply Loctite 515/518 or 3 Bond Thread Sealer on the
bolt threads when reinstalling the cylinder head cover
bolts. Also, if the optional head gasket is installed for
use with poor grade gasoline, a thinner .4mm spacer
(PN 3084687) must be used in place of the original
.Bmm spacer under the rubber O-Ring.
30. Install oil pump in the sequence shown in the lower
right photo.
33. Subtract measurement 8 from measurement A.
Optional shims:
PN 3083671 : .006" (.15mm)
PN 3083672 : .012" (.3mm)
PN 3083673: .024- (.6mm)
End play should be .OOS to .016 ....
34. Connect feed lines to cylinder.
8194
.
.. ~ : ~
5.52
RIDE RED
,#' f
-"----
ENGINES
35. Align stator screws as previously marked on stator
plate and s ~ u r e with hold down screws.
36. Install flywheel and torque flywheel nut to 60.65 ft.
Ibs. (8.28-8.97 kg/mi.
37. Install waler pump and recoil starter cup.
38. Adjust tension on pump belt. Deflection should be
1/8"-3/16" (.3-.4 em).
39. Install recoil housing, carburetors, and oil pump
cable. '
40. Connect COt to stator plug connector.
5.53
RIDE RED
-
ENGINES
Disassembly and Reassembly - PM Twin Cylinder Series
The photo at right shows a complete PM series twin
cylinder engine.
, . Remove carburetors.
2. Unhook oil pump feed ti nes and remove oil pump.
3. Remove ai r shrouds. NOTE: There are gaskets
between shroud and cylinder.
4. Note position of shroud retainer mounts on cylinder
heads. These must be in the same posi tion for
reassembly.
8/94
5.54
RIDE RED
ENGINES
Disassembly and Reassembly - PM Twin Cylinder Series
5. Remove recoi l fan housing, recoil starter cup and
flywheel nut.
6. Using flywheel puller, remove flywheel.
7. Refer to PL series instructions beginning on page
5.47 for remainder of disassembly and reassembly.
and record measurement (AI.
10. Subtract measurement B from measurement A.
Optional shims:
PN 308367' . 006- (.' 5mm)
PN 3083672 . 0' 2- (.3mm)
PN 3083673 . 024- (.6mm)
End play should be .00810 .016 ....
5.55
RICE RED
8/94
ENGINES
-.
Crankcase Truing .'.
"vi:.
1. To correct a situation shown in III. 1, hi t
crankshaft at point A. NOTE: The rod pin position in
relation to the dial indicator position tells you what
2. To correct a situation like that shown in 111. 2,
squeeze crankshaft at point A. NOTE: The rod pin
position in relation to the dial indicator position tell s
6/94
5.56

r-
L--
'--
III. 1

"---
L..
111.2

-
High .004
A
t High .004
+
I---
l
-
I---
J
L-

High .002
+ High .005
I---

l
I
-

RIDE RED
3. If the crank rod pin location is opposite the position
shown in III. 2, page 5.56, or at 180
0
from the dial
indicator it will be necessary to spread the
crankshaft at point A as shown. When rebuilding
and straightening a crankshaft, straightness is most
important. As close to zero runout as possible is
also required.
Crankcase Bearing Fit
Any time crankshaft bearing failure occurs and the case
is to be reused, Polaris recommends checking the
bearing fit into the case halves using the following
procedure.
1. With case halves cleaned, take a replacement
bearing and press it 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 indicate the recommended
interference fit of .0006 ~ (.015 mm) for C-3 bearing,
.001" (.025mm) for C-4 bearing. If the bearing falls
out of the case when the case is inverted, the case
should be replaced.
5.57
,-
,--
'---
'-
r;;: - Ifi
t-
~ t - ~
ENGINES
Crankshaft TrUing
High .002
High .005

l
J
-
8194
RIDE RED
ENGINES
Cylinder Service
... .----
Maximum engine performance and easy starting are directly related to the compression of the fuel and air mixture
in the combustion chamber. II is importanllhallhe cylinder walls are concentric, smooth and perpendicular to
the crankshaft center line. All new engines have these characteristics built into them, however, the stresses and
heat of operation may cause the bore to distort or score, resulting in loss of compression and power.
Inspection
A simple way of checking cylinder/piston condition is to remove the exhaust manifold and look into the exhaust
port. If there is a considerable amount of blow by (brown or black carbon deposit) under the piston rings, the
cylinder should be removed and hones. The piston rings should be replaced also.
The cylinder should always be inspected whenever an engine has been disassembled for repair or any time a
loss of power or cylinder cranking compression is noted. A visual inspection after the cylinder head is removed
will reveal if the cylinder should be removed for honing. Inspect for any scratches or signs of scoring or brown
areas which indicate ring leakage and distortion.
The cylinder shown at right has been damaged by the
engine overheating to the point of piston seizure. Honing
this cylinder would restore it to service. Damage such as
this may be the result of improper fueVoil mixture,
incorrect carburetor jetting, or ignition timing which is too
far advanced.
8194
5.58
RIDE RED
r
ENGINES
Cylinder Service Piston Identification I Engine Designation
Correct installation of pistons into cylinders during reassembly is important. Incorrect installation will result in ring
breakage and seizure due to ring ends passing over open port s.
Viewing pistons from the top, note directional and engine model series identification marks.
The letter"P', ~ " or" " .. must always be toward flywheel side of engine. Pistons may carry a letter such as
"Ln, "An, ''1''', "W", wM", "Ml", or 10 M2" to indicate thei r engine series designation. Oversize pistons and rings will
have an additional marking of "25" indicating .010" (.025 em) oversize or "50" indicating .020" (.050 em) oversize.
Piston identifications are shown below.
S,F
To Flywheel
T
To Flywheel
PT Series
Engine Designation
M1 designates 44-2PM-l1 00/21 00 - ECSOPM-Ol /02
M2 designates 44-2PM-31 00{3300/S000/S1 00 - ECSOPM-03
M6 designates 44-3PM-Ol
W designates SOPL06
4L designates 40PL
6L designates 60PL
L designates 34/S1 PL
A designates SOPU4SPU75PU80PL
C designates 6SPL
B&E designates 58PL
5.59
C,L,A,Wor
B&E
PL Series
M
PM Series
RIDE RED
To Flywheel
To Flywheel
8194
-.;!II
-
ENGINES
Cylinder Service - Piston/Cylinder Clearance
Piston Measurement
Whenever cylinders are honed or bore clearance is
checked, it is important to measure the piston diameter to
arrive al its major dimension. The pistons used in Polaris
engines should be measured at right angles to the pin as
shown. Determine the largest diameter within thi s area
and refer to the chart below for clearance specifications.
The cylinder bore must be straight and concentric. Refer
to the honing information outlined in this section for
specific procedures. The chart below indicates engine
model bore size and recommended rebuild clearances.
Engine Model I Bor.
Inches MM
~
2.4409 62
2.8346 72
~
2.283 58
2.1017 53.4
2.1063 53.5
2.1063 53.5
2.082 52.9
2.4409 62
2.432 6178
2.4546 62.3
2.3622 60
~
2.441 62
2.432 6178
2.559 65
2.559 65
2.556 65
2.6557 67.72
~
2.6557 67.72
2 .... 67.72
2.6673 67.75
2.6673 67.75
2656 67.7
I ECSOPLAI1 2.8346 72
2.8346 72
I EC51PL 2.432 6178
2.952 75
1-5790< 2.521 64
~
2.561 65
2 .... 67.72
~ ~
69.72
o
LJ L
"Rebuild
Piston/Cylinder
Clearance Inches
.005 -.008
.004 -.0065
.004 - .0065
.004 - .0065
.005 - .007
.004 -.0065
. ~
.0045-.
~
.0035 -.0065
.0050 - .0065
.004 -.006
.005 - .0075
.0045 - .007
.0035 - .0060
.0035 -.0055
.005- .0075
.004 -.006
.0035 - .005
.004 -.0065
.0035 - .0065
.0055 - .0075
.004 -.006
.0035 - .0055
.005 - .007
0 0 4 5 ~
Measure 1/2
n
up
from Skirt Bonom
uMaximum
Service Limits
Inches
.009
.009
.009
-
.008
.009
.008
~
.008
.010
-
.008
.0085
.008
.010
.010
.008
.008
.010
-
.009
.0082
.008
.008
.010
.008
.008
.009
.008
~
'Chrome cylinders may be de...glazed and refinished using fine stones.
These numbers represent total piston to cylinder clearances.
one-half of the specified dimension.
8194 5.60
The clearance with the piston installed will be
AIDE RED
ENGINES
Cylinder Service - Oversize Pistons and Rings
.020 Oversize Piston And Ring Chart To Fit All As n Below
NOTE:
Before discarding any cylinder we
recommend honing it. If the cylinder is
damaged so it cannot be cleared without
exceeding the maximum standard
piston-cylinder clearance
recommendations, it may be oversized.
Refer to honing information outl ined in this
section for specific procedures.
When ordering oversize cylinders and
pistons, refer to the engine model tag
located on the engine crankcase or fan
housing for correct ordering information.
Liquid Cooled Engines
5.61
8194
RIDE RED
ENGINES
Cylinder Honing
Cylinder Hone Selection
Selecting a hone which will straighten as well as remove
material from the cylinder is very important. Honing a
cylinder with a common spring loaded finger-type glaze
breaker is never advised. Polaris recommends using a
rigid type hone which also has the capability of Qversizing.
Such hones are manufactured by Sunnen Products
Company of St. Louis, Missouri; Ammco Tools, Inc., of
North Chicago, Illinois, among others.
The photo at right shows an Ammco #3950 hone which has
roughing and finishing stone sets available for large 75mm
bore engines.
Cylinders may be wet or dry honed, depending upon the
hone manufacturer's recommendations.. Wet honing
removes more material faster and leaves a more distinct
pattern in the bore.
Honing
2. Wash cylinder with solvent and clamp in a
vise around exhaust port studs. NOTE: Use
brass stock, wood or cardboard to protect
studs from vise jaw serrations.
3. Place hone in cylinder. Tighten stone
adjusting knob until slone contacts cylinder
walls. CAUTION: Do not over tighten.
4. A finished cylinder should have a cross
hatch pattern. This aids in the retention of
fuelfoil mixture in initial break in.
8194
5,62
-
,
,
,
,
,
,
/
/
~
-
,
~
,
~
/
~
/
~
,
-
,
~
/
,
-
,
/
~
"
,
-
/
-
-
,
-
,
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
~
-
~
-
-
/
RIDE RED
4. Using a 1/2" (1.3 cm) drill motor with a speed of
300-500 RPM, run hone in and out of cylinder
rapidly until cutting tension decreases. NOTE:
Remember to keep hone drive shaft centered and
to bring stone approximately 1/2" (1 .3 cm) beyond
bore at end of each stroke. Release hone at
regular intervals. Inspect bore to determine if it
has been cleared. Check piston fit.
5. With cylinder thoroughly cleaned, install a new
piston into bore as shown. Slip a feeler thickness
gauge alongside skirt at right angles to pin.
Starting with a thinner gauge, progressively work
up to the thickest gauge which may be inserted
between piston and wall with a sliding fit. This will
be tlie total cylinder-piston clearance. NOTE:
Refer to the engine specification chart in this
section to determine if the clearance is within
tolerance for that engine.
6. Position ring 1/2" (1.3 cm) from top of cylinder.
Center ring in cylinder bore. Ring end gap should
be .006"-.018" (.015-.046 cm) for all models.
Honing To Oversize
If the piston-cylinder clearance measures greater
than that given in the chart for a standard bore, it will
be necessary to oversize the cylinder to .020" (.050
cm) using a new .020 oversize piston and rings. This
may be done either by boring or honing.
For oversize honing, always wet hone using honing oil
and a coarse roughing stone. Hone until a check with
a new piston indicates you are within .003" (.007 cm)
of the clearance recommended. Complete sizing with
fine grit stones to provide proper cross-hatch finish
and clearance.
CAUTION: It is very important that the cylinder be
thoroughly cleaned after honing to remove all
grindings which could cause cylinder and piston wear
or damage. Wash cylinder in a solvent, then in hot
soapy water; rinse, blow dry and oil lighUy.
5.63
RIDE RED
ENGINES
Cylinder Honing
8194
ENGINES
Recoil Starter Rope Replacement
5. Tie rope in a slip knot. Pull rope out of handle.
6. Untie knot and remove handle.
7. Pull rope into notch (A) on reel and slowly unwind
spring.
S. Remove retaining nut.
9. Remove ratchet retainer (A). spring, and retainer
disc.
10. Remove three ratchet return springs and smaller
plastic disc.
11 . Remove three ratchets (A), small spring (B), and
washer (C) .
8194
5.64
AIDE RED
I
-
12. Lift reel from housing, making sure that the reet is
free of the recoil spring.
13. Install a new rope and replace the reel.
,
.;
14. Install ratchets (Al , spring (8) and washer (C) .
15. Install small plastic disc and three ratchet return
springs.
16. Install large plastic disc, return spring, and ratchet
relainer (A) .
17. Install retaining nut. Tighten recoil spring by
putting rope in notch (Al, Three to four turns
should give sufficient spring tension.
18. Tie a slip knot in rope to prevent it from rewinding.
19. Attach handle and tie a figure eight knot on the
rope end and push into the handle.
20. Loosen slip knot and reinstall.
1
5.65
ENGINES
Recoil Starter Rope Replacement
8/94
RIDE RED
ENGINES
Recoil Starter Spring Replacement
21. Follow disassembly procedures outlined on page
5.64.
22. Clamp defective spring with a small vise grip. Use
caution when removing spring.
23. Rewind spring and install in housing, hooking end
of spring (A) as shown.
24. Follow reassembly procedures outlined on page
5.65.
8194
- .
5.66
RIDE RED
ENGINES
Recoil Starter Spring Replacement, Late Model
Disassembly
1 . Remove recoil handle and allow rope to retract and
spring to totally unwind.
2. Remove retaining nut, ratchet friction plate and
ratchet pawl from reel face.
3. Lift reel assembly straight up, oul of housing. NOTE:
If the spring tension is relieved and the reel is lifted
straight Qut, the spring will remain in the housing.
Reassembly
1. If the spring was removed, reinstall it by spiraling
counterclockwise toward the center.
2. Lubricate center shaft and spring with Polaris low
temperature grease.
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. Install rope handle.
6. Reinstall ratchet pawl onto reet face. NOTE:
Ratchet spring holds ratchet in.
7. Reinstall friction plate with one end of friction spring
in hole on end of ratchet pawl.
8. Reinstall flange nut and torque to 5 ft.lbs. (.69 kg/m).
9. Pull recoil rope to full extension and align notch on
outside edge of reel wilh housing rope guide hole.
10. Using a needle nose pliers or hooked wire, pull a loop
01 rope through the notch inlo center of housing.
11. Holding side of rope loop attached to reel, wind reel
counterclockwise until coil bind is felt. Then unwind
reel between one and two turns.
12. Pull loop to outside of housing by pulling on rope
handle.
13. Allow rope to fully retract and check for normal recoil
and ratchet operation.
5.67
8/94
RIDE RED
ENGINES
Cooling System EC60PL With Recovery System
::=::e::}- BRAKE COOLER
--i l
11 OVERFLOW BOTIL
.,-
\.,tlERNECK
t=
.r

'- , ,
)
1
(ENGINE
'-- ,=

fr
,
CENTER EXTRUSION
COOLANT FLOW SCHEMATIC
Filling and Bleeding Procedure
1. Elevate front end of machine approximately 10" (25.4
em).
2. Loosen special bleeder plug (A) at water pump.
3. Remove pressure cap and pour coolant into engine
until it flows from bleed plug.
4. TIghten bleed plug and continue fitling until coolant
level is at pressure cap fitting neck.
5. Start engine and lei idle.
6. Observe coolant in filler neck. It must be circulating.
If no circulation is evident, shut engine down and
re-bleed pump.
7. Repeat bleeding and filling procedure until circulation
and coolant level remains constant for a period of
three to five minutes during idling.
8. Fill coolant expansion reservoir bottle to indicated hot level.
9. Field test machine.
E
LEFT EXTRUSION
Coolant level and circulation must always be re-checked duri ng the first five to ten minutes of field operation to
ensure all systems function. This is especially important after refilling and bleeding following complete draining
of the coolant for system repair.
10. Clean, inspect, and, if necessary, repair or replace all parts.
8/94
5.68
RIDE RED
-"
Filling And Bleeding Procedure
1. Fill system with a 50/50 mixture of antifreeze and water.
2. With engine running, crack bleed screws on water pump and head.
3. Continue adding antifreeze mixture until system is purged of air.
4. Close bleed screws.
5. Add antifreeze mixture up to fill line.
ENGINE ASSEMBLY
WATER OUT
~
COOLAN T FLOW SCHEMATIC
ENGINES
Cooling System EC65PL05
WATER IN
fl '""' B
RAKE COOLER
I'
SURGE TAN(I 0 \
FILLERNEC{
11m
u
1 0 (
LEFT EXTR USION COOLER RIGHT EXTRUSI ON COOLER
~
REAR TUNNEL COOLER
5.69
RICE RED
8194
ENGINES
Cooling System EC75PL01/EC80PL01
1. Fill system with a 50150 mixture of antifreeze and water.
5. Add antifreeze mixture up to mlline.
THERMOSTAT
ENGINE ASSEMBLY
A ~
P J l ~

1-\1.:
I

I n l
~
8A AKE
OLEA

CO
IJ I
FILLER
'It
NECK

SURGE 0
TANK r

;1
c--
I
I
.Is!\.

u 0
I

I

LEFT
RIGHT
EXTRUSION
EXTRUSI ON
COOLER
COOLER
I
~
REAR TUNNEL COOLER
8194
5.70
AIDE RED
-
ENGINES
Cooling System - EC80PL02
1. Fill system with a 50/50 mixture of antifreeze and water.
5. Add antifreeze mixture up to filt line.
ENGINE ASSEMBLY
I
THERMOSTAT

t
:y
t
t
In
BRAKE
COOLER
FILLER'r
LEFT
EXTRUSION
COOLER
/
FRONT ClOSEOFF
COOLER
I
t
L---41
,-- t

REAR TUNNEL COOLER
5.71
-
I I
o
NECK t
,=- t
/l

t
o

EXTRUSION
COOLER
AICERED
8194
ENGINES
Cooling Syst em EC40145150158160165PL With Positive Bleed Recovery System
FIlling and Bleeding Procedure
1. Elevate front end of machine approximately 10'" (25
em).
2. Loosen special bleeder plug (A) at water pump.
3. Remove pressure cap and pour coolant into engine
until it flows from bleed plug.
4. Tighten bleed plug and continue filling until the
coolant level is at the pressure cap fitting neck.
5. Fill coolant expansion reservoir to indicated
maximum level line.
BRAKE COOLER (SOME MODELS)
.S!l
OVERFLOW BOTTLE
J2u-
FILTER GOLD eo
II
rIP) ~
-01'. -
~
1 FILLER Nf'K
j //CHECK
JI 4-
NNET
VALVE
~
\:::= -=
~
\ . . )
n (ENGINE ASSEMBLY
1 '-- . ~
l l ~
fr O
9\. '
I, I ; I

CENTER EXTRUSION j RIGHT EXTRUSION
LEFT EXTRUSION 1
L
J)
COOLANT FLOW SCHMATIC
11/95
5.72
RICERED
ENGINES
Oil Pump Bleeding - All Models
The oil pump must always be bled following any ser.vice to the injector system or engine which allows the loss
of oil and subsequent entrapped air during reassembly.
1. Fill oil reservoir with Polaris injector oil.
2. Loosen brass hex head screw (A). After a short lime
oil should flow from beneath the screw head to
indicate t he pump is free of air.
3. Tighten bleed bleed screw.
Oil Pump Adjustment - All Models
After the engine RPM and carburetor adjustments have
_ been made, the oi l pump must also be adjusted.
1. With engine shut off and throttle in its idle position,
the pump lever index mark (A) must align with the
pump housing boss index mark (B).
2. Loosen lock nuts on cable housing sleeve and vary
cable housing length as required. NOTE: Verify
that pump lever is actuated upon initial throttle
opening.
5.73
8194
RIDE RED
ENGINES
011 Pump Operation and Troubleshooting
Any lime 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 3 to Sibs. of pressure.
t . With engine in chassis, oil reservoir full, and pump
bled, remove two oil feed line banjo bolts (A) from
their location on the manifold or carburetors. NOTE:
Use care not to lose the two washers on either side
of the banjo check valve.
2. Blow through the banjo bolts to make sure they are
not plugged or restricted.
3. Loosely thread only the banjo bolts back into the
manifold or carburetors.
4. Place oil feed lines with their check valves away
from the clutch area. Start the engine and let it idle
at normal idle RPM.
5. Lift oil pump control lever up to its maximum flow
position.
6. Drops of oil should be visible from the banjo check
valves after the engine is idled one to two minutes,
with a drop occurring approximately every few
seconds.
7. 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.
8. If oil does not flow with check valves removed from
their feed lines. the malfunction is one of the
following:
Inline fitter blocked;
Feed lines leaking; or
Defective pump.
8/94 5.74
A
\
; a ~
V ~
RIDE RED
Condensed Data
CHAPTER 6
CARBURETION
1985 .. ...... .. .... ....... . .. . ....... . ............ . ... . ... . ........... .. 6.1
1986 ..... . . ...... . . .. .. . . . ... . . ... . . ....... . . . . . . .. . . . . .. ... . . ..... 6.2
1987 ...... . .... . .... . . ....... ............ . .... .................... . 6.3
1988 ...... . ........... .... .... . . ................ ....... . .. . ......... 6.4
1989 .. ... .. ...... ... .. .. . .. . . .. . .. . .... .. ....... . .. . .. . ....... .. 6.5
1990 .. . . ................ 6.6
1991 ....... . ... . .. . .. . .. . . . . . .. .. ..... . ........ . . .......... . ..... 6.7
1992 .. .. .. . .. .. . ..... . ...... ... ... .. .. .. .. .. ... ... .. . ... . ............. 6.8
1993 ...... . . . . . .. . . .. . .... .. ... . ......... . . . . .. . .. . ..... .. . ... ....... 6.9
1994 ...... . .... . .............. . ....... . .... . ....... . .. . ... . .... . 6.10-6.11
1995 ..... . . . . .. . .. .. . . ... .. . . . . .. . .. . .. . . . . .... . ...... . .... . 6. 126.1 3
Systems ........................................ . .. ... .. ... . .. _ . . .... . 6.1 4-6.21
Component Effect vs Throttle Opening . ...... . .. . . . .. . . . . . ... . .. ..... ....... . . 6.22
Component Functions ........................... .. .. .. ...... .. _ ...... . 6.23-6.25
Jetting Guidelines and Part Numbers ................. .. . ... . ... . _ ..... . . ", .. . 6.26
Jetting Compensation for AltitudelTemperature
1985 .. .. .. .............. .. . .. . .. .. ..... . ........ .. . . . . . . .. . .. . ...... 6.27
1986 ... . ....... . .... . ...................... .. . ......... . ........ . . .. 6.28
1987 ....... . .. .... ... .. . . ... .. .. . ...... . ... .. . . . . . . . . . . .. ... . . . . .. .
1988 .. .. .. . . . . . . .. . .. . .. . .. . . . . . . .. . ...... . . . .. .. ...... ............
6.29
6.30
1989 ...... . ... . ..... . .. . .. . .. . .. .. ..... . .. . . . . ... ....... . .. . ... . . 6 . ~ 1 - 6 . 3 2
1990 ......... . . .. . .. . .. . . .. .. . . ...... . . .. . . ... . . . . . . . . . . . ..... 6.336.34
1991 ... . .. .. .... . ..... . . .. . . . .......... . .. .. . ...... . ......... 6.3&-6.36
1992 ... . .... .... . . . . . .. . . ... ... . . . .. .. .. . ... .. . . . .......... .. 6.37-6.38
1993 ........ .. .. ... ......... .... .. .. . .. ...... .. .. . .. .... .......... 6.39-6.40
a
RIDE RED
-
8194
8194
1994 ................. .. ............... . ....... .. ......... . . ....... 6.41-6.43
1995 .... . ............. .... ............... . . . . ... ...... . ... 6.446.48
Adjustments - Jetting ...... ..... ... . ............ .. . . . .... . .. ..... . .... . 6.49-6.50
Adjustments - Synchronizing Throttles - 38mm Carbs . . . . . . . . . . . . . . . . . . . . . . . . .. 6.51
Throttle Synchronization Procedure .................... . ................... 6.52
Adjustments - Choke ......................... . .. . .... . .... . ...... .... . .... 6.53
Adjustments - Jet Needle and Float Level ...... . .. . ......................... 6.54
Carburetor Service . . ....... . ..... . ... . ..... . ....... . ... . . . ..... . ....... 6.55-6.56
Exploded View VM30SS . .... ..... . .. ...... .. ..... ..... .. .. .............. . . 6.57
Exploded View VM34SS ...... . ....... . .... . .................... . .... . ...... 6.58
Exploded View .. VM38SS ......... ........ ... ... .. ....... ... ...... 6.59
Fuel Pump - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.60
Exploded View - Utes and Sports Fuel Pump Prior to 1994 .... ......... . ....... 6.61
Exploded View Lites, Sports, WideTrak GT Models .... . .. . . . .... . ............. 6.61
Exploded View Twin Cylinder (Typical) Fuel Pump ..... . ... . .... . .......... . . . 6.62
Exploded View 650 3 Cylinder Fuel Pump . ............ . . . . . ....... . .......... 6.63
Problem Diagnosi s . .......................................... . ......... 6.646.66
Optional Water Trap InstaHati on . ........ . . ... . . .. . . .. . . . ...... . . .. . ...... 6.67
b
RIDE RED
CARBURETION
1985 Condensed Data
Whenever servicing the carburetor or fuel system, it is important to heed the following warnings.
A WARNING
Always stop the engine and refuel outdoors or in a well ventilated area.
Do nol smoke or allow open flames or sparks in or near the area where refueting is performed or where
Do not overfill the tank. Do nol 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 orclothing, 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.
Machine Engine Cyl. Carburetor Std. Std. Air Screw
Model Model Di sp. Model, Mount Main Jet Pilot Adjust
ce's Type & No. & Type Jet (counterclockwise
from seat)
St"
EC2SP5-06 244 VM30SS (1) 130 60 I 1/2 turn
Zinc He,
55 EC44-2PM- 432 VM34SS (1) 2eo 40 1.01um
3100 Zinc He,
Indy Trail EC44-2PM- 432 VM34SS (2) 230 35 1.0 lurn
2100 Zinc
H"
Indy 400 EC40Pl-Q2 398 VM34SS (2) 220 35 1.0 1um
Zinc
H"
'"",600
ECSOPl-Q2 597 VM38SS (3) 260 35 314 tum
Alum
H"
long Track EC44-2PM- 432 VM3OSS(1) 200 30 I.Olum
5000 Zinc
H"
Engine Jet Needle No. Needle Throttle Throttle Valve Idle Fuel /Oil
Model " E"Cllp Jet No. Valve Valve Seat RPM Mixture
Posi tion Cutaway Spring 200
PN
EC2SPS-06 SOT49-3 0-8 (171) 3.0 313028\ 1.Smm 2100 Variable Ratiol
Automatic Injection
EC44-2PM-31oo 60H7-3 P-6 (166) 2.5 3130289 I.Smm 2300 Variable Ratiol
Automatic Injection
EC44-2PM-21oo 6DH7-3 P-6 (166) 3.0 3130314 I.Smm 2300 Variable Ratiol
Automatic Injection
EC40Pl-02 6DH7-2 P-6 (166) 3.0 3130314 I.Smm 2200 Variable Ratio.'
Automatic Injection
EC60Pl-02 6F4-3 P-8 (247) 3.0 3130334 I.Smm 2000 Variable Ratio!
Automatic Injection
EC44-2PM-SOOO SDP10-3 P-8 (171 ) 2.5 3130281 I.Smm 2300 40:1
6.1
8/94
RIDE RED
CARBURETION
1986 Condensed Data
Machi ne Engine Cyl. Carburetor Std. Std. Air Screw
Model M_' Disp. Model, Mount Main Jet Pilot Adjust
CC' s Type & No. & Type Jet (counterclockwise
from seat)
Sla, EC25PS06 244 VM3QSS (1 )
'30
60 1 IfZ lurn
Zinc He<
Sprint (ES) EC342PM.o1J 339 VM30SS (2) 145 35 1.0 tum
02 Zinc He,
SS EC44-2PM- 432 VM34SS (1) 260 40 1.01um
3'00 linc He<
Indy T r a ~ ECSOPM-Qt 488 VM34SS (2) 210 30 I.O lum
Zinc He<
Indy 400 EC40Pl '()2 398 VM34SS (2) 220 30 1.01um
Zinc He<
Indy 600 (LE) EC60Pl.Q2 597 VM38SS (3) 2BO 35 3I4lum
Zinc He<
Long Track EC44-2PM- 432 VM30SS (1 ) 200 30 1.0 tum
5100 Zinc He<
Engine Jet Needle No. Needle Throttle Throttle Valve Idle Fuel/Oil
Model " E" Cl1p J et No. Valve Valve Seat RPM Mixture
Position Cutaway Spring . 200
PN
EC25PS.Q6 50T49-3 0-8 (171) 3.0 3130281 1.5mm 2100 Variable AatiGI
Automatic Injection
EC34-2PM-QtI02 5DP7-3 0-8 (171) 3.0 3130350 1.5rrvn 2100 Variable Ratio.'
Automatic Injection
EC44-2PM-3100 60H7-3 P-6 (166) 2.5 3130318 I .Smm 2300 Variable Ratio.'
Automatic Injection
ECSOPM-Ol 60H7-2 P-8 (166) 3.0 3130316 2000 Variable Ratio.'
Automatic Injection
EC4OPl-02 6DP172 0.2 (166) 2.0 3130318 1.5rrm 2200 Variable Ratio{
Automatic InjeCtion
EC60PL.()2 6F9-3 P-8 (247) 3.0 3130334 I.Srrm 2000 Variable Ratiol
Automatic Injection
EC44-2PM-5100 5DP10-3 P-8 (171)
2.' 3130218 1.5mm 2300 Variable Ratio(
Automatic Injection
8194
6.2
AICERED
Machine Engine Cyt.
Model Model Disp.
CC's
Star, StarTrak EC25P5-Q6 244
Sprint (ES) EC34 2PM-Ql !
02
339
Indy Sport EC342PM-03 339
Indy Trail (All) ECSOPM-Ol f02 488
Indy 400 EC40PL-02 398
100\' 600 EC60PL-02 597
LoogTrak EC44-2PM- 432
(A.l.A.)
5100
Engine Jet Needle No. Needle
Model "E" Clip Jet No.
Position
EC25P5-06 50T49-3 0-8 (171 )
EC34-2PM-Ol l02 5DP7-3 0-8 (171 )
EC34-2PM-03 50P7-3 0-8 (171)
ECSOPM-{l1 60H7-2 P-8(166)
EC40PL-Q2 60P17-3 0-2 (166)
EC60PL-02 6F9-3 P-8 (247)
EC44-2PM-Sl00 50P1Q-3 P-6(171 )
Carburetor
Model, Mount
Type & No.
VM30SS (1)
Zinc
VM30SS (2)
Zinc
VM3QSS (2)
Zinc
VM34SS (2)
Zinc
VM34SS (2)
Zinc
VM38$S (3)
Zinc
VM30SS ( 1)
Zinc
Throttle Throttle
Valve Valve
Cutaway Spring
PN
30 3130281
3.0 3130350
3.0 3130350
3.0 3130318
2.0 3130318
3.0 3130334
2.5 3130218
6.3
Std.
Main Jet
& Type
130
H ..
155
H ..
180
H ..
220
H ..
220
H ..
260
H ..
200
H ..
Valve
Seat
1.Smm
1.5mm
1.Smm
I .Smm
I.Smm
I .Smm
I .Smm
CARBURETION
1987 Condensed Data
Std. Air Screw
Pilot Adjust
Jet (counterclockwi se
from seat)
60 1 1/2 1urn
35 1.0 turn
35 1.0 turn
30 1.0 turn
30 1 1121urn
40 1.0 turn
30 I.Olum
Idle Fuel/Oil
RPM Mixture
200
2100 Variable Raliol
Automatic Injection
2100 Variable Ratio{
Automatic Injection
2100 Variable Ratio.'
Automatic Injection
Automatic Injection
Automatic Injection
Automatic Injection
Automatic Injection
8/94
RIDE RED
CARBURETION
1988 Condensed Data
Model Model Disp. Model, Mount Main Jet Pilot Adjust
ce's Type & No. & Type Jet (counterclockwi se
from seat)
Star, StarTrak EC25PS06 244 VM30SS (1) '30
60 1 tl2 lum
Zinc
H"
Sprint (ES) EC34-2PM-02 339 VM30SS (2)
' 55
3S I.Olum
Zinc
H"
Indy Sport EC34-2PM-OO 339 VM30SS (2)
' 80
3S I.Dlum
Zinc
He'
Indy Trail (All) EC50PM-OI/02 488 VM34SS (2) 220 3S I.O lum
Zinc He,
Indy 400 EC40PL -02103 396 VM34S5 (2) 220 30 1 112 tum
Zinc He,
Indy 650 (All) EC65PL-Ol 648 VM38SS(3) 260 50 1.0 turn
Zinc
H"
LongTrak EC44-2PM- 432 VM34SS (1) 280 50 I.D lum
(A. L.A.)
4100 Zinc He,
Engine Jet Needle No. Needl e Throttl e Throttle Valve Idle Fuel/Oil
Model "e" Clip Jet No. Valve Valve Seat RPM Mi xture
Position Cutaway Spring 200
PN
EC25P&-06 5DT49-3 0-8 (171) 3.0 3130281 1.5mm 2100 Variable Ratio!
Automatic Inject ion
EC34-2PM-02 50 P7-3 0-8(171) 3.0 3130350 I.Smm 2100 Variable RatiOI'
Automatic Injection
EC34-2PM-03 SOP7-3 0-8(171) 3.0 3130350 I.Smm 2100 Variable RatiOI'
Automatic Injection
ECSOPM-Oll02 60H7-2 P-8 (166) 3.0 3130318 I .Smm 1900 Variable RatiOI'
Automatic Injection
EC40Pl-02lO3 60P17-3 0-2 (166) 2.0 3130318 I.Smm 1900 Variable RatiOI'
Automatic Injection
EC6SPl..{)1 6F9-3 P-8 (247) 3.0 3130334 I.Smm ,900 Variable RatiOI'
Automatic Injection
EC44-2PM-4 100 60H7-3 P-6 (166) 2.S 3130318 I.Smm 2300 Variable RatiOI'
Automatic Injection
8194
6.4
RIDE RED
-
-
Machine Engine Cyl. Carburetor
Model Model Di sp. Model, Mount
ec's Type & No.
Star,StarTrak EC25P$-06 244 VM30SS (I)
linc
Sprint (ES) EC34-2PM-Q2 339 VM3QSS (2)
linc
Indy Sport! EC34-2PM-03 339 VM30SS (2)
Sport GT
Zinc
Indy Trail (All) ECSOPM-OlIQ2 488 VM34SS(2)
Zinc
Indy SuperTrak EC50PM-Q3 488 VM34SS (2)
Zinc
Indy 400 EC40PL-02 396 VM34SS (2)
Zinc
Indy 500 (All) EC50PL-Ol/02 488 VM36SS (2)
Aluminum
Indy 650 (All) EC65PL-Ol 646 VM38SS (3)
Zinc
LoogTrak EC44-2PM- 432 VM34SS (1)
(R. L.R.) 4'00 Zinc
Engine Jet Needle No. Needle Throttle
Model " e"Clip Jet No. Valve
Positi on Cutaway
EC25P$-06 50T49-3 0-8 (171) 3.0
EC342PM..Q2 SOP7-3 0-8 (171) 3.0
EC34-2PM-D3 SOP7-3 0-8 (171) 3.0
EC5OPM-Ol/02 60H7-2 P-8(166) 3.0
EC5OPM-03 60H7-3 P-6 (166) 3.0
EC40PL..Q2 60Pt7-3 0-2 (166) 2.0
ECSOPL-Ol/02 6F9-3 Q-O (247) 3.0
EC6SPL-Ol 60H4-3 P-8 (247) 3.0
EC44-2PM-4100 60H7-3 P-6 (166) 2.5
6.5
-
Throttle
Valve
Spring
PN
3130281
3130350
3130350
3130318
3130318
3130318
3130334
3130334
3130318
Std.
Main Jet
'Type
'30
H"
'55
H ..
'80
H"
230
H"
200
H ..
230
H ..
280
H ..
260
He,
280
He,
Valve
Seat
I.Smm
I.Smm
I.Smm
I.Smm
I.Smm
I.Smm
I.Smm
I.Smm
I.Smm
CARBURETION
1989 Condensed Data
Std. Air Screw
Pilot Adjust
Jet (counterclockwise
from seat)
60 t 1/2 turn
35 I.Dtum
35 I.Dtum
35 I.Dtum
30 t.Otum
30 1 112 1um
40 1.01urn
50 I.Dlum
50 1.0 turn
Idl e Fuel /Oil
RPM Mixture
200
2'00 Variable Aatiol
Automatic Injection
2'00 Variable Ratiol
Automatic Injection
2100 Variable Aatiol
Automatic Injection
Automatic Injection
'900
Variable Aatiol
Automatic Injection
'900 Variable Ratiol
Automatic Injection
'900
Variable RatioJ
Automatic Injection
'900 Variable Aatiol
Automatic Injection
Automatic Injection
RIDE RED
8/94
CARBURETION
1990 Condensed Data
Machine Engine Cyl. carburetor Std. Std. Air Screw
Model Model Disp. Model. Mount Main Jet Pilot Adjust
CC' s Type & No. "Type Jet (counterclockwise
from seat)
Star, StarTrak EC25PS06 244 VM30SS (1) 150 60 1.0tum
Zinc
H"
Sprint (ES) EC342PM-02
33'
VM30SS (2) 155 35 I .Dtum
Zinc He'
'''''' SpO<1J
EC342PM-03
33'
VM30SS (2) 180 35 1.0 tum
Sport GT
Zinc
H"
Indy TraW (All) ECSOPM-01J02 488 VM34SS (2) 230 35 1.0 1urn
Zinc
H"
Indy SuperTral< ECSOPM-03 488 VM34SS (2) 200 30 1.0 turn
Zinc
H"
Indy 400 EC40PL-02 398 VM34SS (2) 230 30 11121um
Zinc
H"
Indy 500 (All) ECSOPL-Q1J02 488 VM3855 (2) 280 40 I.Olum
Aluminum
H"
Indy WideTrak ECSOPL-03 488 VM34SS (2) 190 35 1114 tum
Zinc He'
Indy 650 (All) EC65PL-ol 648 VM38SS (3)
Z'"'
260 45 I.Olum
He,
Engine Jet Needle No. Needle Thronle Throttle Valve Idle Fuel/Oil
Model "E" Clip Jet No. Valve Valve Soat RPM Mixture
Position Cutaway Spring 200
PH
EC25P&06 50T49-3 0-8(171) 3.0 3130281 I .Smm 2100 Variable Ratiol
Automatic Injectioo
EC342PM-{l2 5DP7-3 0-8(171) 3.0 3130350 1.5mrn 2100 Variable Ratiol
Automatic Injection
EC34-2PM-03 5DP7-3 0-8(171) 3.0 3130350 1.5mrn 2100 Variable Ratiol
Automatic Injection
EC50PM-{)1102 SDH7-2 P-8 (166) 3.0 3130318 1.5mrn 1600 Variable Raliol
Automatic Injection
EC50PM-03 SDH7-3 P-6 (166) 3.0 3130318 1.5mm 1600 Variable Raliol
Automatic Injection
EC40PL-02 SDPI7-3 0-2 (ISS) 2.0 3130318 1.5mm 1900 Variable Ratio!
Automatic Injection
ECSOPL-ol102 SF9-3 Q-O (247) 3.0 3130334 t.5mm 1900 Variable Ratio{
Automatic Injection
EC50PL-03 6EJ26.3 P-6 (166) 3.0 3130318 t .5mm 1900 Variable Raliol
Automatic Injection
EC65PL-01 SOH4-3 0-2 (247) 3.0 3130334 1.5mm 1990 Variable Raliol
Automatic Injection
8194
6.6
AIDE RED
-
Machine Engine Cyl.
Model Model Disp.
ee's
StarUte EC25P$-07 244
Indy Lite EC342PM-03 339
,,,,,,,,-
EC44-3PM-Ol 432
Spo<1 GT
Indy Trail (A") EC50PM-01J02 488
Indy SuperTrak ECSOPM'()3 488
Indy 400 EC4QPL-02J04 398
Indy 500 (All) ECSOPL.()l/
02104/05
488
Indy WideTrak ECSOPL-06 488
Indy 650 (AI) EC65PL.()2 648
RXL EC65PL-03 648
Engine Jet Needle No.
Model "E" Clip
Position
EC25PS.()7 5DT49-3
EC342PM-03 SOP7-3
EC44-3PM-Ol SOP7-3
EC50PM-01102 60H72
EC50PM-03 60H7-3
EC4QPl-02lO4 60P173
ECSOPl-Ol/02J 6FS-3
04/05 6F""
ECSOPl-OEi SEJ26-3
EC65Pl-02 60H7-3
EC65Pl-03 EFI
Carburetor
Model, Mount
TYpe & No.
VM30SS (1)
Zinc
VM30SS (2)
Zinc:
VM34SS (2)
ZInc
VM34SS (2)
ZJnc
VM34SS (2)
Zinc
VM34SS (2)
Zinc
VM38SS (2)
Aluminum
VM34SS (2)
Zinc
VM38$S (3)
Aluminum
<l6mmTB"
(31
Needl e Throttle
Jet No. Valve
Cutaway
()'8 (171) 3.0
0-8 (171) 3.0
0-8 (171) 3.0
P-8(166) 3.0
P-6 (IS6) 3.0
0-2( 166) 2.0
0-0 (247) 3.0
P8 (247) 2.5
P-6 (166) 3.0
0-2 (247) 2.5
NlA NlA

6.7
Std.
Main Jet
& Type
160
H"
160
H"
'"
H"
230
H"
200
H"
230
H ..
280
H"
190
H"
260
H ..
NJA
Valve
Seat
I.Smm
1.Smm
1.5mm
1.5mm
1.5mm
1.5mm
1.5mm
1._
1.5mm
,.-
NlA
CARBURETION
1991 Condensed Data
Std. Air Screw
Pilot Adjust
from seat)
60 1 112 turn
35 1.0 tum
35 1 112 turn
35 1.0 tum
30 1.0 tum
30 1 112 tum
40 I.Otum
35 1 1/4 turn
45 I.Otum
NJA NlA
Idle Fuel/Oil
RPM Mixture
200
Automatic Injection
2100 Variable Ratlol
Automatic Injection
2100 Variable Ra60l
Automatic Injection
Automatic Injection
1600 Variable Ratiol
Automatic InJectioo
Automatic Injection
1900 .
Variable Ratiol
'900
Automatic Injection
Automatic Injection
1900 Variable Ra60l
Automatic Injection
NlA Variable Ratiol
Automatic Injection
8194
AIDE RED

CARBURETION
1992 Condensed Oata
Machine Engine Cyl. Carburetor Std. Std. AirScrew
Model Model Disp. Model. Mount Main Jet Pilot Adjust
CC' s Type & No. & Type Jel (countercloekwlse
from seat)
StaTUte EC25PS-Q7 244 VM30SS (1) 160 60 1.0 turn
Zinc
H"
Indy Ute/GT/Del uxe EC34-2PM-02I03J 339 VM30SS (2) 160 35 1.0 turn
04 Zinc
H"
1 1/2 turn (GT)
Indy Sport! EC44-3PM-Ot 432 VM34SS (2) 180 35 11/41um
Sport GT
Zinc He,
Indy TraiV ECSOPM-Ol102 488 VM34SS (2) 230
3'
I.Glum
Trail Deluxe
Zinc He'
Indy SuperTrak ECSOPM-03 488 VM34SS (2) 200 30 1.0 turn
Zinc He'
Indy 440 EC45PL-02 432 VM34SS (2) 230 30 I.O lum
Zinc
H"
440XCR EC45PL-Ol 432 VM38SS (2) 290 40 I.Glum
Aluminum
H"
Indy SOO/Classic ECSOPL-04/05 488 VM38SS (2) 280 40 I.Ol um
Aluminum He,
Indy WideTrak ECSOPL-06 488 VM34SS (2) 190 35 314lurn
Zinc He'
''''' 650
EC85PL-Q2 648 VM385S (3) 260 45 1.0 turn
Aluminum He,
Indy 500 $PI ECSOPL-Q7 488 46MM TBI' N/A NJA NJA
SKS (21
RXLJSKS EC65PL-03 648 46mmTBI' N/A NJA N/A
(31
Engine Jet Needle No. Needle Throttle Valve Idle Fuel/Oil
Model " E" Cllp Jet No. Valve Seat RPM Mixture
Position Cutaway 200
EC25P5-07 5DT49-3 ().S (171) 3.0 1.5 1200 Variable Ratio!
Automatic InjecliOfl
EC34-2PM-02J03l04 50P7-3 ().S (171) 3.0 1.5 1600 Variable Ratio(
5DP7-2 (GT) Automatic Injection
EC44-3PM.Ql 6DH7-3 P-2 ( 166) 3.0 1.5 1600 Variable Ratio(
Automatic Injection
ECSOPM.Ql /02 6DH7-2 P-8 (166) 3.0 1.5 1600 Variable Ratio(
Automatic InjectiOfl
ECSOPM-Q3 6DH7-3 P-6 (166) 3.0 1.5 1600 Variable Ratio(
EC45PL-Q2 6DH7-2 P-4 (166) 2.5 1.5 1600 Variable Ratio!
Automatic Intection
EC45PL-Ql 6F9-3 P-8 (247) 2.5 1.5 1900 Variable Ratio!
Automatic Injection
ECSOPL-04105 6F.., P-S (247) 2.5 1.5 1900 Variable Ratio!
Automatic Injection
ECSOPL-Q6 6EJ26-2 P-6 (166) 3.0 1.5 1600 Variable Ratio!
Automatic Injection
EC65PL-Q2 60H7-3 0-2 (247) 2.5 1.5 1500 Variable Ratio!
ECSOPl.Q7 EFI" N/A NJA N/A NJA Variable Ratio!
Automatic Intection
EC65PL-03 EFI" N/A NJA NJA NJA Variable Ratio!
Automatic Injection
.
T.B.!. (Throttle Body Injectors)
.. E.F.1. (Electronic Fuel Injection)
8194
6.8
RIDE RED
Machine Engine Cyl.
Model Model Disp.
ee's
StarLitefGT EC25PS07 244
Indy Ute/GTIOeIuxe EC342PM.()2104 339
SporVTrail Deluxe EC44-3PM-Ol 432
Trail EC50PM.(l1 488
440XCR EC45PL..o1 432
Indy 440/SKS EC45Pl-02 432
ClassicJTouring ECSOPL-04105 488
WideTrakGT EC50PM-03 488
WideTrak EC50PL-06 488
XlTfSPISKS ECS8Pl-Ol 579
Stom'\lSKS EC75PL-Ol 744
500 EFlfSKS ECSOPL-07 488
RXUSKS EC65Pl-QS 648
Engine J et Needle No.
Mode( " E" Clip
Position
EC25P5-07 50T2-3
EC34-2PM-02I04 50P7-2
EC44-3PM-Ol 60H7-3
ECSOPM-Ol103 60H7-2
60H7-3
EC45PL-Ol 60H3-3
EC45PL-02 60H7-2
ECSOPL.-{)4105 6F9-3
ECSOPL-06 6EJ26-2
EC58PL-Ol 60P17-3
EC75PL-OI 6CEY6-3
ECSOPL-07 EFt-
EC65Pl-05
EFI
T.B.I. (Throttle Body Injectors)
E.F. 1. (Electronic Fuel lnjec1ion)

Carburetor
Model, Mount
Type & No.
VM30SS (1)
l inc
VM3QSS (2)
Zinc
VM34S5 (2)
Zinc
VM34SS (2)
z,'"
VM38SS (2)
Aluminum
VM34SS (2)
Zinc
VM38SS (2)
Aluminum
VM34SS (2)
Zinc
VM34SS(2)
Zinc
VM34SS(3)
Zinc
VM38SS(3)
Aluminum
46MM TBI'
(2)
46mmTBI '
(3)
Needl e Throttle
Jet No. Valve
Cutaway
0-8 (169) 3.0AL
0-6 (169) 2.5AL
P-4 (166) 2.5CH
p-e (166)
P-6 (166)
3.0CH
P-8 (247) 2.0CH
P-4 (166) 2.5CH
P-8 (247) 2.5CH
P-6 (166) 3.0CH
0-2 (166) 2.0CH
R-O (247) 2.5CH
N/A NlA
N/A NlA
6.9
Std.
Main Jet
&Type
140
He.
14'
He'
180
He.
230
290
230
280
200
190
200
390390410
pe M
NlA
NlA
Valve
Seat
1.'
1.'
1.,
1.'
1.'
1.'
1.'
1.,
1.'
1.'
NlA
NlA
CARBURETION
1993 Condensed Data
Std. Ai r Screw
Pil ot Adjust
from seat)
60 1.0 turn
35 I 1121urn
35 I 1/4 turn
35 1.01u-n
40 I.Olum
3'
314 turn
40 1.0 turn
30 I.Olum
3'
314 tum
3'
I .O lum
35 1 1121urn
NlA NIA
NlA NlA
Idle FueUOIl
RPM Mixture
200
Automatic Injectioo
Automatic Injection
Automatic Injectioo
Automatic InjectiOn
Automalic Injection
Automatic Injection
Automatic Injection
Automatic Injection
Automatic Injection
1900 Variable RaIlOr'
Automatic tnjection
Automatic Injection
Automatic InjectiOn
AIDE RED
8/94
CARBURETION
1994 Condensed Data
Machine Engine Cyl. Carburetor Sid. Std. Air Screw
CC's Type & No. & Type Jet (counterclockwise
from seat)
StarUle/GT EC25P5'()7 244 VM3QSS (1) 140 60 1.0 turn
Zinc
"0<
Indy UteJGTI EC34-2PM- 339 VM30SS (2) 145 35 1 1121urn
Deluxe
02104 Zinc
"0<
SporVSKS EC44-3PM-{)1 432 VM34SS (2) 180 35 1 1/41urn
Super Sport
01102 Zinc
"0<
TraiVTrailOelu)(9 ECSOPM-Ot 488 VM34SS (2) 230 35 1.0 turn
Zinc
440 XCR EC45PL-Ol 432 VM38SS (2) 290 40 1,0 tum
Aluminum
440 XCR 5P EC45PL-OJ 432 VM3855 (2)
Aluminum
330 40 1.5 tum
600XCR EC58PL-02 596 VM38SS (3)
Aluminum
260 35 1.0 turn
Indy 4401SKS EG45PL.()2 432 VM34SS (2)
Zinc
230 35 314 tum
Classic ECSOPL-05 488 VM385S (2) 300 40 1.0 turn
Aluminum
WideTrak GT ECSOPM-03 488 VM34SS (2) 200 30 1,0 turn
Zinc
WideTrak LX EC50PL-06 488 VM345S (2) 190 35 314 turn
Zinc
XLTfSP/SK$ EC58PL.()l 579 VM34SS (3) 200 35 1.0 turn
Zinc
XlT Special XTRA EC58PL.()3 596 VM34SS (3)
Zinc
210 35 1.0tum
StormiSKS EC80Pl-Ql 794 VM38SS (3) 380390410 30 1 112 turn
Aluminum peM
500 EFI/SKS ECSOPl-Q7 488 46MMTBI" NIA NIA NiA
Classic Touring lOB 12)
RXL/SKS EC65Pl-Q5 648 46mmTBI" NIA NIA NiA
13)
8194
6. 10
RIDE RED
Model "E" Cllp Jet No.
Position
EC25P5-07 50T2-3 0-8 (169)
EC34-2PM-02/04 5DP7-2 Q.{j (169)
EC44-3PM.()1 60H7-3
P-4 I166J.
01/02 6DH7216FJ 6-3 P-4/p8 (1 )
EC50PM-Ol 6DH7-2 P-8 (166)
103
6DH7-3 P-S (166)
EC45Pl.()1 SOH3-3 P-8 (247)
EC45Pl-02 60H7-2 P-4 ( 166)
EC45PL-03 60H3-3 0-2 (247)
EC50Pl-05 6F9-3 P-8 (247)
ECSOPl-06 6EJ26-2 P-6 (166)
EC58Pl-Ol 6 D P 1 7 ~ 0-2 (166)
EC58Pl-02 60H7-3 0 -2 (247)
EC58Pl-03 60P17-3 0.2 (\66)
EC80Pl-Oi 6CGY3-2 0-8 (247)
EC50Pl-07108 EFl
oO
NJA
EC65Pl-05
EFloO
NJA
I.B.I. (Throttle Body InJect()(s)
E.F.I. (Electronic Fuel Injection)
6.11
Throttle
Valve
Cutaway
3.0 AL
2.S AL
2.5CH
2.0
3.0CH
2.0CH
2.SCH
2.0CH
2.SCH
3.0CH
2.0CH
2.5CH
2.0CH
2.5CH
NJA
NJA
Valve
Seat
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.8
NJA
NJA
CARBURETION
1994 Condensed Data
Idl e Fuel/Oil
RPM Mixture
. 200
1200 Variable RalioJ
Automatic Injection
1600 Variable Ratioi
Automatic Injection
1600 Variable Ratio!
Automatic InjectiOn
Automatic Injection
Automatic Injection
1600 Variable Ratial
Automatic Injection
Automatic Intaction
Automatic In)ection
1600 Variable RatiGI
Automatic Injection
1800 Variable Ralio.'
Automatic Injection
Automatic Injection
1900 Variable RatiOl
Automatic In}ection
Automatic Injection
Automatic Injection
Automatic Injection
RICEREC
6/94
CARBURETION
1995 Condensed Data
ee's Type & No. & Type Jet (counterclockwise
from seat)
StarLile EC25PS07 244 VM30SS (1) 140 60 1.0 turn
Zinc
Indy Lile/GTI EC342PM 339 VM30SS(2) 145 35 I 1121um
Deluxe
02JE02 Zino
SportfTouring EC44-3PMOtI02 432 VM34SS (2) 180 35 I 114 turn
Super Sport
Zinc
TraiVTrail Deluxe ECSOPM04/E04 488 VM34SS (2)
Zinc
240 35 1.51um
Indy 4401SKS EC45PLQ2 432 VM34SS (2)
Zinc
230 35 3/4lurn
ClassiclSOO ECSOPL04fE04 488 VM38SS (2) 300 40 1.0 turn
Aluminum
WideTrak LX EC50PL06 488 VM34SS (2) 190 35 3/4 turn
Zinc
WideTrakGT EC50PMQ3 488 VM34SS (2) 200 30 1.0 1um
Zinc
440 XCA EC45PL05 439 VM34SS (2) 290 40 1.0tum
Aluminum
XLT/SP(SKS EC58PL03 596 VM34SS (3)
Zinc
210 35 1.0 tum
XLT Touring EC58PLE04 596 VM34SS e3l
Zinc
240 35 1.0 1um
600XCA EC56PL02 596 VM38AL (3) 260 35 1.01um
Aluminum
SlormlSKS EC80PL02 794 VM3855 (3) 370380410 45 1 1I41urn
Alumi num pe M
500 EFllSKS ECSOPl07 488 46MM TBIo NIA NIA NlA
108 (2)
RXLJTOlJring EC65Pl05 648 46mmTBIo
(3)
NIA NIA NlA
8/94
6.12
RIDE RED
Model " E" Clip Jet No.
Position
EC25PS07 5DT2-3 0-8 (169)
EC34-2PM02/E02 5DP7-2 ().6 (169)
EC44-3PMOI 60H7-3 P-4 (t 56)
EC44-3PM02 6FJ6.3 P-8 (1 66)
EC50PM04IE04 SDH7-3 P-8 (1 66)
EC45PL02 6DH7-2 P-4 ( 166)
ECSOPL04/E04 6F9-3 P8 (247)
ECSOPL06 6EJ26-2 P-6(1 66)
ECSOPM03 SOH7-3 P-6 (l 66)
EC45PLOS SOH7-3 P.o (286)
EC58PL02 6DH7-3 0-2 (247)
EC58PLE04 6DP17-3 0-2 (166)
EC58PL03 60P17 3 Q..2 (166)
EC80PL02 6CGY3-3 Q..O (247)
ECSOPL07108 EFI" NlA
EC65PLOS EFI"' NlA
T.B.!. (Throttle Body Injectors)
, . E.F.1. (Electronic Fuel Injection)
6.13
Throttle
Valve
Cutaway
3.0Al
2.SAl
2. 5CH
2.0 CH
3.a CH
2. 5 CH
2. 5CH
3.aCH
3.aCH
2.a CH
2.5CH
2.SCH
2.0CH
3.0 CH
NlA
NlA
Valve
Seal
1.5
1.5
1.5
' .5
1.5
1.5
1.5
' .5
1.5
' .5
'.5
1.5
1.5
1.5
NlA
NlA
CARBURETION
1995 Condensed Data
Idle FueUOIl
RPM Mixture
. 200
' 200 Variable Ratial
Automatic Injection
'600
Variable Ratial
Automatic Injection
'600
variable Ratial
Automatic Intection
'600
variable Ratiol
Automatic Injection
'600
Variable Ratial
Automatic Injection
'600
Variable Ratial
Automatic Injection
1900 Variable Ratio!
Automatic Injection
'600
Variable Ratial
Automatic Injection
'600
Variable Ratial
Automatic Injection
'500
Variable Ratial
Automatic Injection
Automatic Injection
Automatic Injection
'900
Variable Ratiol
Automatic Injection
' 600
Variable Ratiol
Automatic Injection
' 900
Variable Ratiol
Automatic Injection
'900
Variable Ratiol
Automatic Injection
8194
AIDE RED
CARBURETION
Systems
Float Chamber Venting
In order to provide consistent fuel flow through the carburetor, the air pressure inside has to remain the same as
the outside air pressure. For this reason, the float chamber is vented. It is very important that the vent lines are
routed properly to the handlebars. Proper routing provides atmospheric pressure to the float chambers rather
than high under hood pressure. If high pressure is introduced into the chamber it could push extra fuel through
the jets, creating a rich running condition. In some cases high air pressure may nol allow fuel to enter the float
bowl , causing a lean mixture.
If the vent line is pinched or restricted, it can result in either a rich or lean condition, depending on how much fuel
is present in the float bowl before the restriction begins. Generally speaking, if the fuel level is low to begin with,
as fuel is trying to get in a pressure is built up inside the float chamber, not allowing fuel in. If the fuel level is high
to begin with, low pressure can be created causing fuel to be siphoned in through the inlet needle and seat.
8194
Vent Line Routing
(OPPOsite Carb to Handlebar)
Tee Fitting
One Way
Check Valve ---$J
Drain Fuel
Through
Valve Some Models Have
Atmospheric
Pressure
Interconnecting Lines Between each Carb

--I
""yacuum Tube _1
Air Box
Tee Fittings Are
V Orientated Vertically
I-I
Some Models Have Interconnecting
Lines Between Each Carbo
l

6.14
RIDE RED
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.
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 Syst em
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 controls the amount of
fuel in the fuel mixture. Too high a level allows
more fuel than necessary to leave the nozzle, en-
riching the mixture. Too Iowa level results in a
leaner mixture, since not enough fuel leaves the
nozzle. Therefore. the predetermined fuel level
should not be changed arbitrarily.
6.15 RICEREC
CARBURETION
Function
Float Guide Pin
Needle Valve
Float Arm
8194
CARBURETION
Starter System - Closed Throttle
The starter system is employed for Mikuni carburetors in place of the 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 in the optimum air/fuel ratio
through the fuel discharge nozzle. The starter is opened and closed by means of the starter plunger. Since the
starter type carburetor is constructed so as to utilize the negative pressure of the inlel pipe, it is important that
the throttle valve is closed when starting the engine.
8194
r--------ar-------------
c---------------------, '
II I I
: I Ig
I I Cable Adjuster I I
I I I I
I I I I
I 1 Cable Adjuster l ock Nut I I
l n ~ Plunger Spring :
"' I I
I I Plunger Cap I
I I Starter Plunger
I I Inlet Starter Air
I
- - ~ J
~ - '
Throttle Valve
- --- - - - - ~ j -
--
Inl et Bleed Air
Starter Jet
6.16
RIDERED
CARBURETION
Pi lot System 10-3/B Throttl e)
The pilot system's main function is that of a low speed jet, 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
Throttle Stop Screw
L---r--..
6.17
RICE RED
8194
CARBURETION
Slide Cutaway (1/8-3/8 Throttle)
Throttle vatve 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 ai r/fuel ratio at part throttle. A sleep 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 boHom of the valve (e.g. 2.5) indicating
the size of the cutaway. The higher the number. the steeper the angle.
Cutaway Angle
Throttle Valve
Needle
AirJel
Pilot Outlet
Pilot Jet
Needle Jet
Main Jet
Leaner
Richer
8/94
6.18
RIDERED
CARBURETION
Jet Needle/Needle Jet (3/8-3/4 Throttle)
The jet needle and needle jet have the most effect at approximately 3/8 to 3/4 throttle opening. Some mixture
adjustment 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 pas
sage and leans the mixture. Letter and number codes are stamped into the needle and the jet indicating sizes
and tapers of each.
Clip Position
Throttle Valve
Jet Needl e
Air
Pilot Outlet
Pilot Jet
Needle Jet
Main Jet
6.19
AICERED
8/94

CARBURETION
Main System (314 to Full Throttle)
The main system is designed for delivering fuel between low speed and high speed operation. This system is
made up of the jet needle, needle jet, and main jet. the main system begins to take effect as soon as there is
enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly. This
system works in conjunction with the needle jet system.
During low speed driving, there is very little clearance between the jet needle and the needle jet; therefore, very
little fuel from the main jel 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.
II
Throttle Valve
Jet Needle
Air
Pilot Outlet
Pilot Jet
Needle Jet
Main Jet
8/94
6.20
RIDERED

CARBURETION
Fuel Delivery System - Typical
The fuel system contains many components which directly affect fuel mixture and driveabilily. When performing
diagnosis or carburetor maintenance, the entire fuel delivery system should be inspected. Illustration 1 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 altha! time for cracks or leaks.
Test run and leak check the fuel system after any parts have been replaced and verify that all lines are routed
correctly away from any moving parts.

,
WEIGHTED PICKUP
AND UNE
VENTUNE
FUEL TANK
FUEL FILTER
AND FUEL UNES
Fuel Hose - Indy Storm/Storm SKS
OPTIONAl WATER
TRAPS
VENT UNES CARB
I MOUNTS

CYlINDER
BASE
GASKET
IMPULSE UNE
CRANK SEAL CHECK VALVES / CRANK SEAL
IMPULSE FTTTlNG
AT CRANKCASE
The Storm model fuel system incorporales dual fuel pumps. It is important to pay particular attention to correct
routing of the fuel lines in order to provide an adequate fuel supply to the engine.
FUEL SHUT
OFF VALVE
FUEL FILTER
?
TO CABUAETORS W
6.21
AIDE RED
-
VACUUM
IMPULSE
UNE
8/94
CARBURETION
Component Effect vs Throttle Opening
The throttle opening chart demonstrates component relationship to fuel flow versus throttle valve opening.
The pilot system's main function is that of a low speed jet. Its most effective range of fuel delivery is form idle
to approximately 3/8 throttle valve opening.
The throttle valve controls the rate of engine air by its movement up and down in the carburetor venturi. At small
throttle openings the air flow is regulated chiefl y by the valve cutaway as sown, with it greatest effectiveness at
1/4 throttle opening. Throttle valves are numbered 1.0, 1.5,2.0, etc., according to the size of the cutaway. De-
creasing the cutaway number will increase the amount of fuel delivered in its effective range.
The jet needle and needle jet have an effective operating range from approximately 1/8 to 7/8 throttle opening.
The amount of fuel delivered during this range relies upon the jet needle clip position, as well as the needle jet
size and other specifications.
The main jet affects fuel delivery at 1.4 throttle and consistently increases to fult throttle opening.
-
"
-
"
z
\
iii
\
"
W
II:
0
I ;;;
I
EFFECT
I
"
I
z
I
iii
I
"
w
I
II:
0
I
w
I
0
0 1/8 1/4 3/8 112 5/8 3/4 7/8 FUll
THROTTLE OPENING
-------- Throttle Valve Cut-Away
---
Jet Needle/Needle Jet
8194
6.22
RIDE RED
Pilot Jet
From idling to low speeds. the fuel supply is measured chie-
fly by the piloljet. In the sides of l he pilot jet, there are sever-
al air bleed openings which serve the same purpose as the
air bleed in the needle jet, which is to reduce the fuel to mist.
The number stamped on the jet is an indication of the
amount of fuel in ec's which passes through the jet during a
one minute interval under a given set of conditions.
Pilot Air Screw
This air screw controls the mixture from idling to low speeds.
The tapered tip of the air screw projects into the ai r passage
leading to the pilot jet air bleeds, and by turning the screw in
or out, the cross sectional area of the ai r passage is varied,
in turn varying the pilot jet air supply and changing the mix-
ture ratio.
6.23
CARBURETION
Component Functions
35
o
o
. ,
RIDE RED
Indicator
Number
Pilot Ai r Screw
~
8194
CARBURETION
Component Functions
Jet Needle
The jet needle has five grooves for adjustment cut into the
upper portion, and is tapered from approximately the middle
of the needle to the lower end. The top is fixed to the center
of Ihe throttle valve by the needle clip, and the tapered end
extends into the needle jet. Fuel flows through the space
between the needle jet and jet needle. This space does not
vary until the throttle reaches the 1/4 open point. At that
lime the tapered portion of the needle begins to move out
of the jet and affect fuel flow as the opening enlarges. It fol-
lows that taper wear and the position of the needle clip in the
grooves also affect the fueillow rate. If the needle clip is
changed from the standard position to a lower groove, the
needle taper starts coming out of the jet sooner, resulting in
a richer mixture. Moving the clip higher produces a leaner
mixture.
Needle Jet
The needle jet works in conjunction with the jet needle to
regulate fuel flow rate. There is an air bleed opening in the
side of the needle jet which brings in air measured by the air
jet. This air initiates the mixing and atomizing process in
side the needle jet. Mixing is augmented by a projection at
the needle jet outtet, called the primary choke. The lerter
number code stamped on the jet indicates jet inside diame--
ter.
Throttl e Opening vs Fuel Flow
In the full throttle condition, the cross sectioned area
between the jet needle and the needle jet is larger than
the cross sectioned area of the main jet. The main jet
therefore has greater control over fuel flow.
8194
--
6.24
Closed
Throttle
2

I
3 Groove
5
I
~
I
t
Leaner
t
Richer
large
Clearance
One-half
Throttle
Full
Throttle
RICE RED
THROTTLE VALVE
The throttle valve controls the rate of engine air intake
by moving up and down inside the main bore. At small
throttle openings, air flow control is performed chiefly
by the cutaway in the valve. By controlling air flow the
negative pressure over the needle valve is regulated,
in turn governing fuel intake.
The throttle valves afe numbered 1.0, 1.5, 2.0, etc.,
according to the size of the cutaway_ The higher the
number, the leaner the gasoline/air mixture.
MAIN JET
When the area between the needle jet and jet needle
increases, as the throttle opening becomes greater,
fuel flow is metered chiefly by the main jet. The
number on the jet indicates the approximate amount
of fuel ee's which will pass through it in one minute.
The larger numbers give a greater flow. resulting in a
richer mixture.
Main jets are located either in their banjo bolt holders
in the carburetor bowl, or are screwed directly into the
needle jet base.
,
I
CARBURETION
Component Functions
.-------.i
Cutaway
,
The following chart lists all main and pilot jets and the part number of each that are presently available.
PILOI JET NO. PART NO
25 .... .. . . . 3130064
30 . . .. . . 3130065
35 . .. 3130066
40 . .. .... 3130067
45 . ........... 3130068
50 ............. 3130069
55 . .... ......... 3130070
60 ... 3130071
65 ..... .. . .. 3130072
ROUND HEAP
MAIN JET NO,
90 ..... ..
95
100 .. . .. .
102.5 ... ..
105 . . . ... .
107.5 ... ..
110 . ... .
112.5 . . .
115 .. . . .
PARI NO.
3130073
3130074
3130075
3130076
3130077
3130078
3130079
3130080
3130081
117.5 .. .
120 .... .
122.5 .. .
125 .... .
....... 3130082
....... 3130083
. ...... 3130084
. .... . . 3130085
127.5
130 . ... .. .
132.5 .. . .
135 . . .. .
137.5 .
140 . . .. .
145 . .. .
150 .. . .
3130086
3130087
3130088
3130089
. . 3130090
. 3130091
. 3130092
.. 3130093
ROUND HEAD HEX HEAD
MAIN JET NO PART NO MAIN JET NO PARI NO.
160 ............. 3130094 210 .... 3130124
165 ..... , ....... 3130095 220 ... .3130125
170 . .. . ...... ... 3130096 230 .... 3130126
175 .. . . . . . .. . . . . 3130097 240 . . . . . . . 3130127
180 . .. . ... . .... . 3130098 250 . . . . ... 3130128
HEX HEAD 260 . . . . . .. 3130129
MAIN JET NO PART NO 270 . . 3130130
80 ............... 3130099 280 .,...... 3130131
85 ............. ,. 3130100 290 ..... . .. 3130132
90 .............. . 3130101 300 .......... . . . 3130133
95 ............... 3130102 310 ........ . ... . 3130134
100 ..... ... . .. .. 3130103 320 . .. .. 3130135
105 ..... ... ..... 3130104 330 ..... .3130136
110 .............. 3130105 340 ..... . . .. . .. 3130137
115 .... .......... 3130106 350 ...... .. . ... 3130138
120 . .......... 3130107 360 ........ . .. . 3130139
125 ............. 3130108 380 ....... ... .. 3130140
130 . 3130109 400 ....... .. ... 3130141
135 ..... . 3130110 420 . . ......... . 3130142
140 ... . 3130111 430 .. .. .. . . . .. . 3130143
145 ... .......... 3130112 440 ....... . . . 3130144
150 ......... 3130113 450 ...... . .. .. . 3130145
155 ..... 3130114 480 ......... ... . 3130146
160 .... 3130115 470 . ......... ... 3130147
165 . . .. 3130116 490 .. . .. . . ...... 3130148
170 .... 3130117 500 . . . ...... ... . 3130149
175 .. 3130118 530 . ........... 3130150
180 . .. . .. . 3130119 560 . .. .. ... . ... 313015\
185 . .. . ..... . . . 3130120 590 . ........... 3130152
190 . .. . ......... 3130121 620 .. .......... 3130153
195 . .. . ........ 3130122
200 . . . .. . ...... 3130123
6.25
RIDE RED
8/94
CARBURETION
Jetting Guidelines and Part Numbers
The number of the main jet is stamped on each jet. Although the jet size is also stamped on the banjo bolt, never
assume that it is correct. Always remove the banjo bott and check the main jet itself.
The original main jet is not necessarily the correct main jel for that particular engine or altitude.
NOTE: Each engine has slighlly different characteristics. Therefore, two engines of one particular cc may not
necessarily be jetted exactly the same.
Pilot jets are instrumental in low RPM performance. If the fuel flow is too great at low RPM, the excess fuel will
build up in the crankcase, and only with increased RPM will the fuel be transferred to the combustion chamber.
CAUTION: Too small a main j et and too small a pilot Jet can cause serious engine damage. Jet the carbu
retors carefully.
It Is t he dealer's responsibility to Insure that the correct jets are Installed In the machine. Be very careful
when jetting down In warm weather. As the weather turns colder It will be necessary to r&-jet up.-
ward to prevent engi ne damage
.&.ETHANOL AND MTBE (Methyl Tertiary Butyl Ether) " OXYGENATED" GASOLINE USE IN
YOUR POLARIS SNOWMOBILE
When using fuels containing ethanol of up to 1 0% in Polaris engines, they will run leaner than non-alcohol blended
fuels. These fuels contain oxygen and in turn the air/fuel mixture ratio changes. Oxygenated fuels cause an en-
gine to experience a leaner burning condition. Thi s leaner mixture can cause engine damage if adjustments are
not made. Usually one jet size over the Altitude!Temperature chart is acceptable.
All engines react the same with these fuels. However, Polaris EFI models have little or no margin to allow for this
leaner condition. Polaris has also found that oxygenated fuels using the MTBE additive versus ethanol are a c ~
ceptable and can be used without adjustments.
Many areas within the U.S. are required to use oxygenated (ethanol) fuels. Polaris customers may not have a
choice in operating their machines using this fuel. These areas are called non-attainment areas.
To reduce the possibility of alcohol-related engine problems, avoid the use of ethanol if possible. Although we
feel this is a good fuel which has many benefits, Polaris engines have not been adjusted or calibrated to run prop-
erly using this fuel. If you must use ethanol blended fuels, we recommend that you use only 90 pump octane,
(R+M)/2, or higher.
Whenever serviCing the carburetor or fuel system, it is important to heed the following warnings.
A WARNING
8194
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
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swall ow 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 lime.
6.26
RICEREC
EC44-2PM-2100
Main Jet - 230
Pilol Jet - 35
Air Screw - 1.0 turn
EC44-2PM-3100
Main Jet - 280
Pilot Jet - 40
EC25PS-06
Main Jet - 130
Pilot Jet - 60
EC44-2PM-5000
Main Jet - 200
Pilot Jet - 30
EC60PL02
Main Jet - 260
Pilo! Jet - 35
Air Screw - 3/4 turn
EC40PL02
Main Jet - 220
Pilol Jet - 35
Jet Needle - 60 H? - 2
Cui Away - 3.0
Jet Needle - 60H? - 3
Cut Away - 2.5
Jet Needle - SOT 49-3
Cut Away - 3.0
Jet Needle - 5DP10-3
Cui Away - 2.5
Needle Jet - P8-247
Jet Needle - SF4-3
Cui Away - 3.0
Needle Jet - P8-166
Jet Needle - 6DH7-2
Cut Away - 3.0
6.27
Allitude- ro 0
''''
1000 240
""
""
3000 230 220 220
5000 220 2" 21'
7000 210 200 200
9000 200 190 190
- -40

AIIJtude - -40
,
''''
-40 20 0
'00'
'000
200 190
'90
3000 '90 '80 180
5000 '80
170 '70
7000 '70 '60 '60
9000
'"
'50 '50
Anilude - Feel .20-
20
,

270 260
260 250

,
Altitude - Feet . 20-
20 0

""
220
=5000 220 2"
5000-7000 210 200
7000-9000 200 190
9000-11000 '90 '80
.
CARBURETION
1985
.20 .40 .60
220 2" 200
2" 200 190
200 190 180
190 180 170
180 170 170
.20
..,
oW
180 170 170
'80
170 160
'"
160 150
'50 '50
140
'40 '40
130
.20-
.20 .40
250 240 230
240 230 220
230 220 210

200 190
>9'
180
.20- ..
.20 .40 .60
220 210 200
210 200 190
200 190
'80
'90 '80 17'
18'
170 '70
8194
RIDE RED
CARBURETION
1986
Star
EC25PS..Q6
Main Jet - 130
Pilot Jet - 60
Sprint IES)
EC34-2PM-Ol/02
Main Jet - 145
Pilot Jet - 35
,
SS
EC44-2PM-3100'
Main Jet - 280
Pil ot Jet - 40
Indy Trail
EC50PM-Ol
Main Jet - 220
Pilot Jet - 30
Indy 400
EC40PL-02
Main Jet - 220
Pilot Jet - 30
Air Screw - I .S turn
Indy 600
EC60Pl-02
Main Jet - 260
Pilot Jet - 40
Air Screw - 1.0 lurn
Long Track
EC44-2PM-5100
Main Jet - 200
Pilot Jet - 30
8194
Cut Away - 3.0
Jet - SOP7-3
Cut Away - 3.0
Jet Needle - 6DH7-3
Cut Away - 2.5
Jet Needle - 6DH7-3
Cui Away - 3.0
Cui Away - 2.0
Jet Needle - 6F9-3
Cut Away - 3.0
Jet Needle - 50P1D-3
Cut Away - 2.5
. Needle Jet - P8-171
....
-ro
Altitude - Feel -40-
-ro
- Feel ....
-ro
U)OO-3DDO
, ..
3OOO-5DOD
,,.
5000-"", m
7000-9DOO
'"
9QOO.11000 200
AlbIude - Feet
Ei=
II
---"'-
----""'--
--'-"'--
""ilude Feel
-ro
2eo

AllJlooe - Feet ....
-ro
)-
'"
3OOO-5DOD 200
5000-7DDD
'"
7000-9DOO ,eo
9000-11 000
'"
-20-
,
-20-
,
-20-
,
230
""
'"
200
'"

"'-
--'-"'--
--'-"'--
-20-
,
",
'----
-20-
,
200
'"
)eo
l7'
)"
0-
.ro
""
'"
200
)'"
)eo
r--c
f-'
'----
----"'-
'"
---'-"'-

,----
I-
-""
--"-"-
0-
.20
'"
'"
'"
)"
)50
6.28
AIDE RED
.20-
,
.20-
...
'"
200
)'"
'"
)"
:
l:::k
-'-'"
:':ii
I-
. 20-
...,
,eo
'"
)"
'50
140'
.<0-
...
-
...
200
"')
U')
'"
'"

)'"
,eo
'"
'"
::
2JO
""
200
)'"
0-
...
'"
)"
)50
'" ),.
Star Trak, Star
EC25PS-06
Main Jet 130
Pilot Jet 60
Air Screw - 1.5 tum
Sprint (ES)
EC34-2PM-01 /02
Main Jet - 155
Pilot Jet 35
Long Track (R.L.R.)
EC44-2PM-5100
Main Jet 200
Pilot Jet - 30
Indy Sport
EC342PM-03
Main Jet 180
Pilot Jet 35
Air Screw - 1.0 tum
Indy Trail (All)
EC50PM-Ol/02
Main Jet - 220
Pilot Jet - 30
Indy 400
EC40Pl -02
Main Jet 220
Pil ot Jet 30
Air Screw - 1.5 tum
Indy 600
EC60Pl-02
Main Jet - 260
Pil ot Jet - 40
Jet Needle SOT 49--3
Cut Away - 3.0
Jet Needle 50P7-3
Cut Away - 3.0
Jet Needle - 50P1D-3
Cut Away - 2.5
Needle Jet - P8-171
Jet Needle - 5DP73
Cut Away 3.0
Jet Needle - 6DH7-3
Cut Away - 3.0
Cut Away 2.0
Jet Needle 6F9--3
Cut Away 3.0
NOTE: Main jet size on Indy 600 is listed for PTa side
(drive clutch side) carburetor. Magneto side and c e n t ~ r
can be adjusted one size leaner.
6.29
Altitude FOOl ~ ..
20
'Q00.3000 ''0
3CO()O()O()
''0
500Q.7000 '20
,,"' .. -
'"
9OQ().11000
'"
Altitude FOOl -40-
20
Allilude FOOl -40-
20
Allilude Feel ~ ..
20
'Q00.3000
''''
3000-6000 ''0
500Q.7000
"0
7000-9000 '60
9OQ().11000 ,SO
Alli1ude FOOl -40-
20
Alti1ude- FOOl ~ ..
20
,Q00.3000
'"
3000-6000
'"
500Q.7000
'"
7000-9000 200
9OQ().11000
,.,
Alli1ude - FOOl ....
20
'Q00.3000
, ..
3000-6000 '70
5000-7000 '50
7000-9000 ''0
9OQ().11000 220
.,..
0
"0
'20
'"
'"
'00
.,..

.,..
o
. ,..
0
''0
'70
'60
''0
, ..
.,..
o
.,..
0
'"
220
200
,'"
, ..
.,..
0
270
260
, ..
'"
'"
RIDE RED
CARBURETION
1987
..
.,.. ....
.20 ...
...,
'20 ''0
'"
' 20
'"
"'"
'" "'" "'"
'00 '00
'"
'00
'" '"
..
.,..
.....
.20 ... 0
""
"0 '60 '60
'60 '60 ''0
''0
,so.
'"
'"
'"
''0
"0 ''0
'"
..
. ,.. ... ..
.20
"'0
. 60
220
'"
200
'"
200
,.,
200
,.,
''0
,'"
''0 "0
170 '60 '60
..
.,..
.....
.20
"'0
""
260 ,SO
'"
'50
'" '"
'"
220
'"
'20
'"
200
200 '00
,'"
8194
CARBURETION
1988
Star, StarTrak Akil l.lde Feel .... -20- ~ .20- ... ~
EC25P$-{)6
-20 0 .20
""
.60
Main Jetl3Q
Pilot Jet - 60 Jet Needle - SOT 49-3
Air Screw - 1.5 turn Cut Away - 3.0
~
" ;-
~ = =it
~ ; -
',----
,,'-
'"
'00 '00 90
,
'"
'00 ' 00
,. ,.
Sprint (ES)
EC342PM..Q2
Main Jet - 155
Pil ot Jet - 35 Jet Needle - 5DP7-3
Altitude - Feel
~
'ci'
~
~ ~
~
--'-"--
"0
--'-"-- --"'--
'30
'" '"
'"
'"
'"
'30
'"
'" ,
'30 '20
'"
'00
""
LongTrak (A.L.A.)
EC44-2PM-41OQ
Main Jet - 280
Pilot Jet - 50 Jet Needle - BOH7-3
Altitude - Feet
Ei
Ei ~
:
~
:'-
'30
----""- ----""- ----""-
'"
----""- ----""-
'30 '00
,
----"'- ----'" ----"-'--
,go
Indy Sport
Altitude - Feet .... -20- ~ .20-
-
EC34-2PM-Qa
-20 0 .20
"'0 .so
Main Jet - 180
")00-3000
, go ,eo
'"
'60 '60
Pilot Jet - 35 Jet Needle - 5DP7-3
3000-5000 ,eo
'70 ' 60 '60 ''0
5000-7000
' 70 '60 ''0 ''0
'"
1000-9000 '60 ''0
''''
'"
'30
9OQO. 11 000
''0
'"
"0
'30
'"
Indy Trail (All)
EC50PM-Ol /02
Main Jet - 220
Pilot Jet - 35 Jet Needle - BOH?-2
Air &crew - 1.0 turn Cut Away - 3.0
I """'" -F ~ '
1" ~ ~
~
~
"'- ----""- ----""
200
""
----""-
'00
200 '90
'00 '00
200 ,go ,eo
20(
"0
,eo ,eo
'70
, go ,eo
'70 '60
Indy 400
EC40PL-02I03
Main Jet - 220
Pilot Jet - 30 Jet Needle - 6DP1 7-3
Ai r Screw - 1 112 turn Cut Away - 2.0
Altitude - Feet
:','i;
- ' . ~
.,
~
r-; ;-
B
;- ---, f---' '----
~
,go
"'-- --""'-
,eo
200
,go
'90 '70
--'-"-- ---'-"'-
'70
"0
Indy 650
EC65PL-Ol
Main Jet - 260
Pilot Jet - 50 Jet Needle - 6F9-3
Air Screw - 3/4 turn Cut Away - 3.0
Altitude - Feet .... -20-
.';.,
Eli
:'S:; -20

,eo
;-
r- :-
ii
'30
'----
f-
'00
---"'- -'"
200
---"'- --"-'- --""'-
,go
8194
6_30
RIDE RED
Star, StarTrak
EC25PS-06
Main Jet ~ 130
Pilot Jet - 60
Sprint (ES)
EC34-2PM-Q2
Main Jet -155
Pilot Jet ~ 35
LongTrak (A.L.R.)
EC44-2PM-4100
Main Jet - 280
Pilot Jet - 50
Indy Sport
EC34-2PM-03
Main Jet- 180
Pilot Jet - 35
Indy Trail
ECSOPM-Ol/02
Main Jet- 230
Pilot Jet - 35
Indy Trail SuperTrak
EC50PM-03
Main Jet - 200
Pilot Jet - 30
Indy 400 (All)
EC40PL-02
Main Jet - 230
Pilot Jet - 30
Air Screw - 1 112 turn
Cut Away - 3.0
Jet Needle - 50P7-3
Cut Away - 3.0
Needle Jet - P6-166
Jet Needle - 6DH7-3
Cut Away - 2.5
Jet Needle - 50P7-3
Cut Away - 3.0
Jet Needle - 60H7-2
Cut Away - 3.0
Jet Needle - 6DH7-3
Cut Away - 3.0
Cut Away - 2.0
6.31
AMude- Feet ... ~ .2<)-
20
,
,000-:3000
"" ''''
~ 5 O O J
'''' ''''
5000-7000
''''
'"
7=9000
'" '"
9000-11000
'"
'00
Altitude FOOl ... ~ .2<)-
20
,
,=-
'"
'"
=
'"
'"
5000-7000
'" ''''
7 ~
'"
''''
9000-11000
''''
''''
AlIi1ude FOOl ... ~ .20-
.",
,
'000-:3000 290 28'
=
280 210
5000-1000 280 250
7 ~ 2" 2'"
9000-11000
2'" 220
Altitude - FOOl ... ~ .20-
20
,
1000-3000
'90 '80
3000-5000
,.,
'10
5000-7000 He
'"
7=9000
""
'"
9000-11000
'" ''''
Altitude FOOl
Altilude FOOl ... ~ .20-
.",
,
'"
2ilO
~
2ilO
' 80
'"
ARilude Feel -40- .20-
,
20
RIDE RED
CARBURETION
1989
~ .2<)-
.'"
... ,
''''
'20
'''' '"
H' H'"
H'" H'"
H'"
90
~ .2<)-
.'"
."
'"
'"
'" '"
'" ""
'" ''''
'"
'"
~ .20-
.'"
."
27'
260
250
'"
'"
2'"
2'" 22il
'"
2ilO
~ .20-
.20
."
'"
'"
"" '"
'50
'"
'" ''''
'''' '"
~ .20-
.20
... ,
'"
'80
, ,
,
,
" ,
... ~
.60
'"
'"
'"
90
90
... ~
.so
'"
''''
'"
'"
'"
... ~
.60
250
2'"
22il
'"
'"
... ~
.60
'"
'"
'"
''''
'"
... ~
.60
'"
;-
'--
. , ~
.60
8/94
CARBURETION
1989
Indy 500 (Alii
EC50PL-Ol/02
Main Jet - 280
Pilot Jet - 40
Indy 650
EC65PI-Ol
Main Jet - 260
Pilot Jet - 50
8194
Jet Needle - SF9--3
Cut Away - 3.0
Jet Needle - SOH4-3
Cut Away - 3.0
6_32
- Feet -4G>
-2<)
AMude- Feet -<0-
-2<)
1000-3000 280
30005000 270
50007000 250
7000-0000 2<,
9000-11000 220
-20-
,
-20-
,
270
""
'"
230
21'

,2<)
260
250
230
220
200
RIDE RED
,20-
.4'

.4'
250
2<10
220
21'
200

,50
'"
2JO
210
200
""
Star, StarTrak
EC25PS.oS
Main Jet - 150 Needle Jet - 0-8
Pilot Jet - 60 Jet Needle - SOT 49-3
Ai r Screw - 1.0 turn Cut Away - 3.0
Sprint (ES)
EC34-2PM-Q2
Main Jet - 155
Pilot Jet - 35 Jet Needle - 5DP7-3
Indy Sport
EC34-2PM-03
Main Jet - 180
Pilot Jet - 35 Jet Needle - 50P?-3
Indy 400
EC40PL.o2
Main Jet - 230
Pilot Jet - 30 Jet Needle - SDP17-3
Air Screw - 1 1/2 turn Cut Away - 2.0
Indy Trail
EC50PM.ot/02
Main Jet- 230
Pilot Jet - 35 Jet Needle - SDH7-2
EC50PM.o3
Main Jet - 200
Pilot Jet - 30 Jet Needle - 6DH7-3
Indy 500
EC50PL.ol/02
Main Jet - 280
Pilot Jet - 40 Jet Needle - SF9-3
6.33
CARBURETION
1990
I A>,,,,,,,. F", ~ O - .20-
0-
~ : ' ~ 20 0 .20
"0 "0
" ":--
~
".
~
-"'- -"
"
'"
'20
'"
"0
H"
,
-"'- "'-
"0 90 90
Attitude - FOOl
~
.,,?"
~ : ' ~
'00
~
-,
'"
"0
~
-"'-
-
'"
130
-"'-
~
'"
'30
'"
'"
130
'25
120
'15
'30
120
'"
."
105
Altitude FOOl
~ 'ci'" .':0
.,
190
~ , ~ r- ;-t- '-- f-
"0
."
-"'- -"'- ."
'30
~ -"'- -"'- ~
'30
'"
Attitude - Feel ~ O - .20- 0- .20-
"0-
20 0 .20 .. 0 .60
llX1O-3OOO
'"
'30 220 2" 200
3IlOO-5000
'30 220
'"
200 190
500<HOOO
'"
200 200 190 180
7000-0000 '00 190
'90
180 170
9000-11000 190
'80
170 100 160
Altitude - Feet
"
: ' ~
~
;;;-
p
=-
200 190
-'" -'" -"'"
'90 '80
'00 '90 '80 '80 17C
1
-"'- -"'- "'-
170 160
AMI.lde - Feet ~ O - .20- 0- .20- .'0-
20 0 .20 .. 0 .60
'"
200 190 180 170
~
1 ~
1
."
-"'- -"'- -"'-
."
'"
Attitude - Feet ~ O - .20- 0- .20-
"0-
20 0 .20
."
.60
200 280 '70 270 260
~
~
I 270
t:i
;-
:-
-"'- -"'- -""-

-""- -"'- -"'-
210 200
RIDE RED
8/94
CARBURETION
1990
Indy WldeTrak
EC50PL-03
Main Jet .. 190
Pilot Jet .. 35
Air Screw .. 1 1/4 turn
Indy 650
Ec65PL-Ol
Main Jet .. 260
Pilot Jet .. 45
Air Screw .. 1.0 turn
8194
Jet Needle .. 6EJ26-3
Cut Away .. 3.0
Jet Needle .. SDH4-3
Cut Away .. 3.0
6.34
Altitude .. Feel ->-
-20
'000-3000 200
3000500O "0
5000-7000 ,so
7000-9000 no
9000-1'000 '60
Altilude .. Feet -40-
-20
-20-
0
"0
,SO
'"
'60
'50
-20-
o
0-
. 20
'"0
'70
'60
'50
'"
0-
.20
RIDE RED
.20- ... 0-
"'0
. 60
no no
'70 '60
'60 "0
'50
'"
'"
""
Starlit.
EC25P5-07
Main Jet - 160
Pilot Jet - 60
Indy lite
EC34-2PM-03
Main Jet -160
Pilot Jet - 35
Air Screw - 1.0 tum
Indy Trail
EC5QPM-Ql/02
Main Jet - 230
Pilot Jet - 35
Air Screw - 1.0 tum
EC50PM-03
Main Jet - 200
Pilot Jet - 30
Indy 500
ECSOPl-Ql102/03I04/o5
Main Jet - 280
Pilol Jet - 40
Indy WideTrak
ECSOPl-06
Main Jet -190
Pilot Jet - 35
Indy 400
EC40PL-02I04
Main Jet - 230
Pilot Jet - 30
Jet Needle - SDT49-3
Cut Away - 3.0
Jet Needle - 5DP7-3
Cut Away - 3.0
Jet Needle - 6DH7-2
CUi Away - 3.0
Jet Needle - 60H7-3
Cut Away - 3.0
Jet Needle - 6F9-3
Cut Away - 3.0
Jet Needle - 6EJ26-3
Cut Away - 3.0
Cut Away - 2.0
Allllude - Foot
'''''''''
3000-5000
SOOO-1OOO
1000900O
9Q00.\1000
Aliliude - feec
, ()()().30()()
JOOO.5000
SOOO-7000
7{)()().g()OO
9000-11000
Akllude - Fael
, ()()().30()()
JOOO.5OOO
SOOO-1OOO
7{)()().g()OO
9000-11000
- Feet
, ()()().30()()
JOOO.5000
SOOO-7000
1000900O
9000-11000
6.35
-4().
20
'"
'"
,W
200
'"
-4().
ro
,W
200
>9,
,OJ
>7,
.. ().
20
200
' 90
, OJ
'70
>6,
-4().
20
'"
'"
'"
200
>9,
.,.,.
,
.,.,.
,
230
220
,W
,"
'OJ
.20-
,
200
'"
'OJ
'70
,,,
.20-
,
'90
'OJ
'70
'so
'50
.20-
,
'30
220
200
>9,
'OJ
AICERED
CARBURETION
1991
().
.20
().
.20
220
,W
200
,SO
>7,
().
.20
'"
>8,
>7,
'so
'50
().
.20
>8,
>7,
'so
'50
,,,
().
.20
220
'"
200
>9,
>7,
.20-
.. '"
,W
200
'"
>8,
'"
.20-

>8,
,,,
'so
'50
,,,
.20-

'"
'70
'so
'50
'"
.20-
."
,W
200
'"
U"
,,,
. .,.
."
200
'"
U"
>7,
,SO
.. ().
."
>7,
,SO
'" ,,,
'"
.. ().
.60
>7,
'so
'50
'"
'30
.. ().
'"
200
>9,
>8.
,70
'so
8194
CARBURETION
1991
Indy 650
EC65PL02
Main Jet - 260
Pilot Jet - 45
Indy Sportl GT
EC44-3PM-Ql
Main Jet - 155
Pilot Jet - 35
Air Screw - 1 1/2 tum
8/94
Jet Needle - 6DH4-3
Cut Away - 3.0
Jet Needle - 5DP7-3
Cui Away - 3.0
Feet
Altitude - Fee'
6.36

.20
RIDE RED
StarLite
EC25PS-07
CarburetOf' Type - VM30SS
Main Jet - 160 Pilot Jet - 60
Cut Away - 3.0 Air Screw - 1.0 turn
Jet Needle - 50T 49-3 Needle Jet - 0 -8( 171)
Indy Lite. lite GT & Lite Deluxe
EC34-2PM-Q2/03/04
Carburetor Type - VM30SS
Main Jet - 160 Pi lot Jet - 35
Cut Away - 3.0 Air Screw - 1.0/1.5 (GT) turn
Jet Needle - 50P7-3 Needle Jet - 0-8( 171)
5DP7-2 (Gn
Sport 440/440 GT
EC44-3PM-Ol
Cut Away - 3.0
Jet Needle - 60H7-3
TralVTraii Deluxe
EC50PM-Ol/02
Ai r Screw - 1 1/4 turn
Needle Jet - P-2 (166)
Jet Needle - 60H7 -2 Needle Jet - P-8 (166)
SuperTrak
EC50PM-Q3
Mai n Jet - 200 Pilot Jet - 30
Cut Away - 3.0
Jet Needle - 60H7-3
Needle Jet - P-6(166)
M
.... ,
(f.)
M
....
(Ft)
M
... ,
(FI)
M
.... ,
IF'I
M
...
,e,
6,37
...
..,.,.
~ , ~
....... ,
l!1OO-21OO
,-,
2700-3700
(9XI}12OC(1)
...
,-,
~ , ~
,-,
l1lOO-27oo
,-,
2100-3700
(9XIl-I2OC(I1
...
,-,
~ , ~
,-,
lIlOO-27oo
,-,
2100-3100
ftI(lOO-'2OC(I)
...
,....,
~ , ~
, ~ ,
'800-2700
(6OCJO.90001
, - ~
1tIOOO-'2(XXl1
. ~
, ....
... , ~
, ~ ,
ll!OC!-27oo
16OCJO.90001
2TOO-37oo
(9XI}12OC(11
BMow-20' F
BMow 2I! C
'"
'M
'"
'"
BeIow 2(I' F
BeIow29' C
oro
'M
'"
,.,
_2(I' F
_-29' C
'"
, ~
,ro
'"
BeIow20' F
_2\I' C
'"
""
""
'"
BeIOw-20"F
BeIOw35' C
'"
'"
,ro
,ro
CARBURETION
1992
AMBIENT TEMPERATURE
2(I' to . IO' F .'O' ""OO' F AI>ttwI ,OO' F
2I!' ",'2 C '2' ", .S' C _S' C
'M
'"
'''''
'" '"
'"
'" '"
'"
''''
'" '"
AMBIENT TEMPERATURE
2Q' tQ.'0' F "0' ", .OO' F _,oIO' F
29' t'H2' C " 2' ", .S' C _S' C
'M
'"
, ..
'" '"
'"
'" '"
'"
'"
'" '"
AMBIENT TEMPERATURE
2Q' ",,'O' F . 'O' ",..a' F _.OO' F
29' tQl:r"C 12' to .S' C _S' C
, ~
'"
,ro
'" '" '"
'" '"
'"
'"
'"
'"
AMBIENT TEMPERATURE
20' '" .10' f ,lD' 1O ,oIO' F _.o4O' F
2\I ' ",12' C 12' ", .S' C _S' C
'" '"
""
'"
..
'"
'"
, ~
'"
'"
'" '"
AMBIENT TEMPERATURE
20' Io " O' F .'0' ", .OO' F _,OO' F
-35' 10 'l' C 12' ", .S' C _SoC
""
,.,
'"
'" '" '"
'"
'" '"
'"
'"
'"
RIDE RED
8/94
CARBURETION
1992
Indy 440
EC45PL-02
Cut Away - 2.5 Air Screw - 1.0 tum
Jet Needle - 6DH7-2 Needle Jet - P-4 (144)
440 XCR
EC45PL-Ol
Main Jet - 290 Pilol Jet - 40
Cut Away - 2.5
Jet Needle -6F9-3
ClassIc/Indy 500
ECSOPL-04/05
Cut Away - 2.5
Jet Needle - 6F9-3
WideTrak
EC50PL-06
Needle Jet - P-a (247)
Cut Away - 3.0 Air Screw - 3/4 turn
Jet Needle - 6EJ26-2 Needle Jet- P-6 (166)
Indy 650
EC65PL"()2
Cut Away - 2.5 Air Screw - ' .0 tum
Jet Needle - SOH7-3 Needle Jet - 0-2 (247)
8194
M
"'"
,A,
,",
-
IF,)
M
...
,A,
M
-
(Fl)
,",
"",
(F! )
6,38
. ~
, ....
~ , ..
, ~ ,
'800-2100
-""'"'
""",.,
..... ,-
-
,-,
~ , ..
, ~ ,
'800-2100
-""'"'
2100-3100
''''''''"'
-
1G-30001
~ , ..
, ~ ,
1800-2100
, ....... ,
""",.,
""""'"'
-
,-,
~ , ..
, ~ ,
1800-2100
-""'"'
2100-3100
....",...
-
,-,
~ , ..
, ~ ,
1800-2100
,--
2100-3100
'"''''''''
AMBIENT TEMPERATURE
_20-f -20 ",.,O"F . '0" o . <\O' F _ .40F
_-29C -29'" -'2C -'2 '" .soC _SoC
"" ""
""
'"'
"" "" '"' ""
""
".
""
n'
'" '"
".
'"'
AMBIENT TEMPERATURE
_-2O"F -20" '" .'OF .'1:t'1O OOf _ . 40
O
f
_-29C -29'" -'2C -'2" 10 .SOC _SoC
''''
""
vo
""
""
"" "" ""
"" "" "" ""
m
""
"" '"
AMBIENT TEMPERATURE
_-roOF -roolO"OF 0100"'04Q"F AIX>WI o40F
_-29C -29"IO -nOC
-' 2" '" .soC
_S' C
=
"" "" ""
,.,
""
,.,
m
"" "" ""
''''
m
"" "" '"
AMBIENT TEMPERATURE
_ -2QOf
-20" "' .'OOf .'0"1O.40F _o<IO"F
_-29 C _2910_12 C
-' 2" '" oS' C
_S' C
"" ""
,.,
'"
'"
no
'" '"'
n.
,.,
'"'
""
'"'
'" '" '"
AMBIENT TEMPERATURE
__ 2QOf
-2O" lOo'O"f o'OO"'040
0
f AbOWIo40F
_-29' C _29I0_'2' C -'2
0
", . s oC _S' C
,.,
'" '"
'"
'" ""
".
''''
"" "" ""
,.,
"" ""
".
no
RIDE RED
StarLlteJGT
EC25PS.Q7
Main Jet -'40 Pilot Jet - 60
Cut Away - 3.0 Air Screw - '.0 turn
Jet Needle - 5DT2-3 Needle Jet - 0-8 (169)
Indy LlteJLite GT & lite Deluxe
EC34-2PM-02/Q4
Cut Away - 2.5
Jet Needle - 5DP7-2
Sport 440lTrall Deluxe
EC44-3PM.Ql
Air Screw - 1 1/2 turn
Needle Jet - 0-6 (169)
Main Jet - '80 Pilot Jet - 35
Cut Away - 2.5
Jet Needle - 6DH7-3
Indy Trail
EC50PM-Ol
Air Screw - 1 1/4 turn
Needle Jet P-4 (166)
Carburetor Type VM34SS
Main Jet 230 Pilot Jet - 35
Cut Away - 3.0
Jet Needle - 6DH7-2
440 XCR
EC45PL.Ql
Needle Jet - p-8 (1 66)
Main Jet -290 Pilot Jet- 40
Cut Away - 2,0
Jet Needle - 6DH3-3
Air Screw - 1,0 turn
Needle Jet- P-8 (247)
M.
""-
If ll
M
... -
Ifll
...
...
,e,
~
....
,A,
M
....
,A,
6_39
"""'
..,..,
~ , ~
""""""
111(lO.21OO
,-,
, ~ ~
, ... ,,"""
-
..,..,
~ , ..
,-,
l111J).2100
,-,
, ~ ~
.... '''''''
. ~
,-,
~ , ..
,-,
111(lO.21OO
,-,
211)0.3100
.... '''''''
. ~
.....
~ , ..
,-,
111(lO.21oo
""""""
211XK11oo
.... '''''''
-
.....
~ , ~
,-,
,!IO().27oo
,-,
2700-3700
1liOOO-'2OXl)
_20' f
_'29' C
""
( l ~ G n
"" (l olS0n
, ~
'"
_ 20' f
_ 29' C
'"
'"
'"
""
_20' F
_2Q' C
""
, ~
'00
'"
_2Q' F
_29' C
""
""
""
'"
_ 20' F
_:?\I' C
""
,.,
""
""
CARBURETION
1993
AMBIENT TEMPERATURE
2Q' '''.'ll''f .'0' '''.OO' f _ , OO' f
29' '''12' C ' 12' ", ,S' C _S' C
"" '" ""
""
(l35GT)
'"
'"
"" '"
'"
"" ""
''''
AMBIENT TEMPERATURE
2O'",.,0' f . '0' '''.OO' f _..a' f
29' '''12' C 12' "'4' C _S' C
'"
'" ""
'" '" ""
'" "" '"
'" ""
''''
AMBIENT TEMPERATURE
2Q' ", . ,0' F . '0' ", .OO' f _.OO' F
2\I' '''I2'C 12' ", ,S' C _S' C
, ~
"" ""
'" '"
,"
"" "" '"
""
, ~
""
AMBIENT TEMPERATURE
2Q' ", . '0' f " 0' ", ,OO' f _..a' F
:?\I' ",12' C 12' ", .S' C _S' C
"" "" ""
"" ""
, ..
'" "" '"
'" '" '"
AMBIENT TEMPERATURE
20' 10, 'O' F >10' ''' .OO' F _,OO' F
2Q' 1O12' C 11' 10 .S' C _S' C
"" "" ""
"" ""
''''
""
""
'"
"" '" '"
8/94
RIDE RED
CARBURETION
1993
Indy 440JSKS
EC45Pl-Q2
Cui Away - 2.5 Air Screw - 3/4 turn
Jet Needle - 6DH7-2 Needle Jet- P-4 (166)
ClasslcITouring
EC50PL-04/05
Cut Away - 2.5 Ai r Screw - 1.0 turn
Jet Needle - 6F9-3 Needle Jet - P-a (247)
Wldetrak
EC50Pl-D6
Cut Away - 3.0 Air Screw - 3/4 turn
Jet Needle - 6EJ26-2 Needle Jet - P6 (166)
XLT/ SP/ SKS
EC58PL..Ql
Cut Away - 2.0
Indy Storm/SKS
EC75PL-Ol
Carburetor Type - VM38
Main Jet - 320-320-340
Cui Away - 2.5
Jet Needle - 6CEY6-3
8194
Pilot Jet - 35
Needle Jet - R-D247
M
"".
,R,
M
"". ,R,
M
"".
,R,
M
"".
IFe)
AA.
"".
1Ft)
6.40
-
,,=,
... , ..
,=,
l1lO().21OO
16()1)().QOOO)
210(l.3100
"",,''''''
-
,-,
... , ..
,=,
,1lO().21OO
-=,
2713100
"",,"'"
-
,-,
... , ..
,=,
l1lO().21OO
,."', ... "
21()()'3100
"",,"'"
-
,-,
... , ..
,,.,...,,,
'800-2100
.... ""'"
2713100
"""" ...
-
(0-3000)
... ,,'"
,,.,...,,,
'800-2100
--
" " " . , ~
"""""""
AMBIENT TEMPERATURE
Below '20' F 2Q" ", .,O"F .'0"1O.40"F _"oIO' F
_2II' C -2II' ''','2"C '12" '" .S C
_SoC
"" ""
m
""
""
,,"
"" ""
"" '"
,.,
'"
'" '" '" '"
AMBIENT TEMPERATURE
!IeIoo<-2I)"F -21)' 10 "'O"F .10" o.40' F _.oIO"F
_-29"C 211"'" 12"C _12" 10 .S"C _SoC
'"'
,.,
"" ""
"" "" ""
""
"" "" "" ""
""
'"
,.,
'"
AMBIENT TEMPERATURE
__ 2Q"F
-2I)" 1O"0"F " 0" 0 . 40"F _.OO"F
_29"C 29""'12"C '2" 10 .S"C _S' C
""
,.,
"" '"
'"
'"
, ~ , ~
"" "" ""
.. "
""
.. ,
'" ""
AMBIENT TEMPERATURE
_2I)' F
-21)" 10 "' O"F "'O"IO"oIO"F _.oIO' F
_2II"C 29' IO'2"C -1 2" IO"S"C _SOC
",
""
,.,
'"
'"
, ~
'"
, ~
,.,
'"
,ro >0,
"" '"
, ..
".
AMBIENT TEMPERATURE
_20' F 20' 10 .'0"f '0""'.OO' F _ . oIO' F
_2II C -29' 10 12 C -12" "'.S C _S' C
(02) 360' (02)340' (02) 330' (02)310'
(02) :>30' (02)310' (02) 3OQ'
'''''''''
(02) 310' (02)290'
",. ""
(02) 210'
(02) 2SO'
"',-
"''''',.
"", ...
RIDE RED
StarLlte/GT
EC25PS-Q7
Main Jet - 140 Pilot Jet- 60
Cut Away - 3,0 Air Screw - 1,0 turn
Jet Needle - 5DT2-3 Needle Jet - 0-8 (169)
Indy LltelGT/Lite Deluxe
EC34-2PM-Q4,02
Main Jet- 145 Pilot Jet - 35
Cut Away - 2,5
Jet Needle - 5DP7-2
SporVSKS
EC44-3PM-Ql
Needle Jet- (}-6 (169)
Cut Away - 2,5 Air Screw - 1,25 turn
Super Sport
' EC44-3PM-Ql,02
Engine EC44-3PM-Ql
Cut Away - 2,5 Air Screw - 1.25 turn
Jet Needle - 6DH7-2 Needle Jet-P-4 (1 44
Engine EC44-3PM-Q2
Main Jet -180 Pilot Jet - 35
Cui Away - 2.0
Jet Needle - 6FJ6-3
Air Screw - 1.25 lurn
Needle Jet - P-a (166)
' Check engine model number on
specification decal located under hood,
6.41
-
<MOOO
..
'"

""
111002700
(Ft)
""", .. "
l700-3700
""""""
- ,.""'"
..
M.

....
1800-2700
,A,
(6000-liIXlOl

!Q(O'l.!2I'lXI1
-
''''''''''
..
'"
"""""""
....
'800-1700
(Ft)
16000-90001
27(X).3700
t9OOQ-12I'lXI)
...
<MOOO
..
'"
"""""""
"". 1800-2700
(Ft)
16000-9000)
271lO-37oo
"""'''"''

BMow,29"C
(O!) !50
(01) 140
".
'"

BeIow,29'C
'"
'"
'"
'"
BeIow,2O' F
BeIow29' C

,.,
".
'"
BeIow-2(l' F
BeIow29' C

,.,
, ..
, ..
CARBURETION
1994
AMBIENT TEMPERATURE
,20' "', !O' F ,!O' ''' .""' F _,""' F
'N"IO-12' C '!2'''' .S' C _S' C
'"
'" '"
(01) 130
'" ".
"" '"
".
". 'oo
,ro
AMBIENT TEMPERATURE
,2(1 ' ''' ,IO' F '\0' ''' .""' F _,""' F
-N' ''' -I 2' C '12' '" .s' C
_S' C
'"
'"
".
'"
'" ".
'" '" '"
'"
".
,ro
AMBIENT TEMPERATURE
2I)' ''''lO' F ,!O' ''' .""' F _,.oo' f
-N' '''-12' C -12' ",.S C _S' C
,.,
H. ,ro
'" '"
'"
".
, ..
".
'"
".
".
AMBIENT TEMPERATURE
,2Q' ",.'O' F ,'0' 10 . ",,' F _.",' F
'2\I ' 1O'12' C ,12'", .S' C _5' C
".
H'
'"
'" '"
'"
,ro
'"
'"
'"
".
'"
RIDE RED
8194
CARBURETION
1994
Tra1ll0 eluxe
ECSOPM-Ql/02
Main Jet 230 Pilot Jet - 35
Indy 440JSKS
EC45PL-02
CuI Away - 2.5
Jet Needle - 6DH7-2
Cl assic
ECSOPL-05
Air Screw - 314 turn
Needle Jet - P4 (166)
Cut Away - 2.5 Air Screw - 1.0 tum
Jet Needle - 6F9-3 Needl e Jet- P-S (247)
Wl deTrak LX
ECSOPL-06
Cui Away - 3.0
WldeTrak GT
ECSOPM-03
Air $crew - 314 turn
Cut Away - 3.0
Jet Needle - 6DH7-3
8194
Air Screw - 1 turn
Needle Jet - P-6 ( 166)
6.42
-
,.-

"'.
"..,.""
.....
,Il0l)-'100
,A,
"""""'"

...",...
-
,-,

"
"..,...,
.....
,Il0l)-1100
<f,)
...... ,
,,.,., ...
...,,,.'"
-
,......,
-''''''
"
"..,...,
MO.
,Il0l)-2100
" .
....... ,
,,.,., ...
...",...
-
,......,
-''''''
"
.........,
.....
1Il0l)-'100
''''
........,
,,,,., ...
-""'"
- "" ....
-''''''
"
,-
.....
,Il0l)-2100
,A,
....... ,
,,,,., ...
""''''''''
AMBIENTTEMPERAT\JRE
s.Iow .2(1" -20' 11\ .10" "0"", ,40" .-.- . OO' F
!ItIoo<2i' C 12" ",.S' C
"" "" ""
,.,
""
".
,.,
""
,.,
".
,.,
""
'"
,"
, ..
'"
AMBIENT TEMPERATURE
_20" 20' "",0" .,0' ", ,4()'f
_ ..a"
_ 2!I ' C 2!I' ''''2' C ' 2""' ,S' C _SoC
"" "" '"
,.,
"" "" '"
".
,.,
'" ""
,.,
'"
, .. ,., ..,
AMBIENT TEMPERATURE
_20" 20' ", ,0" "0' ,,,,40"' _,..o' F
_2II' C 2!I' ''' ' 2' C '2' "'.S' C _5' C
""
..
,.,
""
..
""
,.,
""
"" ""
,.,
""
"" "" "" ""
AMBIENT TEMPERATURE
_20' f 20' "",0" "0' ,,, .40" "'1>0\4 ,..o' F
_2!I' C :!9' ", , '2' C . ,2" '" ,S' C _S' C
,., ,., ,.,
""
'" '"
'"
'"
""
,., ,.,
.. "
,.,
, ..
'"
,.,
AMBIENT TEMPERATURE
_20' F 20' '''.'0' ' ,'0' ", , ..a' F Ab1Mo ,..a' ,
_2!I' C 2II' ''''2' C '2' "',S' C Ab1Mo 5' C
".
,., ,.,
'"
'" '"
m
'"
,.,
""
,ro
,.,
""
".
..,
'"
AIDE RED
440 XCR
EC45PL-01
Cut Away - 2.0 Air Screw - 1 tum
440 XCR SP
EC45PL03
Cut Away - 2.0 Air Screw - 1.0 Tum
Jet Needle - SDH3-3 Needle Jet - 0-2 (247)
XLT/SP/SKS
EC58PL-Ql
Main Jet- 200 Pilot Jet - 35
Cut Away - 2.0 Air Screw - 1 turn
Jet Needle - 6DP17-3 Needle Jet- 0-2 (ISS)
Indy StormlSKS
EC80PL-Ql
Carburetor Type - VM38
Main Jet - 380-390-4 1 0
Cut Away - 2.5
Jet Needle - SCGY3-2
Pilot Jet- 30
Air Screw - 1.5 tum
6.43

,.-
'"

"'. """-
'" M".
laoo.Z700
(FI)
,-
""
2700.3700
.",,"""
""

,MOOO<
'"

M.
,-,
"" M"
IMO-mXl
,A,
,-'"'"
'"
2100.3700
.",'''''
'"
CARBURETION
1994
AMBIENT TEMPERATURE
20'''' ,10' f ,10' .., .-4!l' F
29'IOIZ' C 12' 10 _S' C
'"
,,,
""
'" '" ""
'"
"" '"
'"
'" ".
AMBIENT TEMPERATIJRE
-'20' to , 'O' f .10'.., .-4!l' F _.40- F
29' 1O12' C 12' 10 ,S' C _S' C
"" '" '"
,w
"" '"
m
. " " .
'" '"
n,
c::::=J . s",adfId .011. shoo.i<l drep Jel OII.PQSIIion ( ... s, E-dlp)
AMBIENT TEMPERATURE
S-20' F 2O'lO . IO' F " 0' 10 .-4!l' F _40' F
BoIow29' C 29'1(I 12'C Abov, S'C

,.., .. "
."
'" '" '"
.,,, ..
"'.
"""""" '" '" '" '"
M".
laoo.2100
(FI)
,-
"" '" '" '"
2100.3100
.",'''''
,.,
'" '" '"
AMBIENT TEMPERATURE
S_20' F 20' 10 "O' F "0' 10 .4(l' F _.O'F
B_29' C 29-10 IZ' C IZ' 1(I,S' C _S'C

""
'""
,.,
"" 'MOOO<
'"
,.,
'" ""
""
'"
,.,
'"
'"
.,,, ..
'" "" '" '"
M"
'''''"''''" '"
'""
"" '"
'"
'""
'"
""
(FO
IMO-2700
'" '" '"
.ro
,-,
'"
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""
"" "" '"
..
2700-3700
""
.eo
""
""
,."0<",,
'"
."
."
'"
'" '" '"
'"
11/95
RIDE RED
-,
CARBURETION
1995
StarLite
EC25P807
Carburetor Type VM30SS
Cut Away - 3.0 Air Screw - 1.0 Turn
Jet Needle - 50T2-3 Needle Jet - 0-8 (169)
Indy Lite
EC34-2PM02
Cut Away - 2.5 Al Air Screw - 1.5 Turn
Jet Needle - 5DP7-2 Needle Jet - 0. (1 69)
Lite GT
EC34-2PM02
Cut Away - 2.5 Al Air Screw - 1.5 Turn
Jet Needle - 50P7-2 Needle Jet - 0-6 (169)
Lite Deluxe
EC34-2PME02
Cui Away - 2.5 Al Air Screw - 1.5 Turn
Jet Needle - 5DP7-2 Needle Jet- 0-6 (169)
Sport
EC44-3PMOI
Cui Away - 2.5 CH Air Screw - 1.25 Turn
Jet Needle - BDH7-3 Needle Jet- P-4 (166)
8194
~ .
....
IFI)
M
....
IF!)
M.
....
IF!)
M .
....
IF!)
M
"'"
,A,
6.44
.."
, .... ,
.. , , ~
"".,.,."
111002100
,-,
, - ~
.... ',..,
. ..,
(0-3000)
~ , ~
, ~ ,
01100-2100
(6OO()-SOOOI
2100-3100
.... ',..,
.."
, .... ,
~ , ~
,..,.,."
11100-2100
,-,
2700-3100
.... ',..,
.."
10-30001
- , ~
, ~ ,
11100-2100
(6OO()-SOOOI
2100-3100
.... ',..,
. ..,
(0-30001
.." ..
,..,.,."
18JO.2700
,-,
2100-3700
""",,..,
AMBIENT TEMPERATURE
SeIow 2\l ' F 20' Ia ,10' F . 10' 10 . 4(l' F .o..txwa , 4(l ' F
SeIOw2\I' C -2\l' 1O'12' C -12' 10 . S' C _S' C
""
,.,
'"
""
,., , ~
'" ""
, ~
"" '" ""
'" '" ""
'"
AMB)ENT TEMPERATURE
_2\l' F -:10"' Ia .IO' F .10' 10 .40' F _ . 4(l' F
_2\I' C 2\I' '''12' C -12' 10 .S' C _5' C
'" '"
'"
, ~
,.,
, ~
'"
'"
'"
'" '"
".
""
'''' " "
AMBIENT TEMPERATURE
_2\l' F 20' 1O . 10' F .IO' 1a '40' F _,4(l' f
_2\I' C 2\I' 1O-12' C -12' 10 .5' C _S' C
'"
'" '" '"
,.,
"" '" '"
'" '" ""
''''
""
''''
"
..
AMBIENT TEMPERATURE
_20' F 20' IO.l0' F .10' !C.40' F _,4(l' F
BaIow -2\l' C -2\1'IO'2' C '2' 10 .S' C _S' C
'M
'" '"
, ~
,., , ~
'" '"
'"
'" ""
''''
'"
''''
" "
AMBIENT TEMPERATURE
_20' F 20' '" "O' F
. 10" o . 40' F _ . 4(l ' F
_ -2\l' C 2\I' ",12' C 12' 10 .S' C """"eS' C
n.
,.,
"" ""
,.,
'"
'M
'"
,.,
"" ""
, ~
'"
,., , ~
'"
RIDE RED
Sport Touring
EC44-3PM01
Main Jet - 1S0 Pilot Jet - 35
Super Sport
EC44-3PM02
Cut Away - 2.0
Jet Needle - 6FJ6-3
Trail
EC50PM04
Air Screw - 1.25 Turn
Cut Away - 3.0
Jet Needle - 60H7-3
Trail Deluxe
EC50PME04
Needle Jet - P-S (166)
Cut Away - 3.0
Jet Needle - 6DH7-3
440 we
EC45PL02
Cut Away - 2.5 CH Air Screw - 3/4 Turn
".
....
lA'
"
""'.
(Fl)
".
....
IF1)
".
....
(Fl)
'".
""
Ifl)
6.45
...
I.,.,.
.,.,..,
".""""
1800-2100
16000-9000)

..... " .. "
-
,,-
.,.,..,

(6000-9000)
2100-3100
-,,..,,
...
""",I
.,.,..,

'800-2100
"""""
2700-3700
(9OCl\-'2000)
...
"""" .,.,..,

'800-2100
I."'''.''

..... ',.."
-
""",I
.,.,'"

1800-2100
I-,
2700-3700
('lOOJ-'20001
_20' F
_-WC
'"
,.,
'"

_ -2O' F
_-WC
''''
,.,
'"
,"
_-20' F
_-WC
'"
'"
""
'"
_20' f
_ 29' C
'"
'"
""
,.,
Solow -20' F
_;>g' c
'"
'"
""
'"
CARBURETION
1995
AMBIENT TEMPERATURE
-20' IO.l0- F .HI' IO,-\O' F _.-\O' F
-29' 10 -'2' C -'2' 10 _5' C
,.,
'"
'"
'" '" '"
'" '"
'"
, ..
'.
'"
AMBIENT TEMPERATURE
-20' 10 .10' F .10' 1O.4Q' f _.4Q' F
-29' IO-I2'C 12' 10 'S' C
,.,
'"
,.,
'" '"
'"
'"
, ..
'"
'"
'" '"
AMBIENT TEMPERATURE
-20' 10 ,I O' F ,10- 10 ,4Q' F _.-\o' F
-29' 1O-12' C -12' 10 .S' C _S' C
, ..
'" '"
'" "" '"
''''
'"
'"
'" '" '"
AMBIENT TEMPERATURE
-20' IO.l0' F .'O' IO.4Q f _.4Q' F
-29' 10 _12' C -12' 10 ,S' C _S' C
'" '" '"
'" "" '"
''''
,.,
'"
'" '" '"
AMBIENT TEMPERATURE
20' 1<).10' F ,10- 1<) ,4Q' F _.4O"F
-;>g '1O -12"C -12' 10 .S' C _S' C
'"
'"
""
'" '"
, ..
'"
'"
'"
'" '"
'"
8194
RIDE RED
CARBURETION
1995
440 SKS
EC45Pl02
Main Jet - 230 Pil ot Jet - 35
Cut Away - 2.5 CH Air Screw - 3/4 Turn
Jet Needle - 6DH7-2 Needle Jet- P-4 (166)
Classic
EC50PLE04
Cui Away - 2.5
Jet Needle - 6F9-3
Indy 500
ECSOPL04
Ai r Screw - 1.0 Tum
Needle Jet- P-8 (247)
Cui Away - 2.5 CH Air Screw - 1 Turn
Jet Needle - 6F9-3 Needle Jet- P-8 (247)
WideTrak GT
EC50PM03
Cut Away - 3.0 CH Air Screw - 1 Turn
Jet Needl e - SDH7-3 Needle Jet - P-6 (166)
WldeTrak LX
ECSOPL06
Main Jet - 190 Pil ot Jet - 35
Cut Away - 3.0
8194
AMBIENT TEMPERATURE
IieIr::M' 2f!-F . 2(1" 10 .10' F .1Q+\(I.40' F _.40' F
_ 29 C _ S' C

,...."
"" "" '"
,.,
..
M .
..".,..,
""
'"
'"
,as
....
18002100
If I)
,.,
'"
'"
'"

"""'"..
'" '" ""
'"
AMBIENT TEMPERATURE
_20-f -20' ..,*IO*f . ,0' 10 _...o-f
_-:!9' C -:/9'.., -12' C -12' .., . S-C _S' C

,-,
"" '"' ""

-, ..
M .
,-,
,.,
"" ""
"" ....
1800-2100
If I)

"" "" "" '"
2700-3100
"""" ...
'" '"
..,
'"
c=J _ SI>aded .one should drop.lel _ on. I'O'i1iDI1I'aise E-dip)
AMBIENT TEMPERATURE
Be/oW-20' F -20-"' .'O-f . 10' 1O+<I0 f _,..o-f
_29' C -29' ''-12' C -12' ''' . 5*C _S' C
-
(0-30001
""
'"' "" ""
..
M.
''''''"'''
,.,
,ro
""
"" ....
1800-2J'OO
IF1)

"" "" '" ""

..... " ...
"" '" '"
'"
AMBIENT TEMPERATURE
_-20' F -2Q' '''.'0' F .10' 10 . 40' f _,..o F
_29' C -29' '''-12' C -'2' \O.S' C _S' C
-
"""""
'"
,.,
H" H"
-, ..
M.

'" '" '"
'"
""
1800-2J'OO
,A,
-,
H"
,ro
"" ""
2100-3100
""",,,..
""
".
'"
",
AMBIENT TEMPERATURE
_2Q f -20 ..,.10 F . 10' 10 _"'O' F
_29' C -29' \o -12' C 12' ", _S' C

,...."
,.,
H"
""
,ro
-, ..
..
,-,
'"
'" '"
'" MO.
1800-2700
,A,
(5000-9000) ,ro
'00
"" ""
2700-3100
..... ''''''
"" '" '" ""
6.46
RIDE RED
440 XCR
EC45PL05
Cut Away - 2.OCH Air Screw - 1 Turn
Jet Needle - 60H7-3 Needle Jet - P-o (286)
600 XCR
EC58PL02
CarburetOf' Type - VM38AL Slide
Cut Away - 2.5 CH Air Screw - 1.0 Turn
Jet Needle - 60H7 -3 Needle Jet - 0-2 (247)
XLT
EC58PL03
CarburetOf' Type - VM34SS
Main Jet - 21 0 Pilot Jet - 35
Jet Needle - 60H17-3 Needle Jet - Q-2 (166)
XLT SKSIPT
EC58PL03
Main Jet - 21 0 Pilot Jet - 35
Cut Away - 2.0
Jet Needle - 60H17-3
Xl TSP
EC58Pl03
Main Jet - 21 0 Pilot Jet- 35
Cut Away - 2.0
Jet Needle - 60P17-3
Ai r Screw 1.0 Turn
~
""
I ..
~
"".
lA'
M
....
,A,
~
.....
I ..
M
""
'"
6.47
...,
......
_,m
I_I
'aJO.21OO
1_'
noo-sroo
..... '''''''
...
10.3000>
_,m
,-,
'aJO.21OO
-- ",.,'"
...... '''''''
...,
.......
_,m
1""-'
laJO.21OO
I"""""
2TIlO-31OO
...... ',..,
...,
.......
_,m
...... ,
'800-2100
....,...,
2100-3100
.... '''''''
...
..... ,
_,m
"." .....
,800-2100
I"""""
''''''''
.... '''''''
_-20-F
_29' C
"'"
""
""
""
_-20"
_-29' C
,ro
, ~
'"
'"
_ -:/0-'
_ -wc
'"
'"
,.,
,ro
_-20"'
_29"C
'"
""
,.,
,ro
_-20"
_wc
'"
""
,.,
'"
CARBURETION
1995
AMBIENT TEMPERATURE
20' 10 ,IO' f ,10' 10 ..o' F _,00"
29' 10 -12' C '12' lOoS'C _SOC
,.,
'" '"
'" '" '"
'" '" '"
'" '" '"
AMBlENTTEMPERATURE
-20' '" "O'F
,'0' ",..0" _ . ..,"'
2Ij"1O-'2' C -12" 10 . ~ ' C _SoC
'"
"" ""
""
'"
'"
'"
'"
,.,
'"
,.,
,m
AMBIENT TEMPERATURE
' :/0' 10 .10" ,'0' 10) "oIO' F _,""F
29' ''' ' 12"C 12' 10 ,S' C _S' C
'" '"
,"
'" ""
,.,
""
,ro
'"
'" '" '"
AMBIENT TEMPERATURE
20'IO ,IO"F ,'0"10 ,010"' _,00"
29' 10 -'2' C -'2" 10 .5' C _6"C
'" '"
'"
'"
,., ,.,
,.,
""
'"
'" '"
,"
AMBIENT TEMPERATURE
-:/0' '" .IO'F .10' ''' .00' f _...,'F
-29-!O , U' C 12- 10 , ~ " C _SoC
"" '" '"
'"
,., ,.,
'"
,ro
'S>
'"
,.,
'"
RICEREC
8194
CARBURETION
1995
440 XCR SP
EC45PL05
Cui Away - 2.0
Jet Needle - 6DH7-3
XLT Touring
ECS8PLE04
Air Screw - 1 .0 Turn
Needle Jet - pO (268)
Jet Needle - 6DP17-3 Needle Jet- Q-2 (166)
StonnfSKS/PT
EC80PL02
Carburetor Type - VM3B
Main Jet - 370-380-410
Cut Away - 3.0 CH
Jet Needle - 6CGY3-3
11/95
Pilot Jet - 45
AMBIENT TEMPERATURE
S-2(l" F t(I .10 F .10"1O.-4!l ' F
_ ..o' F
::/II-t(l12 C 12' tQ*S' C ADo 5' C

"...,
'" '" "" ""
.,., ..
AA.
(3001HOOO)
"" "" ""
""
"". leoo.2100
(F!)
,-
"" "" '"
'"
21(l(>.3700
-,,..,
'"
," ,"
'"
AMBIENT TEMPERATURE
S __
w", . 1() F ,'0' 1<> '-4Il' F _.O' F
2!i ' OO-12 C 12' IO.5 C AI:IOviIS' C
,..
"...,
'" '" '" '"
.,., ..
AA.
(300().6000)
""
"" '"
'"
""
11112700
(ft)
,000>"""
'" '"
'"
,.,
2713700
""'"",,
'"
'" '"
'"
c:::J . Sh.:!ed ,,,,,,.1Iouid dropJet Needle on. POIIIOO (raise E-dp)
..
AMBIENT TEMPERATURE
_-2Q' F :l(I' IO.IO' F .10' 1O . ,jQ' F
_2$' C ;>9' 10 -12' C -12' to AOOV. 5' C
, ..
'" '" '" '"
,,.,,..
"" '" '"
,.,
'"
'"
'" '"
M
.,., ..
'"
,.,
'" '"
"".
,="""
'" '" '" '" ,e,

"" '"
,.,
1Il00-2100
'" "" '" '"

'" '" '"
,.,
'" "" '"
'"
2700-3700
'" '"
,.,
'" -,"""
"" '" '"
".
'" '"
"" ""
CJ . snaoed lone slloold d'oo Jet Needl, one position (raise
6.48
RIDE RED
The amount of air drawn into the cylinders is in
fJuenced by such factors as attitude, temperature, hu
midity, etc. Suppose the amount of air drawn into the
cylinders at an elevation of zero is taken as 100 (the
temperature and humidity in this case are considered
constant). The amount of air in question decreases
in proportion to a rise in elevation as shown in Chart
A. Reduction in the amount of air drawn into the cytin
ders changes the air/fuel mixture ratio, resulting in a
maf1(ed drop in power output.
Chart B shows the relationship between a rise in tem-
perature and the amount of air drawn into the cylin
ders. In this case, the atmospheric pressure (eleva
tion) and the humidity are considered unchanged and
the amount of ai r going into the cylinders at 32F (0
C) is taken as 100.
On Mikuni VM carburetors the pilot system and the
main system are of independent construction. The
fuel flow in these two systems is shown on Chart C.
6.49
100
90
80
100
90
80
Chart A
CARBURETION
Adjustments
o 500 1000 1500 2000
o
32
Anitude 1m)
Chart B
-----------
to
50
,
20 30
68 86
Temperature
CHAAT C
RIDE RED
401C)
104 1F)
8/94
CARBURETION
Adjustments
-
On engines which have more than one carburetor, it is of vital importance that carburetor systems by synchro-
nized. The steps listed below should be followed in sequence for best engine performance and throttle response.
1. Support rear 01 machine off 1100r.
2. Check drive belt condition and tension. These have an
effect on engine idle RPM.
3. Remove air silencer and back out idle screws until slide
valves (C) are seated in carburetor bore.
4. Loosen cable sleeve jam nuts (8) and adjust cable
sleeves (A) until slide valves rise equally or at the same
lime the throttle control flipper is actuated.
5. Turn idle screws (0) in until they contact the slide
valves. Then turn in an additional two turns.
6. Adjust pilot air screws (El to recommended settings.
Refer to carburetion data at the beginning of this
section.
7. Start engine and allow it to reach operating
temperature.
S. Using a tachometer, turn idle screws in until desired
engine idle RPM is reached. NOTE: 3Smm carburetors
have a vacuum fitting provided for mercury stick or
muttiple vacuum gauge usage. See page 6.51 .
9. With Uni-Syn gauge, move from carb to carb and adjust
idle screws until the float rises and equal amount at
each carburetor.
TIps:
The Uni-Syn gauge must be centered on car-
buretor air horn as shown.
The gauge sight tube should always be held
verticaUy.
The gauge must be held on each carburetor
for short. equal periods of time.
Initial Uni-Syn float adjustment is controlled
by turning the air flow valve in or out (A).
Before adjusting carburetors, Uni-Syn float
should be centered in the sight tube.
10. Adjust throttle lever free play. Throttle lever (A) to
throttle block (8) clearance should be between
.010"'-.030'" (.25-.76 mm) . This is most critical on
machines equipped with a throttle safety switch.
11 . Equalize air flow or vacuum at off idle throttle position.
12. Start engine and block throttle to approximately 1000
RPM above idle RPM.
13. Install and adjust Uni-Syn gauge air flow control valve.
Synchronize carburetor slide valves by adjusting cable
sleeves. The float should rise an equal amount on all
carburetors. Release blocked throttle and shut off
engine.
14. Re-check throttle lever free play. If adjustment is
required, the cable sleeves must be turned equally to
maintain off idle synchronization. Hold cable sleeves
and lock jam nuts. Install air silencer.
B
D
E
15. On models with oil injection, pump lever cable adjustments should also be checked and adjusted at this time.
Refer to Chapter 5 for specific oil pump settings.
8194 6.50
AIDE RED
CARBURETION
Adjustments
Synchronizing Throttles - 38 mm Carbs
Follow the sleps li sted on page 6.50 for carburetor synchronization procedures.
Tips on mercury stick usage:
Synchronize the carbs by adjusting each throttle SlOp screw unlil the columns of mer
cury are equal in height.
With pressure applied to the throttle lever (fast idle), adjust each cable adjuster until
the col umns of mercury are equal in height.
High Vacuum
Throttle Slide
Needs to be Raised
Low Vacuum
Throttle Slide
Needs to be Lowered
Columns of Mercury
I I I
I n
6.51
AICERED
8/94
CARBURETION
Adjustments
Throttle Synchronization Procedure
1. Remove air box, noting the position of the throttle cable junction block. Reposition throttle cable and junction
block in this same position when air box is reinstall ed.
2. Rotate the slide valve adjustment screws out (counterclockwise) approximately two turns. Then loosen the
throttle cable adjuster sleeve jam nuts and turn the adj uster down (clockwise) two turns.
Engine Model Throttle AI. Idle
Gap Under Screw RPM
Cutaway (Turns
Out)
EC80Pl-QlI02 .218"/5.5mm 1.0 1900
EC58PL-Ol .18S"/4.7mm 1.0 laoo
EC58PL02 .221"/S.6mm 1.0 1900
EC58PL-03 .193"'4.9mm 1.0 1900
EC58PL-E04 .230"' 5.8mm 1.0 1900
ECSOPl-05I(E)04 .210"/S.3mm 1.0 '900
EC50Pl-OS .240"/6.1 mm .75 1600
0
ECSOPM-Ot /02I03 240"16.1mm 1.0 1600
ECSOPM-(E)04 .240"16. 1 mm
1.' 1S00
EC4SPl-Ol .210"/S.3mm 1.0 1900
EC4SPl-02 .210"/S.3mm .75 1S00
EC4SPl-03 .210"/S.3mm 1., 1900
See chart r;;..
for size
'I
L
---
Jl )
r---
EC4SPl-OS .210"/S.3mm 1.0 1500
EC44-3PM01 .23S"I6.0mm 1.25 1S00
\.i
EC44-3PM02 .200"/S. 1 mm 1.25 lS00
EC34-2PM-( E)02l04 .236"/S.Omm
1.'
1S00
Insert All The
u
Same Distance
EC25PS07 .29S"fT.Smm 1.0 1200
3. Referring to the above chart, select the correct diameter throttle gap drill gauge for your engine.
4. Place the drill gauge beneath the slide valve cutaway as shown in the illustration above.
5. Turn the idle screw out until there is a slight drag on the gauge. NOTE: The drill gauge must be in the centero!
the carb bore. This indicates proper throttle gap. Repeat this procedure on all cyli nders.
6. Hold the throttle cable junction block in the same location as noted in step #1. NOTE: This is very important,
as the synchronization changes if the throttle cable or junction block are improperly positioned.
7. With drill gauge installed under throttle slide as shown, turn cable adjuster out (up) until the gauge starts to
move. NOTE: The drill gauge must be centered in the carb bore.
8. Turn the cable adjuster clockwise (down) 1.3 turn. Repeat for all cylinders.
9. The throttle sl ides must raise from the idle position in unison. Check by visually observing the drill gauge, noting
and comparing while lightly depressing the throttle.
NOTE: Check throttle lever freeplay. Throttle lever to throttle block clearance should be between 0.01 0" and
0.030". If adjustment is requi red, the throttle cable adjusters must be turned equally to maintain synchronization.
Tighten jam nut while holding cable adjusters.
1 O. Check oil pump adjustment.
11 . Reinstall ai r box and correctly position throttle cable and junction block. Start engine and adjust idle stop
screws evenly until proper idle RPM is achieved. (See chart above.) Ae-check throttle lever freeplay and
reset by turning cable adjusters evenly. Re-tighten cable adjuster jam nuts.
11 /95
6.52
RIDE RED
With the dash mounted choke control toggle flipped to the
fuU off position, the choke plunger must be seated on the
fuel passage way in the carburetor. If the plunger is not
seated on the passage way, the engine will flood or run too
rich. causing plug fouling and very poor engine perlor-
mance.
If cable slack is too great there will be excessive toggle free
play resulting in hard cold starting. Also, the half on position
used for intermittent applications will not function.
If the choke lever assembly becomes damaged, a lever kit
is available. This allows replacement 01 the lever assembly
rather than the entire cable assembly. Installation instruc-
tions are included with the kit .
Adjustment Procedure
1. Flip choke toggle to futl off position.
2. Loosen adjustment locknut (A) on carburetor(s).
3. Turn cable sleeve adjusting nut (8) 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 unlill/8"-1/4" (.3-.6 cm) toggle free
play is evident.
5. Tighten adjustment locknut (A).
6. Repeat steps 4 and 5 for remaining carburetor(s) .
. 060 -.120
6.53
CARBURETION
Adjustments Choke
Choke Toggle Position
c:::::ql J=
~ Hall0n
o II ':F-
Full On
Contents of Lever Kit
8/94
RICEREC
CARBURETION
Adjustments Jet Needle and Float Level
Fine Tuning the Mikuni Carburetor
A carburetor with a pi ston type throttl e valve is also called
a variable venturi type carburet or. In this type of carburetor,
the needle jet and jet needle serve to control a proper airl
fuel mixture ratio at the medium throttle valve opening (be-
tween 1/4 and 3/4 opening). Having the proper needle jet
and jet needle has a maj or impact on engine performance
at partial load.
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 airlfuel mixture ratio ~
is controlled by the height of the WE" ring inserted into one ;:::
of the five slots provided in the head of the jet needle. The l
chart at right shows the variation of fuel flow based on the
height of the "E" ring.
Float Level Adjustment
1. Remove float bowl.
2. With carburetor in an inverted position, float arm (A)
should be parallel with body (8). See illustration at
right.
3. To adjust float arm , bend tang contacting inlet needle.
CAUTION: Never bend the float arm itself.
Leak Testing Needle and Seat
1. After adjustment of float level, with carburetor still in an
inverted position, install float chamber and connect
pressure tester PN 2870975 to fuel inlet fitting.
2. Apply approximately 5 Ibs. pressure and wait for one
minute. Pressure should drop very slowly jf at all. If the
pressure drops rapidl y the needle, seat, andlor gasket
need replacement.
8194
6.54
.r- 2
-,
"L. 4
\5
4
,
2
50 75
Throttle Valve Opening
0
114
L
II
" J ~ ' , @
I; " l < , l ~ 7J
"I _7"'1" a '>- - -
~
RIDE RED
100%
i
I
,
A WARNING
Gasoline is extremely flammable and explosive under certain conditions .
CARBURETION
Carburetor Service
.&. 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-
l..ll. formed .
.&. If you should gel gasoline in your eyes or if you should swallow gasoline, see your doctor immediately .
.&. If you should spill gasoline on your skin or cl othing. Immediately wash II off with soap and water and change
. clothing.
*- Never slart the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poison-
.ill. aus and can cause loss of consciousness and death in a short time.
The Mikuni carburetor consists of various precision machined parts. Care should be exercised when removing
jets or disassembling the carburetor for cleaning. This type of carburetor has few mechanical functions, so prob-
lems are mostly due to wear or obstructions. When servicing this carburetor, use a solvent or carburetor cleaner
to wash all parts. Blow dry using compressed air.
1. Remove carburetor from engine. Before
disassembling, clean outside of carburetor thoroughly
with solvent. CAUTION: Do not use compressed air to
dry at this time. The float chamber could become
pressurized resulting in damage to the floats.
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 pate 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 somewhere along the
taper.
4. Remove choke plunger. Check condition of neoprene
seal at the tip of the plunger. Any nicks or cuts will
cause leakage and over fueling of the engine,
especially at idle.
5. Check choke cable movement. Plungers and springs
should move back and forth freely.
6.55
8194
RIDE RED
CARBURETION
Carburetor Service
6. Remove float bowl and main jet banjo bolt (Al. NOTE:
Banjo bolts are used only on VM30 carburetors. Refer to
exploded view corresponding with carburetor being
serviced.
7. Remove inlet needle and seat assembly. Inspect needle
(Al for any wear at its tip.
CAUTION: Do nol bend float arm during disassembly. Do
not use excessive force to remove float arm pin. The float
pin tower castings are very easily damaged and are nol re-
pairable.
8. Remove jet setter and push needle jet into the slide valve
chamber.
9. Remove pi lot jet (Al and needle jet {8l.
10. (VM30SS Only) Inspect neoprene O-Ring (e) located on
needle jet setter for nicks or cuts.
11. Wash all parts in solvent and blow all passages and jets
with compressed ai r. Replace gaskets and any parts
which show wear or damage.
12. Reassemble carburetor, adjusting float level before
installing float bowl.
Refer to page 6.54 for float level and leak testing procedures.
Bl94
6.56
RIDE RED
_'0
"
-- 12
CARBURETION
Exploded View - VM30SS
Description of Parts
1. Float Chamber and Body
2. Top Cap
3. Rubber Gasket
4. Return Spring, Throttle
5. Throttle Plate
6. E Clip
7. Jet Needle
8. Throttle Slide Valve
9. Needle Jet
10. Choke Plunger Cap
11. Plunger Return Spring
12. Choke Plunger (enricher)
13. Throttle Stop Screw
14. Spring
1 S. Air Screw
16. Spring, Air Screw
6.57
17. Pilot Jet
18. Needle Jet Setter
19, Washer
20. O-Ring
21. Needle and Seat Assembly
22. Seat Gasket
23. Float Arm
24. Float Pin
25. Fl oat Chamber Gasket
26. Float
27. Fl oat Retainer Cap
28. Banjo Bolt, Main Jet
29, Gasket
30. Main Jet
31. Screw
RIDE RED
8194
CARBURETION
'-0
3 "", _'2J
4-1/
,=
,-
5 ~
: ~
9
Parts Description
1. Float Chamber and Body 17. Pilot Jet
2. Top Cap 18. Needle and Seat Assembly
3. Rubber Gasket 19. Seat Gasket
4. Return Spring, Throttle 20. Float Arm
5. Throttle Plate 21 . Float Pin
6. EClip 22. Fl oat Chamber Gasket
7. Jet Needle 23. Float
8. Throttle Slide Valve 24. Fl oat Retainer Cap
9. Needle Jet 25. O-Ring
10. Choke Plunger Cap 26. Bolt. Chamber Drain
11 . Plunger Return Spring 27. Main Jet
12. Choke Plunger (enricher) 28. Screw
13. Throttle Stop Screw 29. Washer
14. Spring
15. Air Screw
16. Spri ng, Air Screw
8/94
6.58
AIDE RED
"
'"
CARBURETION
"
Parts Description
1. Float Chamber and Body 20. Needle and Seat Assembly
2. Top Cap 21. Spacer Ring
3. Rubber Gasket 22. Bowl Vent Hose
4. Return Spring 23. Float Arm
5. Throttle Plate 24. Float Pin
6. E Clip 25. Float Chamber Gasket
7. Jet Needle 26. Float
8. Throttle Slide Valve 27. Float Retainer Cap
9. Needle Jet 28. O-Ring
10. Choke Plunger Cap 29. Drain Bolt w/fitting
11. Plunger Return Spring 30. Main Jet
12. Choke Plunger (enricher) 31 . Screw
13. Throttle Stop Screw 32. Hose Retainer Plate
14. Spring 33. Vacuum Fitting Cap
15. Air Screw 34. Sediment Tube
16. Spring 35. Clamp
17. Pilot Jet 36. Check Valve
18. Seat Gasket 37. Plug
19. Plate 38. Tee Fitting
6.59
RIDE RED
8/94
CARBURETION
Fuel Pump - Operation
The fuel pumps on all Polaris engines are bilsically the same.
The differences are in the size and location of the pumps.
Pumps may be mounted on the crankcase or on the machine
by using an impulse hose.
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 oullet 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 removing the fuel supply line from the
carburetor and placing it into a container. With the engine idling at approximately
2000 RPM, a steady flow of fuel should be visible.
Cleaning:
The pump and impulse line must be disassembled and cleaned of foreign material in
the event of piston or other internal engine part failures which produce fragments.
Inspection:
The diaphragms and check valves must be carefully examined for cracks, tears,
'\ holes, or other damage. If in doubt as to the condition of any internal parts, replace
all diaphragms, check valves, and gaskets.
8194
6.60
RIDE RED
LITE AND SPORT PRIOR TO 1994
1. Fuel Inlet (from tank)
2. Gasket
3. Diaphragm (transparent)
4. Membrane
5. Screw (4 used)
6. Vacuum (from crankcase)
7. Fuel Outlet (to carbs NOTE: one
only on StarUte fuel pump)
6
7
_---5
3
~ __ 4
7
6.61
CARBURETION
Exploded View Fuel Pump
Tal yo Glken
1. Vacuum (from crankcase)
2. Diaphragm
3. Gaskets
4. Check Valves
5. Fuel Outlets (to carbs)
6. Fuel Inlet (from lank)
3
--';;>---2
5
3>---2
/
RIDE "fED
8194
..
-
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
8/94
6.62
AIDE RED
2
7 - - ~
-
CARBURETION
Exploded View - 650 3 Cylinder Fuel Pump
Parts Description
1. Pump Valve Body
2. Diaphragms and Gaskets
3. Screw (6 used)
4. Check Valves
NOTE: Be sure of proper order and
position of gaskets and diaphragms
upon reassembly.
5. Fuel Outlet (3 to carbs)
6. Fuel Inlet (from tank)
7. Vacuum/Pressure (from crank-
case)
6.63
AIDE RED
8/94
CARBURETION
Problem Diagnosis
Fuel system diagnosis should follow a specific path, 'irst 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 fuellair 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 100 rich or too lean.
Next, use the throttle lever to determine al what degree of throttle valve opening the problem exists.
CONDITION SYMPTOMS
Mixture Too Rich -Black spark plug tip
-Heavy exhaust smoke
-Engine runs worse after warm up
-Runs better without air silencer
-Combustion chamber has heavy deposits of carbon
Mixture Too Lean -Spark plug electrodes white
Fluctuation in engine speed
-Power loss
-Engine overheats
-Cylinder scoring
-Backfiring - detonation
-Throttle diagnostic opening check points
Poor Fuel Mileage -Incorrect ignition timing
-Improper track tension (too tight)
-Incorrect carburetor jetting
-Fuel leaks (Hnes, fittings, fuel pump)
-Needle and seat leaks
-Plugged exhaust
-Carburetor vent line problems
-Clutching incorrect for conditions
Troubleshooting Tips, 1).114 Throttle:
Pilol air screw misadjusled
Pilot jet of wrong size
Obstruction of pilot jet
Pilot jet loose
Choke plunger nol seating (rich)
Carburetor mounting air leak (lean)
Crankshaft seal air leak (lean)
Fuel pump diaphragm damaged (rich)
Floal level incorrect
8194
6.64
RIDERED
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, 3/8-314 Throttle:
Main jet incorrect size or clogged (lean)
Needle jet seller O-Ring damaged or loose
Needle jet/jet needle worn (rich)
Troubleshooting Tips, Full Throttle:
Main jet size (rich or lean)
Fuel filler blocked (tean)
Fuel venllines or check valves plugged
Exhaust system plugged
Air box restricted
Fuel pump weak
Exhaust leaking into engine compartment (rich)
Water in float bowl (lean)
6.65
I ! '
CARBURETION
Problem Diagnosis
8194
RIDE RED
CARBURETION
Problem Diagnosis
Explanation of Gasoline Vol atility
In order for an engine to slart easily and run properly, gasoline must be able to burn without causing detonation,
vapor lock, flooding, or icing of fuel lines, fuel pumps, or carburetors. One of the sometimes misunderstood pro!>,
erties of gasoline is its volatility, or ability to atomize at different ambient temperatures and altitudes during the
year.
When gasoline is blended, it is given a Reid Vapor Pressure 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 contai ner and applying a specified amount of heat to the container for a certain amount of time. This
pressure will vary form about 9.0 PSI during the summer to approximately 15.0 PSI during the coldest months.
Service stations selling a large volume of fuel will normally have the correct blend to work well at all times through-
out the year.
When the weather is very cold, gasoline must be able to atomize very quickly in order for an engine to start and
warm up properly. II summer blend fuel, which has a low Reid Vapor number, is being used, tittle or no vaporization
will occur. Droplets will form causing flooding and very hard starting.
During the summer months, if winter blend fuel is being used it may cause vapor lock (boiling fuel) inside the fuel
lines, pump, or carburetor. This will cause warm engine driveability problems and hard starting when warm. Some
state are limiting the Reid Vapor number to 9.0 PSI year around to help meet evaporative emissions standards.
Warm Weather
Maximum Reid Vapor Ambient Air Temp. Range
Low Vaporization Rate
Class Pressure Low High
A g.O PSI 60
0
F 110<>F+
B 10.0 PSI 50
0
F 110" F
C 11.5 PSI 40
0
F 9]0 F
D 13.5 PSI 30
0
F 85 F
E 15.0 PSI 20 F 69 F
Add 2.4 F for each 1000 feet above seal level.
Cold Weather High Vaporization Rate
8194
6.66
RIDE RED
/II'
A WARNING
CARBURETION
Optional Water Trap Installation
Fuel spillage will occur during t his installation. Gasoline is extremely flammable and explosive under certain
conditions.
&. Do nol smoke or allow open flames or sparks in or near the area where refueling is performed or where
gasoline is stored.
*" 00 not weld or operate a torch near the fuel system. Remove fuel tank before any chassis welding is per-
~ formed.
&. If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately .
.&. If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.
*- Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poison-
~ aus and can cause loss of consciousness and death in a short time.
Following are instructions for optional water trap installation for 34 and 38mm carbs (Kit PN 2870688). NOTE:
Not available on side jet type carburetors.
1. Turn fuel valve off.
2. Remove air silencer. (600 only)
3. Position a shop cloth or container below drain
plug and loosen drain plug.
4. Remove drain plug and sealing a-Ring.
5. Install removed a-Ring onto drain plug and water
trap assembly.
6. Install water trap assembly into bottom of float
bowl and tighten.
7. Turn fuel on, start engine and check for possible
fuel leaks.
8. Reinstall air box.
The water traps should be periodically inspected and
drained. Draining frequency wi ll depend upon fuels
purchased and riding conditions. Once a week is a
fairly good rule of thumb.
6.67

Float
Bowl
Jli
- ~ - - O - R i n g
Drain Plug----r{P
Clamp
I
1--- Hose
I
&--water Trap
Plug
RIDE RED
8/94
CHAPTER 7
TORQUE-O-MATIC DRIVE
Drive Bel t Part Numbers and Application ........................ . . . .... .. ..... 7. 1
P-85 Drive Clutch Information
1972-1984 . . ................... . .. . ... . .............. . . ........ .. . . . ... .
1985-1 988 . . .. . ..... . . .. . . .......... . . . ..... .. ... . .. .... ... . .... . ...... .
19891 990 ........ . . . . ... . ... . . . .............. . .... . ................... .
7.2
7.3
7.4
1991-1992 ..... . . ... . ..... . . .. ...... . .............. . ........ .. . .... 7.5
1993-1994 . .. .... . . . .. . . . . . ........ . . . .. .. ..
1 ~ 5 ........... . .. . . . .. . .. .......... .. ..
Service Tools . . .. . .. . . . . ..... . . . . . ..... . . . . . . . ....... .. .... . ......... . .
7.6
7.7
7.8
,
Operation ............ . .. . . . . . . . . . . ... . . . . . . ..... . .. .. . .. ........ 7.9-7. 11
Data
1985 .. . .... . .. . . ...... . . ... . . .. . .. . . . . . ...... . ..... . . . .. . .. .. . . . 7. 12
1986 .. . ...... ....... . .. .. . . ....... .. ... . ....... . .. . .. . . .... . . .... 7. 13
1987 ... . ...... . .................................. . ...... .. .......... 7.14
1988 ........ . . .. . . . .. . . . .................. . . ~ ... . ...... . ......... . . 7.1 5
1989 .... . .... . .... ... ........ . ... . .. .. .. . . . .. . . . ............ . ...... . . . 7.1 6
1990 . . .. . ... .. . .. . . . ........................... . .. . . . . . . . . .... . .... 7. 17
1991 ...... . .... .. ..... . ......... . . ..... . ................. . ....... 7. 18
1992 . . .. . . . ..... . . . . .. . . . . .. . ... . .... . .. .. ... . .. . . . . . . ..... . ... . 7.19-7.20
1993 .... . ... . . . .. . . .. . ... . .. .. . . . . ... . . . ... . . .. .. . . . .. . ..... 7.21-7.22
1994 ..................... . . .. . . ... .. . ... . . . . . . . . .. . .. . . .. . . . ..... 7.23-7.24
1995 ...... . ........................ . .. . .. . . . ... . . . .... . . . . . . . . ... 7.25-7.26
Drive Cl utch Service Part s . ........... . ........... . . . . .. .. . ... ............ 7.27
Drive Cl utch Weight Identificati on - Actual Size ...... . . .. . . . . .. ... .. . ....... 7.28-7.31
Drive Clutch Spri ng Rates ............... ......... . ............. . ........ . ... 7.32
Drive Cl utch Spring Data ... . ... . .. . . . . .. . .. . ...... . . ... . . . . ... .. . ..... ...... 7.33
Drive Bel t Adjustments . .. . .... . . . .. . .. . . . .. .... . .. .. .. . . . . .. . . .. ....... 7.34-7.35
Clutch Ali gnment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
P-85 Drive Clutch ... . . . ...... . ... . . . . . ...... . ....... . . . .. . . .............. 7.37
Drive Clutch Identification and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7.38
Drive Clutch Disassembl y and Inspection .............. . . . .. . . .. . . . ..... . 7.39-7.40
Spider Assembly . .......................... .. .... . ....... ... . . .. . ... 7. 41 -7. 43
Spider Indexing . . .......................... . .......... . ..... . ... . .... . . 7.44-7.45
Al uminum Driven Clutch Service P85 ........... . ......... . ~ .. .. ... . .. . .. 7.46-7.47
Aluminum Driven Clutch Service P-90 ........ . .. . ............................ 7.48
Troubleshooting . . .......... . .. . .... . .. . . . . . . . .. ... ....... ...... .. ..... 7.49-7.50
RIDE RED
- -
8/94
Drive Belt Part Numbers and Applications
3211042 ..... Allindys except Indy Spcrts, Indy Lites, Star 1985-1990, Star Trak 1987-1990,
LongTrak 1985-1989
3211045 ..... Close tolerance version of 3211042
3211046 ..... Spcrt and Sport GT 1987-1991 with P85 Clutch
3211051 ..... Ute 1991-1992
3211052 ..... Sport, Sport GT, and StarUte Pilot Build 1990 with P90 Clutch
3211054 . . . .. Sport, Sport GT 1991-1992
3211055 ..... StarUte 1991-1992
3211053 ..... Lite GT 1992
3211058 ..... Lite, Lite GT 1993-1995
3211060 ..... StarLite 1993-1995
3211057 ..... Storm 1993-1995
3211059 ..... Spcrt 1993-1995
7. 1
RICE RED
11/95
--
TORQUE ()..MATIC DRIVE
P85 Drive Clutch Information
197279 Models
MODEL
All MODElS
1980 Models
MODEL
GEMINI 250
APOLLO 340
GALAXY 340
GALAXY 440
TXfTX-C 340
TX440
TX L 340
CENTURION 500
TX- L INDY 340
1981 Models
MODEL
GEMINI 250
GAlAXY 440
CUTLASS 340
CUTLASS 55 340
TX-C 440
TX-L 340
CENTURION INDY 500
1982 Models
MODEL
GEMINI 250
CUTLASS 55 440
TX-C 440
TX-l 340
TX-L INDY
CENTURION
1983 Models
MODEL
GEMINI 250
STAR 250
SPOAT 440
55440
TRAI L 440
INDY CC 340
600
LONG TRACK 440
1984 Models
MODEL
STAR 250
55440
TRAIL 440
600
STAR 250fl T
LONG TRACK 440
400
8/94
SERVICE CLUTCH NO. BASIC NO.
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321470 19
1321471 20
1321471 20
1321471 20
1321440 13
1321470 19
1321470 19
1321471 20
SERVICE CLUTCH NO . BASIC NO.
1321471 20
1321440 13
1321470 19
1321470 19
1321470 19
1321471 20
1321471 20
1321471 20
1321440 13
1321 440 13
1321440 13
1321 470 19
1321471 21
1321440 13
1321471 20
1321463 17
1321463 17
1321480 21
1321471 20
1321440 13
1321 440 13
7.2
RIDE RED
1985 Models
MODEL
STAR 250
$$440
TRAil 440
400
600
LONG TRACK 440
1986 Models
MODEL
STAR
SPRINT
5$440
TRAil 488
400
600
600 LE
LONG TRACK 440
1987 Models
MODEL
STAR
STAATRAK
SPRINT
SPRINT ES
SPORT
TRAil
TRAil (ES)
TRAIL 133 SKS
400
400 133 SKS
600
LONG TRAK REV 440
1968 Model s
MODEL
STAR
STARTAAK
SPRINT ES
SPORT
TRAIL & TRAi l DELUXE (ES)
TRAIL (ES)
TRAIL SKS
400
400 SKS
CLASSIC
650
650 SKS
LONG TRACK REV 440
-
SERVICE CLUTCH NO.
1321440
1321463
1321463
1321481
1321480
1321440
SERVICE CLUTCH NO.
1321440
1321493
1321463
1321463
1321481
1321480
1321480
1321440
SERVICE CLUTCH NO.
1321440
1321440
1321493
1321493
1321463
1321463
1321463
1321463
1321515
1321515
1321480
1321440
SERVICE CLUTCH NO.
1321440
1321440
1321493
1321463
1321463
1321463
1321463
1321515
1321515
1321516
1321480
1321480
1321440
7.3
BASIC NO.
13
17
17
22
21
13
BASIC NO.
13
23
17
17
22
21
21
13
BASIC NO.
13
13
23
23
17
17
17
17
25
25
21
13
BASIC NO.
13
13
23
17
17
17
17
25
25
26
21
21
13
RIDE RED
8194
TORQUEO-MATIC DRIVE
P 85 Drive Clutch Information
1989 Models
MODEL
STAR
STARTRAK
SPRI NT ES
LONG TRAK REV 440
SPORT
SPORTGT
TRAIL & TRAil DELUXE (ES)
TRAIL I ES)
TRAil SKS
TRAIL SP
400
500
500 SKS
500 CLASSIC (ES)
500 SP
650
650 SKS
1990 Models
MODEL
STAR
STAR TRAK
SPRINT ES
SPORT
SPORT (P90 BASIC)
SPORTGT
SPORT GT (P90)
TRAIL & TRAil DELUXE (ES)
SUPERTRAK
400
500
500 SKS
500 CLASSIC (ES)
500SP
WIDETRAK
650
650 SKS
8194
SERVICE CLUTCH NO. 8ASICNO.
1321440 13
1321440 13
1321493 23
1321440 13
1321463
..
17
.
1321463 17
1321463 17
1321463 17
1321463 17
1321463 17
1321481 22
1321515 25
1321515 25
1321516 26
1321515 25
1321480 21
1321480 21
SERVICE CLUTCH NO. 8ASICNO.
1321463 17
1321463 17
1321493 23
1321463 17
1321512 24
1321463 17
1321512 24
1321463 17
1321463 17
1321481 22
1321515 25
1321515 25
1321516 26
1321515 25
1321463 17
1321480 21
1321480 21
7.4
AICERED
1991 Models
MODEL
STARLITE
LITE
SPORT & SPORT GT
TRAIL & TRAIL DELUXE (ES)
SUPERTRAK
UTE GT
400 xc
.00
500
500 SKS
500 SP
500 CLASSIC (ESI
WIDETAAK
650
RXL
1992 Models
MODEL
STAALITE
UTE & lirE DELUXE
LITE GT
SPORT & SPORT GT
TRAIL & TRAIL DELUXE
WIDETRAK & SUPERTRAK
440
440 XCR
500
500 SKS
500SP
CLASSIC (ESI
650
RXL
RXl SKS
SERVICE CLUTCH NO.
1321538
1321538
1321512
1321463
1321463
132151 2
1321481
1321481
1321515
1321515
1321515
1321516
1321463
1321480
1321480
SERVICE CLUTCH NO.
1321538
132 1538
1321512
1321512
1321548
1321548
1321549
1321549
1321549
1321549
1321549
1321550
1321551
1321551
1321551
7.5
BASIC NO.
27
27
2'
17
17
24
29
22
25
25
25
26
17
21
21
BASIC NO.
27
27
2'
2'
28
28
29
29
29
29
29
30
31
31
31
AICERED
8194
1993 Models
Toea
'GT
INDY LITE
HE
ITEGT
I
TRAIL
440 LIOUID INDY
440
~
1500 EFI
IsOOSi<S
I XLT
I XLT SKS
LTSP
~
I STORM SKS
" STARn
1994 Models
Tooer
I STARL TE
ITEGT
I INDY LITE
~
LITE Gl
I SPORT
I SUPER SPORl
ITRAiL
I TRAIL
I LX
1440 LIOUID INDY
~ S K S
1500EFI
I silOSKS
I XLT
I XLT SKS
:LT SP
lAX
I STORM
I STORM SKS
I RXL I
I SPORT SKS
I (G"
I 440xeR
8194
, CLUTCH NO. : NO.
27
"
~
27
2'
2'
~
27
2'
34
~
34
36
36
36
~
35
36
36
36
~
37
37
37
36
38
41
41
I 40
,CLUTCH NO. :NO.
42
42
42
i
I 42
43
~
43
43
36
36
~
44
44
I 44
44
37
37
37
38
48
48
45
~
4 2
43
36
7.6
AICERED
1995 Models
l iND' LITE
1 INDY LITE !
LITE Gl
1 SPORT
1 SUPER SPORl
~
1440 LIQUID INDY
: : : ~ S K S
I LX
I ( Gl
~
500 EFI
500EFJ
XLT I
XLT
LT SP
RXL
RXI I
~
'iCE CLUTCH NO.
~
~
~
~
1321610
~
7.7
:NO.
42
42
"
42
" 42
"
43
46
36
36
50
43
43
44
44
T.
44
37
37
37
49
45
48
11/95
RIDE RED
TORQUE O-MATIC DRIVE
Servi ce 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 cl utch, it is absolutely essential that
no attempt al clutch disassembly and/or repai r be made without factory authorized tools and service procedures.
Drive Clutch Essential Tools
Description Pad Number
Offset Alignment Tool- 2 1 1 3 2 ~ (1.7 em) P-90 Clutches ... .... 2870914
Offset Alignment Tool - 518" (1.6 em) e-B5 Clutches ......... 2870426
"T" Handle Clutch Puller ................................. 2870506
Strap Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . ... 2870336
Strap Replacement ..... . ........ . . . . .. . . . . ........ 2870389
Spider Spanner Nut Driver ............................ 2870338
Spider Torquing Tool ................................... 287034 1
Holding Fixture Tab ................... . .. .......... 5130518
Holding Fixture ........................................ 2870547
Torque Wrench. 250 ft. lb. . ....... ..... .... ........ Not available through Polaris
Clu1ch lubricant ........................... . ........... 2870510
Torque Wrench. 0-600 in. lb .. .. . .. ...... . ............ Not available through Polaris
Tapered Reamer ....... ... . . ........ .... ...... ........ 2870576
Spider Button Tool ......... . .................. .. ........ 2870985
Clutch Bushing Rebuild Tool Kit . ....................... 2871025
P-85 Compression Tool ................ . ............ 2870984
Driven Clutch Puller .................... ....... ........ 2871056
8194
7. 8
RIDE RED
I
TORQUEO-MATIC DRIVE
Operation
The Polaris torque..o-matic drive system is a centrifugally actuated variable speed belt drive unit. The drive clutch,
driven clutch, and bett 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 convert er operation diagnosis .
.&. CAUTION: All converter maintenance repairs must be performed only by an authorized Polaris service
technician who has attended a Polaris sponsored service training seminar and understands the proper
procedures as outtined in this manual. Because of the cri tical nature and precision balance incorporated into the
drive clutch, it is absolutely essential that no attempt at cl utch disassembly and/or repair be made without factory
authorized special tools and service procedures. Any unauthorized modifications to cl utches, 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 lorce from the engine RPM.
The spring and weights won< 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 cli mb up the drive clutch sheave and increase vehicle speed.
9000 -----,;;;:::-::-::;;;;:
8000 .r ------
~ :: ____ ENGIN)'oPERATING RANGE 250 RPM __ _
It
5 O O O - - - - - i ~ - - - - -
ENGAGEMENT 4000 :.:_:..:_:.:==::7:...-_____ _
3000------------------
lithe weights are too light , or the spring rate too high, the maximum RPM will be too great and the drive bett will not
move into high gear at the top of the clutch.
7.9
RICEREC
8/94
'.
Operation
-
0000------------------
8000------------------
______ ENGINE OPERATING RANGE 250 RPM
7000
8000 --

ENGAGEMENT"4000 --
3000---------------------
---
If the weights are 100 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.
0000------------------
8000---------------------

::Ii ----7 --- --- ENGINE OPERATING RANGE 250 RPM
g; 6000 7

ENGAGEMENT
3000------------------
If the weights and spring afe matched properly, the engine RPM will go to the desired range and remain there
on both upshift and backshift.
8/94
7. 10
AIDE RED
,
-
TORQUEO-MATIC DRIVE
Driven Clutch Operation
The driven clutch operates in conjunction with the drive clutch. lis function is to maintain drive belt tension, pre-
venting slippage and to sense variations in load requirements necessary to maintain optimum engine torque out-
put 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 toad on the driven clutch is increased and becomes greater than the torque del ivered from the engine,
the driven clutch becomes dominant and overrides the drive clutch. The driven clutch downshifts into a ratio which
wilt supply the amount of torque needed for the increased load.
Because the driven clutch can sense and shift into the proper ratio, engine RPM will remain within the specified
range.
Oriven Clutch Adjustments
The aluminum driven clutch has a provision for varying the torque requirement to change its ratio. To do this, it
relocates the spring in the helix which in turn increases or decreases the amount of load requi red to change the
ratio.
Aluminum Driven Clutch
7.11
RICE RED
8194
..
Data
1985 PRODUCTION SETUP
Machine Engine Model

Production Spring ShiftWt. Bore Taper Clutch Driven
Model R M2 Clutch Color, LDJGram Diameter Center Helix
Part No. Wire Dia. Distance Angle
Sta, EC25PS06 6300 1321449 Brown 08147.5 , .174" 12.0" 36"
.200"
SS EC44-2PM-3100 6000 1321450 White 07152.0 1.174" 11.5" 36"
. 177"
Trail EC44-2PM-2100 6800 1321455 Brown N-l Mod. 1.174" 12.0'" 34"
.200- 51.5
400 EC40PL-02 7800 1321459 Gold N-' Mod. 1.174" 12.0- 34"
.20r 51.5
600 EC60PL.()2 7800 1321458 Gold 05153.5 1.177" 12.D" 34"
.20r
LongTrak EC44-2PM5OOQ 6300 1321454 Yellow
.19T
04157.5 1.174" 12.D" 36"
1985 HIGH ELEVATION RECOMMENDATIONS
Machine 5000 Feet to 8000 Feet 8000 Feel 10 12000 Feet
Model
ShiftWeighl Clutch Driven Chaincase Shift Weight Clutch Spring Driven Chaincase
Spring Helix Gearing Helix Gearing
Sta, 08 Brown 36"
.....
08 RedflNhite 36"
.....
SS 07 Orange 36"
.....
07 Orange 36"
.. ...
Indy Trail N-' Mod. 34" 19135 N-l Mod. Gold 34" 19135
Indy 400 P-1 Rod 34" 19/35 p1 Rod 34" 19/35
600 06 81.., 34" 21/35 06 81.., 34" 19/35
longTrak 04 Orange 36" 19139 04 Silver 36" 19139
8/94
7. 12
RIDE RED
Gearing
Chain
Pitch/Type
Direct
Drive
Direct
Drive
19f35
54P Silent
19135
19135
63P Silent
1913'
54P Silent
Options-

Warranty
. ....
S Tooth
F,o'"
Sprocket
.....
.....
.....
.....
Machine
"""'I
Engine Model
51"
EC25PS-06
Sprint &
Sprint ES
EC342PM.ol /02
SS EC44-2PM-3I00
Trail EC50PM.{)l
Indy 400 EC40Pl-02
600, EC60PL.02
600 LE
LongTrak EC44-2PM-S\OO
Machine
Model
Shift Weight
SIa, 08
Sprint & Sprint ES 05
SS 07
Indy Trail M-I Mod.
Indy 400 M-I Mod.
600, 06
600LE
LoogTrak 04
TORQUE"O-MATIC DRIVE
Data
2r,"''':;&
Proruction Spring Shift WI. Bore Taper Clutch
Drive"
Gearing
R M;t:2 Clutch C o ~ , tDJGram Diameter Center HeliK Chain
Part No. Wire Dia. Distance Angle PitctVType
6300 1321449 B,own 08147.5 1. 174 12,0" 36" Direct
.200 Drive
6500 1321 451 B,own 05153.5 1.174 11.5" 36" Direct
1321 456 .207 Drive
6000 1321 450 While 07/52.0 1.174 lIS 36" Direct
.177 Drive
7000 1321461 RedlWhite 10151.5 1.174 12.0- 36" 21/35
.192
noo 1321459 Blue 10/M0d. 1.174 12.0" 34" 19135
.207 SO.O
7800 1321458 Blue/Gold 15155.5 1.177 12.0" 34" 21/35
.207
6000 1321 454 Yellow 04/57.5 1.174 12.0- 36' 19139
.192
5000 Feel 10 8000 Feel 8000 Feel 10 12000 Feet
CI_ Driven Chalncase Shift Weight Clutch Spring Driven Chaincase
Spring Helix Gearing Helix Gearing
RedWhite 36"
.....
08 AeGWhite
36'
BluafGold 36"
.....
06 Blue/Gold 36"
.....
Orange 36'
.....
06 AecWJhite 36"
... ..
Orange 36' 21/35 1.4-1 Mod. AecWJhite 36' 21/35
Gold 34' 19135 P-Ior M-I
Rod "
34" t9J35
Mod. BloeIGoId
Blue/Gold 34' 2 1/35 06 BloeIGoId 34" 21/35
Orange 36' 19/39 04 Silver 36" 19/39
7,13
RIDE RED
8/94
Data
-
Machine
Model
Engine MOdel

SIM EC25PS.()6 6300
StarTrak
s.,rinl&
s.,rinlES
EC34-2PM-Ol102 6500
,,,,,, Sport
EC34-2PM-03 6500
Trail (AU) ECSOPM-Ot 7000
Indy 400 EC40Pl-02 nOll
600 EC60PL-02 7BOO

EC44-2PM-5100 6000
(Al )
--
Production Spring Shift Wt. Bore Taper
Clutch I.O./Gr&m Diameter
Part No. Wire Oia.
1321449 B.own 08147.5 1.174
.200
1321451 Gold 05153.5 1.174
1321456 .207
1321461 10151.7 1.174
.192
1321477 Re<:VWhile 10151.7 1.174
.192
1321459 BluelGoId 101M 1. 174
.207 49.5
1321458 Blue/Gold lOlA 1.177
.207 55.0
1321454 Yellow 04/57.5 1.174
.192
Clutch Driven
Center Helilr.
Distance
12.D'" 36'
11.5" 36"
11.5"
","
12.0" 36"
12.0-
"'"
12.0-
""
12.0" 36"
Machine 5000 Feet to 8000 Feet 8000 Feel 10 12000 Feet
Modo<
Shift Weight C1u1ch Driven Chaincase Shift Weight Clutch Spring Driven
Spring Helix Gearing Helix
5""
08 Ae<:VWhite 36"
.....
08 AedlWhite 36"
StarTrak
.....
Sprint & Sprint ES 05 81uelGokI 36"
.....
06 Blue1Go1d 36"
,,,,,, Sport
10 Gold
","
17135 10 Blue/Gold
","
Indy Trail (All) M-1 Mod. 0 .....
36" 21135 M-1 Mod. AedJWhite 36"
Indy 400 M-1 Mod. Gold
"'"
19/35 P-1 or M-1
Red '"
"'"
Mod. .,ue1Go1d
600 06 BlueJGoId
","
21/35 06 Blue/Gold
","
04
(RL )
0,_ 36" 19/39 04 Sillier 36"
8/94
7, 14
RIDERED
Gearing
Chain
PitctvType
Direct
Drive
15139
Direct
Drive
17135
21/35
19135
21/35
19139
Chaincase
Gearing
D. Drive
1513
.....
17/35
21/35
19/35
21/35
19/39
Machine
Mode'
Engine Model
Sw EC25PS.{)6
StarTrak
Sprint ES EC342PM02
'''''' Sport
EC34-2PM03
T",it
ECSOPM-Ol
Trail K
400 Classic EC40PL-{l2lO3

4 SKS
650 EC65PL-{l1
650SKS

EC442PM-4100
(RL )
Machine
Mode'
Shift weighl
SIs, 08
Sl ar Trak
Sprinl ES 05
Indy Sport 10
Trail (AM) M-l Mod
Trail SKS or 10M
400 Classic 10M Red

4 SKS
650 10M Blue
650 SKS
10
(RL )
....... -_.
Data

p- Spring Shift WI. Bore Taper Clutch Driven Gearing
R M2 Clutch """,,, LDJGram Diameter Center Helix Chain
Pari No. Wire Dia. Distance Angle Pilch/Type
6300 1321449 Brown 08147.5 1.174 12.0" 36' Oirect
,200 Drive
15/39
6500 1321456 Gokl 05153.5 1. 174 11 .5" 36' Direct
.207 Drive
6500 1321461 Re<V'Nhite 10151.7 1. 174 11.5" 34' 17/35
. 192
7000 1321461 RedlWhite 10151.7 1.174 12.0" 36' 21 /35
. 192 19/35
8000 1321485 8'", 10M 1.174 12.0" 34' 19/35
1321459 .207 BIue/47.5 19/35
1321459 18/35
7800 1321458 lOlA 1.177 12.0" 34' 21/35
.207 55.0 19/35
6300 1321478 Silver lOA 1.174 12.0" 36' 19139
.208 55.0
5000 Feel 10 8000 Feet 8000 Feel to 12000 Feel
Clutch Oriven Chalocase Shift Weight Clutch Spring Driven Chaiocase
Spring Hel ix Gearing Helix Gearing
RedlWhite 36'
.....
08 RedlWhite 36'
.....
15/39 15139
Blue 36'
.....
06 8'",
36'
.....
Gokl 34' 17/35 10 8'",
34' 17135

36' 2 1135 10M Red RedlWhile 38' 21135
R hile 19J35 19135
8'", 34' 19135 10M Red
8''''
34' 19/35
19/35 19135
19135 19135
Aod 34' 21/35 10M While Blue 34' 21/35
19/35 19/35
Silver 36' 19/39 10 Silver 38' 19139
7,15
8/94
AIDE RED
Data

Model R M2
SIa'
EC25PS06 6300
StarTrak
Sprint ES EC342PM02 6500
Indy SiXHt. EC34-2PM03 6500
GT
Indy TraH
Super Trak
ECSOPM-OJ 6600
T""
EC5QPM-{)lfQ2 7000
Trail K
Indy 400 EC40PL-02 8000

EC50PL-Ol/02 7800
SK
Classic:
650 EC65PlOl 7800
650SKS

EC44-2PM-4100 6300
(RL )
Production Spring Shift WI. Bore Taper
Clutch Colo<. I.DJGram Diameter
Part No. Wi re Dia.
1321449 Brown 08147.5 1.174
.200
1321493 Brown 05153.5 1.174
.207
1321461 RedlWhite 10151.7 1.174
.192
1321461 Brown 10151.7 1.174
.200
1321461 Aecl'While 10/51.7 1.174
.192
1321459 91"" 10M 1.174
47.5 Blue/47.S
1321459 Silver 10M 1.174
1321 459 .209
1321493
1321458 Gold lOlA 1.177
.207 55.0
1321478 Silver lOA 1.174
.209 55.0
Clutch Driven
Center Helix
Oistance Angle
12.0" 36"
1'.5" 36"
ItS 34"
,
12.0" 36"
12.0" 36"
12J)" 34"
12.0" 36"
12.0" 34"
12.0" 36'
Machine 5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Model
Shift Weight Clutch Driven Chaincase Shift Weight Clutch Spring Driven
SIa, 08 RedlWhite 36"
...
08 RedllNhite 36"
Star Trak 15/39
Sprint ES 05
9'""
36"
.....
06 91""
36"
Indy Sport, GT 10 Go. 34" 17/35 10 or Blue or 34"
10M Blue G.d
SuperTrak 10M RedJWhite 36" 21/39 10M Blue RedllNhite 36"
Trail jAil) M-l Mod

36" 21135 10M Red RedlWhite 36"
TraJi SKS or 10M R hile 19/35
Indy 400 10M Red
9'""
34" 19135 10M Red
91""
34"

10M Blue 91""
36" 19135 10M Blue 61""
36"
SKS 18135
650 10M Blue Rod 34" 21/35 10M Blue 91""
34"
6@SKS 19/35

10 Silver 36" 19/39 10 Silver 36"
(Al )
8194
7.16
RIDE RED
Gearing
Chain
PitchfType
Direct
Drive
15/39
Direct
Drive
17/35
21139
21/35
19/35
19135
19135
lBi35
19135
21135
19135
19/39
Chaincase
Gearing
... ..
15/39
.. ...
17/35
21139
21135
19135
19135
19135
18135
21135
19135
19139
Machine
Model
Engine Model
EC25PS06
StarTrak
SprinlES EC34-2PM-02
I"" Sport.
GT
EC342PMOJ
Indy Trail
SuperTrak
EC5QPM-Q3
l::itr Trail ECSOPM-Ol102
(All
Indy 400 EC40PL-02

ECSOPL-QI I02
SK
Classic
WideTrak ECSOPL{)3
650 EC6SPL-Ol
650SKS
Machine
Model
Shift Weight
08
Star Trail:
SprintES 05
Indy Sport, GT
'0
SuperTrak 'OM
'ZitrTrail
10M
(All
Indy 400 10M Red

10M Blue
SKS
WideTrak 10M Blue
650 10M Blue
650SKS
....
Data
1990 PROOUCTION SETUP
r,"m
Production
s.,n""
Shift Wt Bore Taper Clutch Driven
R M, Clutch CoIo<. I.OJGram Diameter Cerner Helix
Part No. Wire Dia. Oistance Angle
6300 1321463 Brown 08147.5 1;174 12.0" 36'
.200
6500 1321493 Brown 05153.5 1.174 11 .5" 36'
.207
6500 1321463 RedlWhite 10/51.7 1.174 11 .5" 34'
1321512 . 192 1.160 GT
6600 1321463 B,_ 10151.7 1.174 12.<r 36'
.200
7000 1321463 AedM'hile 10151.7 1.174 12.0" 36'
.192
8000 1321481 Blue 10M 1.174 12.'0" 34'
47.5 81ue 47.5
7BOO 1321515 Silver 10M 1.174 12.0" 36'
1321515 .208
1321516
7BOO 1321516 AedfWhite
'0
1. 174 12.D'" 36'
. 192
7BOO 1321480 Gold
'0
un 12.0" 34'
.207 51.7
5000 Feel 10 8000 Feet 8000 Feet 10 12000 Fe.at
Clutch Driven Chaincase Shift Weight Clutch Spting Driven
Re<UWhite 36'
.....
08 Re<UWhite 36'
'5/3'
Illue
36'
.....
06 Blue 36'
Gold 34' 17/35 '0", Blue or 34'
10M Blue Gold
Re<UWhite 36' 21139 10M Blue Recl-White 36'
RedlWhite 36' 21135 10M Red Re<YoNhite
36'
Ill""
34'
'9135
10M Red Blue 34'
Blue 36'
'9135
10M Blue Blue 36'
,B/35
RedlWhite 36' 19141 10M Whfte Re<UWhrte 36'
Illue 34'
2'/35 10M White Blue 34'
'9/35
7. 17
AICERED
Gearing
""'.
PitchfType
Direct
Drive
1513'
Direct
Drive
17/35
21139
21/35
19135
19135
'8/35
'9135
19141
2'/35
'9135
Chaincase
Gearing
.. ...
'5/3'
.....
17/35
21139
21135
'9/35
'9135
'8/35
19/41
2'/35
'9/35
, .

8194
Data

Model R M.t2
StarLite EC25PS07 6300
Indy Ute EC34-2PM-03 6500
Indy Sport,
GT
EC443PMOl 6800
Indy Trail
SuperTrak
EC50PM-03 6600
Imrrail ECSOPM-Ol /02 7000
(All
Indy 400 EC40Pl02J04 8000

EC50PL01l0204f05 7800
SK ISP
Classic
WideTrak EC50PL06 7000
650/RXl EC65Pl02l03 7800
RXlSKS
Production

Shift Wt. Bore Taper
Clutch Ire la. I.DJGram Diameter
Part No.
1321514 Brown 08147.5 1. 174
.200
1321513 Brown 10151 .7 1.174
.200
1321507 RedflNhile 10151.7 1.174
.192 1.160 GT
1321498 Brown 10151.7 1.174
.200
1321 461 RecVvVhite 10/51.7 1.174
.192
1321 459 Blue 10M Bluel 1.174
.207 47.5
1321502 SilYer 10M 1.174
1321502 .208
1321501
1321 508 Aad'While 10 1.174
.192
1321517 Gold 10Al 1.177
.207 53
Clutch Driven
Center Helix
Distance Angle
12.0-
,,'
11.5"
,,'
11 .5"
,,'
12.0" 36'
12.0-
".
12.0-
".
12.0"
".
12.0"
,,'
12.0" 36'
Machine 5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Model
Shift Weight Clutch Driven Chaincase Shi ft Weight Clutch Spring Driyen
Starlite 08 RedlWhite 36'
.. ...
08 RedNv'hite 36'
15/39
Indy Lite OS Blue
,,'
.....
06 Blue 36'
Indy Sport , GT 10 Gold 36' 17/35 10 or Blueor 36'
10M Blue Gol d
SuperTrak 10M RedNv'hlte 36' 21 /39 10M Blue RedNv'hite 36'

10M RedlWhile
,,'
21/35 10M Red RedlWhite 36'
(All
Indy 400 10M Red Blue
,,'
19/35 10M Red Blue
,,'
''::lI
SOO 10M Blue Blue 36' 21139 10M Blue Blue
,,'
5 SKS 18/35
WideTrak 10M Blue RedJWhite 36' 19/41 t OM White RedlWhite
,,'
6501RXl 10M Blue Blue 36' 21 /35 tOM Whil e Bl ue
".
RXLSKS 19/35
11 /95
7.1 8
RIDE RED
Gearing
Chain
Pitch/Type
Di rect
Drive
Direct
Drive
16135
21139
21135
19/3S
19/3S
18/35
19/35
19/41
21 /35
19/35
Chaincase
Gearing
.....
.....
17/35
21/39
21/35
19/35
21 /39
18135
19/41
21/35
19/35
;- .
Spring
Operating Production Color,
Machine Engine RPM Clutch Wi re Shift WI.
Modo' Mode' .200 Part No. Dia. I.DJGram
StaTUte EC25PS-07 6300 1321514 Orange 10M Red
.196
Indy Ute EC34-2PM-0302 6500 1321513 Gold 10
Ute Deluxe
1321552 .207
Indy UteGT EC342PM-04 7000 1321507
R"'"
10MB
White
.192
Sport 440 EC44-3PM-O\ 6800 1321523 Brown 10
Sport 440 GT
.200
Trail ECSOPM-Ol 7000 1321539 Rod! 10
Trail Deluxe 102 1321540 White
.192
SuperTrak EC50PM-03 6600 1321541 Brown 10
.200
WideTrak EC5OPL06 7000 1321545 Brown 10
200
440 Indy EC5OPL-02 7800 1321547 Blue 10 MB
Bushed
440 XCR ECSOPL-Ol 8000 1321547 Blue 10 MB
Bushed
Indy 500 ECSOPL-04 7800 1321543 Gold 10 M
Classic 105
1321544 Bushed
500 SP EFI ECSOPL-07 7800 1321543 Gold 10M
500 SKS
Bushed
Indy 650 EC65Pl-02 8000 1321546 Blue 10Al
Bushed
RXL EC65Pl-03 8000 1321546 Blue 10Al
RXlSKS
Bushed
7 _19
TORQUE O-MATIC DRIVE
Data
Driven
60" Clutch Helbr.
T.p,,,
Center Angle & Chaincase
Dia. Distance Location Gearing
1.160 ".SO" 36' Direct Drive
6-2
5 Toolh
1.160 10.625" 36' Di rect Drive
6-2
6 Tooth
1.160 11.03" 36' 16:39
6-2
1.160 12.00" 36' 16:35
6-2
16:39
1.174 12.00" 36' 21:39
#2
1.174 12.00" 36' 21:39
#2
1.174 12.00" 36' 19:41
#2
1.174 12.00" 34' 21:39
#2
U74 12.00"
,..
21:39
#2
1.174 12.00" 36' 21:39
#2 20:39
1.174 12.00" 36' 21:39
#2 20:39
1.177 12.00" 36' 20:35
#2
1.177 12.00" 36' 20:35
#2 21:39
8/94
RIDE RED
Data
3000 Fllo 6000 FI. 6000 FI.IO 9000 Ft. 9000 FllO 12000 FI.
Machine
Chain- Chain-
Mode'
Shift Clutch Driven
""'"
Shift Clutch Driven
"""
Shift Clulch Driven
Weight Spring Helix. Gearing Weight Spring Helix Gearing Weight
Spri""
Helix
SlarUte 10M Red! 36- D. Drive 10M G o ~ 36- D. Drive 10M
B'oo
36-
Rod White B-2
5 Tooth
Red B-2
5 Tooth
Red B-2
Indy lile 10
B'oo
36- O. Drive 10M G o ~
:,..
D. Drive 10M B'oo
36-
Deluxe
B-2
6 Tooth
B-2
6 Tooth
B-2
Indy Lite 10M G ~ 36- 16:39 10M G ~ 36- 16:39 10M B'oo
36-
GT Blue B-2 White B-2 While or
'"
B-2
10M Red
~
Sport 440 10 Red! 36- 16:35 10 G ~ 36- 16:35 10",
B'oo
36-
~ 4 4 0
White B-2
16:39
B-2
16:39 10M Blue
~ B-2
Trail 10 Red! 36- 21:39 10M Red! 36- 21:39 10M Red! 36-
Trail While #2 White
"
Blue
While #2
Deluxe
SuperTrak 10 Red! 36- 21:39 10M Red! 36- 21:39 10M Red! 36-
White #2 White #2
Blue
White #2
WideTrak 10 Red! 36- 19:41 10M Red! 36- 19:41 10M Red! 36-
White
"
B'ue White #2
While
Whil. #2
440 Indy 10M B'ue
34- 21:39 10M Blue 34- 21:39 10M B'oo
34-
White
#2
Red
"
Red
#2
440 XCR 10M Blue 36- 21:39 10M
B'oo
34- 21:39 10M Aed
B'oo
34-
White
#2
White
"
Bu,"""
#2
Bushed Bushed
Indy 500 10M Gold 3'- 21:39 10M
B'oo
36- 21:39 10M White
B'oo
36-
Classic
Blue
#2
20:39
B'oo
#2
20:39 Bushed
#2
Bushed Bushed Of 10M Red
Bu,,,,,,,
500 SP EFI 10M Gold 36- 21:39 10M B'ue
36- 21:39 10M White B'oo 36-
500 SKS
B ..
#2
20:39 B ' ~
#2
20:39
Bu,"""
#2
B"_ B"_ Of 10M Blue
Bu,"""
6501RXl 10 B'oo 36- 20:35 10M
B'oo
36- 20:35 10M White B'oo 36-
RXL SKS Bushed
"
21:39 B'oo #2 21:39
Bu,""" #2
Bushed
8/94
7_20
RICE RED
Chain-
ca,.
Gearing
D. Drive
5 Tooth
O. Drive
6 Tooth
16:39
16:35
16:39
21:39
21:39
19:41
21:39
21:39
21:39
20:39
21:39
20:39
20:35
21:39
Spring
Operating Production Coio<,
Machine Engine RPM Clutch Wire ShiftWt.
Model Model .200 Part No. Ola. tDJGram
EC25P$-07 6300 1321514 Orange 10M Red
StarUte GT
.196
Indy liteJGT EC342PM-Q4 7000 1321560 SilverI 10
lila Deluxe
1321561
Gold
218
Span EC44-3PM-Ql 8800 1321568 Brown 10
200
Trait Deluxe EC44-3PM-Ol 8800 1321568 Brown 10
.200
Trail ECSOPM-Ol 7000 1321570 Rod' 10
White
Bushed
.192
WideTrak ECSOPM..()6 7000 1321567 B,own \0
.200 B","'"
440 Indy EG45PL.()2 7800 1321580 Gold 10MB
440 SKS
.207 B","'"
440 XCR EC45PL-ot 8000 1321584 Blue 10MB
.207 Bushed
Classic ECSOPL-04 7800 1321569 10 M
Classic Touring
EC50PL"()S 1321544 .207 Bushed
500 SP EFt ECSOPL-07 7800 1321569 Gold 10M
500 EFI SKS
.207 Bushed
XLTIXLT SP EC58PL-Q1 8000 1321571 Go<d 10M
XLT SI<S
.207 Bushed
"XL EC65PL-05 8000 1321546 Blue lOAL
RXLSI<S
207
eo"""
Storm EC75PL-Ql 8000 1321581 Bloe! 10<>4
StormSKS Gold
Bushed
207
7.21
Data
Driven
Bo<o Clutch Helix
r""",
Cenler Angle & Chaincase
Dis. Distance Location Gearing
1.160 12.236" 36.5" 15:41
B-2
1.160 11.030" 36.5 16:39
B-2
1.160 12.00" 36" 16:35
B-2
1.160 12JlO" 36.5" 16:39
B-2
1.190 12.00" 36" 21:39
#2
1. 190 12.00" 36" 19:41
#2
1.190 12.ocr 34" 21:39
It2 20:39
1.190 12.00" 36" 21:39
#2
1.190 12.00" 36" 21:39
It2 20:39
1.190 12.00- 36" 21:39
#2 20:39
1.177 12.00" 34" 21:39
20:39
1.177 12.00' 36" 21:39
#2 20:39
1.177 12.50" 34" 23:37
AIDE RED
8194
Data
.. aq
3000 FI. to 6000 Ft. 6000 Ft. to 9000 Ft. 9000 Ft. to 12000 FI.
Machine
Chain- Chain-
Mode'
Shift Cll1Ich Driven
"""
Shift Cll1Ich Driven
"""
Shift Clutch Driven
Weight Spring HeliK Gearing Weight Spring HeliK Gearing Weight Spring HeliK
StarLite 10M Rod! 36.5 15:41
'OM G o ~ 36.5" 15:41 10M
6'""
36.5"
StarUl eGT
Rod White B-2 Rod 6-2 Rod 6-2
UteGT 10M
-
36.5" 16:39 10M G o ~ 36.5 16:39 10M White Blue 36.5
Ute
6'""
6-2 White 6-2
or 10M Red
G o ~ 6-2
Ule Deluxe
Sport 10 Aod! 36" 16:35 10 G o ~ 36" 16:35 10 or Blue 36"
White B-2 6-2
10M Blue
Gold B-2
Trail Deluxe 10 Aod! 36.5" 16:39 10 G o ~ 36" 16:39 100r
6'''''
36.5"
While B-2 B-2
10M Blue
G o ~ B-2
Trail 10 Aod! 36" 21:39 10M Aod! 36" 21:39 ' OM Aod! 36"
Bushed While #2 Bushed White #2 6''''' Whit e #2
WideTrak 10 Aod! 36" 19:41 10M Aod! 36" 19:41 10M Aod! 36"
Bushed White #2
6'oe
White #2
White
White #2
Bushed
440 Indy 10M Blue 34" 21:39 10M Blue 34" 21:39 'OM 6'''''
34"
White
#2
Aod
#2
Aod
#2
Busned Bushed 6",,,,,,,
440SKS
'OM
Blue 34" 20:39
'OM
Blue 34" 20:39 'OM
Blue 34"
White
#2
Rod
#2
Aod
#2
Busned Bushed 6",had
440 XCR
'OM
Blue 34" 21:39 'OM Blue 34" 21:39 10M Red
6'""
34"
White
#2
White
#2
6",,,,,,,
#2
Bushed Bushed
Classic 'OM G o ~ 36" 21:39 10M Blue 36" 21:39 10M White
6'""
36"
"'""
#2 6'"" #2
or 10M Red
#2
Bushed Bushed
Classic 'OM G ~ 36" 20:39 10M Blue 36" 20:39 10M White
6'""
36"
Tooring Blue
#2 6'"" #3
or 10M Red
#3
Bushed Bushed
SOOEFI 10M G o ~ 36" 21:39 10M Blue 36" 21:39 10M White
6'""
36"
6'"" #2 6'"" #3
or 10M Blue
#3
Busned Bushed
500 EFI SKS 10M Gold 36" 20:39
'OM
Blue 36" 20:39 10M White Blue 36"
Blue
#2
6'oe
#3
or 10M Blue
#3
Bushed Bushed
XLTIXLT SP 'OM G o ~ 34" 21:39 'OM Blue 34" 21:39 10M Red
6'""
34"
Blue White Bushed
Bushed
Bushed
XLT SKS 'OM G o ~ 34" 20:39 'OM Blue 34" 20:39 10M Red
6'""
34"
"'""
White 6",,,,,,,
Bushed
Bushed
AXL
'0
Blue 36" 20:35
'OM
Blue 34"#2 20:35 10M White
6'""
36"
Bushed #2 6'""
or36" Bushed 2#
Bushed #3
RXLSKS 10 Blue 36" 21:39 10M Blue 34"#2 21:39 10M White
6'""
36"
Bushed #2
6'""
or 36 Bushed #2
Bushed #3
Storm
'O-SO
SilverI 34" 23:37
'OA
SilverI 34" 23:37
'0 Silveri 34"
StormSKS Bushed G o ~ #2 Bushed G o ~ Bushed G o ~
8/94
7.22
RIDE RED
Chain-
"",.
Gearing
15:41
16:39
16:35
16:39
21:39
19:41
21:39
20:39
21:39
21:39
20:39
21 :39
20:39
21:39
20:39
20:35
21:39
21:37
--
Machine Engine Operating Production Spring Shift WI.
Model Model RPM Clutct1 Color, I.D.fGram
200 Part No. Wire
Dia.
SlarUle EC25PS-07 6300 1321599 Orange 10M Red
51arlite GT
.'96
Indy LitelGT EC34-2PM-04 7000 1321601 SilverI '0
Lila Deluxe -02
1321602
Gold
.218
Sport EC44-3PM-Ol 6800 1321594 Brown 10
Sport SKS
Super Sport
1321619 .200
Trail Deluxe EC50PM-D2 6800 1321592 Brown 10
.200
Trail EC50PM-Dl 7000 1321570 Rod! 10
White
Bushed
.192
WideTrak GT EC50PM-03 7000 1321583 Brown 10
WideTrak LX
EC50PL-06 .200 Bushed
440 Indy EC45Pl-02 7800 1321580 Gold 10MB
440 SKS
.207 Bushed
440 XCR EC45Pl-Ol 8000 1321564 Blue 10MB
.207 Bushed
Classic EC50Pl-05 7800 1321606 Gold 10M
Classic
Touring
EC50PL-08 .207 Bushed
500 SP EFI EC50Pl-07 7800 1321569 Gold 10M
500 EFI SKS
.207 Bushed
XlTlXlT SP EC58Pl-Ol 8000 1321571 Gold 10M
XlT SKS
.207 Bushed
RXl EC65Pl-05 8000 1321608 Blue 10 Al
RXl Touring
EC65Pl-06 .207 Bushed
Slorm EC80Pl-Ol 8000 1321607 Blue '0-62
SlonnSKS
.207 Bushed
7_23
Data
Bm, Clutch Driven Chalncase
Taper Center HeliK Gearing
Diamet Distance Angle &
"
Location
1.160 12.24" 36.5' 15:41
B-2
1.160 11.030" 36.5' 16:39
B-2
1.160 12.00" 36" 16:35
B-2
1.160 12.00" 36.5" 22:41
B-2
1.190 12.00" 36" 21:39
#2
1.190 12.00" 36" 19:41
#2
1.190 12.00" 34" 21:39
#2 20:39
1.190 12.00" 36" 21:39
#2
1.190 12.00" 36" 21:39
#2 20:39
1.190 12.00" 36" 21:39
#2 20:39
1.174 12.00" 34" 21:39
20:39
1.177 12.00" 36" 21:39
#2 20:39
1.177 12.50 42-36-34" 23:37
Combina-
21:37
lion
11/95
RIDE RED
Data
.c.
3000 Ft. to 6000 Ft. 6000 Ft. to 9000 FI. 9000 Fl. lo 12000 Ft.
Machine
Chain- Chain-
Model
Shift Clutch Driven
"".
Shift Clutch Driven
"'".
Shift Clutch Driven
Weight Spring Helix Gearing Weight Spring Helix Gearing Weight Spring Helix
StarUte 10M Rod! 36.5 15:41 10M Gold 36.5 15:41 10M Blue 36.5
Starlite GT
Aod While #B-2 Aod #B-2 Aod #8-2
LiteGT 10M Gold 36.5" 16:39 10M Gold 36.5 16:39 10M While Blue 36S
Lite
Blue #8-2 While #B-2
or 10M Red
G o ~ #8-2
Lite Deluxe
Sport 10 Aed! 36" 16:35 10 G o ~ 36" 16:35 10", BI.,. 36"
While #B-2 #8-2
10M Blue
G o ~ #8-2
Sport SKS 10 Aed! 36" 16:39 10 G o ~ 36" 16:39 10", Blue 36"
While #8-2 #B-2
10M Blue
G o ~ #8-2
Super Sport 10Al Aed 36" 17:35 10Al G o ~ 36" 17:35 10 or Aed! 36"
Bushed
#B-2
Bushed
#2
10M Blue While
#8-2
Bushed
G o ~
Trait Deluxe 10 Aod! 36" 22:41 10M Red! 36" 22:41 10M Blue Aod! 36"
Bushed
'v'Ihile #2
Bushed While
#2
Bushed White
#2
Trail 10 Aod! 36" 21:39 10M Red! 36" 21 :39 10M Aod! 36"
B,_ While #2 Bushed While #2
Blue
While #2
Bushed
WideTrak LX 10 Aod! 36" 19:41 10M Red! 36" 19:41 10M Aed! 36"
Bushed While #2
Blue
While #2
White
While #2
Bushed Bushed
WideTrak 10 Aed! 36" 19:41 10M Aed! 36" 19:41 10M Aed! 36"
GT
Bushed While #2 Bushed While
., Blue
While
.,
Bushed
440 Indy 10M Blue 34" 21 :39 10M BI.,. 34" 21:39 10M Blue 34"
While ., Aod ., Rod .,
Bushed Bushed B",had
440SKS 10M Blue 34" 20:39 10M Blue 34" 20:39 10M Blue 34"
White
#2
Aod ., Aed .,
Bushed Bushed Bushed
440 XCR 10M Blue 34" 21:39 10M Blue 34" 21 :39 10M Red Blue 34"
White ., White ., Bushed
#2
Bushed Bushed
Classic 10M Gold 36" 21:39 10M Blue 36" 21:39 10M White Blue 36"
Blue ., Blue ., Bushed .,
Bushed Bushed or 10M Red
Bushed
Classic 10M Gold 36" 20:39 10M Blue 36" 20:39 10M While Blue 36"
Touring Blue
#2
Blue
#3
Bushed
#3
Bushed
SOO EFt 10M Gold 36" 21:39 10M Blue 36" 21 :39 10M While Blue 36"
Blue ., Blue
#3
Bushed
#3
Bushed Bushed or 10M Blue
Bushed
500 EFI 10M Gold 36" 20:39 10M BI.,. 36" 20:39 10M White Blue 36"
SKS Blue
#2
BI.,.
#3
Bushed
#3
Bushed Bushed or 10M Blue
Bushed
XlTlXl T SP 10M Gold
""
21:39 10M Blue 34" 21 :39 10M Red Blue 34"
Blue While Bushed
Bushed
Bushed
XlT SKS 10M Gold 34" 20:39 10M Blue 34" 20:39 10M Red Blue 34"
Blue While Bushed
Bushed
Bushed
AXL 10 Blue 36" 20:35 10M Blue 34"., 20:35 10M Whi le Blue 34""
Bushed
., Blue or 36" Bushed or 36"
Bushed #3 #3
RXl Touring 10 Blue 36" 21 :39 10M Blue 34"" 21:39 10M White Blue 34".,
Bushed #2
Blue or 36" Bushed or 36"
Bushed #3 #3
Siorm 1(H;0 Blue
S1"""
23-37 10-58 Blue S1""" 23-37 10 Bushed or Blue Siock
Bushed Bushed 10Al Bushed
Siorm SKS 21-37 21-37
8194
7.24
RIDE RED
Chain-
"'".
Gearing
15:41
16:39
16:35
16:39
17:35
22:41
21:39
19:41
19:41
21:39
20:39
21 :39
21 :39
20:39
21 :39
20:39
21 :39
20:39
20:35
21:39
23-37
21-37
Machine Engine Operating
M o d ~ Model RPM :!:
200
Starlite EC25PSQl 6300
Indy LitelGT EC34-ZPM02 7000
L ~ e Deluxe
Sport EC44-3PMQl 6800
Sport Touring
"",",Sport EC\4-3PM02 7000
Trail ECSOPM04 7000
Trail Deluxe EC50PME04 7000
WideTrak GT EC50PM03 6600
Wide T rak LX EC50Pl06 7000
440 Indy EC45PL02 8000
440 SKS
440 XCA EC45PL05 8250
I""" 500
ECSOPL04 7750
Classic EC50PLE04 7750
500 EFI EC50PL07 8000
500 EFI SKS
XLTlXlT SP EC56PL03 8000
XLT SKS
XLT Touring EC58PLE04 8000
600 XCA EC58Pl02 8500
RXL EC65PL05 8000
RXL Touring EC65PLE05
Storm EC80PLOI 8250
Storm SKS
Production
Spri""
Shift Wt.
Clutch ","0<. toJGram
Pan No. Wire
Oia.
1321599 Orange 10M Red
.196
1321601 Sil .... erl 10
1321602 G o ~
.218
1321594 Brown 10
_200
1321619 Rod' tOAl
While Bushed
.192
1321570 Rod' tCAL
White Bushed
.192
1321592 R<>d' tCAl
White Bushed
.192
1321583 Brown 10
_200 Bushed
1321583 Brown 10
.200 Bushed
1321580 G o ~ 10 MB
.207 Bushed
1321643 Blue 10 MB
.207 Bushed
1321569 G o ~ 10MB
.207 Bushed
1321606 G o ~ 10M
.207 Bushed
1321569 G o ~ 10 M
.207 Bushed
1321571 G o ~ 10M
.207 Bushed
1321642 G o ~ 10M
.207 Bushed
1321626 Blue 10MB
.207 Bushed
1321620 Blue 10AL
.207 Bushed
1321608
1321607 Blue \0-62
.207 Bushed
7.25
Data
60"
Clutch Oriven Chaincase
T .... Cemer Helix Gearing
Diamet Distance Angle &
"
Location
1.160 12.24" 36.5" 15:41
6-2
1.160 11.030" 36.5" 16:39
B-2
1.160 12.00" 36.5
0
16:35
B-2 16:39
1.160 12.00" 36.5 17:35
B-2
1.190 12.00"
'W
21:39
#2
1.190 12.00" 36" 20:39
#2
1.190 12.00" 36" 19:41
112
1.190 12.00' 36" 19:41
#2
1.190 12.00" 34" 21:39
#2
20:39
1.190 12.00" 34" 21:39
#2
1.190 12.00" 36" 21:39
#2
1.190 12.00" 36" 21:39
#2
1.190 12.00" 36" 21:39
#2
20:39
1.177 12.00" 34" 21 :39
#2
20:39
1.177 12.00" 34" 20:39
#2
1.177 12.00" 34" 21:39
112
1.177 12.00" 36" 20:35
#2 21:39
1.177 12.50" 34" 23:37
#2 20:35
8/94
RICE RED
Data
.. -
3000 Ft. to 6000 Ft. 6000 Ft. to 9000 FI. 9000 Ft. to 12000 Ft.
Machine
Chai n- Chain-
Model
Shift Clutch Driven
""'"
Shift Clutch Driven "",e Shift Clutch Driven
Weight Spring Heli. Gearing Weight Spring Heli. Gearing Weight Spring Hen.
StarUte 10M Red! 36.5" 15:41 10M G o ~ 36.5" 15:41 10M BI", 36.5"
Red White #B-2 Red #B-2 Red #8-,
LiteGT 10M G o ~ 36.5" 16:39 10M G o ~ 36.5" 16:39 10M White
BI"" 36.5"
Lite
Bl ue #B-2 White
#B-'
or 10M Aed
G o ~ #8-,
Lite Delu.e
Sport 10 Red! 36.5 16:35 10 G o ~ 36.5" 16:35 10",
BI"" 36.5"
White #B-2 #B-2 10M Blue G o ~ #8-,
Sport 16:39 16:39
Touring
Super Sport 10 Red! 36.5" 17:35 10AL G o ~ 36.5" 17:35 10M Blue
R""
36.5"
Bushed White #B-2 Bushed
#B-'
Bushed or White #8-,
10 Bushed G o ~
Trail 10AL R.d! 30- 21:39 10 Red! 30- 21:39 10M Blue Red! 30-
Bushed White #2 Bushed White #2
B""hod
While #2
Trail Oelu.e 20:39 20:39
WideTrak LX 10
R""
30- 19:41 10M Red! 36- t9:41 10M Red! 30-
Bushed Whit e #2
BI""
White #2
White
White #2
Bushed Bushed
WideTrak 10 Red! 30- 19:41 10M Red! 36- 19:41 10M Red! 30-
GT
Bushed While #2 Bushed White #2
Bloo
White #2
B""had
440 Indy 10M Blue 34- 21:39 10M
BI""
34- 21 :39 10M Blue 34-
White
#2
Red
#2
Rod
#2
Bushed Bushed Bushed
440 SKS 20:39 20:39
440XCR 10M Blue 34- 21:39 10M
BI""
34- 21:39 10M Red BI""
34-
White
#2
White
#2
Bushed
#2
Bushed Bushed
600XCR 10MW Blue 34- 21:39 10MA
BI""
34- 21;39 10MA BI""
34-
Bushed #2 Bushed
.,
Bushed #2
Indy 500 10M G ~ 30- 21:39 10M Bloo 36- 21:39 10M White
BI""
30-
Blue
#2
BI""
., Bushed or
#2
Bushed Bushed 10M Red
Bushed
Classic 10M G ~ 30- 21:39 10M Bloo 36- 21:39 10M White
BI""
36-
500 EFI Blue
#2
BI""
#2
Bushed
#2
Bushed
500 EFI SKS 10M G o ~ 30- 20:39 10M
BI""
36- 20:39 10M White BI""
36-
Blue
#2
BI",
#3
Bushed
#3
Bushed
XLTfXLT SP 10M G o ~ 34- 21:39 10M
BI""
34- 21:39 10M Aed BI""
34-
Blue
#2
White
#2
Bushed
#2
Bushed Bushed
XLT SKS 20:39 20:39
XLT Touring 10M G o ~ 34- 20:39 10M Bloo 34- 20:39 10MAed Blue 34-
Blue ., White
#2
B""hod
#2
Bushed Bushed
RXL 10 Blue 30- 20:35 10M
BI"" 34" #2 20:35 10M Whil e BI", 34-"
Bushed
.,
BI""
or 3S Bushed or 36"
Bushed #3 #3
AXL Touring 10 Blue 30- 21:39 10M Bloo 34"#2 21 :39 10M While Blue 34-"
Bushed
., BI", or 36" Bushed or 36"
Bushed #3 #3
Storm H>-OO Blue 34- 23:37 1 ()'58 Blue 34- 23:37 10 Bushed or Blue 34-
Bushed #2 Bushed #2 10ALBushed #2
Storm SKS 20:35 20:35
8194
7.26
RIDE RED
Chain-
""" Gearing
15:41
16:39
16:35
16:39
17:35
21:39
20:39
19:41
19:41
21:39
20:39
21:39
21:39
21:39
21:39
20:39
21:39
20:39
20:39
20:35
21:39
23:37
20:35
.
1.
..
2. 75t2265
3. 7552801
4. 3576510
5. nl0417
6.
..
7. 5020436
5020422'
8. 5410374
9. 5430728
5430728
10. 5020425
11. 5430945
--
1 .
17
TORQUEO-MATIC DRIVE
Drive Clutch Service Parts

1.
loty I Description I QIy I Description
1 Asm., Drive Clutch Basic
6 Bolt
6 Washer, Spring Lock
1 Cover, Bearing
1 Ring, Retaining, Cover
1 Spring, Clutch
12. 1321457 3 Asm., Roller & Bushing
1321622 3 Asm., Roller & Bushing
(Storm Only)
13. 5430768 3 Button, Guide
14. 5210754 AR Spacer, .050mm
5210753 AR Spacer, .032mm
3 Pin, Roller
3 Pin, Roller
15.
..
3 WeighVBushing
16. 7541906 3 Nol
3 Seal
17. 7512266 3 Bolt
3 Button, Guide
6 Button, Guide
1 Nut, Jam
18. 3576502 1 Bearing, Sleeve
3576503 1 Bearing, Sleeve (Trail
w/EC5 PM)
6 Washer, Multilube
19. 5010188 1 Insert, Moveable
All other P-85 BaSIC except 500 90/91
2. 3.
5.
7.
13 ---z:?
12-4 \ /
. ,
\,/ .
'v

$
7. 10. 11. 14. /
,,-----------
1 .
I Qty I Description I Qty I Description
1. 1321523 1 Asm.,Orive Clutch Basic
2. 7512265 6 Bolt
3. 7552804 6 Washer, Split Lock (6mm)
4. 3576510 1 Cover, Bearing
5. 7041061 1 Spring, Clutch (Brown)
6. 5020422 3 Pin, Roller
10. 5210754

I :?pacer, .050mm
5210753 Spacer . 032mm
11. 3576504 1 Bearing, Moveable
12. 5630272 2 Shift, Weight (10)
13. 7512266 3 Bolt , Shoulder
14. 7541906 3 NUl, Flex l oc
8. 5430945 6 Washer, Multi lube
9. 1321457 3 Asm., Roller and Bushing
7.27
RIDE RED
8194
Drive Clutch Weight Identification - Actual Size
u
u
Gram Weight: 34 1
PN 5630107
0
A
A
Gram Weight: 47.S 1
11195
PN 5610080
0
o
o
Gram Weight: 51
PN 5610088
o
w
W
Gram Weight: 37.S 1
PN 5630109
0
01
01
Gram Weight: 48. 5 1
PN 5630224
0
o
o
Gram Weight: 53 1
PN 5630174
o
G
G - (8 Modified)
Gram Weight: 41.S 1
PN 5630063
0
02
02
Gram Weight: 49 1
PN 5630225
0
04
Gram Weight: S7.S'
PN 5630229
7.28
o
B
8
Gram Weight: 43 1
PN 5630084
0
03
03
Gram Weight: 32.5 1
PN 5630227
0
M1 (Modified)
Gram Weight: 46.0 1
PN 5630301
AICERED
o
P1
Pl
Gram Weight: 42 1
PN 5630089
o
05
05
Gram Weight: 53.5 1
PN 5630234
o
09
09
Gram Weight: Sl.S 1
PN 5630249
J1
Jl
Gram Weight: 44 1
PN 5630065
o
06
06
Gram Weight: 50.5 1
PN 5630243
o
15
Gram Weight: 5S.S 1
PN 5630274
o
1

Nl (Modilied)
Gram Weight: Sl.S 1
PN 5630302
K1
Kl
Gram Weight: 39 1
PN 5630144
o
07 08
07 08
Gram Weight: S2 1 Gram Weight: 47.5 1
PN 5630244 PN 5630245
10
Gram Weight: 51.7 1
PN 5630272
lOA
Gram Weight: 55.0 1
PN 5630286
7.29
RIDE RED
11195
10M
Gram Weight: 49.S 1
PN 5630273
10A
L
10A/L
Gram Weight: 53 1
PN 5630368
10M
B
10M Blue Bushed
Gram Weight: 47.S 1
PN 1321529
11 /95
10M Blue
Gram Weight: 47.S 1
PN 5630324
10 Bushed
Gram Weight: 51.5 1
PN 1321526
10M
R
10M Red Bushed
Gram Weight: 44 1
PN 1321530
10M Red
Gram Weight: 44 1
PN 5630325
10MIW
Gram Weight: 46 1
PN 5630369
10
M
W
10M
5
10MW Bushed 10M Bushed
Gram Weight: 46 1 Gram Weight: 49.S 1
7.30
PN 1321527 -""...... PN 1321528 -""--,,,
o 0
10
A
L
1 D-AL Bushed
Gram Weight: 53 1
PN 1321531
IDA Bushed
Gram Weight: 5S1
PN 1321589
AICERED
10
66
10-66 Bushed
Gram Weight: 661
PN 1321584
10-58 Bushed
Gram Weight: 58l
PN 1321588
TORQUEO-MATIC DRIVE
Drive Clutch Weight Identification Actual Size
10
64
, 0-64 Bushed
Gram Weight: 54,
PN 1321585
10-56 Bushed
Gram Weight: 561
PN 1321684
10
62
1 0-62 Bushed
Gram Weight: 621
PN 1321586
10-60 Bushed
Gram Weight: BOl
PN 1321587
1 ()"54 Bushed
Gram Weight: 541
PN 1321685
7.31
RIDE RED
-
11195 _.
TORQUEO-MATIC DRIVE
Drive Clutch Spring Rates
The following chart will aid in the setup and balance of engine RPM power curves for special converter luning
requirements such as high operating al titude, heavy loads, mountainous terrain, etc.
DRIVE CLUTCH SPRING COMPRESSION RATE CHART
300 "T----.,---,.-----,----,----,-, / _ ---BlueIBlue-Gold
I
7041080
P-90 TRAVEL __ / ___ Silver/Gold
P-85 TRAVEL 7041286
_ _____
7041148
__ Silver
7041062
____ R'"
240 l .Y'oV/ 7041083

_ _ _ _ AedlWhite
_
+-----+----+-----+7''-+ ' Lj-.... ,/-''-_, 7041150
220 -,
[6:
, ----.'OWO
# 7041061
/'. Orange
7041060 2Ol
....... Pink

7041065
,/
__ Yellow
z
::::>

-
w
u
a:
o
u.
8/94
,/ -<-f-i 7041102
.__-- __ Green
/ ./,/ "v I ____
/" ,. 7041063
__ .. _ While
7041132

_ ___ Black
__ ( 7041022
40

ojo;L ...... .. , 19
COMPRESSED SPRING LENGTH (INCHES)
7.32
RIDE RED
/
PART NUMBER COLOR COOE
7041021 Clear
7041022 Black
7041063 Purple
7041062 Silver
7041065 Pink
7041060 Orange
7041080 Blue/Gold
7041083 Red
7041102 Yellow
7041061 Brown
7041132 White
7041168 Green
7041148 Gold
7041150 RedIWhite
7041286 Silver/Gold
-
Drive Clutch Spring Data
WIRE DIAMETER FREE LENGTH +/- .125-
.157" 4.38-
.140- 4.25-
.168- 4.37"
.208- 3. 12-
.177- 4.69-
.196- 3.37"
.207" 3.50-
.192- 3.77-
.192- 2.92-
.200- 3.06-
.177- 2.92-
.177- 3.05-
.207" 3.25-
.192- 3.59-
.218- 3.05-
CAUTION: Never shim a drive clutch spring to increase its compression rate. Thi s may resul t in complete stack
lng of the coils and subsequent clutch cover failure.
Maximum efficiency of the variable speed drive system is dependent upon many faclors. Included in these are
converter alignment, bell tension, Elnd internal condition of the and driven clutch components. One of the
most critical and easily serviced parts is the drive cl utch Due to the severe stress the spring is subject
to during operation, it should always be inspected and for tolerance limits during any clutch operation
diagnosis or repair. .
. -,
With the spring resting on a flat surface, measure its
free length from its outer coil surfaces as shown. Refer
to the chart above for speci fi c free length measure-
ments and tolerances.
In addition to proper free length, the spring coi ls should
be parallel to one another when placed on a ftat sur-
face. Distortion of the spring indicates stress fatigue.
Replacement is required.
7.33
AIDE RED
8/94
Drive Belt Adjustments
The drive belt is an important component of the converter
system. Critical dimensions and construction have been pro-
vided for at the time of manufacture. In order to achieve max-
imum efficiency from the converter, the drive belt must be ad-
justed property for tension and cl utch offset.
If the belt is 100 long or the center distance too short, the initial
starting ratio will be too low, resulting in performance loss.
This is due to the belt rising too high in the drive clutch
sheaves upon engagement.
If the drive belt is too short or the center distance 100 long,
the ratio will again be incorrect. In addition, the machine may
creep when the engine idles, causing damage to the internal
face of the drive belt.
8194
7.34
RIDE RED
Aluminum Driven Clutch
Drive Belt Adjustments
Ideal belt deflection is 1 1/4" (3.2 em). Measure belt deflection with both clutches al rest and in their full neutral
position. Place a straight edge on the bell and apply downward pressure while measuring at the point shown.
To change belt deflection, add or delete thrust washers. NOTE: One thrust washer should always be left between
the driven clutch sheaves.
Straight Edge
11W(3.2cm)
IMPORTANT NOTE: Do not apply excessive pressure to force the belt into the driven sheaves. this will result
in an improper measurement.
Aluminum Driven Clutch with Outer Cam Adjuster
Belt deflection can be adjusted removing the clutch from the jacks haft.
1. Pull belt into driven clutch to slightly open sheaves.
2. Loosen Ihree bolts on adjustment cam.
3. Turn cam counterclockwise to reduce distance between sheaves.
4. Torque bolts to 10 ft.lbs. (1.38 kg/m).

May use optional, thinner washer PN 7555899
a
7.35
RIDE RED
8194
,.'
Clutch Alignment
NOTE: The drive belt must be removed for this mea-
surement.
Clutch Alignment (Tools)
P90 - 21132" Offset (PN 2S709t4)
PBS - SlS"Offset (PN 2S70426)
P90 Electric Slart -
1.2S"Offset (straight edge)
PBS Electric Start -
I" Offset (straight edge)
Clutch Offset Inspection
, . Remove drive belt.
NOTE: Belt deflection adjustments affect offset.
belt deflection first.
Sel
2. Install proper alignment tool, depending on type of
clutch, as shown in III. 1.
3. Rear of driven clutch moveable sheave should just
contact 1001 when clutch is pushed inward on
jackshaft.
4. Remove or install washers on jackshaft behind
driven clutch to achieve proper offset.
NOTE: When checking electric start models, use a
straight edge as shown in III. 2.
Clutch Alignment Inspection
After clutch offset has been verified, inspect alignment.
There should be a 1/16" (1.6 mm) gap at the front of the
driven clutch. Up to l IS" (3.2 mm) gap is acceptable on
new machines.
The engine mounts are slotted on some machines to al-
low alignment of the clutches. If the engine is moved,
re-check clutch offset.
1fi95
7.36
III. 1
...
: . .'
,','
';'

' .:'
. ,
,.
..

...
Offset -
Non-electric Start
Models
21 /32" Offse1
All models with P90
driven clutch
5/S" Offsel
All models with P85
driven clutch
:t-.\.l._ NOTE: Up to 1/8" air gap
\. allowed on new machines
, ..
r-
L
Offset Alignment Tool
'"

LJ
Offset -
Electri
Model
c Start
s
Sirai
Edge
gh1
'.:r
111.2
I-- 1.2S" P90 Ele
1 ,. PB5 ElectriC
ctric Start
Start
"<:
f-
I D II II
f-

RIDE RED
1.
loty I Description
1. 1321551 1 Asm., Drive Clutch Basic 34
(less6& 14)
2. 7512265 6
8",
3. 7552801 6 Washer, Spring Lock
4. 3576510 1 Cover, Bearing
5. nl0417 1 Ring, Retaining,Cover
6. 7041080 1 Spring, Clutch (Blue)
7. 5020422 3 Pin, Roller
B. 2200387 1 Kit - Shim. Drive Clutch
10. 5430945 6 Washer. Multitube
11 . 1321457 3 Asm., Aoller & Bushing
1321622 3
I .. Rol:r;)& Bushing
,
Storm Onl
[Rel.1 Part No.
12. 5020425
13. 5210754
5210753
5210752
14. 1321531
15. 7515105
16. 7541906
17. 3576502
3576503
lB. 5010188
7.37
P-85 Drive Clutch
7.
r Qty.] Description
1 NUl, Jam
AR Spacer .. 000mm
AR . 032mm
AR Spacer, .020mm
3 Asm., WeightIBushing
(10A-L)
3 Pin, Weight
3 Nut
1 Bearing. Sleeve
1 Sleeve (Trail
w/EC PM)
1 Insert, Moveable
AICERED
8/94
Drive Clutch Identification and Removal
1. Install strap wrench PN 2870336 to clutch cover.
Remove drive clutch retaining bolt and install
puller PN 2870506 into clutch. Tighten puller with
a wrench, or strike I-bar with a hammer until
clutch is removed.
2. Prior to reinstalling drive clutch to engine. bore
taper should be trued by using tapered reamer PN
2670576. Pl ace reamer in a vise and lubricate
with cutting oil. Clean taper by manually rotating
cl utch clockwise.
3. Positiorl cl utch on engine crankshaft. Install
retaining bushing and bolt using strap wrench PN
2870336 to hold clutch. Torque retaining bolt to
40-45 tt. lbs. CAUTION: Never use an ai r impact
wrench for installing or removing a drive clutch. II
will loosen the spider torque value and could
cause engine crankshaft damage.
While all drive clutches may look alike, each bears a
different number. Thi s number indicates internal
clutch component variation for individual engines. For
easy identification, refer to the three numbers behind
date code on moveable sheave. These numbers are
the last three digits of that clutch part number.
-
- ~ .......
Used up to 1993
8/94
7.38
@ @
@ 15>< ~ ~
~ ~
@
1994 & Later
RIDERED
1. Carefull y remove cover attaching screws.
Remember thallhere is spring lens ion on the cover.
\
2. Install drive clutch into cl utch holding fixture PN
2870461.
3. On models equipped with a spider jam nut. install jam
nul 1001 PN 2870338 and remove jam nut.
4. Install spider removal 1001 PN 2870341 and remove
spider.
5. Count the number of spacer washers installed
beneath the spider .

7.39
Drive Clutch Disassembly and Inspection
RIDE RED
8/94
Drive Clutch Disassembly and Inspection
10. Using a liS'" Allen wrench and 3/8'" combination
wrench, remove drive cl utch fly weights.
11. Remove spider buttons using button removal tool
PN 2870985.
12. Place spider on a vise. Using a pin punch, dri ve
out the roller pin.
13. Inspect all roll ers, bushings, thrust washers, and
roller pins.
8194
7.40
RIDERED
1. Start a replacement roller on each leg, dri ving a pin in
about .1 (.25-.32 cm) beyond the first land
of the spider leg (A). TIP: This enables you to locate
the first washer and align the roller until the pin is flush
with the second land.
2. Install one washer onto the pin.
3. Place a few drops of Polaris clutch and cable lube
(PN 287051 0) onto the roller bushing. Place roller on
pin as it protrudes from first land.
4. Place a second washer on the other side of the roller.
5. Install service tool as shown in photo 2.
6. Place spider on a vise anvi l and drive the roller pin
through to the second land of the spider. CAUTION:
Use care to start the pin straight. Alumi num burrs
could pass through into the roller bushing causing it to
bind and stick. Also use care to make sure the roller
remains aligned when the pin is driven through. The
roller bushing could be damaged causing premature
wear and roller failure.
7. Determine how many shims are to be used. NOTE:
Shim Kit PN 2200387 contains an assortment of
shims, including .002", .005'", and .010 ....
8. Measure the dimension between towers at the lower
half of the towers as shown.
9. Install spider buttons using a soft face hammer.
7.41
Spider Assembly
RIDE RED
8194
Spider Assembly
10. Record width of spider buttons on each leg.
11 . Add shims beneath spider button to obtain . 0 0 2 ~ (.05
mm) clearance between button and tower when
assembled.
12. Place the correct number of spacer washers
beneath the spider.
13. Assemble clutch making sure ~ X " marks are aligned
to achieve proper balance .

-
8/94
7.42
RIDE RED
27. Torque spider to 200 ft. Ibs. (27.6 kg/mi. (Applies to
either PBS or P90 models.)
28. Torque jam nut to 235 ft. Ibs. (32.43 kg/m). (Select
PBS models only.)
29. Install spring and cover. Torque cover screws to 90
inch Ibs.
7.43
Spider Assembly
RIDE RED
8194
~
, .
Spider Indexing
1 . Remove drive cl utch from engine and remove drive
clutch cover and spring.
2. Mark spider, cover, moveable sheave, and
stationary sheave in line as shown in photo 1 .
Fine Tuning
The distance between the belt and the moveable sheave
on the drive clutch is very important. This distance
controls the starting ralio (lowest starting ratio is most
preferable) and the position of the clutch weight to en
gine RPM. The distance between the bell and moveable
sheave should be as close to ,020" (.5 mm) as possible
without creating a drag on the belt when positioned
around the hub at the bottom of the sheaves.
New bell measurement width specification is 1.375" +/-
.032.
1. Measure tolal belt to sheave clearance with a feeler
gauge as shown in photo 2. NOTE: Any clearance
over .020" requires disassembly and re-shimming of
the spider.
Spider Shimming
1. Place drive clutch on holding fixture and unscrew
spider.
2. Adjust spider washer pack to achieve desired bell to
sheave clearance as described above.
The following washers are available for fine tuning:
8194
PN 5210754 .050'
PN 5210753 .032-
PN 5210752 .020-
7.44
RIDE RED
3. Inslall spider washer(s) and spider. The spider musl
be rolaled clockwise into Ihe moveable sheave 10
maintain relative clutch balance after reassembly.
Reindexing the spider 1/3 turn clockwise, or 1 leg, will
allow the realignment of the moveable and stalionary
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
reindex clockwise 2/3 turn
NOTE: Alignment marks should be within 1" (2.5 cm) af
ter final assembly and torquing.
7.45
Spider Indexing
8194
RIDE RED

Aluminum Driven Clutch Service - P8S
1. Remove snap ring and washer.

2. Inspect ramp buttons and bushing for wear.
3. Note condition of moveable sheave bushing. Install
helix into bushing. It should slide freely without
binding.
4. Polish helix with a fine emery cloth to remove any
sharp edges which may cause sticking.
5. Clean atl parts.

.6. Reassemble stationary and moveable sheaves. Note
the placement of the two thrust washers shown.
These washers may be used to adjust the effective
belt tension measurements as <;tescribed earlier.
Removal 01 a thrust washer increases neutral belt
tension. NOTE: Addition or subtraction of these
washers affe<;ts cl utch al ignment.
7. When driven offset is properly adjusted, the washers
(A) (PN 7555734) are used to adj usl for free floal on
drive. Without a slight free floal , the jackshaft
bearings could be side loaded, causi ng premature
bearing fai lure. Torque bolt to t 2 ft. lbs. (1.66 kg/m) .

8194
7.46

RIDE RED
Helix Angles And Effects
Aluminum Driven Clutch Service - P-85
The driven clutch helix was selected for overal l performance in relalion 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 aluminum drive clutch. Refer to the chart below for specific angle
effects and identification .
Helix RPM Effect Identification
34PN 5630168 Increasing Number 34 marked on back side of helix
36" PN 5630185 Decreasing Number 36 marked on back side of helix
42 - 36- 34Combination N/A Identification T- t marked on back side of
PN 5131013 helix
The helix spring should always be adjusted within its l imits before a helix change is performed. The normal rate of
change between helix angle steps is250 RPM under full throttle. This is approximately the same result as in going
from the No.1 to NO.4 spring position. NOTE: Increasing spring tension i ncreases engine RPM. RPM changes
may not be evident if other drive or driven clutch components are substandard.
8. Reassembleclutch, installing spring into helix. On all
models the production helix spring hole location is
No.2. Tension the spring 1/3 turn. Install helix key,
thrust washer and snap ring.
9. With drive belt removed, insert a pin punch or drill bit
into a balance hole on Ihe moveable sheave. Using a
good quality force gauge, record poundage al the
point where the sheave just begins 10 break away. A
desirable range for the Polaris OEM spring is from 9
to 131bs. To obtain this range, it may be necessary 10
move the spring 10 Ihe NO.3 position. NOTE: This
range may not be desirable under some riding
conditions, such as slow trail riding. The higher
spring tension will slow the upshift, decreasing fuel
economy.
'lI.47
~ t D
NOTE: Always Inslall Snap Ring with
Chamfer TowardS Heli x

8194
RIDE RED
- "
Aluminum Driven Clutch Service - P90
Used to adjust
belt tension. One must
always be installed.

The driven clutch helix/moveable assembly has several different spring locations which affect clutch shifting and
RPMs. The lightest spring tensi on will raise engine RPMs during clutch upshi ft and allow quicker downshift when
pulling or negotiating a hill. The lighter tension positions will lend to have a slower downshift and a harder upshift.
Moveable Spring
Exame:le:; Iensioo
B -
1

Spring! B - 2
Position A - 1
B - 3
A - 2
A
- 3 Soft
Production settings arB usually 82
The driven clutch ramp buttons are secured by
Torx screws. The ramp buttons should be ra
placed when worn.
After rebuilding, the driven cl utch can be reas-
sembled.
NOTE: Preload on the driven spring from any of
the various spring positions is 113 turn preload ten
sion (counterclockwise) .

8194
r
I
7.48
RIDE RED
SITUATION
Harsh drive clutch engage-
ment
Drive belt turn over
Noise in drive system
"
DETENT SHIFT WEIGHTS
Over rev during initial accel-
eration or during heavy pull ing
at low ground speeds.
Engine ~ s after engage-
ment.
..
PROBABLE CAUSE
Drive bett worn too narrow
-Excessive belt to sheave clearance with
new belt (high performance version with-
oul detent shift weight)
-Wrong belt for application
-Clutch alignment out of spec
-Engine mount broken or loose
-Driven clutch sheaves have excessive
runout, are bent or damaged
-Broken drive clutch components
-Excessive drive clutch bunon - tower
clearance
-Searing failurel chaincase, jackshaft or
front drive shaft
-Drive chain loose or worn, sprocket teeth
broken
-Driven clutch bushing worn excessively or
spring
broken
-Drive belt surface flat spots
-Spider roller position remaining in detent
-Worn belt
-Excessive belt deflection
- ~ ~ . - - .
Troubleshooting
REMEDY
-Replace
-Perform belt to sheave clear-
ance adjustment with shim
washers beneath spider
-Replace
-Adjust alignment offset
-Inspect. adjust or replace
-Measurement should be lak-
en 12"' (30.S em) in from outer
circumference on sheave
face. Maximum allowable tol-
erance is .015'" (.6 mm).
-Inspect/replace
-Install new buttons or shim
out existing buttons
-lnspecUreplace
-Inspect/adjust or replace
-Inspect/replace
-Inspect/replace
-Add spider shim washers
-Add driven washers
-Reduce gear ratio (chaincase
models)
-Replace
-Subtract driven clutch wash-
ers
~ -
"
8194
7.49
RIDE RED

,
Troubleshooting
SITUATION
Engine RPM below specified
operating range, although en-
gina is in property tuned
Erratic engine operating RPM
during acceleration or load
variations
Engine RPM above specified
operating range
8194
PROBABLE CAUSE
Wrong or broken drive clutch spring
-Drive clutch shift weight too heavy
-Driven clutch spring broken or installed in
wrong helix location (aluminum clutch)
-Drive belt too long
-Converter sheaves greasy; belt slippage
-Drive cl utch binding
-Driven clutch malfunction
-Incorrect drive clutch spring (too high
spring rate)
-Drive clutch shift weights incorrect for ap-
plication (too light)
-Drive clutch binding
-Driven clutch binding
7.50
REMEDY
-Replace with recommended
spring
-Install correct shift weight kit
to match engine application
-Replace spring; refer to prop-
er installation location
-Clean clutches; install new
belt
-Install new belt and/or adjust
belt tension
-Disassemble drive clutch; in-
spect shift weights for wear
and free operation
Clean and polish stationary
shaft hub; reassemble clutch
without spring to determine
probl em area
-Replace ramp buttons
-Inspect moveable sheave for
excessive bushing clearance!
replace
-Install correct recommended
spring
-Install correct recommended
shift weights
-Disassemble and clean
clutch, inspecting shift weights
and buttons. Reassemble
without the spring to further
determine probable cause.
-Disassemble, clean and in-
spect driven clutch, noting
worn sheave bushing and
ramp buttons and helix spring
location
RIDE RED
CHAPTER 8
BRAKES/FINAL DRIVE
Data
1985-1986 ...... . .... . . . .. . ... . .. . .. . . . . .. . ..... 8.1
1987-1988 ...... . .... . . . ..... . . . . . ... ... . . 8.2
1989-1990 ............ . . . ...... . ... . . . .. . ........ 8.3
1991-1992 ...... .......... .............. . . .. . . . ......... 8.4
1993 ........... . ....... . . ..... . . .. . . . . .. . . .. ...... 8.5
1994 .................... . ............ . . . ..... . .... ...... 8.6
1995 ............................... . . . . . . .. ... . .... ..... 8.7
Hydraulic Brake System Operation ..... . .. ... . . .. . .. . . . .............. B.8
Type 1 Master Cylinder Overhaul ................ , ........ . ................ 8.9
Type 2 Master Cyli nder Overhaul ..................................... B. 10-8. 11
Type H 1 Brake Caliper Removal and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8. 12
Type Hl Brake Caliper Repai r and Assembly ........... . ...................... 8.13
Type H2 Brake Caliper Removal and Repair ................ ............ 8.14-8.15
Type H2 Brake Caliper Assembly .......... . ................ .............. 8.16
Type 3 Master Cylinder Overhaul ............ ......................... 8.17-8.18
Type H3 Brake Caliper Overhaul ....... . .............. . ............ 8. 19-8.21
Type H4 Brake System Service ...................... . .. . . ......... 8.22-8.24
Type H5 Brake System Service .... . .................. . ....... ...... 8.25-8.27
Bleeding Procedures for Polaris Brake Systems ....... . ....... . . . . . .. .......... 8.28
Type Ml Brake Overhaul and Pad Repl acement ...... ........ .... . . 8.29-8.30
Type M2 Exploded View .......................... .. .......... . ............. 8.31
Type M3 Exploded View ............ . .. ... . .. . .. . . ................ 8.32
Jackshaft Speed VS MPH Chart ...... . _ ... . . .. . . . .. . . .............. 8.33
Type 1 Drive System Overhaul ....... . ...... .. ................ . .......... 8.34-8.35
Type 2 Drive Syslem Overhaul ... . .. .. ......... .. ... . ......... . . ......... 8.36-8.40
Type 3 Drive Syslem Overhaul ........... .. . . .. . . . . ........... 8.41-8.48
Type 4 Drive Syslem Overhaul ........... .. . . . . .. . . .. . . . .... . .... 8.49-8.52
Drive Shaft Sprocket Installation Tips ..... .. ...... ............. ....... 8.53-8.54
Series 300 Transmission Overhaul ....................... . ............... 8.55-8.59
Reverse Kit Service Tips ............... ....... .................... 8.60-8.61
RIDERED
8/94
1985
BRAKE DRIVE GEARS
MODEL TYPE TYPE CHAIN
Star MI 1 Direct
Drive
88 Ml 1 Direct
Drive
Trail H2 2 19/35/64
400 H2 2 19/35/64
600 H3 2 19/35/64
Long Track M2 2 19/35/64
1986
BRAKE DRIVE GEARS
Star Ml 1 Direct
Drive
Sprint Ml 1 Direct
Sprint ES Drive
S8 Ml 1 Direct
Drive
Trail H2 2 21 /35/64
400 H2 2 19/35/64
600 LE H3 2 21/35/64
DRIVE
SPROCKET
A
DIAMETER
3.01 8.93
3.69 8.93
7.06 8.58
7.06 8.58
7.06 8.58
5.03 8.58
DRIVE
SPROCKET
A
DIAMETER
3.01 8.93
3.69 8.93
3.69 8.93
7.06 8.58
7.06 8.58
7.06 8.58
5.03 8.58
8.1
BRAKES I FINAL DRIVE
Data
DRIVE SPROCKET POSITION
Reference Page 8.53
B C D E
13.77
13.77
13.42
13.42
,
13.42
13.42
Reference Page 8.53
B C D E
13.77
13.77
13.77
13.42
13.42
13.42
13.42
RIDE RED
8/94
BRAKES f FINAL DRIVE
Data
1987
BRAKE DRIVE
MODEL TYPE TYPE
Star M1 1
StarTrak M2 2
Sprint M1 1
Sprint ES
Sport H2 2
Trai ls H2 2
400 H2 2
600 H3 2
Long Track ALA M2 4
1988
BRAKE DRIVE
MODEL TYPE TYPE
Star M1 1
StarTrak M2 2
Sprint M1 1
Sprint ES
Sport H2 2
Trail H2 2
Trai l SKS
400 H2 2
400 SKS
650 H2 2
650 SKS
l ong Track RLA M2 4
8194
GEARS
CHAIN
Direct
Drive
15/39/64
Direct
Drive
17/35/62
21/35/64
19/35/64
21/35/64
19/39/66
GEARS
CHAIN
Direct
Drive
15/39/64
Direct
Drive
17/35/62
21/35/64
19/35/64
19/35/64
18135164
21/35/64
19/35/64
19/39/66
DRIVE Reference Page 8.53
SPROCKET
A B C D E
DIAMETER
3.01 8.93 13.77
5.45 8.58 13.42
3.69 8.93 13.77
7.06 8.58 13.42
7.06 8.58 13.42
7.06 8.58 13.42
7.06 8.58 13.42
5.03 4. 85 9.69
SPROCKET
A B C D E
DIAMETER
3.01 8.93 13.77
5.45 8.58 13.42
3.69 8.93 13.77
7.06 8.58 13.42
7.06 8.58 13.42
7.06 8.58 13.42
7.06 4.58 8.58 13.42 17.42
5.03 4.85 9.69
8.2
RIDE RED
1989
BRAKE DRIVE GEARS
Star M1 1 Direct
Drive
StarTrak M2 2 15/39/64
Sprint ES M1 1 Direct
Drive
Sport H2 2 17/35/62
Sport GT
Trails H2 2 21/35/64
400 H2 2 19/35/64
500 H2 2 19/35/64
500 SKS 18135164
650 H3 2 21/35/64
650 SKS 19/35/64
RLA
SuperTrak M2 4 19/39/66
1990
BRAKE DRIVE GEARS
Star M1 1 Direct
Drive
SlarTrak M2 2 15/39/64
Sprint ES M1 1 Direct
Drive
Sport H2 2 17/35/62
Sport GT
Trails H2 2 21 /35/64
400 H2 2 19/35/64
500 H2 2 19/35/64
500 SKS 18135164
650 H3 2 21 /35/64
650 SKS 19/35/64
SuperTrak H1 4 19/39/66
WideTrak H1 4 19/41/66
DRIVE
SPROCKET
A
DIAMETER
3.01 8.93
5.45 8.58
3.69 8.93
7.06 8.58
7.06 8.58
7.06 8.58
7.06 8.58
7.06 4.58
5.03 4.85
7.06 4.90
DRIVE
SPROCKET
A
DIAMETER
3.01 8.93
5.45 8.58
3.69 8.93
7.015 8.58
7.015 8.58
7.015 8.58
7.015 8.58
7.015 4.58
7.015 4.90
6.813 .52
8.3.
Data
Reference Page 8.53
B C D E
13.77
13.42
13.77
13.42
13.42
13.42
13.42
8.58 13.42 17.42
9.69
9.74
Reference Page 8.53
B C D E
13.77
13.42
13.77
13.42
13.42
13.42
13.42
8.58 13.42 17.42
9.74
4.54 9.32 14.11 17.60
8194
RIDE RED

.'
Data
1991
BRAKE DRIVE
MODEL TYPE TYPE
StarUle Ml 1
Ute Ml 1
Sport H2 2-3
Sport GT
Trail H2 2-3
Trail Deluxe
440 H2 2-3
500 H2 2-3
500 SKS
650 H3 3
650SKS
RXL
SuperTrak Hl 4
WideTrak HI 4
1992
BRAKE DRIVE
MODEL TYPE TYPE
StarLite Ml 1
Ute Ml 1
Ute Deluxe
Lite GT M2 3
Sport H2 3
Sport GT
Trail H2 3
Trail Deluxe
440 H2 3
440 XCR H3
500SP H2 3
Classic
500 SKS
650 H3 3
RXL
650 RXL SKS
SuperTrak M2 4
WideTrak M2 4
8/94
GEARS
CHAIN
Direct
Drive
Direct
Drive
16/35/62
16/39/64
21/35/64
21/39/66
21139/66
21139166
20139/66
21135164
19135/64
20135/64
19/39/66
19/41 /66
GEARS
CHAIN
Direct
Drive
Direct
Drive
16139/64
16/35162
16139/64
21 /39/66
21139166
21139/66
20139/66
21139/66
20135/64
20135/64
21139/66
19/39/66
19/4 1/66
SPROCKET
A B C D E
DIAMETER
3.69 8.70 13.54
3.69 8.70 13.54
7.015 8.58 13.42
7.015 8.58 13.42
7.015 8.58 13.42
7.015 8.58 13.42
7.015 4.58 8.58 13.42 17.42
7.015 4.90 9.74
6.813 .52 4.54 9.32 14.11 17.60
SPROCKET
A B C D E
DIAMETER
3.69 8.70 13.54
3.69 8.70 13.54
7.015 8.58 13.42
7.015 8.58 13.42
7.015 8.58 13.42
7.015 8.58 13.42
7.015 8.58 13.42
7.015 4.58 8.58 13.42 17.42
7.015 4.90 9.74
6.813 .52 4.54 9.32 14.11 17.60
8.4
AICERED
1993
BRAKE DRIVE GEARS
StarUte M2 2 15/41 /66
StarUte GT M2 2 15/41166
Ute M2 2 16/39/64
Ute Deluxe M2 2 16/39/64
Lite GT M2 2 16/39/64
Sport H4 3 16/35/62
Trail H4 3 21139/64
Trai l Del uxe H4 3 16/39/64
440 H4 3 21139/64
440SKS H4 3 20139/66
XCR H5 3 21139/66W
WideTrak M2 4 19/41166
Classic H4 3 21139/66
500 EFI H4 3 21139/66
500 EFI SKS H4 3 20139/66
XLT H4 3 21139/66W
XLT SKS H4 3 20139166W
XLTSP H4 3 21139166W
Classic Touring H4 3 20/39166
RXL H5 3 20135164W
RXLSKS H5 3 21139/66W
Storm H5 3 23137166W
Storm SKS H5 3 23/37/66W
DRIVE
SPROCKET
DIAMETER
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.86
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
Data
Reference Page 8.53
A B C D E
7.48 12.32 All 1993 models. ex
7.48 12.32
cept WideTrak, the
drive shaft is .250"
7.48 12.32 longer and sprocket
7.48 12.32
posi tions are mea
sured to sprocket hub
7.48 12.32 and not idler center.
7.48 12.32
Check pages 8.53
and 8.54.
7.48 12.32
7.48 12.32
7. 48 12.32
7.48 12.32
7.48 12.32
Use 1992 Specs. & Procedures
7. 48 12.32
7. 48 12.32
7.48 12.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
7.48 12.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
OW .. denotes a 13 link wide chain and wide sprocket; others are 11 link wide.
8.5 AICERED
8/94
Data
1994
BRAKE
MODEL TYPE
StarUte M3
StarUte GT M3
Ute M3
Ute Deluxe M3
Ule GT M3
Sport H4
Super Sport H4
Sport SKS (Renlal) H4
Trail H4
Trai l Deluxe H4
440 H4
440SKS H4
XCR H5
XCR SP H5
WideTrak Gr M2
WideTrak LX' M2
Classic H4
500 EFI H4
500 EFI SKS H4
XLT H4
XLT SKS H4
XLTSP H4
Classic Touring H4
RXL H5
RXLSKS H5
Storm H5
Siorm SKS H5
600XCR H5
Xlra H4
DRIVE GEARS
TYPE CHAIN
2 15/41/66
2 15/41/66
2 16139/64
2 16139/64
2 16/39/64
3 16/35/62
3 17/35/62
3 16139/62
3 21/39/66
3 22/41164
3 21/39/66
3 20/39/66
3 21139/66W
3 21/39/66
4 19/41 /66
4 19/41 /66
3 21/39/66
3 21 /39/66
3 20139166
3 21/39/66W
3 20/39/66W
3 21139/66W
3 20/39/66
3 20/35/64W
3 21 /39/66W
3 23/37/66W
3 21/37/66W
3 21139166
3 21/39/66W
SPROCKET
A B C D E
DIAMETER
6.94 7.48 12.32 All 1994 models, ex-
6.94 7.48 12.32
cepl WideTrak, the
6.94 7.48 12.32 longer and sprocket
6.94 7.48 12.32
positions are mea-
6.94 7.48 12.32 and not idler center.
6.94 7.48 12.32
Check pages 8.53 and
8.54.
6.94 7.48 12.32
6.94 7.48 12.32
6.94 7.48 12.32
6.94 7.48 12.32
6.94 7.48 12.32
6.94 7.48 12.32
6.94 7.48 12.32
6.94 7.48 12.32
6.86 .52 4.54 9.32 14.11 17.60
6.86 .52 4.54 9.32 14.11 17.60
6.94 7.48 12.32
6.94 7.48 12.32
6.94 7.48 12.32
6.94 4.35 7.48 12.32 16.32
6.94 4.35 7.48 12.32 16.32
6.94 4.35 7.48 12.32 16.32
6.94 7.48 12.32
6.94 4.35 7.48 12.32 16.32
6.94 4.35 7.48 12.32 16.32
6.94 4.35 7.48 12.32 16.32
6.94 4.35 7.48 12.32 16.32
6.94 7.48 12.32
6.94 4.35 7.48 12.32 16.32
"W' denotes a 13 link wide chain and wide sprocket; others are " link wide .
WideTrak sprocket placement as shown on VIJI -39 lypical4 drive with center idler.
8194
8.6
RICERED
1995
BRAKE DRIVE GEARS
StarUte M3 2 15/41 /66
Ute M3 2 16/39/64
Lite Deluxe M3 2 16/39/64
Lite GT M3 2 16139/64
Sport H4 3 16/35/62
Super Sport H4 3 17135/62
Sport Touring H4 3 16139/62
Trail H4 3 21139/66
Trai l Deluxe H4 3 22/41164
440 UC H4 3 21139/66
440 SKS H4 3 20/39/66
440 XCR H5 3 21139/66W
600 XCR H5 3 21139/66
WideTrak GT* M2 4 19/41166
WideTrak LX- M2 4 19/41/66
Indy 500 H4 3 21139/66
Classic H4 3 21139/66
500 EFI H4 3 21139/66
500 EFI SKS H4 3 20/39/66
500 EFI SKS PT H4 3 20/39/66
XLT H4 3 21139/66W
XLT SKS H4 3 20/39/66W
XLT SKS PT H4 3 20/39/66W
XLT SP H4 3 21139/66W
XLT Touring H4 3 20/39/66W
RXL H5 3 20/35/66W
RXL Touring H5 3 21139/66W
Storm H5 3 23/37166W
Storm SKS H5 3 20/35/66W
Storm SKS PT H5 3 20/35/66W
DRIVE
SPROCKET
DIAMETER
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.94
6.86
6.86
6.94
6.94
6.94
6.94
6. 16
6.94
6.94
6.16
6.94
6.94
6.94
6.94
6.94
6.94
6.16
Data
Reference Page 8.53
A B C D E
7.48 12.32 All 1995 models, ex-
7.48 12.32
cept WideTrak, the
7.48 12.32 longer and sprocket
7.48 12.32
positions are mea-
7.48 12.32 and not idler center.
7.48 12.32
Check pages 8.53 and
8.54.
7.48 12.32
7.48 12.32
7.48 12.32
7.48 12.32
7.48 12.32
7.48 12.32
7.48 12.32
.52 4.54 9.32 14. 11 17.60
.52 4.54 9.32 14.11 17.60
7.48 12.32
7.48 12.32
7.48 12.32
7.48 12.32
7.48 12.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
4.35 7.48 12.32 16.32
W denotes a 13 link wide chain and wide sprocket; others are 11 link wide .
WideTrak sprocket placement as shown on VIU-39 typical 4 drive with center idler.
8 Tooth drive sprocket
8.7 RIDE RED
8/94
Hydraulic Brake System Operation
~
F
A
D--
The Polaris snowmobile hydraulic brake system consists of the following components or assemblies: brake lever,
master cylinder, hydraulic hose, brake caliper (slave cylinder), brake pads, and a brake disc which is secured to
the drive line.
When the hand activated brake lever (A) is applied, it contacts a piston (8) within the master cylinder. As the
master cylinder piston moves inward it closes a small opening called a port within the cylinder and starts to build
pressure within the brake system. As the pressure within the system is increased. the piston (0) 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 side pad into the brake disc. This action reduces
brake disc speed and vehicte speed. 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 these pads wear, the piston within the caliper
self-adjusts and moves further outward.
Brake fluid level is critical to proper system operation. A low fluid level allows air to enter the system causing the
brakes to feel spongy. A high fluid level does not allow enough room for fluid expansion. Both conditions will result
in loss of brakes.
Located within the master cylinder is a small 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 withi n 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 fi ll ed to the top of the fluid level mark on the inside of
the reservoi r:
Type t Master Cylinder 1/8" (.3 cm) below lip of reservoir opening;
Type 2 Master Cylinder 1/4" (.6 cm) below lip of reservoir opening;
Type 3 Master Cylinder 1/4" - 5/16" (.6 - .8 cm) below lip of reservoir opening.
WARNING: Never overfill the reservoir. This could cause brakes to lock, resulting in severe injury or death.
This system also incorporates a diaphragm (E) as part olthe 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.
8/94
8.8
RIDE RED
Type 1 Master Cylinder Overhaul
Removal
1 . Brake Hose
2. Housing (cylinder)
3. Cover Gasket
4. Cover
5. Cover Screw
6. Pivot Boll
7. Piston
B. O-Ring
1
9. Seal U-Pack
10. Compression Spring
11. Brake Lever
'.=== = ~ -
12. Pivot Bushing
13. Set Screw
14. Washer
CAUTION: Due 10 the critical na-
ture of these parts and proce-
dures, be sure you have read and
understand hydraulic brake op-
eration on page B.B.
11
1. Remove handlebar grip. To assist in grip removal, plug one end of the handlebar and apply air pressure to the
opposite end.
2. Remove brake line. Be prepared 10 catch all fluid in a shop cloth. NOTE: Special care must be used to see
that brake fluid does not come in contact with any finished surfaces.
3. Loosen brake cylinder set screw and remove cylinder.
4. Remove brake lever. Note position of brake lever pivot bushing.
5. Remove piston assembly, return spring, and washer (ilem14).
Inspection and Reassembly
1 . Always replace O-Ring seals, U-pack seals, and cover gasket.
2. Apply clean brake fluid onto piston, piston seals and cylinder bore.
3. Install U-pack seal with lip towards bore, and O-Ring seal.
4. Install spring seat washer (item 14) into cylinder.
5. Place spring into piston end and install piston assembly. CAUTION: Use care not to damage the U-pack seal
when installing into the cylinder.
6. Rei nstall brake lever with bushing, bolt and nut.
7. Prior to installing the master cylinder, it is possible to bench bleed by attaChing a short, flexible hose to the
outlet fitting and back into the reservoir. Fill the reservoir and slowly squeeze and release the lever until air
bubbles no longer appear.
B. Reinstall master cylinder onto handlebar and reconnect
brake line.
9. Adjust master cylinder to a level position centered on the
handlebar and tighten the set screw. NOTE: The set
screw should be adj usted to allow the cyl inder to rotate on
the handlebar if it should ever be hit hard.
10. After final bleeding, make sure fluid level is l IB" (.3 cm)
below the top of the reservoir.
11. Field test machine, checking for proper braking action
and lever reserve. Lever reserve should be no less than
1/2'" (1.3 cm) from the handlebar with the lever fi rmly
applied.
12. Recheck unit for any possible fluid leaks.
8.9
No Closer Than
1/2"" (1.3 em)
lever Travel
RIDE RED
8/94
1. Cover Screw
,--------------------------,
2. Cover
y----- ,
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
, o. Park Lever Pivot Bolt
,1. Park Lever Pivot Bushing ,9 L-.
'2.
Spring Seat Washer
'3.
Compression Spring
'4.
U-Pack Seal
'5.
Piston
'6.
O-Ring Seal
'7.
Clamp Boll
Optional
, 8.
Attaching Clamp
at customer
'9.
Lever Pivot Bolt
request
20. Baffle
21. Baffle Washer
Park Brake Lever Lock
WARNING: Release park brake lock before driving
or brake system failure or fire may result. Apply brake
lever to release.
Type 2 - Removal
1. Position clean shop cloths to catch spilled fluid
and remove brake hose. CAUTION: Brake fluid
will damage finished surfaces. Do not allow brake
fluid to come in contact with finished surfaces.
2. Remove brake clamp attaching bolts (ll em 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 special service tool PN 2870962, position
push rod through small hole in spring seat washer
(Item 12) as shown. Remove piston assembly,
spring and washer.
Type 2 - Inspections
NOTE: Due to the critical nature of these parts and
procedures, be sure you have thoroughly read and
understand Hydraulic Brake Operation, page 8.8.
1 . Thoroughly clean aU brake parts with hot soapy
water. Rinse with isopropyl alcohol. Inspect
piston for wear or scratches and replace if any are
noticed. Check master cylinder bore for
scratches or score marks and replace if any are
noticed.
CAUTION: Whenever inspection reveals worn,
damaged or defective parts, replacement is
necessary in order to avoid serious damage to the
machine or injury to the operator.
8194
5
6
7
9
"=1 10
8.10
17
4
' 8
/'2
'3
.,,- ,4
,
/'6
8 0
,--

--------
nsf ... f........:
OM FIRE ....

"""" 1.1,,"

RIDE RED
Reassembly
1. Always replace O-Ring seal, U-pack seal, and cover
gasket.
2. Apply clean brake fluid onto piston, piston seals and
cylinder bore.
3. Install seals onto piston with the U-pack lip towards the
bore.
4. Insert piston assembly into special 1001 PN 2870962.
5. Position special 1001 as shown. This tool is used to
guide the lip seal into the cylinder bore without damage.
6. Install spring seal washer into bore and place spring
into piston.
7. Install piston (tool installed) into bore.
S. On models with dust seal, install this seal using special
tool PN 2870962. NOTE: Use stepped end of tool for
piston installation and opposite end for dust seal
installation.
9. Reinstall brake lever with bushing boll and nut.
10. Prior to installing the master cylinder, it is possible 10
bench bleed by attaching a short, flexible hose to the
outlet fitting and back into the reservoir. Fill the
reservoir and slowly squeeze and release the lever until
air bubbles no longer appear.
11. Reinstall master cylinder onlo handlebar and reconnect
brake line.
12. Adiust master cylinder 10 a level position centered on
the handlebar and l ighlen Ihe set screw. NOTE: The
set screw should be adjusted to allow the cylinder to
rotate on the handlebar if it should ever be hit hard.
13. After final bleeding, make sure fluid level is 1/4" (.6 cm)
below the top of Ihe reservoir.
14. Field test machine, checki ng for proper braking action
and lever reserve. Lever reserve should be no less than
1/2" (1.3 cm) from the handlebar with the lever firmly
applied.
15. Recheck unit for any possible fluid leaks.
8.11
No Closer Than
112- (1.3 em)
Lever Travel
RIDE RED
8/94
Type H1 Brake Caliper Removal and Inspection
1. Remove hydraulic line. Be prepared to catch fluid in a
shop cloth. Do not allow fluid to come in contact with
painted surfaces.
2. Remove two bolls (A) holding caliper halves together
and four bracket mounting screws (8).
3. Remove friction pads, noting difference between
stationary side and piston side pads. NOTE: When
replacing friction pads only, it is important to make
room for new pads. The piston must be pushed back
into the slave cylinder bore. Apply Loctlle to the two
friction pad attaching screws when reinstalling.
4. Remove piston by using compressed ai r at the inlet
fitting. CAUTION: Wear eye protection to avoid
getting brake fluid in eyes. Cover assembly as shown.
5. Inspect cylinder and piston for scoring. Evidence of
severe scoring in the caliper bore will mean replacing
the housing and piston to obtain a proper piston seal.
8194
8.12
RIDE RED
Type H1 Brake Caliper Repair and Assembly
6. Dip piston assembly and O-Ring seal in brake fluid.
Assemble seal to piston.
7. Press piston into caliper bore, keeping it square to
avoid scoring the bore. Push it firmly all the way in.
B. Reassemble unit by reversing disassembly
procedures. Be sure all components are clean and
serviceable before reassembling.
9. Apply Leetite (PN 2870326) on the two caliper carrier
bolts and four bracket attaching cap screws.
10. Purge system of alilrapped air.
'1 . Inspect system for leaks.
12. Check caliper unit mount for free floating action.
Caliper must float freely from end to end on carrier
bolls.
8.13
I
8194
AIDE RED
..,
Type H2 Brake Caliper Removal and Repair
1. Remove hydraulic line. Be prepared to catch fluid in a
shop cloth. Do not allow fluid to come in contact with
painted surfaces.
2. Remove spring clips holding pad retaining pins.
3. Remove two bridge bolts (A) holding caliper halves
together and four bracket mounting screws (B).
Replacing Friction Pads
The pad is attached to a pad holder and is replaced as a set.
1. To make room for new pads. the piston must be pushed
back into the caliper bore. loosen bleeder screw and
work piston back into bore.
2. Take out pad retaining pins and remove worn friction
pads.
3. Install new pad holders. Brake pads should be
replaced only as a set.
4. With unit reassembled, apply brakes lighlly several
times to seat the new pads against the disc.
1 . Piston Casting
2. Carrier Casting
3. Piston Seat
4. Piston
5. Pad Assembly (2)
6. Seal Insert (2)
7. Brass Adaptor
B. Stop Ught Switch
9. Spring Clip (2)
10. Pad Retainer Pin (2)
11. Bleeder Screw
12. Bridge Bolt (2)
13. Spacer Bushing (4)
14. Nut (2)
15. Bracket
16. Male Adaptor
17. Ferrule Fitting
1B. Female Connector
8194
8.14
RIDE RED
BRAKES I fiNAL DRIVE
Type H2 Brake Caliper Removal and Repair
Disassembly
Refer to the exploded view while performing steps below. Numbers in parenthesis correspond to callauts on ex-
ploded view. NOTE: Do not disassemble and further than necessary to make repai rs.
CAUTION: Protect eyes from fluid.
1. Disconnect hydraulic lines.
2. Disassemble on a clean bench.
3. Open bleed screw (11) and drain brake fl uid from caliper assembly.
4. Remove spring clips (9) holding pad relainer pins (10) and remove pins.
5. Remove two bridge bolts (12).
6. Separate castings (1) and (2).
7. Place caliper with piston down and remove piston (4) from piston casting (1) by applying compressed air to the
hydraulic inlet port. CAUTION: Do not apply too much air pressure as damage may result to the piston or
piston bore.
8. Using a small wooden or plastic stick, work out piston seat (3) from its groove in the piston bore. Discard old
seal. CAUTION: To avoid scratching piston or burring edge of seal groove, do not use a metal tool such as a
screwdriver when removing seal.
Cleaning and Inspecting
Check all parts for wear or damage and replace as necessary.
1. Clean all parts with denatured alcohol and wipe dry with a clean, linHree cloth.
2. Using an air hose, blowout the drilled passages and bores.
3. Inspect casting cylinder bore for scoring, pitting, orcorrosion. A corroded or deeply scored casting should be
replaced; light scores and stains may be removed.
4. Polish any discolored or stained area with 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 or abrasive cloth. Black stains on the bore walls are caused by the piston seals and are not harmfuL
5. Check piston tosee ifit is pitted, scored, or worn. If so, discard and replace the piston. Do not attempt to polish
or sand piston.
6. Clean piston with denatured alcohol and wipe dry with a clean, lint-free cloth. Blow dry with compressed air.
7. Check inlet and bleeder hole threads for damage.
8. Inspect seat inset (6) for damage and replace if necessary.
8.15
8/94
RIDE RED

Type H2 Brake Caliper Assembly
1. Piston Casting
2. Carrier Casting
3. Piston Seal
4. Piston
13
1
t
15
. ~

5. Pad Assembly (2)
6. Seal Insert (2)
7. Brass Adaptor
8. Stop Ugh! Switch
9. Spring Clip (2)
12
}
,
/
/
.'
10. Pad Retainer Pin (2)
11. Bleeder Screw
12. Bridge Bolt (2)
14. Nut (2)
15. Bracket
16. Male Adaptor
17. Ferrule Fitting
18. Female Connector
1. Reassemble unit by reversing disassembly procedures. Be sure all components are clean and serviceable
before reassembling.
2. Dip a new piston seal (3) into clean brake fluid and place in groove in cylinder bore. Seal should be positioned
at one point in groove and then genlly worked around groove by hand until properl y seated. Never use an old
seal.
3. Coat piston thoroughly with brake fluid and carefully work piston ~ o w n the bore until bottomed. CAUTION:
Apply even force to avoid cocking piston in bore.
4. Examine pads for wear or damage. If pads are worn to tess than half the original thickness, install new pad
holder assemblies, If pads are not worn or damaged they may be reused. Be sure to reinstall pads in their
original positions. If pads are replaced, they must be replaced in sets.
5. Replace pad retainer pin (10) and spring clips (9).
6. Make sure nuts and bolts are clean and dry. Apply Loctite (PN 2870326) to the two cali per carrier bolts and
four bracket attaching cap screws. Torque caliper carrier bolts to 30 ft. Ibs. (4.14 kglm) . Torque caliper
attaching bracket cap screws to 8 ft. Ibs. (1.10 kg/m).
7. Purge system of all trapped air.
8. InsPe0 system for leaks.
9. Check caliper unit mount for free floating action.
8194
8.16
RIDE RED
Cover Screw
Cover
Cover Gasket
Cylinder Housing
Brake Lever Bushing
Brake Lever
Park l ever Return Spring
Pivot Bolt Nut
Park Lever
Park Lever Pivot Bolt
Park Lever Pivot Bushing
Spring Seat Washer
Compression Spring
U-Pack Seal
y------- 1 . /' 21
ov 17

/'2
19 L-.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Piston
O-Ring Seal
Clamp Bolt

7
Optional
Attachi ng Clamp
Lever Pivot Bolt
at customer 9 8._
Baffle
Baffle Washer
request 11 =i
....."w ......w.
--- ... "
1 0 :':;;'''
Park Brake Lever Lock
WARNING: Release park brake lock before driving
or brake system failure arfire may result. Apply brake
lever to release.
Type 3 - Removal
1. Position clean shop cloths to catch spilled fluid
and remove brake hose. CAUTION: Brake fluid
will damage finished surfaces. Do not allow brake
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 special service tool PN 2870962, position
push rod through small hole in spring seat washer
(Item 12) as shown. Remove piston assembly,
spring and washer.
Type 3 - Inspecti on
NOTE: Due to the critical nature of these parts and
procedures, be sLire you have thoroughly read and
understand Hydraulic Brake Operation, page 8.8.
1. Thoroughly clean all brake parts with hoI soapy
water. Rinse with isopropyl alcohol. Inspect
piston for wear or scratches and replace jf any are
noticed. Check master cylinder bore for
scratches or score marks and replace if any are
noticed.
8.17

RIDE RED
8194
Type 3 - Reassembly
,. Always replace O-Ring seal, U-pack seal and
cover gasket.
2. Apply clean brake fluid onto piston, piston seals
and cylinder bore. Install seals onto piston
positioning U-pack lip (Al towards spring. Snap
spring into place on piston.
3. Install piston assembly into special service tool
PN 2870962 until U-pack seal is covered by tool
as shown. NOTE: This tool is used to guide the
lip seal into the cylinder bore without damage.
4. Install spring seat washer into bore. Insert piston,
still installed in tool, into bore. Push piston
through special 1001. Remove tool.
5. Reinstall brake lever with bushing, bolt and nut.
6. It is possible to bench bleed master cylinder
before installing it on machine. Attach a short,
flexible hose from outlet fitting back into reservoir.
Fill reservoir. Slowly squeeze and release lever
until air bubbles no longer appear in reservoir.
7. Reinstall master cylinder onto handlebar and
reconnect brake line. Adjust master cylinder to a
level position centered on handlebar. Torque
clamp screws to 4555 in. Ibs.
8. Rebleed brake system. Check fluid level in
reservoir. The Type 3 Master Cylinder should be
1/4" . 5/16" (.6 . 8 em) below lip of reservoir
opening.
9. Field test machine before putting into service.
Check for proper braking action and lever
reserve. With lever firml y applied, lever reselVe
should be no less than 1/2" (1.3 em) from
handlebar.
10. Check brake system for any possible fluid leaks.
WARNING: Although snowmobile and ATV master
cylinder pistons are very simil ar, they are not
interchangeable. Piston (Al is a snowmobile piston.
Piston (8) is an ATV piston. Notice the difference on
the lever end of the piston. Using the wrong piston will
cause a build up of pressure in the brake system and
could result in a fire.
8194
, -
8.18 RIDE RED
Type H3 Brake Caliper Overhaul
H3 brake caliper overhaul is primarily the same as H2. However, this unit incorporates a coolant manifold for
insulating or cooling the caliper pi ston. Due to this design, pad replacement and caliper overhaul require slightly
different procedures. Listed below are those differences. Refer to Type H2 Brake Caliper Overhaul for other ser-
vice procedures, cleaning, inspection, etc.
Brake Pad Replacement
1. Remove master cylinder cover and gasket. Prepare to
catch spilled brake ftuid.
2. Force cali per piston inward (A).
3. Remove four caliper carrier bracket attaching bolts
(B) .
4. Loosen, butdo not remove, the two caliper carrier bolts
(C).
,
~ - - -
5. Remove brake pad pin spring clips and remove pines.
Note these pins hold the pads (A) and coolant manifold
(B).
6. Remove brake pads. On some units, area (C) on the
chaincase may require additional clearance.
7. Replace pads which are worn to more than 1/2 their
original thickness. New pad material thickness is
.190' (4.8 mm).
8. Reinstall pads, pins, and spring clips using the
following sequence. Install one brake pad pin through
forward end of caliper, brake cooler and inner brake
pad (piston side). Install outer brake pad, align forward
end and install pin and pin spring clip. Install rear pin
through caliper, cooler, inner and outer brake pad.
Install pin spring clip. Carefull y inspect pads and
coolant manifold to ensure proper pin installation and
positioning.
8.19
8/94
RIDE RED
The following procedure should be foll owed to ensure proper alignment between caliper and brake disc.
1. Install and fi nger lighten four caliper bracket attaching bolts (photo 1, B)
2. Pump up brake system. While holding a small amount of pressure in the system. evenly tighten the two
caliper carrier bridge bolls (photo 1, C). Torque bridge bolts to 30 ft.lbs. (4.14 kglm). NOTE: While lightening
these bol ts, the brake lever will move outward.
3. Again, pump up the brake system and evenly tighten and torque the four caliper carrier bracket attaching bolts
to 8 ft. Ibs. (I. t kg/mi.
4. With brake lever released, re-torque the four caliper bracket attaching bolls (photo 1, B) to 8 ft.lbs. (1. 1 kg/m)
and the bridge bolts (photo I, CI to 30 ft. Ibs. (4. 14 kg/mi.
5. To ensure proper positioning of the piston seal it is important to move the piston back into its bore at least 1/4"
(.6 cm). Then pump brakes and adjust master cylinder fluid level to 1/4'" (.6 cm) from the top of the cyl inder.
6. Test machine for proper braking performance.
Brake Caliper Removal
The piston side caliper casting can be removed and ser-
vice as outlined in the following procedure. However, if
the stationary side carri er casting should need service,
the chaincase will have to be removed.
1. Remove coolant recovery tank attaching bol t (A) , four
caliper bracket attaching bolts (B), and two cal iper
bridge bolts (C).
2. Note that the caliper halves are separated by two
steel spacers (A). As the bridge bolts are removed,
these spacers will fall out.
3. Remove brake pads.
4. Remove piston side cali per casting (A). Refer to H2
procedures for cleaning and inspection.
8194
8.20
RIDE RED
Brake Caliper Casting Reinstallation
1. Temporarily install a bridge bolt (A) as shown to align
the carrier bracket, stationary side casting, and two
spacers (8).
2. Position piston side caliper casting and install the
remaining bridge bolt as shown (A). NOTE: The
bridge bolt installed in step 1. is used to pilot bridge
bolt (A) through the spacers, casting and bracket.
Push bridge bolt (A) through while holding slight
tension on bolt (8).
3. Install the forward bridge bolt through bracket, piston
side casting, spacers, stationary casting, and bracket.
NOTE: It is extremely important that spacers (A) are
positioned properly.
4. Replace brake pads.
5. Reinstall coolant recovery tank and tank retaining bolt.
8.21
Bl94
RIDE RED

Type H4 Brake System Service
Maintenance
The routine maintenance procedures below are suggested as a means of keeping the brake system in good work
ing order.
1 . Clean any dirt from master cyl inder cover and remove cover.
2. Check fluid level in reservoir. Add new DOT 3 fl uid to within (.6 em) of the top of the reservoi r. Do not
overfill.
3. Make sure floating parts move freely and all other parts are mounted securely. Tighten hardware as required.
4. Inspect for hydraulic leaks and repair any found.
5. Inspect disc surface condition. If warped or badly pitted, replace.
6. Check to see if friction pads are worn to less than 1/32" (.08 em) thick. Replace if they are.
7. Check brake lever travel. Brake lever should not feel spongy. Replace pads. Bleed or add fluid as needed.
1. Carrier Bracket Attaching Bolts
2. Carrier Bracket
3. Piston
4. Piston Seal
5. Spring Clip
6. Stop Ught Switch
7. Brake Pads
8. Brake Line
9. Bleeder Screw
10. Caliper
11. Rope Guide
WARNING: The rider's safety de-
pends on correct installation. Fol-
low the procedures carefully.
1. Clean any dirt from mount bracket and bolts.
10
"
9
5
8 ",...::......::......,
4
\ V'\ Figure 1
. ,' 6 5
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.
4. Slide brake assembly out of bracket. Discard old pads and clips. NOTE: Pad and holders must be replaced
as a pair.
5. Clean dirt from end of piston and nearby area with a clean shop cloth.
CAUTION: Protect eyes from brake fluid.
6. Remove reservoir cover. Using a hardwood dowel or the flat of a large screwdriver, work piston back into bore
by carefully prying between parts.
8/94
8.22
RIDE RED
2. Carrier Bracket
3. Piston
4. Piston Seal
5. Spring Clip
6. Stop Ught Switch
7. Brake Pads
8. Brake Line
9. Bleeder Screw
10. Caliper
1 t. Rope Guide
NOTE: Pushing the piston back
into the bore will cause the fluid
level to rise in the reservoir and
possible to overflow. Remove
this excess fluid and discard.
10
t
11
9
I
5
8
Figure 1
1. Place new pads with friction material facing each other into housing. Hole in place using clips. See illustration.
2. Slide brake assembly into bracket until both clips snap into grooves in bracket.
3. Clean top of chaincase where brake mounts.
4. Separate pads for installation over disc. If brake assembly does not slide easily over the disc with loose pads,
work piston back into bore by carefully prying between parts using a hardwood dowel or the flat of a large
screwdriver.
5. Place brake assembly over disc and push bracket into chaincase.
6. Replace 3/8 bolts, washers, and rope guide. Torque to 25-30 fl. Ibs. (3.45-4.14 kg/m).
7. Actuate brake several times to set brake pads to proper operating position.
8. Check for proper fluid level in master cyl i nder and replace cover.
9. Field test at low speeds before putting into regular service.
Disassembly
Refer to the exploded view whi le performing the following steps.
1 . Remove bracket bolts.
2. Disconnect hydraulic line.
4. Open bleed screw and drain operating fluid from caliper assembly. CAUTION: Protect eyes from fluid.
5. Slide brake assembly out of bracket and remove old pads and clips.
6. Place caliper on bench with piston down.
7. Place a shop cloth in front of the piston and remove piston from casting by applying compressed air to the
hydraulic inlet port. CAUTION: 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. CAUTION: To
avoid scratching bore or burring edge of seal groove, do not use a metal tool such as a screwdriver.
9. Discard old seal.
8.23
8/94
RIDE RED
,
,
Cl eaning 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, blowout 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 fi nger 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. Black stains on the piston are caused by the seal and do no harm.
4. Check piston to see if it is pitted, scored or worn. If so, discard and replace the piston. CAUTION: Do not
attempt to polish or sand piston.
5. Clean piston with denatured alcohol and wipe dry with a clean, lint free cloth. Using compressed air, blow dry.
7. Inspect seat insert for damage and replace if necessary.
Assembly
1. Reassemble by reversing disassembly process. Be sure all parts are clean and serviceable before
reassembli ng the unit.
2. Coat a new piston seal in clean DOT 3 brake fluid and place in groove in the cylinder bore. Seal should be
positioned at one point in groove and then gently worked around the groove by hand until properly seated.
CAUTION: Never reuse an old seal.
3. Coat piston thoroughly with brake fluid and work down into bore by hand carefully until bottomed. CAUTION:
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 cm) install new pad holder
assemblies. If pads are not worn or damaged, they may be reused. Be sure pads are reinstalled in their
original positions. If pads are replaced, replace in sets and make sure the new pads have the same friction
material type code number as the old set.
5. Connect hose or line to caliper.
6. Place new pads with friction material facing each other into housing. Hold in place using clips.
8. Separate pads for installation over disc.
10. Replace 3/8" bolts, rope guide, and washers. Torque to 25-30 ft. Ibs. (3.45-4.14 kglm).
11 . Actuate brake several times to set brake pads to proper operating position.
12. Make sure master cylinder reservoir brake fl uid level is 1/4" (.6 cm) from the top of the reservoir.
Bleeding
Each hydraulic brake is fitted with a bleeder valve. This is a special valve which seals when turned in tight, but
which allows air or fluid to pass out through a hole in the valve nipple when the valve is loosened one turn.
1. Clean any dirt from master cylinder cover and remove cover.
2. Attach a flexible tube to nipple of bleeder screw on caliper.
3. Place other end of flexible tube into a jar containing a small amount of clean brake fluid. See that end of tube is
below fluid surface to prevent air from getting back into the system.
4. Loosen bleeder screw.
5. Slowly operate brake and check for air bubbles rising in fluid, indicating air is being forced out of the system.
6. Tighten bleeder screw as master cylinder is being depressed and reaching end of stroke.
7. Repeat steps 4 through 6 un!il air bubbles stop. adding new fl uid to reservoi r as needed.
8. Add new DOT 3 brake fluid to reservoir to bring level back up to within 1/4" (.6 cm) of top. Replace diaphragm
and cap.
9. Re-check system for proper operation and for leaks.
10. Discard fluid in jar. This fluid contains air and should not be reused.
11. WARNING: Upon completion of brake service, test vehicle at low speeds before putti ng vehicle in regular
service.
A thoroug0)lrake check should be made every ten days under normal conditions. This check should be made
more often as the pads wear down. Under hard usage, check the fluid level often. As the brake pads wear, fluid
fills the area behind the piston, lowering the fluid level in the reservoi r.
8194 8.24
RIDE RED
Maintenance
The routine maintenance procedures below are suggested as a means of keeping the brake system in good work
ing order.
2. Check fluid level in reservoir. Add new DOT 3 fluid to within 1/4'" (.6 em) of the top of the reservoir. Do not
overfill.
3. Make sure floating parts move freely and all other parts are mounted securely. Tighten hardware as required.
4. Inspect for hydraulic leaks and repair any found.
5. Inspect disc surface condition. If warped or badly pitted, replace.
6. Check to see if friction pads are worn to less than 1/32" (.08 em) thick. Replace if they are.
7. Check brake lever travel. Brake lever should not feel spongy. Replace pads. Bleed or add fluid as needed.
8. Check cooler hose connections for leaks and replace hoses as required.
2. Carrier Bracket
3. Piston
4. Piston Seal
5. Spring Clip
6. Stop Light Switch
7. Brake Pads
8. Brake line
9. Bleeder Screw
10. Caliper (Liquid Cooled)
11. Rope Guide
12. Water Cooler Manifold
13. Screws (Cooler Manifold)
WARNING: The rider's safety de-
pends on correct installation. Fol-
low the procedures carefully.
,. Clean any dirt from mount bracket and bolts.
13
2. With a 9/16 socket , remove two 3/8 hex bolts and washers from bracket. Remove rope guide. NOTE: Donat
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. lift bracket and brake assembly off vehicle. Raise open end of cooler and pad assembly to trap antifreeze in
cooler.
5. Slide brake assembly out of bracket. Discard old pads and clips. NOTE: Pad and spring clip must be
replaced as a pair.
6. Clean dirt from end of piston and nearby area with a clean ShOp cloth.
CAUTION: Protect eyes from brake fluid.
7. Remove reservoir cover. Using a hardwood dowel or the flat of a large screwdriver, work piston back into bore
by carefully prying between parts.
8.25
RIDE RED
8194
2. Carrier Bracket
3. Piston
4. Piston Seal
5. Spring Clip
6. SlOp Light Switch
7. Brake Pads
8. Brake Line
9. Bleeder Screw
10. Caliper (Liquid Cooled)
, 1. Rope Guide
12. Water Cooler Manifold
13. Screws (Cooler Manifold)
NOTE: Pushing the piston back
into the bore will cause the fluid
level to rise in the reservoir and
possible to overfl ow. Remove
this excess fluid and discard.
13
11
12
Z'l--- 2
8
10
7
1. Place new pads with friction material facing each Qtherinto housing. Hold in place using cl ips. See illustration.
3. Clean top of chaincase where brake mounts.
4. Separate pads for installation over disc. If brake assembly does not slide easi ly over the disc with loose pads,
work piston back into bore by carefully prying between parts using a hardwood dowel or the flat of a large
screwdriver.
5. Install coolant hose and clamp on cooler assembly.
7. Replace 3/8 bolls, washers, and rope guide. Torque to 25-30 ft.lbs. (3.45-4. 14 kg/m).
9. Check for proper fluid level in master cylinder and replace cover.
10. Be sure to bleed coolant system by opening cap lever and runni ng unit until all air in system has been
displaced. Fill reservoir and close cap lever.
11. Field test at low speeds before putting into regular service.
Disassembly (For Caliper or Piston Replacement)
Refer to the exploded view while performing the following steps.
1 . Remove bracket bolts.
2. Disconnect hydraulic line.
3. Disconnect and plug coolant lines, catching and disposing of antifreeze properl y.
5. Open bleed screw and drain operati ng fluid from caliper assembly. CAUTION: Protect eyes from fluid.
6. Slide brake assembly out of bracket and remove old pads and clips.
7. Place cal iper on bench with piston down.
8. Place a shop cloth in front of the piston and remove piston from casting by applyi ng compressed air to the
hydraulic inlet port. CAUTION: Use onl y 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. CAUTION: To
avoid scratching bore or burring edge of seal groove, do not use a metal tool such as a screwdriver.
10. Discard old seal.
8194
8.26
RIDE RED
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, blowout 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 cfoth only. Use finger pressure
and rolate 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. Black stains on the piston are caused by the seal and do no harm.
4. Check piston to see jf it is pitted, scored or worn. If so, discard and replace the piston. CAUTION: Do not
attempt to polish or sand piston.
5. Clean piston with denatured alcohol and wipe dry with a clean, lint free cloth. Using compressed air, blow dry.
7. Inspect seat insert for damage and replace if necessary.
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 cylinder bore. Seal should be
positioned at one point in groove and then gently worked around the groove by hand until properly seated.
CAUTION: Never reuse an old seal.
3. Coat piston thoroughly with brake fl uid and work down into bore by hand carefully until bottomed. CAUTION:
Apply even pressure to avoid cocking the piston in the bore.
4. Examine pads for wear or damage. If pad thicknes's is less than 1/32" (.OB cm) install new pad holder
assemblies. If pads are not worn or damaged, they may be reused. Be sure pads are reinstalled in their
original positions. If pads are replaced, replace in sets and make sure the new pads have the same friction
material type code number as the old set.
5. Connect hose or line to caliper.
6. Place new pads with friction material facing each other into housing. Hold in place using clips.
B. Separate pads for installation over disc.
10. Install coolant lines and hose clamps and tighten securely.
11. Replace 3 / B ~ bolts, rope guide, and washers. Torque to 25-30 ft. Ibs. (3.45-4.14 kgJm).
13. Make sure master cylinder reservoir brake fluid level is 1/4" (.6 cm) from the top of the reservoir.
Bl eeding
Each hydraulic brake is fitted with a bleeder valve. This is a special valve which seals when turned in tight , but
which allows ai r or fluid to pass out through a hole in the valve nipple when the valve is loosened one turn.
2. Attach a flexible tube to nipple of bleeder screw on caliper.
3. Place other end of flexible tube into ajar containing a small amount of clean brake fluid. See that end of tube is
below fluid surface to prevent air from getting back into the system.
4. Loosen bleeder screw.
5. Slowly operate brake and check for air bubbles rising in fluid, indicating air is being forced out of the system.
6. Tighten bleeder screw as master cylinder is being depressed and reaching end of stroke.
7. Repeat steps 4 through 6 until air bubbles stop, adding new fluid to reservoir as needed.
8. Add new DOT 3 brake fluid to reservoir to bring level back up to within 1/4" (.6 cm) of top. Replace diaphragm
and cap.
9. Re-check system for proper operation and for leaks.
10. Discard fluid in jar. This fluid contains air and should not be reused.
11. Be sure to bleed coolant system by opening cap lever and running unit until aJi air in system has been
displaced. Fill reservoir and close cap lever.
12. WARNING: Upon completion of brake service, test vehicle at low speeds before putting vehicle in regular
service.
A thorough brake check should be made every ten days under normal conditions. This check should be made
more often as the pads wear down. Under hard usage, check the fluid level often. As the brake pads wear, fluid
fills the area behind the piston, lowering the fluid level in the reservoir.
8.27
RIDE RED
8194
Bleeding Procedures for Polaris Brake Systems
The Polaris hydraulic brake mechanism consists of the following components or assemblies: handlebar mounted
master cylinder, hydraulically operated plunger assembly (slave cyli nder) integrally mounted in chaincase rear
cover, adjustable brake pad, and self-aligning brake disc mounted in chaincase.
The maslercylindercontains a fluid reservoir and a cylindrical pressure chamber. Force applied to the brake lever
is transmitted to the fluid, which actuates the plunger assembly in the chaincase rear cover. A coil spring located in
the master cylinder holds the piston assembly against the actuating force afthe brake lever. The piston assembly
consists of a piston, U-seal and rubber O-Ring.
SERVICE
Air in the hydraulic system will cause a springy or spongy
action of the brake lever. Follow directions below for
bleeding.
1. Fill master cylinder reservoir to recommended level
with DOT 3 brake fluid PN 2870990: Type 1 Master
Cylinder 1/8" (.3 cm) below lip of reservoir opening;
Type 2 Master Cylinder 1/4" (.6 cm) below lip of
reservoir opening; Type 3 Master Cylinder 1/4"- 5/16"
(.6 - .8 cm) below lip of reservoir opening.
2. Slip a flexible rubber tube over ball of bleeder valve and
direct fluid away from painted areas. CAUTION: Brake
fluid will damage finished surfaces. Do not allow brake
3. Slowly squeeze brake lever a full stroke and hold.
Unscrew bleeder valve 3/4 turn to release air. Close
bleeder valve. Release brake lever. Repeat this
procedure until fluid flows from bleeder valve in a solid
stream. free of air. Re-check fluid level in reservoir.
8/94
8.28
RIDE RED
Type M1 Brake Overhaul and Pad Replacement
22
19
21
19
16 ~ - .
3 .'
u ~ " , / " 1 0 11
,\
4 5
, 7 8
6 9
1 . Adjuster Bolt and Stop
2. Jam Nul
3. Jam Nut Locking Tab
4. Actuating Lever
5. Helix Shaft
6. Brake Pad Retainer
7. Caliper Casting
8. Moveable Brake Pad
9. Brake Disc
10. Carriage Bolt
11 . Stationary Pad Assembly
1. Open adjuster bolt jam nut locking tab (A) .
2. Loosen jam nut and remove adjuster bolt (8).
3. Remove actuating lever (C) and return spring.
4. Remove two brake caliper attaching nuls (0).
5. Remove cable bracket and caliper assembly. Check
cable condition al both ends. Frayed or binding brake
cables must be replaced.
8.29
12
12. Front Drive Shaft
13. Drive Shaft Bearing Flangene
14. Brake Disc Key
15. Front Drive Sprocket
16. Nut, 5/16"
17. Caliper Attaching Boll (2)
18. Return Spring
19. Cable Sleeve Jam Nul (2)
20. Caliper Attaching Nut (2)
21. Brake Cable Bracket
22. Brake Cable
RIDERED
15
14
8/94
Type M1 Brake Overhaul and Pad Replacement
6. Slide brake disc off front drive shaft. Check disc
condition and mounting. Replace if necessary.
7. Clean drive shaft in brake disc area. Lightly
lubricate with anti-seize.
e. Remove carriage bolt (Al. Remove pad assembly
and replace with new assembly.
9. Install brake disc. The disc must float or slide
freely on the front drive shaft.
10. Replace moveable pad assembly and install
caliper onto attaching bolls.
11. Install brake cable bracket and torque attaching
nuts to 30 ft. Ibs. (4.14 kg/m).
12. Loosen cable sleeve jam nuts and adjust brake
cable sleeve to its shortest position.
CAUTION: The following slep is critical for proper
positioning of the actuating arm to the caliper helix
shaft.
13. With brake lever bottomed on handlebar, and helix
shaft (A) bottomed in caliper, install actuating arm,
jam nut locking tab, jam nut, and adjuster bolt.
14. Insert a .015" feeler gauge between the brake disc
and moveable brake pad. Release brake lever.
Install return spring and finger tighten bolt. Set
adjuster bolt jam nut , bend locking tab, and
remove feeler gauge.
15. Field test unit for proper braking action.
8194
8.30
RIDE RED

1. Brake Cable
2. Cable Sleeve Jam Nut (2)
3. Bridge Boll (2)
4. Brake Cable Bracket
6. Carrier Bracket
7. Nul (2)
8. Brake Pad (2)
9. Caliper Casting
10. Return Spring
11 . Nut
12. Cable Clevis
13. Clevis Bolt
14. Adjuster Bolt
8.31
Type M2 Exploded View
J
'5. Adjuster Bolt Stop
16. Jam Nul
17. Jam Nut Locking Tab
18. Bushing
19. Actuating Lever
20. Helix Shaft
21. Pad Backing Plate
22. Caliper Casting
23. Bracket Cap Screw (4)
24. Lock Washer (4)
25. Snap Ring (2)
26. Brake Disc
27. Key
28. Jackshaft

8194
RICERED
Type M3 Exploded View
1 . Cable, Brake
2. Bracket, Brake
3. Washer
4. Washer, Spring Lock
5. Bon
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. 8011
17. Clevis, LT
18. Boll
19. Retaining Ring
20. Brake Disc
21. Seat
22. Jackshaft
23. D-Ring
Adjusting Procedure
1. Open adjuster bolt jam nut locking tab (A).
Loosen jam nUl and remove adjuster bolt (8).
2. Remove actuating lever (e) and return spring.
3. Remove top mount bracket and brake assembly
mounting bolts (Item 5). Remove washers (I tems
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 jf necessary.
5. Inspect rotor disc and replace jf necessary.
NOTE: Reassembly is made easier by clipping
moveable brake pad into position under holder clip.
Stationary pad can be held in place by use of a rubber
band while placi ng assembly over rotor disc and
mounting to chaincase.
8/94
6. Install alignment spacers (Item 9), washers
(Items 3 and 4) and bolts (Item 5) . Torque
assembly to 25-30 ft. Ibs.
7. Loosen cable sleeve jam nuts and adjust brake
cable sleeve to its shortest position.
WARNING: The following step is critical for proper
positioning of the actuating arm to the caliper helix
shaft. Improper positioning will result in minimal
resistance and ineffective brakes.
8. With brake lever bottomed on handlebar and helix
shaft (D) bottomed in caliper, install actuating
arm, jam nut locking tab, jam nut and adjuster
boll.
9. Insert a .015" (.04 cm) feeler gauge between
brake disc and moveable brake pad. Release
brake lever. Install return spring and finger tighlen
bolt. Set adjuster bolt jam nut, bend locking lab
and remove feeler gauge.
10. Field test machine for proper braking action
before putting into service.
8.32
RICEREC

1. 1 .

1. 1 .
I.
I;
I. Iii
Jackshaft Speed VS MPH Chart
la I.
Iii I; III
I; .
I.
10 1# . I; I,
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llli. Ii 12 . I. I.
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.
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;
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8.33
AICERED
8194
..
Type 1 Drive System Overhaul
1. Remove drive belt, driven clutch and driven
clutch spacer washers.
2. Open adjuster bolt jam nut locking tab (A).
Loosen jam nul and remove adjuster boll (8).
3. Remove actuating lever (C) and return spring.
4. Remove two brake caliper attaching nuls (D).
5. Remove cable bracket and caliper assembly.
Check cable condition al both ends. Frayed or
binding brake cables must be replaced.
6. Slide brake disc off front drive shaft and remove
half moon key.
7. Remove four suspension mounting bolts and
suspension. Note placement of two rear torque
arm idler wheel thrust spacers for reassembly.
8. Loosen lock collar Allen head set screw. With a
punch and hammer, loosen bearing lock collar
located on brake end of drive shaft.
9. Remove three flangette attaching bolts (A).
NOTE: The longest of these bolts attaches the
stationary brake pad.
10. Slide drive shaft toward brake side of chassis
untit driven clutch end is free. Ti lt shaft and
remove it from brake end bearing.
11. Remove track.
8194
8.34
RIDE RED
12. Before reassembly check drive shaft, drive shaft
sprocket, and drive shaft bearings. Replace if
necessary.
13. Reverse disassembly procedures to reassemble.
Sprocket or drive shaft centering is controlled by
the hex portion of drive shaft (A) being bottomed
on driven clutch side bearing (B). NOTE: Driven
clutch must be installed and torqued before lock
collar is tightened.
14. Refer to brake adjustment procedures in this
chapter.
8.35
8194
RIDE RED
- - - - - ~ , -
Disassembly
1 . Remove hood.
2. Remove ai r silencer and exhaust system. NOTE:
Exhaust silencer and expansion chamber can be
removed as a unit.
3. Remove drive belt and driven clutch, noting
position of clutch offset washers.
4. Loosen jackshaft beari ng locking collar and slide it
away from bearing.
5. Remove three flangette attaching nuts and
washers located on left side of front drive shaft.
6. If unit is equipped with a battery, remove the
battery.
7. Drain or siphon fuel tank.
S. Remove four suspension mounting bolts.
9. Place a protective mat on the floor and tip the
machine on its left side.
10. Remove suspension.
11 . Loosen fronl drive shaft locking collar set screw.
Rolale bearing lock collar and slide it away from
bearing.
12. Remove four caliper attaching bracket capscrews
(A) and three chaincase cover bolts (8).
8194
8.36
RIDERED
13. Loosen chain adjuster bolt jam nut and remove
adjuster.
14. Remove chain, and top and bottom gears. Note
position of gear spacer and shims for proper gear
alignment upon
15. Remove three chaincase attaching nuts and
carriage bolts (A).
16. Install a 5/16 x bolt into the jackshaft and
drive the shaft out through the upper case
bearing.
17. Remove front drive shaft and track.
18. Remove stop light switch wires and lift brake
caliper assembly from brake disc. CAUTION:
Do not squeeze brake lever with caliper
removed.
19. Remove three flangette attaching bolts from left
side of jackshaft. NOTE: The bottom flangette is
accessible from the underside of the tunnel as
shown in the photo at right.
20. Remove jackshaft.
8_37
8194
RIDE RED
Inspection
21. Inspect jackshaft bearing in support area as
shown. If any wear is noted, the shaft must be
replaced.
22. Remove brake disc and inspect brake disc key
and keyways. If the key or keyways show signs of
wear, the brake disc and jackshaft should be
replaced. If the brake disc is glazed, it should also
be replaced.
23. Lubricate jackshaft between snap rings with
anti-seize and reinstall brake disc.
Reassembly
Be sure aU parts are clean and serviceable before pro-
ceeding with reassembly. It is important thai the fol-
lowing reassembly steps be performed in sequence
to prevent misalignment and possible component fail-
ures.
1. Remove and replace upper and lower chaincase
bearings.
2. Replace chaincase cover gasket. Use a small
amount of silicone sealer at the ends of the cover
gasket.
3. Install jackshaft as shown and place caliper
assembly onto brake disc.
4. Place chaincase into position on bulkhead and
onto jackshaft. Do not bolt chaincase to bulkhead
at this time.
5. Install jackshaft alignment tool with bolt and
washer as shown. Tighten alignment tool bolt
until jackshaft is seated into upper chaincase
bearing.
8194
8.38
RIDE RED
6. Install and tighten three chaincase attaching
carriage bolts and locking nuts.
7. Apply Loctite to four caliper attaching bracket
capscrews and finger tighten into carrier bracket.
With brake applied, torque capscrews (A) to 8 ft.
Ibs. (1.1 kg/m).
8. Reinstall slop light switch wires.
9. Install a flangette into left bearing support hole.
10. With alignment 1001 torqued to 6 ft. Ibs. (.83 kg/m),
the shaft should be cenlered as shown. If not, the
chaincase will have to be shimmed between the
bulkhead and case. Using Shim Kit PN 2200126,
install shims as needed to position shaft on
center.
11. Install track and front drive shaft assembly.
12. Remove jackshaft alignment tool and install top
and bottom gear shims, chain and gears.
13. Tighten gear retainer bolts. Check gear
alignment and chain tension.
14. Install bearing assembly onto left side drive shaft
and tighten three carriage bolts.
15. Lightly rotate bearing locking collars on jackshaft
and drive shaft. Tighten Allen head set screws.
8.39
RIDE RED
8/94
16. Add three ounces of Polaris chaincase oil into
the chaincase and reinstall chaincase cover.
NOTE: One full stroke on the pump equals one
ounce of oil. Polaris highly recommends the use
of this oil for extended gear and chin life.
17. Install cover and fill to check plug opening.
18. Reinstall suspension. Torque suspension
mounting bolts to 35-40 ft. lbs. (4.83-5.52 kg/mI.
19. Reinstall air silencer, exhaust system and driven
clutch. Check and adjust clutch offset. Refer to
Chapter 7 for correct offset specifications and
tool. CAUTION: If this step is not performed,
bearing side loading and clutch misalignment
during driven clutch bolt tightening may occur.
20. With driven clutch properly positioned, measure
distance between alignment spacer (A) and
outer edge of driven clutch hub (B). This
distance must be taken up by using washer(s)
PN 7555734 (e).
21. Reinstall clutch retaining bolt and torque to 12 ft.
Ibs. (1.66 kg/mI.
,.
ti2. Reinstall drive belt.
2 ~ . Reinstall hood and field test unit for proper front
drive operation.
8/94
8.40
RIDE RED
1. Remove hood, air silencer, exhaust system and
battery, if so equipped.
2. Turn fuel valve off.
3. Remove drive belt and driven clutch. Note
position of washers for controlling drive to driven
offset (Al and washers to control clutch free
floating (8).
4. Loosen jackshaft bearing lock collar set screw.
Loosen tack collar by rotating in opposite direction
of rotation.
5. Remove two upper flangette attaching bolts {Al.
6. Remove three bolts securing angle drive and
bearing flangettes.
7. Remove four suspension mounting bolts.
8. Place a protective mat on floor and tip machine
onto left side.
9. Remove rear suspension.
10. Position track as shown and remove third
jackshaft flangette attaching bolt (Al.
11. Loosen drive shaft lock collar set screw and rotate
tack collar.
8.41
8194
RIDE RED

12. Remove chaincase cover attaching bolts and
remove cover.
13. Remove castle nut cotter pin and castle nut.
14. Remove chain adjustment bolt and chain
tensioner assembly.
15. Remove bottom gear attaching bolt, chain and
sprockets.
16. Note position of top gear spacer (A) and gear
alignment washers (B). Remove spacer and
washers.
17. Remove four bolts securing caliper carrier
bracket to chaincase (A) .
18. Remove three chaincase to bulkhead attaching
nuts and bolts. NOTE: On some machines it
may be necessary to remove the rear exhaust
bracket (9) prior to lifting chaincase or removing
drive shat! assembly.
8194
8.42
RIDE RED
19. Remove chaincase and slide brake caliper
assembly (A) outward from brake disc as shown.
20. Remove oil tank aHaching bolt (A). On liquid
cooled models, remove coolant recovery tank
bolt (B).
21. Raise jacl<shaft assembly as shown.
22. Remove O-Ring, seal sleeve and brake disc by
tapping onjackshaft end with a soft face hammer
as shown.
23. Remove jackshaft and drive shaft.
24. Inspect drive shaft and jackshaft in bearing
contact area. If diameter is .001" (.025 mm) less
than non-contaci area, shafts should be
replaced.
25. Remove bearing retaining snap rings.
8.43
8194
RIDERED
.,
26. Pry out old seal.
27. Pressoutotd bearing from side shown. NOTE: If
bearing appears tight, use heat to expand
chaincase bore.
28. Apply Loctile 680 (PN 2870584) to outer race of
bearing and press into position.
29. Reinstall snap rings.
30. Press new seals in until outer edge is flush wi th
chai ncase shoulder.
31. Install drive shaft and jackshaft as shown with
new seal sleeves (A) and O-Rings. NOTE:
Recessed area on seal sleeve is posi ti oned
outward and O-Ring rests in this recess.
32. Grease seal sleeves and O-Rings.
33. Reinstall brake caliper onto brake disc and install
chaincase. NOTE: On some models, prior to
installing the drive shaft it will be necessary to
install the chaincase to bulkhead attaching bolts
(A).
34. Install jackshaft alignment tool (PN 2870399)
and secure with castle nut as shown.
8194
8.44
RIDE RED
35. Slide a bearing onto driven clutch end and check
shaft alignment to bulkhead opening (A).
36. If alignment is not correct. shims may be added
between any of the chaincase to bulkhead
attaching points. Use Shim Kit PN 2200126.
37. Reassemble by reversing disassembly
procedures.
38. Torque castle nut to 50 ft. Ibs. (6.9 kg/m).. If
cotter pin does not align, tighten nut until cotter
pin aligns.
39. Finger tighten four carrier bracket attaching
bolts.
40. Apply parking brake to align caliper to brake disc.
Torque bolts with brake applied. Rel ease brake
and retorque bolts to 8 ft. Ibs. (1.1 kg/m).
8.45
8/94
RIDE RED

Maximum sprocket and chain life are directly related to proper sprocket alignment and chain tension.
41. Before installing drive chain, place a straight
edge against upper and lower installed
sprockets. The edge should contact equally on

42. If misalignment is evi dent, the addition or
subtraction of washers (PN 7556509) behind the
bottom sprocket will be necessary.
43. To obtain correct chain tension, place a slight
reverse tension on the chain as indicated in the
illustration at right (A).
44. There should be approximately (.6-.95
em) deflection on the chain al point (8). Loosen
adjuster bolt locknut and turn adjuster bolt (C)
until correct chain deflection is obtained.
45. Lock adjuster boll locknut white holding a wrench
on the adjuster bolt.
46. Install chaincase cover and add Polaris
chaincase lubricant (PN 2870337) through cover
upper plug hole until lubricant trickles from check
plug hole.
47. Reinstall plugs.
8/94
@ @
8.46
RIDE RED

48. The illustration at right shows a cross section
view of the upper chaincase. Always replace
seals and O- Rings. Check seal sleeve for wear
and/or nicks. Replace if any are noticed.
49. Castle nut is torqued to 50 ft. tbs. (6.9 kg/m).
Cotter pi n must be installed and fixed so it will nol
hit chai ncase cover. NOTE: If cotter pi n does nol
align, tighten nut until alignment is achieved.
50. When install caliper assembly. tighten four
bracket attaching bolts (Al finger light.
51. Apply brakes and torque to B ft. Ibs. (1.1 kg/m).
Release brakes and retorque to 8 ft. Ibs. (1.1
kg/m). This procedure aHows better alignment of
brake cal iper to brake disc.
52. When reinstall drive shaft flangelles and
speedometer angle drive, always replace drive
key (Al and install a new gasket (8).
53. Check cable routing and lubricate with Polaris
clutch and cable lube PN 2870510.
54. Grease angle drive and bearing with Polaris low
temp grease.
55. When reinstalling jackshaft f1angelte and bearing
be sure to align bearing outer race hole (A) with
flangette hole (8). This will allow a more positive
grease entry into the bearing.
8.47
.,..,.
"."
w ......
c ..... "
CoIt..- Pin
RIDE RED
8/94
. .
56. lubricate top bearing using a needle point
adaptor and Polaris low temp grease.
57. Jackshaft and drive shaft locking coll ars are
tightened only after chaincase lOp and bot1om
gears have been torqued. Lightly rolate collars in
the same direction as the shaft rotates and
tighten set screw.
58. When driven clutch offset is properly adjusted,
the washers (A) PN 7555734 are used to adjust
for free 110alon driven. Without a slight free float,
the jacks haft bearings could be side loaded and
cause premature bearing failure.
59. If only the jacks haft needs service, loosen left
rear nosepan to foot rest mounting bolts and
slide shaft out left side without removing
chaincase.
60. For reassembly, use jackshaft installation tool
(A) PN 2870974. Grease tool and guide
jackshaft through brake disc hub, seal sleeve.
O-Ring and beari ng. NOTE: Jackshaft with tool
installed must slide freely. If not, reposition
O-Ring.
61. Field test machine and check for proper braking
action and drive train efficiency.
8194
8.48
RIDE RED
Jackshaft and Drive Shaft Disassembly
1. Remove rear suspension.
2. Clean, lubricate and inspect.
3. Loosen drive shaft tock collar set screw (Al and
rotate collar.
4. Remove clutch guard, drive belt, driven clutch.
driven clutch offset washers and air silencer.,
5. Remove jackshaft and drive shaft bearing
flangette attaching bolts.
6. Remove drive shaft and jackshaft.
7. Remove bearing from each shaft and inspect
bearing support area (Al. If this area shows any
sign of wear the shaft must be replaced.
8.49
AICERED
8194
Type 4 DrIVe System Overhaul
8. Check shafts at the splined coupling ends. If
excessive wear or play is noted here and inside
the coupling, the shafts and couplings should be
replaced. NOTE: If this wear is premature, it is
very important to check jackshaft alignment.
9. If the transmission is to be removed, refer to
transmission overhaul procedures at the end of
this chapter.
10. Move collar (A) tight against coupler and set.
/
11. Lubricate drive shaft coupling and shaft splines
with grease. NOTE: On 1992 to current models,
the coupler is greasable.
12. Install coupler with O-Rings, positioning coupler
shallow recessed end towards transmission.
13. Install drive shaft through bulkhead and onto
transmission output shaft.
8/94 8.50
...--.-.. -
T
A
RIDE RED
o
14. Lubricate flangette and outer race of bearing.
15. Install bearing lock coliar, inner flangette, new
bearing and outer flangette onto drive shaft.
16. Install speedometer drive key, angle drive and
attaching bolts, washers, and nuts. Tighten.
17. Tightly position bearing lock collar against
bearing inner race. Tighten Allen head set screw
while pulling up on drive shaft in direction shown.
8.51
8/94
RIDE RED
Jackshaft Alignment
18. Lubricate jackshaft coupling and splines with
multi-purpose automotive chassis grease.
19. Install jackshaft through bulkhead and onto
transmission input shaft.
20. Orbit shaft in bulkhead bearing support opening.
NOTE: There should be an equal distance
between shaft and bulkhead bearing support
during this orbit.
21. To correct any jackshaft misalignment, shim
transmission between bulkhead and transmission
(A). Use Shim Kit PN 2200126. See illustration at
right for possible shim locations.
22. Clean bearing support area with Loctile Primer T.
Install a stud and bearing mount on shaft in
bearing area.
23. Install new bearing. outer flangette and flangette
attaching bolts.
24. Install driven clutch and check driven clutch
offset.
25. Torque driven clutch bolt to 12 ft . lbs. (1.66 kg/m).
26. Rei nstall rear suspension, drive belt, air Silencer,
and clutch guard.
27. Field test for proper operation.
8/94
)
8.52
RIDE RED
Drive ShaH Sprocket Installation Tips
Refer to brake and drive data pages at the beginning of this chapter for specific distance from shaft end to sprocket
idler center.
Direct drive units are measure from
clutch end while all others are measure
from splined end of shaft.
Prior to pressing sprockets. clean
shafts with sandpaper to remove rust.
Replace shaft if nicked or damaged.
When pressing new sprocket onto
shaft, press in hub or center of sprock
et.
Sprockets must be started from the end
that has a smooth entry onto the hex
portion of the shaft (A) .
To ensure proper sprocket tooth align-
ment , be sure the vendor logos are ori-
ented in the same position on all
sprockets.
NOTE: Some direct drive sprockets require the recessed area on the sprocket idler be positioned towards the
driving side of the sprocket tooth.
B
A - -
r-r-J
'-0. <.<' j
S"":O \ 1h
VENOOA LOGO [-J I
Typical 2 Drive Sprocket
o

B --,
Ai
Typical 4 Drive Sprocket
,

-- 1
l
hl

1
8.53
RECESSED AREAS
Typical Direct Drive Shaft
E
o
C
B - -
i
rl
l.

-
U
lJ
- -
l
r. J
l:ll L W-.l
Typical 4 Drive with Center Idler
8194
RIDE RED
BRAKES / FINAL DRIVE
Drive Shaft Sprocket Installation Tips
Driveshaft Sprocketlnslallation Tips, 1993 to Current
8/94
1993 to current models, except Wide-
Traks, have a longer spline on the
chaincase end of the jackshaft and
drive shaft.
Drive shaft sprocket poSitions are mea-
sured to sprocket hub edge instead of
sprocket idler center.
1993 to Current 2 Drive Sprocket
8.54
D
C - ~ B d
1993 to Current 4 Drive Sprocket
AIDE RED
Series 300 Transmission Overhaul
Transmission overhaul should also include drive system overhaul. After removing drive shaft and jackshaft, pro-
ceed as indicated below.
,. Remove four caliper carrier attaching bolts (A).
2. Remove two caliper bridge bolts (8).
3. Remove brake caliper and brake disc.
4. Remove shift linkage (Al and stop light switch
wires (B).
5. Remove exhaust system.
6. Remove three nuts securing transmission to
front bulkhead. Remove transmission. NOTE:
Note position of transmission shims for
reassembly (A). these shims control jackshaft
alignment.
7. Remove transmission drain plug (Al and drain
oil.
8.55
RIDE RED
8/94
8. Place transmission as shown and remove shift
lever and key (A), neutral light switch (B), detent
set screw, spring, and ball (C).
9. Loosen chain tensioner jam nut and remove
tensioner boll.
10. Remove transmission housing attaching bolts
IAl
11. Lift upwards on inner housing and tap with a soft
face hammer on input shaft. output shaft, and
shift shaft.
12. Remove high range long silent chain (Al.
8194
8.56
RIDE RED
13. Remove input cluster and shift cluster as an
assembly (A).
14. Remove output cluster (A), reverse cluster (8)
and silent chain as an assembly.
t 5. Remove low range cluster (A).
16. Thoroughly clean and inspect all parts. Refer to
correct parts book for replacement parts.
17. Reverse disassembly procedures for reassembly.
Transmi ssion Servi ce Tips
Before reassembly, remove all oi l seals,
and chain tensioner bolt. After trans-
mission is assembled, install tape
around shaft splines and shaft sealing
area. Grease seal inner and outer di-
ameters. Grease shift shaft D-Ring.
These precautions will protect the seals
and O-Ring from damage.
8.57
8194
RICEREC
Transmission Service Tips
8/94
Be sure the case half mating surfaces
are clean and free of any nicks or
scratches. Place a small amount of
Loclile 515 Gasket Eliminator (PN
2870587) on one of the case halves.
Install bearings and seals using service
tool PN 2870676. Bearings, gears,
etc., are assembled until they bott om
onto each other or onto snap rings or
shoulders.
Install detent ball and spring. Apply a
medium strength thread locking com-
pound to the Allen head set screw and
install it to a depth of .060-.120'" (1.5-3
mm) below the casting surface. During
field lesting, check the detent preload.
If the detent is adjusted too tightly, the
unit will become hard to shift. If the
delent is 100 loose, it wi ll affect the op-
erator's perception of the shift position.
To adjust chain on Hi/lo range trans-
missions, loosen lock nut on adjuster
bolt (A). Place slight reverse tension on
chain by turning brake disc, then tighten
adjuster bolt (B) to 20 inch. Ibs. Back
bolt off 1 1/4 to 1 1/2 turns and tighten
jam nut while holding adjuster bolt.
'>,
Sel Screw
,061.12
8,58
RIDE RED
Transmission Service Tips
After transmission is installed onto bulk-
head, be sure to align jackshaft as d e ~
scribed in drive system overhaul in this
chapter .
With transmission installed on unit, fill
transmission to correct level. Use only
Polaris chaincase oil.
8.59
0>, ~ - - - r
Mag'"''' " ('0' - - / Check
Plug I
,
. ~ - - - - ----
'.'
. ' 0
Drain Plug
RIDE RED
'.
l".,,,,
Fill Plug
Oil Level
8194
Reverse Kit Service Tips
The following illustration indicates gear position with the Polaris Reverse Kit in the forward and Teverse selection.
Instaliatlon Tips (Refer to Illustration on page 8.61)
When installing pinion shaft, be sure the
chamfered end of pinion shaft is toward
case cover.
Install chain, top sprocket, bottom op-
tion sprocket and wide face pinion gear
into case at the same time.
When installing case cover, be sure that
shift lork has slipped into fork groove of
reverse gear.
Forward Position
TOp Sprocket _ 1_
j;;I--
Drive Chain
(Wide Face) -- - (Narrow Face)
Reverse Position
_I ./" Top Sprocket
- - ~
Chain Pinion Gear
B-..".-B __ (Narrow Face)
Chain Pinion Gear ~ Chain Pinion Gear
- -.... .-'
Chain Pinion Gear E;J-"-Ej
(Wide Face)
,
/
............ Spur Pinion Gear
/
Spur Pinion Gear
Shift Fork Groove
Reverse Kit Option Gear
Reverse Kit Option Gear
Drive Coupler
8194
8.60
AIDE RED
...
Reverse Kit Maintenance
R.,."""
L
Supplied with Options B & C (Top Sprocket, Chain, Bottom Sprocket)
Suppl ied with Opel ions A & D (Bottom Sprocket Only)
Chain Tension:
1. Maintain proper chain tension by loosening lock nul and applying 20 inch Ibs. of torque on adjuster bolt.
2. Loosen adjuster bolt 1/2 turn.
3. Hold adjuster bolt in position and lighten locknut.
Oil Level :
1. Using Polaris chaincase lubricant, maintain proper oUleve!. Proper level is checked by removing magnetic
check plug.
2. Wipe off any metal particles from the magnetic pl ug. Small amounts of particles will be common on this plug.
3. Add lubricant until a small amount of oil flows from the check plug hole. Do not mix or use other types of
lubricant.
Oil Change:
1. Change annually, prior to off season storage.
Adjustment:
1 . Due to break in 01 components and cable stretch, the shifter may need readjustment. Readjust with the shifter
in the forward position.
2. Adjust nuts on lower cable end so the endplay movement 01 the cable housing in the holder on the handlebar is
1 I 3 2 ~ (.08 em). Do not adjust beyond this point.
8.61
8/94
RIDE RED
. +.
General Specifications
CHAPTER 9
SUSPENSIONS
1985-1987 ............................................ . ................ ... 9.1
1988-1989
1990-1991
9.2
9.3
1992 .......... . ......... .......... ............. .. . . .... . ....... .......... 9.4
1993
1994
9.5
9.6
1995 ....................... _ ........ . ...... .. .. . .... _ .. . .. . . . ......... 9.7
Suspension Operation ............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9.8
Track Tension Specification ........... . ..... . .... ... . .......... 9.9
Track Tension and Alignment ........................................ 9.' 0-9.11
Type XI, XV, XVI, and XVIII Tunnel Adjustments ............................. 9.12
Hi-Fax and Rubber Track Clip Replacement .......... . ........................ 9.13
Direct Drive Track and Front Drive Shaft Removal and Inslallation ............ 9.14-9.15
Track Removal - Two Sprocket Drive Shaft ......................... ...... 9.16-9.17
Track Removal- Four Sprocket Drive Shaft .................................... 9.18
Track, Transmission and Suspension Removal/Reassembly - WideTrak ....... 9.19-9.22
Type IX Extruded Aluminum E1.ploded View and Adjustments .................... 9.23
Type XI Exploded View and Adjustments ............................. : ...... 9.24
Type XII Exploded View and Adjustments ...... ........ ........... ...... 9.25
Type XI II Exploded View and Adjustments ..... . . ... . ... .. ...... .. . .. . .. ....... 9.26
Type XIV Exploded View and Adjustments ..... .. .... ....... ....... . ..... 9.27
Type XV Exploded View and Adjustments ........................ . ...... 9.28
Type XVI Exploded View and Adjustments . . ............................ .... .. 9.29
Type XVII Extruded Aluminum Exploded View and Adjustments ................. 9.30
a
AIDE RED
8194
Type XVIII Extruded Aluminum Exploded View and Adjustments ..... .... ...... 9.31
Type XIX Expl oded View and Adjustments .................................... 9.32
Type XX Extruded Aluminum Exploded View and Adjustments ..... ......... 9.33-9.35
Type XXII Exploded View and Adjustments . . .............................. 9.36-9.37
Type ITS Exploded View and AdjuSiments (Type I and II ) ..... ... ... . ..... 9.38-9.4 t
Type XXIII Exploded View ................................................... 9.42
Type XC- t OO Exploded View .................... .. .............. .. .......... 9.43
Type XC101 Expl oded View ................................ . ... .. ......... 9.43a
Deep Snow Adjustments ............ ... ... . .. .......... .... . . 9.44-9.45
XC100Adjustments ................................ .. ... . .. ............... 9.46
Type XTRA Suspension Exploded View ............................ . .... ...... 9.47
XTRA Suspension Adjustments .... , . , .. , .. . .... . .... .. . .. . . . ... . ........ 9.489.49
XTRA Suspension Shock Removal ................. .. ... .. ................... 9.50
XTRA Suspension Shock Reassembl y .......... . .... . ..... . .... . ............. 9.51
t995 IFS Shock Spring Chart .............. . .. .............. .. ............... 9.52
Optional Suspension Springs .......................... .. .... .. .... . ......... 9.53
1994 Rear Suspension Center Shock Spring Chart ...... .. ... .... . ...... ..... .. 9.54
1995 Rear Suspension Center Shock Spring Chart ...... .. .... .. ............... 9.55
1994 Rear Suspension Rear Shock Spring Chart, ...... . ................... .... 9.56
1995 Rear Suspension Rear Shock Spring Chart ............ . ........ . .... ..... 9.57
Troubleshooting ...................................... . . . . . . . ....... 9.58
Fox Shocks - Maintenance 1992 ......... . ............................... 9.59-9.64
Fox Shocks Maintenance 1993 ............................. .. .......... 9.65-9.68
Fox IFP XTRA Shock Rebuild (1994-1995) ......... .. ... .. ... .. ........... 9.69-9.72
Fox IFP XTRA Shock Oil Change (1994-1995) ............................. 9.73-9.75
Fox Shocks Valving Charts .............................................. 9.76-9.86
Additional Fox Shock Hardware ...... . ...... . ................................ 9.87
11195
b
AIDE RED
1985 Models
1987 Models
9.1
Length on
Ground
,,.
SUSPENSIONS
AICERED
8/94
SUSPENSIONS
1988 Models
Model Model
SUSf;;:,on
Number
S'"
08B()927 Extruded
Aluminum
Type XIII
StarTrak 0881027 Extruded
Aluminum
Type XVI
Sprint ES 08B()931 Extruded
Aluminum
Type XIII
Spon 0880433 Extruded
Aluminum
Type XV
Trail SP 08B0661 Extruded
Deluxe 0880262 Aluminum
Trail 0880761
Type XV
Trail ES 0680762
400 0680759 Extruded
Classic 0680859 Aluminum
TypeXIJ
133" SKS
Trail 0880561 Extruded
Indy 400 086055'
Aluminum
Indy 650 0860558
Type XVI
Indy 650 0880757 Extruded
Aluminum
Type XV
""'JI T '"
0881549 Extruded
IR )
Aluminum
Type XVII
Track
T,pe
Molded
Rubber
""''''
R_,
Mold'"
R-'
M""'" ROObe,
M""'"
R_,
"""''''
R_,
Mold'"
ROObe'
Mold'"
Rubber
Mold'"
Rubber
'ReqUires additIOn of tunnel wear stnps.
1989 Models
Model Model
SUSf;;:,on
Track
Number Type
51"
0890927 Extruded
""''''
Aluminum
R_,
Type XIII
StarTrak 0891027 Extruded
"""''''
Aluminum ROObe,
Type XVI
Sprint ES 0890931 ",,1Ndod
""d'"
Aluminum
R_,
Type XIII
Spon 0890443 E.lIruded
""''''
Aluminum
R_,
Type XV
SportGT 0892443 Extruded
""''''
Aluminl.lm
R,""""
Type XVI
Trail SP 0890661 Extruded
"""'"
Oell.lxe 0890262
Aluminl.lm R",,,,.,
Trail 0890761
Type XV
TrailES 0890762
"""'"
Aluminum Rubber
Type XV
133" SKS
""''''
Indy 500 0890564
All.lminum Rubber
Indy 650 0890558
Type XVI
""''''
Classic 0890865 Aluminum Rubber
Type XV
Indy 650 0890758 E.lIruded
""''''
Aluminum Rubber
Type XV
"""'"
SuperTrak All.lminum Rubber
Type XVIII
L ~ T f a k
0891549 Extruded
"""'"
IR I
Aluminum Rubber
Type XVII
8/94
Tmc'
Width
,,"
,,"
,,"
""
""
""
,,"
""
""
Track
Width
,,"
,,"
,,"
""
,,"
""
""
,,"
""
""
,,"
""
Track Track Bogle Rear Idler Drive Ice Studs
Length Length on Wheel Wheel Sprkt.
Overall Ground Ola. OIa. Dla.
108" 40.5" 5.625" 6.38" 3.0'" Cannol
Be U"",
133" 54.3" 5.625" 6.38" 5.45" Cannot
Be Used
120- 40.5" 5.625" 6.38" 3.69" Cannot
Be Used
12'"
""
5.625" 6.38" 7.06" Cannot
Be Used
121"
""
5.350" 6.38" 7.06" ' Traction
Studs
Optional
12'"
""
5.350" 6.38" 7.06" 'Traction
Studs
Optional
133" 54.3" 5.350" 6.38" 7.06" Cannot
Be Used
121" 49" 5.350" 6.38" 7.06" 'Traction
Studs
Optional
t 48" 59.5" 5.625" 6.38" 5.03" Cannot
Be Used
Track Track Bogle Rear Idl er Drive Ice Studs
Length Length on Wheel Wheel Splitt
Overall Ground Ola. Ola. Dla.
108" 40.5" 5.625" 6.36" 3.01 " Cannot
Be Used
133" 54.3" 5.625" 6.38" 5.45" Cannot
Be Used
120- 40.5" 5.625" 6.38" 3.69" Cannot
Be Used
121" 49" 5.625" 6.38" 7.06" Optional
141" 54.3" 5.350" 6.38" 7.06" Optional
121" 49" 5.350" 6.38" 7.06" Optional
121" 49" 5.350" 6.38" 7.06" Optional
133" 54.J" 5.350" 6.38" 7.06" Cannot
Be U"",
121" 49" 5.350" 6.38" 7.06" Optional
121" 49" 5.350" 6.38" 7.06" Optional
156" 65.5" 5.350" 6.38" 7.06" Optional
148" 59.5" 5.625" 6.38" 5.03" Cannot
Be Used
9.2
RIDE RED
1990 Models
Model Model
SuSr;;:lon
I
Tn>ck Tr.>ek
Number TYpe Width
S,," 0900927 E,,,",,,,,
Mo.'"
15"
Aluminum A..-
XIU
StarTrak 0901027 Extruded Mo.", 15"
Aluminum
A,_
Type XVI
SprinIES 0900931 E,,,",,,,, Molded 15"
Aluminum
A,_
Type Xlii
-
0900433 E,"""'" Molded 15"
Aluminum
A,_
Type XV
_GT 0902433 Extruded Molded 15"
Aluminum
A,_
Type XVI
T'"
0900761
Mo"'"
15"
0900262
Aluminum
A,_
Type XX
400 0900759 Edruded Molded 15"
Aluminum
A,_
Type XX
133" SKS E,1ruded Molded 15"
,,,,,, 500
0900564 Aluminum
A,_
,,,,,, 650
0900558
Type XX
500 0900764 E,1ruded Molded 15"
aa""
0900865 Aluminum
A,_
Type XX
,,,,,,650
0900758 extruded
Mol"'"
15"
Aluminum
A,_
Type XX
Trail Extruded
Mol"'"
15"
SuperTrak 0900161 Aluminum
Type XVIII
Rubber
WIdeTrak 0902064 extruded
Mo"'"
20"

A,_
T XIX
1991 Models
Model Model

I
Track Track
Number T,pe Width
StarLile 0913027 MoIkled 15"
Aluminum
A,_
Type XIII
wOO 0913033 E.truded
Mo.'"
15"
Aluminum
A,_
Type XVI
-
0910443 E,1rudOO
-'"
15"
Aluminum A..-
Type XV
_GT 0912443 Exlruded
-'"
15"
Alummum A.-.
Type XVI
Trail 0910761 E.truded 15"
Aluminum
A"""'"
Type XX
-'"
15"
Aluminum
A,_
Type XX
133" SKS 0910564 Extruded
"""'"
15"
500 0910764 Aluminum
A,_
Deluxe 0910262
Type XX
500 Extruded 15"
Classic O9HllI65 Aluminum
A,_
Type XX
'm.
650 0910758 E,1ruded Molded 15"
AX 0910768 Aluminum
A,_
Type XX
Trail E,1ruded Molded 15"
"'-Trnk 0910161 Aluminum
A,_
Type XVIII
0912064 Extruded Molded 20"

Rubber
T po XIX
n ack Tr.>ek
Length
OVerall
Length on
Ground
lOS" 40.5"
133" 54.3"
I2\)" 40.5"
121" 49"
14'" 54.3"
12'" 49"
121" 4,-
133" 54.3"
121" 4'-
12'" 49"
156" 66"
156" 66"
Track Track
Lenglh
Over all
Length on
Ground
116- SO"
116-
'0"
121" 49"
141" 54.3"
121" 4'-
12 1" 49"
133" 54.3"
121" 49"
121" 49"
156" 66"
156" 66"
9.3
Bogle
Wheel
Ola.
5.625"
5.625"
5.625"
5.625"
5.350"
5.350"
5.350"
5.350"
5.350"
5.350"
5.350"
5.625"
Bogie
Wheel
Ola.
5.625-
5.625-
5.625-
5.350"
5.350"
5.350"
5.350"
5.350"
5.350"
5.350"
5.625"
SUSPENSIONS
Rear Idler Spring Ice Studs
Wheel Wire
Ola. Ola.
6.38" Std. Co,,,,,,
Be Used
6.36" Co,,,,,,
Be Used
6.38" Std. Co",,,,,
Be u.ed
6.38"
"""""
6.38" Sid.
"""""
6.38" .437" Optional
6.38" .437" Co",,,,,
Be """
6.38" .437"
""""'''
6.38" .437" Oplional
6.38" Std. Optional
I
Rear Idler Spring
l ice Siuda
Wheel Wire
Dia. Dla.
6.38- Std.
""-
6.38" Std. Optional
6.38" Std. Oplional
6.38" Std.
""-
6.38" .406"
""_
6.38" .421" Cannol
.406" Be Used
.437"
6.38" .406"
""",,'"
6.38" .421"
"""""
6.38" Sid.
""""'"
6.38" Std. Optional
RICE RED
8194
SUSPENSIONS
1992 Models
Model Model
SUSr;;:iOn
Number
SlarUte 0923027 Extruded
Aluminum
Type XIII
u te 0923033 Extruded
Ute Deluxe 0923231 Aluminum
Type XVI
U!eGT 0923133 Extruded
Aluminum
Type XVI
Sport 09203 ExlrVded
Aluminum
Type XV
Sport GT 0922443 Extruded
Aluminum
Type XVI
Trail 0920761 E><trudod
Aluminum
Type XX
'"
0920760 Extruded
Aluminum
Type XX
440 XCR 0921760 Extruded
Aluminum
Type XXII
500SP 0920674 Aluminum
Type XX
500 SKS 0920574 E.!rudOO
C""'"
0920865
Aluminum
Type XX
Trail Deluxe 0920262 Extruded
RXLSKS 0920568
Aluminum
Type XX
' ~ 6 5 0
0920758 Extruded
RX 0920768 Aluminum
Type XX
Trail E><trud""
SuperTrak 0920161 Aluminum
Type XVIII
WldeTrak 092206< E><trud""
Aluminum
Type XIX
8/94
Track Track
T,pe Width
Molded
,,"
Rubber
Mold'" ,,"
Rubber
-..
""
R_,
Mold'" ,,"
Rubber
Molded
""
Rubber
Molded
,,"
Rubber
-..
,,"
Rubber
"""'"
,,"
R_,
Mold'" ,,"
Rubber
Mold'" ,,"
Rubber
Molded
,,"
Rubber
Molded
,,"
Rubber
Molded
,,"
Rubber
Molded 2(r
Rubber
Track Track Bogle Rear Idler Spring
lice Studs
Length Length on Wheel Wheel WI ..
OYerall Ground OIa. ola. Dla.
116" 30" 5.625" 6.38" SW. Optional
116" 30" 5.625" 6.38" Std. Optiooal
133.5" 55" 5.625" 6.38" SW. Cannot
Be Used
121"
,,"
5.625" 6.38" SW. Optional
141" 54.3" 5.350" 6.38" SW. Optional
121"
""
5.350" 6.38" .406" Optional
12'"
""
5.350" 6.38"
.42" Oplional
12' "
""
5.350" 6.38" .42' " Optional
121"
""
5.350" 6.38" .421" Optional
,,," 54.3" 5.350" 6.38" .421" Cannot
6e Used
,,," 54.3" 5.350" 6.38" .421" Cannot
.. "m
12,"
,,.
5.350" 6.38" .421" Optional
156"
""
5.350" 6.38" Std. Cannot
.. ""'"
156"
""
5.625" 6.38" Sid. Cannot
.. ""'"
9.4
RIDE RED
1993 Models
Model Model
SuSr;;:IOn
I T .. " Number Type
StarUle 0933427 Ext. Aluminum Block
Type XV
StarUte GT 0933127 Ext. Aluminum Inline
Type XVI Block
"to
0933433 Ext. Aluminum Block
Type XV
Ute Deluxe 0933431 ext. Aluminum Block
Type XV
liteGT 0933133 Ext. Aluminum Inline
Type XVI Block
Sport 0930443 EXI . Aluminum Block
Type xv
Trail 0930761 ITS B_
Typel
Trait Deluxe 0930243 ITS Wi"",
Type II
440 0930760 ITS B_
Type I
440 SKS 0930560 ITS
W"'"
Typall
XCR 0931760 E.l.l . Aluminum B_
Type XXII
WIdeTrakGT X932061 Ext. Aluminum 0...,
Type XXI W;"..
WideTrak 0932064 Exl. Al uminum Block
Type XIX
ClaSSic 0930864 ITS B_
Type I
<to""
ITS Wiper
Touring 0930685 Type II
500 EFI 0930674 ITS B_
Typel
500 EFI SKS 0930574 ITS Wi"..
Type II
XLT 0930767 ITS B_
Type I
XLT SKS 0930667 ITS Inline
Type II Block
XLT Special 0930567 ITS Bk>d<
Type I
RXL 0930768 ITS B_
Type I
RXLSKS O93056B ITS Inline
Typetl B_
51""" 0932770 ITS B_
Type I
Storm SKS 0932570 ITS
=
Type II
Track Track T"",
Width L.ength
(Overall)
L.ength on
Ground
IS" 121"
"'"
IS" 133.5" 4B"
IS" 121"
"'"
IS" 12'"
"'"
IS" I33S .. "
IS" 12'"
"'"
,,"
121" .. "
,,- 133.5" 5(J'
IS" 12," .. "
IS" 133.5" 5(J'
IS" 12'" .. "
141" 51"
20- 156" 59"
IS" 121"
""
IS" 133.5" 5(J'
IS" 121"
,.-
IS" 133.5" 5(J'
IS" 12' "
,.-
IS" 133.5" 5(J'
IS" 12'"
,.-
IS" 121" .. "
15" 133.5" 5(J'
IS" 12' "
,.-
IS" 133.5" 5(J'
Wheels
(I
Id er II
0
3
0
3
0
3
0
3
0
3
0
3
0
3
0
,
0
3
0
3
0
,
0
,
0
0
0
3
0
3

3
0
3
0
3
6
3
,
0
,
0
4
10
4
10
4
SUSPENSIONS
IFS Spg. RearSpg. HI-Fax
Rate WI .. Width
IlbsJln.) Olameter
105 .393 1 'I.
105 .393 IV.
lOS .393 1 'I.
lOS .393 I Y.
lOS .393 I '/.
105 .393 1 '/.
105 .406 1 'I.
105 .421 l Y.
lOS .421 I '/.
lOS .421 1 ,t:.
120 .421 1 '/.
150 .468 1 'I.
105 .421 I 'I.
105 ,421 1 '/0
lOS .421 1'10
105 .421 IV.
105 ,421 1 '/0
105 ,421 1 y.
105 .421 1'10
120 ,421 1 'I.
lOS ,421 1 V.
105 . 421
, y
160 ,421
' '''
160 .421
''''
NOTE: All models using ITS suspensions may use 1 1/2" (3.8 cm) wide hi-fax if track guide clips are installed. AU
models have 15" wide track except WideTrak and WideTrak GT, which are 20".
9.5 AIDE RED
8/94
SUSPENSIONS
1994 Models
Model Model
SUS;f;;:,on
Numbet'
Starlile 0943427 Ext. Aluminum
Type XV
StarUte GT 0943127 Ext Aluminum
Type XVI
lile ,..,." Ext Aluminum
Type XV
Ute Deluxe 09<3<3' Ext Aluminum
Type XV
UteGT 0943133 Ext. Aluminum
Type XVI
""""
""'03
Ext. Aluminum
Type XV
Sport SKS 0940443 ITS
Rental Type I
S....,
""""
0940743 XCHIO
Trail 0940761 ITS
Type I
Trait
""'02'"
ITS
0 ".
Type II
""
0942760 ITS
Type I
440 $KS ""'2560 ITS
Type II
XCR 0941760 XC-tOO
440 XCR 0941760 XC-101
SP
600 XCR 0941667 XC-l01
WIdeTrak 094206' EJL Aluminum
GT Type XXI
WIdeTmk
""''''''
ExL Aluminum
UI Type XXlII
C""" ""'2865
ITS
Type I
CO"", 0942875 ITS
Touring

TypaU
500 EFI 0942774 ITS
Typel
500 EFI 0942574 ITS
SKS Typell
XLT 0940767 XC 10C1
XLT SI<S
""""'7
XC-lOCI
XLT
""'0667 XC-lOCI
Special
XLT 0946767 X
~ "
RXL 0940768 XC- l00
RXL
""'066'
ITS
Touring Type 11
S_ 0940782 XC lOO
Stoon SI<S
""'0582
XC-lOO
Track
Type
Block
Inline
Block
Block
Block
Inline
-"k1d<
Wiper
"k1d<
"k1d<
.. ""
Block
=
"kxk
"k1d<
Bk1d<
=
Block
"k1d<
Wiper
"look
Deep
.. ""
"look
Deep
.. ""
Block
~ r
"k1d<
Wipe!'
Deep
.. ""
=
W .. ,
n."
T"", Wheels Center Rear HI-Fax
Strips l ength L.ength on
":'JI
"
"
Spring
~ .
Width
(Overalll Ground I . , DlaJL.angth I,.
Diameter
NJA 121" ,,-
6 .31216.88 .393 I V.
3
NJA 133S
, ..
6 .31216.88 .393 IV.
3
NJA 12'"
".
6 .31216.88 .393 IV.
3
NJA 12'"
".
6 .31216.88 .393 1 'I.
3
NJA 133.5" , ..
6 .312/6.88 .393 1 V.
3
A ~ . 12"
,,-
6 .312/6.88 .393 1 V.
3
A ~ . 133S <n 6 .31217.SO . 421 1 'f
3
A ~ . 12'
,,-
6 .31217.50 .421 1 'I.
3
~ . 12'"
,,.
6 .31217.50 ..... 1 Y.
3
~ . 133.5" <n 6 .31217.50 . 421 I 'I
3
~ . 12'"
,,.
6 .31217.50 .<2, 1 'I.
3
~ . 133S <n 6 .31217.50 A21 I Y.
3
SId. 121"
,,-
6 .33m.50 .421 1 V
,
SId. 121"
,,-
6 .3121.750 .421
, ~
,
S ~ . 121"
,,-
6 .3121.750 .421 'n
,
~ . 141 " ,,-
6 .31217.50 .468 I 'I.
,
~ .
'56-
SO' 6 .31217.50 . '68 I 'I
,
~ . 121"
,,.
6 .31217.50 .421 1 'I.
3
~ . 133.5" <n 6 .31217.50 . 421 1 'I
3
~ . 121"
,,-
6 .31217.50 .421 1 'I.
3
~ . 133.5" <n 6 .31217.50 . 421 1 'I
3
S ~ . 121"
,,-
6 .31217.50 .421 1 'I.
3
~ . 133's- <n 6 .31217.50 .421 1 'I
3
Std. 121" ,,-
6 .33117.50 .42 1 1 'I.
,
Std. 121" 43.5" 6 .3121.750 .421
'"
,
Std. 121" ... 6 .31217.50 .421 1 'I.
,
Std. 133.5" <n 6 .33117.50 .421 1 'I.
,
Std. 121"
,,-
'"
.31217.50 .421 , ~
,
Std. 133.5- <n .0 .31217.50 .421
, ~
,
NOTE: All models using ITS suspensions may use 1 1/2" (3.8 em) wide hi-fax if track guide cl ips are installed. All
models have 15" wi de track except WideTrak LX and WideTrak GT, which are 20".
8/94
9.6
RICERED
1995 Models
Model Model
I
SUS.f!nSiOn
Number ,pe
StarUte 0953427 Ext. Aluminum
Type XV
Ute
""'33
Ext. Aluminum
Type XV
Ute Deluxe 0953431 Ext. Aluminum
Type XV
UteGT 0953133 Ext. Aluminum
Type XVI
Sport 0950443 Ext . Aluminum
Type XV
Spon Touring 0950:243 XC.l00
SUPef Sport 0950743 XC-tOO
Trai l 0952761 XC-tOO
Trail Deluxe 0952262 XC-t OO
440 LC 0952760 XC-HlO
440SKS 0952560 XC-lOO
440 XCR 0951660 XC-lOt
600 XCR 0951676 XC-IOI
WideTrakGT 0952061 Ext. Aluminum
Type XXI
WideTrak LX 0952064 Ext. Aluminum
Type XXIII
Classic 0952865 XC-WO
500 Carb 0952764 XC-lOO
500 EFI 0952774 XC-lOO
500 EFI SKS 0952574 XC-lOO
500 EFI SKS PT 0952874 XC-lOO
XLT 0950756 XC-lOO
XLT SKS 0950556 XC-lOO
XLT SKS PT 0950956 XC-l00
XLT Touring 0952857 XC-lOO
XLT SP 0956756 X.,
RXL 0956768
,.,
RXL Touring 0950869 XC-lOO
Storm
"
0950782 XC- l OO
Storm SKS 0950582 XG- IOO
Storm SKS PT 0950982 XC- lOO
Track Wear Track
Type Strips Length
(Overall)
810ck NJA 121"
Block NJA 121"
810ck NJA 121"
Wiper NJA 133.5"
Block A ~ , 12' "
Wiper A ~ , 133,5"
BlocI< A ~ , 121"
Block A ~ , 121 "
Wiper A ~ , 133.5"
Block A ~ , 121"
R=
A ~ , 133.5"
81"'" Std. 12"
81"'" Sid. 121"
~ ~
NfA 141"
81"'" NfA
, 56"
81"'"
A ~ , 12, "
BI"'"
A, 121"
81"'"
A ~ , 12'"
0.."
A, 133.5"
Wiper
Paddle NJA 133.5"
810ck Std. 12'"
=
A ~ , 133.5"
Paddle NJA 133.5"
Wiper A ~ , 133.5"
0.." Std. 121"
Wiper
0.." Std. 121"
Wiper
Wiper Std. 133.5"
Ooep Std. 121"
Wiper
!Jr
Std. 133.5'
'pe'
Paddle NJA 133.5"
SUSPENSIONS
Track Wheel s HI-Fall
Length on BOJflesl Width
Ground
, ..
44" 6 1 'I.
3
44" 6 1 'I,
3
44" 6 1 Y.
3
48" 6 1 'I.
3
44" 6 1 ,/.
3
50" 6 1 V.
3
44" 6 1 V.
3
46" 6 1 V.
3
50" 6 1 '/.
3
46" 6 1 'I.
3
50" 6 I 'I.
3
44" 6
, ~
4
<4" 6 1 'h
4
51 " 6 1 V.
4
59" 6 1 'I.
4
46" 6 1 ,/.
3
46" 6 1 '/0
3
46" 6 1 'I.
3
5fY" 6 1 'I.
3
50" 6 1 'I.
3
" 6 1 'I.
3
50" 6 1 'I.
3
50" 6 1 'I.
3
50" 6 I V.
3
43.5" 6 1 'h
4
43.5" 6 1 'h
4
50" 6 1 'I.
4
46" 10 1 ~
4
50" 10 1 ~
4
50" 10 1 ~
4
NOTE: All models usi ng ITS suspensions may use 1 1/2" (3.B em) wide hi-fax if track guide clips are installed. All
models have 15" wide track except WideTrak LX and WideTrak GT, which are 2 0 ~ .
9.7
RIDE RED
8194 "
SUSPENSIONS
Suspension Operation
The primary function of the rear suspension is to provide a comfortable ride in all type of riding conditions. The
rear suspension has many adjustable features for fine tuning to achieve optimum comfort.
The secondary function is to provide superb handling and stability, such as adjustments to vary ski pressure for
steering and controlling the snowmobile's center of gravity.
Refer to the suspension type identification chart on page 9.9 to identify your suspension type. For example, 1992
Indy 440 - Type XX. Adj ustment procedures for each type are explained on the following pages.
8.i94
9.8
RIDE RED
SUSPENSIONS
Track Tension Specifications
TYPE TOLERANCE
Extruded Aluminum Types XI, XII, XIV, XXII
ITS Types I & II , Type XX 121", XC-l00
3/8" - 1/2" <1 - 1.3 em) between track clip and hi-fax
with 10 lb. (4.5 kg) weight. See page 9.10.
Extruded Aluminum Types XVI, XXI 1 1/4" - 1 1/2" (3.2 - 3.8 em) between track clip and
hi-fax wi th 10 lb. (4.5 kg) weight. See page 9.10.
Extruded Aluminum Types IX, XI II , XV, XVII, XVIII , XIX, 3/4" - 1" (2 - 2.5 em) free hanging between track clip
XXIII and hi-fax; measured at rear of front hi -fax with 10 lb.
Type XX 133" (4.5 kg) weight. See page 9.10.
Xlra Elevate machine e n O U ~ h to assure track doesn't
contact ground. 1/2" c earance, measure free
hanging. See page 9.10.
Suspension Identifications
Extruded Aluminum Type IX .... . . ..... 1986 Long Track Models
Extruded Aluminum Type XI ........ . ...... 1985 Indy Models
Extruded Aluminum Type XII .... . . . ........ 1985 SS
Extruded Aluminum Type XiII ............... 1986 - 1990 Star, Sprint (ES), StarUte, Indy Ute
Extruded Aluminum Type XIV ... .. . .. ..... 1986 SS
Extruded Aluminum Type XV ..... . ........ 1986 - 1992 Indy Models Except 133" SKS;
1993 - Current Standard Ute Models
Extruded Aluminum Type XVI ............... 1987 - 1990 StarTrak; 1993-Current Indy Ute GT,
StarUte GT
Extruded Aluminum Type XVII .............. 1987 - 1990 LongTrak ALR
Extruded Aluminum Type XVIII ........ . ..... 1990 -1992 SuperTrak
Extruded Aluminum Type XIX ...... . . . ..... 1990 - 1992 WideTrak
Extruded Aluminum Type XX ..... ... . ..... 1990 - 1992 Indy Models
Extruded Aluminum Type XXi ................ 1990 - 1992 141" Models; 1994 WideTrak GT
Extruded Aluminum Type XXII ....... . .... . 1990 - 1993 XC & XCA
ITS Type I ... . ...... . ............... 1993 Standard 121" Indy Models;
1994 Trail, 440, Classic, 500 EFI
ITS Type II .. . ........................... 1993 Trail Deluxe and all SKS Models;
XC-lOO
XC- l 01
1994 Trail Deluxe, Sport SKS, 440 SKS,
Classic Touring, 500 EFI SKS, RXL Touring
.. . . . . , . ,., , . , , ', .. , .. 1994 Super Sport , XCR, XLT, XLT SKS,
XLT Special, Storm, Storm SKS, RXL
......................... ...... .... 1994 - Current 440 XCR SP, 600 XCR
Extruded Aluminum Type XXiII .. . ..... . .... 1993 - Current WideTrak LX, Military WideTrak
XTRA-12 .... . ................ . ... .. .... , .. 1994 XLT Special XTRA; 1995 XLT SP, RXL
9,9
RIDE RED
Bl94
SUSPENSIONS
Track Tension
Track Tension
Tension adjustments should be made only after the
track is warmed up and limber. Refer to track tension
specifications on page 9.9.
1. Turn the machine off.
2. Lift the rear of the machine and safely support it
off the ground.
3. Proper track tension is obtained by placing a 10
lb. (4.54 kg) downward pressure on the track at a
point approximately 1 6 ~ (40.6 em) ahead from the
center of the rear idler wheel.
Always align the track after tensioning the track. See
page 9.11.
Track Tension XTRA Suspension
CA UTION: This dimension is critical for prevention of
derailing. drive shaft ralcheting and excessive hi-fax
wear.
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. Check track tension 2'" (5. 1 cm) forward of the rai l
jounce bumper.
Properly adjusted, slack in track should be 1/2" (1.3
cm) at the point described in step 3, free hanging.
4. Loosen rear idler shaft bolt.
5. Loosen locknuts.
6. Tighten or loosen track adjusting screws as
necessary to provide equal adjustment on both
side of the track.
7. Rotate track 1/3 of its travel and measure again.
Tension should be checked frequenlly on new units
and!D marginal snow or hard packed snow conditions.
Always align the track after tensioning the track. See
page9.11.
8/94
9. 10
3/8" - 1/2"
(1-1.3cm) 1
4.54 Kg.
1/2'" ,,,, ,ekat this point
RIDE RED
Track Alignment - All Models
Track alignment affects track tension. Misalignment
will cause excessive wear to the track and slide rail.
Lift the rear of the machine and safely support it with
the track off the ground. Start the engine and
accelerate slowly to turn the track.
If the track runs to the left, loosen idler shaft bolt (C);
loosen the left locknut (Al and tighten the left adjusting
screw {Bl. If the track runs to the right loosen the right
locknut (Al and tighten the right adjusting screw (B).
After adjustments are completed, lighten the
locknuts. NOTE: Be sure to re-tighten lock nuts (Al
and idler shaft bolts (C). Tolerances at points (D) and
(El should be as close to the same as possible.
WARNING: When performing above checksl
adjustments, slay clear of all moving parts to avoid
serious personal injury. Use a shielded jack stand
when test running track for alignment check to prevent
serious injury.
9_11
RIDE RED
SUSPENSIONS
Track Alignment
B A
c
8/94

SUSPENSIONS
Type XI , XV, XVI and XVII Tunnel Adjustments
8194
(Does not include Dial Adjust or ITS)
Rear Torque Arm Tunnel Positions Front Torque Arm Tunnel Positions
Rear
Torque Arm
Tunnel
Location
o 3
3
3
,
1
1
1
5
, 5
- .-1 4
o , 3
'--1
I .II I 5
I 0 I 4
o I 3
I, 2
I 1
Limiter Strap Positions
A Longest
Front
Production Location
o ~ Indy 121 " Tracks
- Indy Long Tracks
, ___ B Middle
><;;",....- C Shortest
Limiter
Indy 121 ' GT, SKS,
Torque Arm Strap
Mounting
Condition
SuperTrak
Tunnel Posi tion Mounting
Location Condition
Use Do Not Use Do Not
Use Use
o 4 OA,B,C X X
3 A,B
X
X
3 C X
X
,
4
,
A,B,C X
X
3 A
X
X
3 B,C
X X
5 A,B,C X X
9. 12
RIDERED
Slide rail material replacement on all Polaris models is
similar. When any area of the slide rail material 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
adequate snow cover to provide sufficient lubrication.
Excessive wear may be due to improper alignment or
machine operation on surfaces without snow.
Replace HiFax when worn to 3/8'" (.95 em) on
conventional suspension; 5/16" (.79 em) on Xtra
Suspension.
SUSPENSIONS
Hi-Fax Replacement
s ~
[----==
j
3/8"
!
j
5 ~ 5/16"
[----== l+---"-T' !
Hi-Fax wear patterns are somewhat different on machines equipped with the Xtra Suspension than on
conventional models. The fear of the rai l will wear rapidly at first. After reaching a certain point, this rapid wear will
cease. This area should be checked frequently, however, replacement is not necessary until a thickness of 5/16'"
(.79 cm) is reached.
New Hi-Fax are best used in deep snow conditions. Marginal snow or hard-pack conditions are better suited to
worn Hi-Fax.
1. Remove suspension from machine.
2. Remove front Hi-Fax retaining bolt as shown.
3. Use a block of wood or drift punch and a hammer to
drive Hi-Fax rearward off the slide rail.
4. With Hi-Fax material at room temperature, install
new Hi-Fax by reversing above procedure.
Rubber Track Cli p Replacement
1. Install replacement clip and clipping tool (PN
2870380) as shown. NOTE: For ease of operation,
the tool may be placed in a vise.
2. Tighten drive bolt against forming die until cl ip is
formed.
9.13
8/94
RIDE RED
SUSPENSIONS
Direct Drive Track and Front Drive Shaft Removal and Installation
1. Remove drive belt. driven clutch, and driven clutch
spacer washers.
2. Open adjuster bolt jam nut locking tab (Al.
3. Loosen jam nut and remove adjuster bott (8).
4. Remove actuating lever (el and return spring.
5. Remove two brake caliper attaching nuts (D).
6. Remove cable bracket and caliper assembly. Check
cable condition at both ends. Frayed or binding brake
cables must be replaced.
7. Slide brake disc off front drive shaft and remove half
moon key.
8. Remove four suspension mounting bolts and
suspension. Note placement of two rear torque arm
idler wheel thrust spacers for reassembly.
9. Loosen lock collar Allen head set screw.
, O. With a punch and hammer, loosen bearing lock collar
located on brake end of drive shaft.
11. Remove three flangette attaching bolls (A). NOTE:
The longest of these three bolts attaches the
stati onary brake pad.
12. Slide drive shaft toward brake side of chassis unti l
driven clutch end is free.
13. lilt shaft and remove it from brake end bearing.
14. Remove track.
8194
9. 14
RIDE RED
SUSPENSIONS
Direct Drive Track and Front Drive Shaft Removal and Installation
15. Before reassembly, check drive shaft, drive shaft
sprocket, and drive shaft bearings.
16. Reverse disassembly procedures for reassembly.
Note that sprocket or drive shaft centering is
controlled by hex portion of drive shaft (A) being
bottomed onto driven clutch side bearing (8).
17. Driven clutch must be installed and torqued before
lock collar is tightened.
18. Refer to Chapter 8 for proper brake adjustments.
9.15
8/94
AIDE RED
SUSPENSIONS
Track Removal - Two Sprocket Drive Shaft
1. Remove rear suspension bolts.
2. Remove front suspension bolts.
3. Place a protective mat on the floor and tip the
machine on its side.
4. USing an Allen wrench, loosen set screw on lock
collar on left side drive shaft bearing.
5. Tap lock collar with a hammer and punch to loosen it.
Rotate lock collar against the normal direction of
rotation to loosen, with normal direction of rotation to
tighten.
8/94
9.16 .

RIDE RED
SUSPENSIONS
Track Removal - Two Sprocket Drive Shaft
6. Remove three cap screws holding flangette and
bearing in place on left side of machine.
7. Remove bearing and lock collar from drive shaft.
8. Remove chaincase cover and remove bottom
sprocket.
9. Remove drive shaft by pulling shaft first from
chaincase and then from left side of machine.
10. Reverse process for reassembly. Be sure to install
and torque lower chaincase sprocket before locking
lock collar.
9.17
RIDE RED
8194
SUSPENSIONS
Track Removal - Four Sprocket Drive Shaft
1. Follow steps '-7 of Two Sprocket Drive Shaft
Removal pages 9.16-9.17.
2. Remove handlebar cover. Remove cable tie on
steering post securing throttle cable and brake
hose. Remove two phillips screws securing ai r
intake silencer. Taking care not to damage throttl e
cable, lift si lencer oul.
3. Remove secondary clutch and loosen jacks haft lock
collar set screw. Using a hammer and punch,
unlock the lock collar. Remove three cap screws
holding jackshaft left hand bearing and f1angettes in
place. Remove bearing from jacks haft.
4. Remove chaincase cover, loosen chain adjuster
and remove lower sprocket and drive chai n.
5. Remove three mounting bolls (A, S, C) securing
chaincase to chassis. Carefully tip machine on its
left side onto a mat. lift chaincase up until drive
shaft is out of lower chaincase bearing. lift drive
shaft up until it clears tunnel on LH side (bott om) and
can be pulled out of tunnel . Remove drive shaft and
track.
damaged or defective parts, replacement is necessary
in order to avoid serious damage to the machine or injury
to the operator.
6. After inspecting all parts, reverse process for
reassembly. The lower forward chaincase mount
bolt (C) must be in place before installing drive shaft.
Drive sprocket interference will not permit
installation after drive shaft is installed. The lower
chaincase sprocket must be installed and torqued
before locking lock collar.
8/94 9.18
, ,
RICERED
SUSPENSIONS
Transmission, Suspension and Track Removal - WideTrak Models
1. Remove hood assembly and set aside to prevent
damage.
2. Remove drive belt.
3. Remove driven clutch retaining bolt assembly and
drive clutch. Note number of spacers which are
behind driven clutch for install ation during
reassembly procedures.
4. Remove muffler springs and muffler from unit.
5. loosen brake cable jam nut (A) and remove cable
bolt, nul and spacer (8). Use care not to loose
spacer.
6. Remove cable from transmission.
7. Note location of shift linkage on transmission (A) to
assure proper location during reassembly. Remove
cotter pin, washers, and pin from transmission arm.
8. Remove brake light wire connector from sensor.
9. Loosen rear idler wheels and bolts.
, O. Loosen jam nuts on adjustment bolts on both sides.
Back out adjustment bolts to allow rear idler
assembly to come forward, relieving track tension.
11. Tighten idler wheel bolts so that spacers on shafts
do not rotate and lose alignment.
12. Remove front and rear carrier shaft bolts (A), and
front and rear suspension bolts from both sides (B).
13. Tip unit onto right side and remove suspension.
9.19
RIDE RED
8/94
SUSPENSIONS
Transmission, Suspension and Track Removal - WideTrak Models
14. Using""" handle Allen wrench, loosen set screw on
lock collar.
, 5. Tap lock collar with a hammer and punch to loosen.
16. Rotate lock collar against normal drive shaft rotation
to loosen.
17. Loosen and remove three carriage bolts and nuts
retaining angle drive housing and flangettes.
18. Remove angle drive housing, adaptor key,
flangettes, bearing, and lock collar 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.
19. Tip machine back onlo floor.
20. Remove right side bumper plug (A).
21. Remove bolt retaining rear of bumper to fool rest.
22. Bend muffler mount out of the way to allow
transmission removal.
8/94
9.20
RIDERED
SUSPENSIONS
Transmission, Suspension and Track Removal -WideTrak Models
23. Remove three transmission retaining bol ts. Note all
alignment shim quantities and locations for
reassembly. NOTE: Retaining bolts have to be held
in place from underside while removing nuts. The
lower fronl bolt cannot be removed at this time. It
must be lowered to the drive sprocket.
24. Lift and maneuver transmission to free drive shaft
coupler.
25. Lower drive shaft and remove lower front bolt.
26. Maneuver transmission until it can be removed from
the unit. Use care not to damage coolant tines.
27. 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.
28. Remove track.
29. Inspect transmission, brakes, suspension and track
for excessive wear. Check bearings for excessive
movement or rough feeling. Replace if necessary.
Reassembly
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 and Ilangette on
drive shaft, positioning bearing flush with end of drive
shaft.
5. Set lock collar lighlly to hold in place.
6. Align fiangette holes with tunnel.
7. Replace adaptor key in drive shaft. Install angle
drive housing aligning adaptor key with angle drive.
8. Install nuls and finger tighten.
9. Tip machine onto its left side.
9.21
RIDE RED
8194
SUSPENSIONS
Transmission, Suspension and Track Reassembly - WideTrak Models
10. Reinstall transmission, using care not to damage
coolant hoses. Be sure transmission shift linkage is
properly located.
11. Install lower front mounting bolt 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 graduall y to prevent
binding of couplers.
12. Tip machine onlo its right side.
13. Loosen lock collar and seat drive shaft in transmission
coupler stub shaft. For ease of assembly, make sure
track has no pressure against drive shaft.
14. Tighten nuts retai ning angle drive housing to tunnel.
15. Reinstall lock collar and lock wi th hammer and punch
in direction of rotation of drive shaft.
16. Using 'T" handle Allen wrench, tighten set screw.
17. Reinstall front of suspension inside track and al ign
with tunnel mounting holes.
18. Install and hand tighten suspension bolts.
19. Inslall front carrier shaft assembly inside track and
mount to tunnel wilh bolts. Hand tighten bolts.
20. Install rear carrier shaft assembly. Make sure bolts
are not cross threaded and hand tighten.
21. lip machine back onto floor and tighten all suspension
bolts to proper torque specs. Refer to pages
10.4-10.5.
22. Reanach transmission shift linkage and brake light
connector.
23. Anach brake cable to transmission mounting with
bolt, nut and spacer. Refer to Chapter 8 for
adjustment specifications.
24. Install bumper onto footrest bolt and tighten.
25. Reinstall bumper plug.
26. Reinstall and secure muffler.
27. Loosen rear idler bolts.
28. Lift and support rear of unit and align track to
specifications found on page 9.11 . Make sure rear
idler wheel spacer location is correct before lightening
idler wheels.
29. Reinstall driven clutch and spacers onto jackshaft and
tighten.
30. Reinstall hood.
8194
9.22
RIDE RED
SUSPENSIONS
Type IX Extruded Aluminum Exploded View and Adjustments
Type IX Exploded View
Rear springs are changed or adjusted primarily
for different rider weight. To adjust, release front
leg from carrier wheel (8) , insert screwdriver
under spring leg (A) , and either raise or tower
short spring leg. Raising the spring leg will
increase spring preload. Lowering it will
decrease preload.
The front torque arm limiter strap can also be
altered for varying ski-Io-ground pressure.
Lengthening the limiter strap will decrease
ski-to-ground pressure. Shortening the strap will A
increase Ski-to-ground pressure.
9,23
. ~
-V
>
,
,""
B
RIDE RED
8194
SUSPENSIONS
Type XI Exploded View and Adjustments
Type XI Exploded View
Front Torque Arm Spring and Limiter Strap Adjustments
Ski pressure can be increased or decreased using the
following adjustments.
The front torque arm limiter straps (A) can be shortened
to increase ski pressure. The front torque arm shock
assembly may also be repositioned to either increase or
decrease travel firmness.
In the photo at righi , the shock and spring assembly are
in the most firm position. If a less firm spring is desired,
the shock can be mounted in the lower position (8).
On all suspension seNings, Polaris has set the machines
up for average riding condi tions and average rider weight.
Rear Shock Adjustment
If the ride seems a little firm after making the rear spri ng
adjustments, the rear shock can be moved to the upper
mounting hole (A) for a softer ride.
Rear Spring Adjustment
Rear springs are adjusted primarily for rider weight. To
check ride in, raise rear of machine to relieve rear spri ngs.
Slowly lower the machine and measure the distance from
the floor to a mark on the running board. Have the rider
carefull y mount the machine. Adjust the eye bolts equally
so there is approximately a 1 1 / 2 ~ (3.8 cm) drop as the
rider mounts the machine.
8194
9.24
RIDE RED
SUSPENSIONS
Type XII Exploded View and Adjustments
Type XII Exploded View
Rear Torque Arm Springs
Rear spring adjustment is primarily a control for rider
comfort. To check for recommended setting, Jift rear of
machine to relieve rear springs. Slowly lower the
machine and measure the distance from the ground to
the running board. Have the rider carefully mount the
machine. The difference between the two readings
should be approximately 1 1/2" (3.8 em). If the difference
is greater than 1 1/2" (3.8 em), the rear spring (A) should
be adjusted equally on both sides until the desired drop
is obtained.
NOTE: Rear spring settings will affect ski-la-ground
pressure. If ski pressure is too light, it may be desirable
to tighten rear springs for an increase in ski-to-ground
pressure.
9.25
8194
RIDE RED
SUSPENSIONS
Type XIII Exploded View and Adjustments
Type XIII Exploded View
Rear springs are changed or adjusted primarily
for rider weight. To adjust, release front leg from
carrier wheel (8) by inserting a screwdriver under
spring leg (A) and either raising or lowering short
spring leg. Raising the spring leg witl increase
spring preload. Lowering the spring leg will
decrease preload.
The front torque arm limiter strap may also be
adjusted for varying ski-to-ground pressure.
Lengthening the strap will decrease ski-to-ground
pressure. Shortening the strap will increase
skHo-ground pressure.
8194
A
9.26
RIDERED
SUSPENSIONS
Type XIV Exploded View and Adjustments
Type XIV Exploded View
Rear Torque Arm Springs
Rear spring adjustment is primarily a control lor rider
comfort. To check for recommended setting, lift rear of
machine to relieve rear springs. Slowly lower the machine
and measure the distance from the ground to the running
board. Have the rider carefully mount the machine. The
difference between the two readings should be
approximately 1 1/2" (3.8 em). If the difference is greater
than 1 1/2" (3.8 em), the rear spring (A) should be
adjusted equally on both sides until the desired drop is
obtained.
NOTE: Rear spring settings will affect ski-tOiJround
pressure. If ski pressure is too light, it may be desirable
to lighten rear springs lor an increase in ski-to-ground
pressure.
9.27
8194
RIDE RED
SUSPENSIONS
Type XV Exploded View and Adjustments
Type XV Exploded View
Front Torque Arm Spring and Limiter Strap Adjustments
In the photo al right. the shock and spring assembl y are
On all suspension settings, Polaris has set the machines
up for average riding conditions and average rider weight.
If the ride seems a little firm after making the rear spring
check ride in, raise rear of machine to relieve rear springs.
Slowly lower the machine and measure the distance from
the floor to a mark on the running board. Have the rider
carefully mount the machine. Adjust the eye bolts equally
so there is approximately a 1 1/2" (3.8 cm) drop as the
rider mounts the machine.
8/94
9.28
RIDE RED
SUSPENSIONS
Type XVI Explod>d View and Adjustments
~ .

Type XVI Exploded View
. Front Torque Arm Spring and Limiter Strap Adjustments
In the photo at right, the shock and spring assembly are
On all suspension settings, Polaris has set the machines
up for average ridi ng conditions and average rider
weight.
If the ride seems a little firm after making the rear spring
check ride in, raise rear of machine to relieve rear
springs. Slowly lower the machine and measure the
distance from the floor to a mark on the running board.
Have the rider carefully mount the machine. Adjust the
eye bolts equally so there is approximately a 1 1/2'" (3.8
cm) drop as the rider mounts the machine. Adjust
springs so there is equal tension on the long leg of each
spring.
9.29
8194
RIDE RED
SUSPENSIONS
Type XVII Extruded Aluminum Exploded Vi ew and Adjustments
Adjustments
Compensating adjustments for heavy or light drivers or
cargo loads can be made by adjusting the rear spring
eyebolt length. Rear spring settings also affect
ski-to-ground pressure. Increasing spring tension also
increases ski pressure. Adjust spring tension so there is
equal tension on the long leg of each spring (Al.
The front torque arm limiter strap can also be altered for
varying ski-Io-ground pressure. Lengthening the limiter
strap will decrease ski-to-ground pressure. Shortening
the limiter strap will increase skHo-ground pressure.
8194
9.30
RIDE RED
SUSPENSIONS
Type XVIII Extruded Aluminum Exploded View and Adjustments
Type XVIII Exploded View
Adjustments
Compensating adjustments for heavy or tight drivers or
cargo loads can be made by adjusting the rear spring
eyebolt length. Rear spring settings also affect
ski-to-ground pressure. I ncreasing spring tension also
increases ski pressure. Adjust spring tension so there is
equal tension on the long leg of each spring (A).
The front torque arm limiter strap can also be altered for
varying ski-to-ground pressure. Lengthening the limiter
strap will decrease ski-la-ground pressure. Shortening
the limiter strap will increase ski -to-ground pressure.
9.31
RIDE RED
8194

SUSPENSIONS
Type XIX Extruded Aluminum Exploded View and Adjustments
Tunnel
l
I
Refer to Type XV Adjustments Page 9.28
8/94
9.32
RIDERED
SUSPENSIONS
Type XX Extruded Aluminum Exploded View and Adjustments
, .
Rear Suspension Adjustments
In addition to the main eccentric block adjustments, a
provision for intermediate adjusting has been provided
with the adjusting knob (1).
This feature provides for fine adjustments. To adjust,
rotate adjuster knob as shown for spring tension
changes.
9.33

RIDE RED
8/94
SUSPENSIONS
Type XX Extruded Aluminum Exploded View and Adjustments
Dial Adjust Slide Rails
The rear torque arm must be mounted in Ihe
rear slide rail hole, indicated by Ihe arrow on
the illustration al right. CAUTION: Never
mount in either of the forward holes or
suspension damage will result.
Rear spring tension adjustments are made by
rotating the eccentric spring block with the
engine spark plug tool as shown. 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.
1 Soft
2 Short End, Medium
3 Long End, Most Firm
Suspension Adjustment Springs for
Dial Adjust Suspension Only
AVAILABLE SPRING
7041246 Left Hand
7041247 Right Hand
7041248 Left Hand
7041249 Right Hand
7041235 Left Hand
7041236 Righi Hand
WIRE DIAMETER
.406
.406
.421
.421
.437
.437
Although the snowmobile suspension has the
capability of providing the best ride possible,
the following accessory springs are available
to better suil individual riding preferences.
8194
Lighter
I
Heavier
9.34
RICERED
Perfecti ng the Ride
SUSPENSIONS
Type XX Adjustments - Dial Adjust
The Polaris long travel Dial Adjust suspension has many adjustment features which many customers are nol
taking advantage of. This suspension can be individually tailored to a rider's size and riding style for maximum
comfort and performance.
The rear suspension springs are the main load carrying part of the rear suspension. they have eccentric blocks
which can be turned with a spark plug socket to one of three primary positions: soft, medium, or firm. In addition
to the primary adjustment , a secondary adjustment dial is provided to fine tune the rear spring tension to any
setting between the steps 01 the primary adjustment block by turning the dial clockwise to increase spring tension,
or counterclockwise to decrease spring tension. The adjustability of the dial adjust suspension will provide proper
handling and ride comfort for most Polaris riders.
When changing rear suspension spring rate andlor rear ride height, the amount of downward ski pressure will
change. If the pressure 100 great, the handlebars will be hard to turn. If the pressure is too light, the skis will not
dig in and the machine won't turn. The rear suspension front shock top has two mounting positions. The more
vertical position provides a stiffer and less ski pressure, while the more down" position provides
a smoother ride with more ski pressure.
In addition to the shock, there is a front torque arm limiter strap. This strap controls the amount of downward travel
in the front of the suspension rail. If the strap is lengthened, the front of the rail will push down more, lifting some
pressure off the skis. Shortening the limiter strap will lift the front of the suspension. increasing downward ski
pressure.
Dial adjust suspensions must be adjusted at both the front and rear mounting positions in unison. If you move
down a hole in the front , you must do the same in the rear. You may move down one hole in the rear without moving
down in the front, but never the reverse.
Rear Torque Arm Tunnel Positions
Production:
Optional :
x 5
-){- . 4
I 0 3
o
3-3 (Rear - Front)
1-2 (Rear - Front)
Front Torque Arm Tunnel Positions
,--,
I )(' I 5
4
I 0 3
I '.' 2
,
A Longest
"''>.-_--B Middle
Y'".-- C Shortest
Adjustments are open to driver preference. Remember that limiter strap adjustment will affect steering.
CAUTION: Using any location or track tension other than that recommended will result in severe tunnel and/or
drive shaft damage.
9.35
AICERED
8194
SUSPENSIONS
Type XXII Exploded View
1991 _ 1992 XCR AS SHOWN HERE
8194
9.36
AIDE RED
This suspension is equipped with Fox Shocks. It has
limiter straps on the front and rear torque arms
(1991-1992 XCR shown).
When shortening the front limiter strap you will have
more ski pressure and when shortening the rear
limiter strap you will have tess ski pressure.
There is a three position eccentric block for rear spring
tension adjustments. The front torque arm shock and
spring is more aggressive when mounted on the back
side of the front torque arm.
NOTE: On XCR Models it is not recommended that
any mount position other than the factory position (A)
be used.
9.37
SUSPENSIONS
Type XXII Adjustments
RIDERED
8194
SUSPENSIONS
Type ITS - Improved Transfer Suspension
The Improved Transfer Suspension (ITS) is designed to retain less snow, transfer more unit weight to the rear of
the suspension for improved performance and hook up more aggressively for a better hole shot. With the ITS
there will be more track bearing surface on the ground. The ITS suspension is very responsive to the rider's body
shifting forward and aft, increasing or decreasing ski pressure. Additional wheel kits are available (PN 2871 073).
A complete suspension, front and rear, will require two kits. NOTE: These wheels are standard on the Storm
model.
Wheel Kit PN 2871073
The ITS suspension has new design rails, rear springs, rear torque arms and bumper pads. CAUTION: The ITS
suspension is not to be used in previous production models without tunnel modifications. Severe tunnel and/or
drive shaft damage will result.
The ITS suspension must be adjusted in unison in the front and rear mounting holes. If you move down a hole in
the front, you must do the same in the rear. You can move down one hole in the rear without moving the front. but
not the reverse.
Rear Torque Arm Tunnel Positions
5
~ ) ( - I 4
I 0 I 3
o
NOTE: When drilling additional suspension mounting holes in
the tunnel, the unused holes should be secured with a bolt
and nut to increase tunnel and pad strength.
Front Torque Arm Tunnel Positions
1--'
I )( I 5
< 4
I 0 3
I '. 1 2
1
A Longest
B Middle
'S<'<,----c Short est
Adjustments are open to driver preference. Remember that limiter strap adjustments will affect steering.
CAUTION: Using any location or track tension other than recommended will result in severe tunnel and/or drive
shaft damage.
8194
9.38
RIDE RED
Rear spring tension adjustments are made by rotating
the eccentric spring block as shown with the engine
spark plug tool. The block provides three spring
tensions positions. NOTE: This adjustment is easier
if the long spring leg is lifted over the roller and
replaced after the block is properly positioned.
1. Softest position - long end forward
2. Medium position - short end up
3. Most fi rm position -long end up
CAUTION: The long end of the block must never be
positioned facing toward the rear of the machine or
the block will break, or the spring may slip off the
eccentric and gouge the track.
Rear scissor lower mount (4) should not be changed
unless the eccentric block is positioned with the long
end forward (softest position).
Suspension Adjustment Springs ITS
SUSPENSIONS
Type ITS Adjustment
Long end must face
front of machine
1 _---'" 0""",'5/)
Softest
Position
2-----'f,J
Medium
Position
3 - - - ~
Most Firm
Position
Although the snowmobile's suspension has the capability of providing the best ride possible, the following
accessory springs are available to better suit individual riding needs. Refer to the specification page in this section
to find the spring used as standard equipment and determine from the chart below which spring best suits the
individual's needs.
1993
Available Spong
7041276 left Hand
7041277 Right Hand
7041273lefl Hand
7041274 Right Hand
7041278lefl Hand
7041279 Right Hand
1994
7041337 left Hand
7041338 Right Hand
7041339 left Hand
7041340 Right Hand
Wire Oia.
.406
.406
.421
.421
.437
.437
.421
.421
.437
.437
C.olor
Tan
Tan
Orange
Orange
Red
Red
C.olor
Gray
Gray
Brown
Brown
Yellow
Yellow
Heavier
Ughler
t '
Heavier
When changing rear suspension spri ng rate and/or rear ride height, the amount of downward ski pressure will
change. If the pressure is too much, the handlebars will be hard to turn. If the pressure is too little, the skis will not
dig in and the machine won't turn. The front of the rear suspension provides a number of adjustments so that the
right ski pressure can be maintained. The rear suspension front shock top has two mounting positions. The more
vertical position provides a stiffer suspension and less ski pressure while the more laid down position provides a
smoother ride with more ski pressure. NOTE: The lower rear torque arm shock mount cannot be used or the
suspension will nol pivot.
In addition to the shock, there is a front torque arm limiter strap which controls the amount of downward travel in
the front of the suspension rai l. If the strap is lengthened, the front of the rail will push down more, lifting some
pressure off the skis. Shortening the limiter strap will lift the front of the suspension, i ncreasing ski downward
pressure.
9.39
RIDE RED
8/94
SUSPENSIONS d d View _ Type I
Type ITS Explo e .
XLT Special
r;, Storm
~
- < .,.
~ .
" .
. \
<l,

XLT Special
~ RXL
~ . ~ Storm
" ' ~ ~
"'. ~ If
/ ~
~ "
. ~
,
\
I
8194 9.40
AICERED
-
SUSPENSIONS
Type ITS Exploded V,ew
. . Type II
I
Storm SKS
9.41
8/94
RIDE RED
SUSPENSIONS
XXIII - Exploded View
8194
Reference Type XV Suspension for
Adjustments Page 9.28
9.42
AIDE RED
SUSPENSIONS
XC-100 Exploded View
The XC-l00 rear suspension combines the best of the ITS and XCR suspensions. It provides improved steering.
reduced ski lift for more positive handling in the corners, and improved driveability in deep snow conditions. The
front torque arm is longer, with tunnel mounting of the suspension 1" (2.5 em) further back than the ITS. The
XC-l 00 utilizes rails and rear scissors with shock linkage rods similar to the XCR. The shock linkage rods insure
maximum performance of the shock. The XC-' 00 suspension has the option of changing shock position on the
upper rear mount. Repositioning the shock changes its action, having much the same effect as re-valving the
shock softer.
! ~
I I \
I \
Wheel Kit Assembly
PN 2871073 (1 Kit per Suspension)
Use of the optional wheel kit is recommended in areas where snow conditions are marginal and snow is hard
packed. Occasional snow dipping of the rail is advised for lubrication 01 hi-lax in hard pack conditions.
9.43
RICE RED
8/94
SUSPENSIONS
XC-101 Exploded View
The XC-l01 suspension was used in , 995600 XCR and 440 XCR SP models.
11 /95
9.43a
RICERED
SUSPENSIONS
Deep Snow Adjustments
Front Torque Arm
Positioning the limiler strap al its longest length and the center shock in the lower position (see illuslralion) will
improve flotation in deep snow. NOTE: Some models will have two limiter straps.
Reposition Shock - ---::-'=--"
To Lower Mount
Repositioning Limiter Strap
Changing the spring rale of the center spring can improve snowmobitity. The lighter the rale of the spring, the more
improvement will be noticed. However, there is an adverse effect on ride quality when lighter springs are used.
Following are center spring options:
Light 181 #/i n PN 7041127
PN 7041140
PN 7041289

Heavy
181 #/in (longer free length than above)
Variable (stock on Storm model)
NOTE: Fox shocks can be adjusted without changing the spring.
Rear Torque Arm
Adjusting the rear spring block (A) to its highest
position (as illustrated) will increase spring preload,
also improving snowmobility.
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.
the block will break.
8194
9.44
Q
A----=
Firm Tension
(Long
RIDERED
SUSPENSIONS
Tunnel Mounting Locations For Deep Snow
There are some suspension adjustments which can be made to help in deep snow, such as lowering fronl and rear
torque arms. (Options are illustrated.) CAUTION: Both front and rear torque arms must be moved down or up
together to prevent severe tunnel damage.
Additional front holes may be transfer drilled into the tunnel from the inside using the suspension pad as a
template. CAUTION: Do not dri ll any lower than the middle hole or tunnel damage will occur.
WARNING: No opti ona/ tunnel mountings are avai lable for the XTRA Suspension. Any variation from
stock positions will damage the tunnel and suspension.
STANDARD LENGTH TUNNEL
Rear
,
B
Factory Setting: A-A
Option: 88
SKS LENGTH TUNNEL
Rear
,
, B
C
Factory Setting: B-B
Option: C-B
Front
I 0 I B
I
Front
1--'"
I 0 I A
I 0 I B
WARNING! Any other combination will result in tunnel damage.
NOTE: When drilling additional suspension mounting holes in the tunnel. the unused holes should be secured
with a bolt and nut to increase tunnel and pad strength.
9.45
8194
RIDE RED
SUSPENSIONS
XCtOO Adjustment
the eccentric spring block as shown with the engine
spark plug tool. The block provides three spring
tensions positions. NOTE: This adjustment is easier
if the long spring leg is lifted ovef the roller and
replaced after the block is properly positioned.
1. Softest position - long end forward
2. Medium position - short end up
3. Most firm position - long end up
the block will break.
Suspension Adjustment Springs
Although the snowmobile's suspension has the
capability of providing the best ride possible, the
following accessory springs are available to better suit
individual riding needs. Refer to the specification
page in this section to find the spring rate.
When changing rear suspension spring rate and/or
rear ride height, the amount of downward ski pressure
will change. If the pressure is too much, the
handlebars will be hard to turn. If the pressure is too
tittle, the skis will not dig in and the machine won't turn.
The front of the rear suspension provides a number of
adjustments so that the right ski pressure can be
maintained. The rear suspension front shock top has
two mounting posi ti ons. The more vertical position
provides a stiffer suspension and less ski pressure
while the more laid down position provides a smoother
ride with more ski pressure. NOTE: The lower rear
torque arm shock mount cannot be used or the
suspension will not pivot.
In addition to the shock, there is a front torque arm
limiter strap which controls the amount of downward
travel in the front of the suspension rail. If the strap is
lengthened, the front of the rail will push down more,
lifting some pressure off the skis. Shortening the
limi ter strap will lift the front of the suspension,
increasing ski downward pressure.
8194
9.46
Long end must face
front of machine
1 _---"'E'I
Softest
Position
2 --------<'.j
Medium
Position
3 ----""'1\
Most Firm
Position
SIXiog Oia.
7041246 Left Hand .406
7041247 Righi Hand .406
7041248 left Hand .421
7041249 Righi Hand .421
7041235 left Hand .437
7041236 Right Hand .437
RIDERED
Lighter
Heavier
XTRA Susp
9.47
NSIONS
SUSPE View
. Exploded
enslon
E
RED
RID
8/94
SUSPENSIONS
XTRA Suspension
XTRA Suspension
The XTRA suspension system
has been designed to provide the
rider with a wide range of
adjustment. Polaris also has
available many optional springs
which will allow the suspension
to be customized to any rider
weight and riding style. The
optional springs and suggested
set-up charts are on page 9.49.
The XTRA suspension is also
equipped with FOXTM take apart,
re-valvable shocks to allow the
rider flexibility in complete
suspension tuning.
Rear Suspension Adjustment
Rear suspension settings on the XTRA suspension are
determined by rider weight. aggressiveness, and terrain
conditions.
This suspension is made up of two coil springs, each over a shock
absorber. and a pair of torsion springs on the rear torque arm. See
suspension illustration above.
The large coil spring on the front track shock has the most effect on
ride and handling characteristics. The preload on this spring is
adjusted in the same manner as on the front skis. (See chart on
page 9.49 for initial setting for rider weight.)
NOTE: Additional wheel kits are available for the XTRA
Suspension.
Front Suspension Adjustment
High
Low
Rear Track
Shock Assy.
"-
" E
~
~
Rear Torque
A,m
Increases
Preload
Generally, the softest spring and spring preload give the best ride and also the best traction. The spring preload
can be adjusted by grasping the spri ng and turning in a counterclockwise direction to increase preload.
CAUTION: Do not screw the plastic nut off the threaded body or the nut may break. Always maintain full thread
engagement.
Rear Torque Arm Stop
The XTRA rear torque arm has both front and rear pivot stops. The
front stop is adjustable. The normal position is with the longest side
toward the rear. In most conditions this is the preferred position.
For deep snow conditions where more weight transfer is desired,
this block should be adjusted with the short side toward the rear.
CAUTION: Be sure both blocks are in the same position or
suspension damage may occur.
8/94
9.48
Front Stop Shown
Long Side to Rear ~
~ \ I : W
RIDE RED
Suspension Adjustment Springs
SUSPENSIONS
XTRA Suspension
Although this snowmobile suspension has the capability of providing the best ride possible, the following
accessory rear springs are available to better suit individual riding preference.
Coil Spri ng Part No.
7041396 ............... .
7041405 .... ... . .... . . .
7041398 .................. .
7041351 . .... ...... .. ..... .
7041404 .................. .
Torsi on Spring Part No.
7041394 &
7041395 .. . ............... .
7041406 &
7041407 .................. .
Spring Wire Di a. x Free Length - Rate
.283 x 11.88 - 50 #/in. (Stock on XLT SP)
.283 x 11.88 - 65 #/in. (Stock on RXL)
.318 x 11.88 - 75 #/in.
.318 x 11.88 - 75/125 #/in.
. 331 x 11.88-90/200#/in.
Wire Dla.lDegrees
NOTE: Springs on the front ski shocks and front (center) track shock are interchangeable.
CAUTION: Springs on front skis must be the same rate. Valving in shocks may havetQ be changed in some cases
or loss of control could result. See pages 9.76-9.86, or the suspension wallchart for additional valving information.
Initial Suspension Set Up
The following chart is only a guideline to be used for initial suspension set up. Set up may vary based on desired
riding style . Indicates factory set up.
Rider Front Track Torsion Rear Track
Weight Spring Spring Spri ng
110-1601bs. 75 #r.n. .406 Low 200 Var #lin .
(50-73 kg) Setting
160-210 75/125 #lin .406 Low 200 Var #/in .
Ibs. Low-Mad Setting
(73-95 kg) Preload
210-260 Ibs. 75/125 #/in .406 High 200 Var #/in.
(95-118 kg) High Pre- Setting
load
260+ Ibs. 90/200 #/in .406 High 200 Var #/in.
(118+ kg) Low Preload Setting
.421 Low
Setting
Suspension Shafts
All suspension shafts which are housed in a tubing will
have O-Rings installed on either end of the shaft. This wi ll
keep moisture out of pivoting areas and help retain
lubrication.
Suspension Shaft Maintenance
As suspension shafts are cleaned or replaced, the
O-Rings should be inspected and replaced as required.
1. Lubricate shafts and install in pivot tubes without
O-Rings. CAUTION: If O-Rings are installed first
they may be damaged when pushed past the grease
fitting. Remember to install O-Rings last.
2. With the shaft in place, extend shaft far enough to
allow O-Ring installation on either end.
9.49
O-Rings
RIDE RED
8/94
SUSPENSIONS
XTRA Suspension
XTRA Suspension Shock Removal
Both front and rear suspension shocks and Hi-Fax can be removed from the rear suspension without removing the
suspension from the machine. Sleps 1-4 (immediately below) may be used for either front or rear.
1 . Turn fuel valve to off
position.
2. Lift and securely
support rear of
machine high
enough to assure
access to track and
suspension.
3. Loosen rear idler
bolts (A) and track
adjuster bolts (8)
with lock nuts (C).
4. Lift rear torsion
springs (0) from
their lower mounts.
0
C
Rear Shock Removal
1 . Remove scissor
stops from rail in front F
of rear torque arm.
To aid in removal,
collapse rear of
suspension slightly
by applying pressure
on rear bumper.
2. Remove retaining
botts, nuts, washers
and scissor SlOP
block (H) from both
sides.
3. Remove rear lower
shock bolt (8).
4. Remove upper
shock bolt (C).
5. Remove shock (0).
Front Shock Removal
1. Remove lower shock mount bolt (E), noting orientation of parts.
2. Remove upper shock boll (F).
3. Remove shock (G).
8/94
9.50 RIDE RED
Front Shock Reassembly
To reinstall front shock, the suspension must be fully extended and the track loose.
1. Install shock with
booled end (A)
toward top mount
brackets. Using a
new FlexLoc
n
.. nut,
tighten nut and bolt
securely, making
sure the shock still
pivots and does not
bind on spacer.
Torque to 15-18 ft.
Ibs. (2.07-2.48
kg/m).
2. Fully extend shock
and align with lower
brackets (8). Posi-
tion shock so valves
point downward.
A
8
3. Position bolt, washer, bushing. and rod with shock to brackets (8).
SUSPENSIONS
XTRA Suspension
4. Install a new FtexLoc
TW
nut and tighten assembly securely. CAUTION: Do not over tighten or shock will not
pivot correctly. Torque to 12 ft. Ibs. (1.66 kg/mI.
S. Secure jam nuts and tighten rear idler bolts.
6. Position torsion springs with top eccentric and lower mount.
7. Readjust and align track. See pages 9.10-9.11.
8. Secure jam nuts and tighten rear idler bolts.
Rear Shock Reassembly
To reinstall rear shock. suspension must be fully extended and track loose.
t. Install shock with
body up toward
mounts (A), and
valve pointing
downward.
2. Using a new
FlexLoc
Tli
nut,
tighten nut and bolt
securely. making
sure the shock still
pivots freely. Torque
10 15-18 H. Ibs.
(2.07-2.48 kg/m) .
3. Position lower shock mount (8) with brackets and insert bolt. Secure using a new FlexLoc' II nut. Torque to
15-18 H. Ibs. (2.07-2.48 kg/m) .
4. Reinstall scissor stops (C) and position for rider preference.
S. Install a new FlexLoc
Tw
nut and torque to 22 ft.lbs. (3.03 kg/mI
6. Position torsion springs on top eccentric and lower mount.
7. Readjust and align track. See pages 9.1 0-9.1l.
8. Secure jam nuts and tighten rear idler bolls. __
9.51
RICEREC
8194
SUSPENSIONS
IFS Shock, Spring Chart
1995 INDEPENDENT FRONT SUSPENSION (IFS) SHOCK
Model Model No. Shock PN Shock Shock Maker Spring
Description Descriptlon Description
Starlite 0953427 7041264 Hyd Gabriel 105#lin
Indy Lite 0953433 7041284 Hyd Gabriel 105#fi n
Indv lite Deluxe 0953431 7041284 Hyd Gabriel 105#lin
Indy Lite GT 0953133 7041284 Hyd Gabriel 105#li n
Sport 0950443 7041284 Hyd Gabriel l05#lin
Super Sport 0950743 7041388 G.a.Cam Gabriel l05#/in
Sport Touring 0950243 7041264 Hyd Gabriel 105#/in
Trail 0952761 7041288 G.B. Cam Gabriel 105#lin
Trail Deluxe 0952262 7041288 G.B. Cam Gabriel 120#lin
440 0952760 7041288 G.B. Cam Gabriel 105#lin
440 SKS 0952560 7041282 G.B. Cam Gabriel 12O#lin
440 XCA 0951660 7041346 Gas IFP Fo, 12O#lin
600 XCA 0951676 7041346 Gas IFP Fo, 12O#lin
Classic 0952865 7041288 G.B. Cam Gabriel 12O#/ln
500 Carb 0952764 7041288 G.B. Cam Gabriel 120#lin
WideTrak GT 0952061 7041284 Hyd Gabriel 105#lin
Wide T rak LX 0952064 7041284 Hyd Gabriel 105#lin
500 EFI 0952774 7041288 G.B./Cam Gabriel 12O#lin
500 EFI SKS 0952574 7041282 G.B. Cam Gabriel 120#/in
500 EFI SKS PT 0952974 7041282 G.B. Cam Gabriel 120#lin
XLT 0950756 7041285 Gas-Bag Gabriel 105#/in
XLT SKS 0950556 7041285 Gas-Bag Gabriel 105#/in
XLT SKS PT 0950956 7041285 Gas Bag Gabriel 105#/in
XLT SP 0956756 7041385 Gas IFP Fo, 50#lin
XLTTouring 0952857 7041288 G.8. Cam Gabriel 120#lin
RXL 0956768 7041385 Gas IFP Fo, 75#lin
RXL Touring 0950869 7041282 G.B. Cam Gabriel 120#/in
Storm 0950782 7041390 G.B. Cam Gabriel-Select 16O#tin
Storm SKS 0950582 7041393 G.B. Cam Gabriel-Select 160#lin
Storm SKS PT 0950982 7041393 G.B.Cam Gabriel-Select 160#tin
KEY: Hyd - Hydraulic Standard Shock Gas IFP - Gas Charged Internal Floating Piston, Fox Shock
Select - Gabriel Select Adjustable Shock
NOTE: AU pounds referred to in the spring descripti on column are .t 10%
8194
9.52
RICEREC
Spring PN
7041261
7041261
7041261
7041261
7041261
7041261
7041261
7041261
7041344
7041261
7041334
7041252
7041252
7041334
7041334
7041261
7041261
7041261
7041334
7041334
7041261
7041261
7041261
7041396
7041334
7041398
7041261
7041287
7041287
7041287
OPTIONAL SUSPENSION SPRINGS
SUSPENSIONS
Rear Shock
Although the snowmobile's suspension has the capability of providing the best ride possible, the following
accessory springs are available to better suit individual riding needs.
XG-l00andXC-l01 Sospens,ons; L ~ e Type SuspeoSlOOS:
Spring WireOia. Spoi",
7041246
0""
Lighter
1041318
7041247
0.""
t
7041319
7041248 0.421
7041119
1041249 0.421 7041120
7041235 0.431 704132Q
1041236 0.437 Heavier
7041321
Compression Adjustable Shocks
Indy Select Shocks are standard equipment on all 1995
Storm models. AFX shocks are standard on the XLT
Touring model. Both shocks allow the dealer or consumer
the ability to adjust the compression rate. All that is
required to adjust compression is a simple turn with a
regular screwdriver. Turning the screw clockwise
increases compression. Turning . the screw
counterclockwise decreases compression. Maximum
adjustment is 2 1/2 turns.
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. FOXH.I Shocks
should be installed with the charge fitting up.
9.53
Wire Cia.
0.315 Lighter
0.375
t
0.393
0.393
0.406
0.406 Heavier
Damping Force
/ ~ \ Adiu,tment
" 0) AdJu,Jment Se<ew
RIDE RED
8/94
SUSPENSIONS
Center Shock, Spring Chart
1994 REAR SUSPENSION (CENTER)
Model Description Model PH Shock PH Shock Shock S p r i n ~ Spring PN
Description Maker DescriptIon
StarUte 0943427 7041142 Hyd Gabriel 181#/in 7041127
SlarLile GT 0943127 7041142 Hyd Gabriel 181#/in 7041127
Indy Ule 0943433 7041142 Hyd Gabriel 181#lin 7041127
Indy lite Deluxe 0943431 7041142 Hyd Gabriel 181#/i n 7041127
Indy lite GT 0943133 7041142 Hyd Gabriel 181#lin 7041127
Sport 0940443 7041142 Hyd Gabriel 181#fi n 7041127
Sport SKS (Rental ) 0940243 7041281 Hyd Gabriel 181#fin 7041140
Super Sport 0940743 7041281 Hyd Gabriel 181#/in 7041140
Trail 0940761 7041281 Hyd Gabriel 181#/in 7041140
Trail Deluxe 0940262 7041281 Hyd Gabriel 181#lin 7041140
440 liquid Indy 0940760 7041281 Hyd Gabriel 181#lin 7041140
440 liquid Indy SKS 0940560 7041281 Hyd Gabriel 181#lin 7041140
440 XCR 0941760 7041294 Gas IFP
Fo' 202#lin 7041253
440 XCR SP 0941660 7041344 Gas IFP Fo, 181#lin 7041253
BOOXCR 0941667 .7041344 Gas IFP
Fo'
181#lin 7041253
Classic 0942865 7041281 Hyd Gabriel 181#lin 7041140
Classic Touring 0942875 7041281 Hyd Gabriel 181#/in 7041140
WideTrak GT 0942061 7041281 Hyd Gabriel 181#/in 7041140
WideTrak LX 0942064 7041281 Hyd Gabriel 181#li n 7041140
500 EFI 0942774 7041281 Hyd Gabriel 181#lin 7041140
500 EFI SKS 0942574 7041281 Hyd Gabriel 181#li n 7041140
XLT 0940767 7041281 Hyd Gabriel 202#lin 7041289
XlT SKS 0940567 7041281 Hyd Gabriel 181#lin 7041140
XlT SP 0940667 7041294 Gas IFP
Fo' 202#lin 7041253
XlT Special Xlra 0946767 7041386 Gas IFP
Fo' 751125#lin 7041351
AXL 0940768 7041281 Hyd Gabriel 181#/in 7041 140
RXl SKS 0940869 7041294 Gas IFP Fo, 202#lin 7041253
Storm 0940782 704 1281 Hyd Gabriel 202#lin 7041289
Storm SKS 0940582 7041281 Hyd Gabriel 2D2#lin 7041289
NOTE: All pounds referred to in the spring description column are 10%
8/94
9.54
RIDERED
1995 REAR SUSPENSION (CENTER)
Model Model PH Shock PN Shock
Dascrlptlon
StarLite 0953427 7041142 Hyd
Indy Ute 0953433 7041142 Hyd
Indy Llle Deluxe 0953431 7041142 Hyd
Indy Lite GT 0953133 7041142 Hyd
Sport 0950443 7041142 Hyd
Sport Touring 0950243 7041142 Hyd
Super Sport 0950743 7041281 Hyd
Trail 0952761 7041281 Hyd
Trait Deluxe 0952262 7041261 Hyd
440 0952760 7041281 Hyd
440 SKS 0952560 7041281 Hyd
440 XCA 0951660 7041413 Gas IFP
600 XCR 0951676 7041413 Gas IFP
Classic 0952865 7041281 Hyd
600 0952764 7041281 Hyd
WldeTrak GT 0952061 7041281 Hyd
WldeTrak LX 0952064 7041281 Hyd
SOD EFI 0952774 7041281 Hyd
500 EFI SKS 0952574 7041281 Hyd
500 EFI SKS PT 0952974 7041281 Hyd
XLT 0950756 7041281 Hyd
XLT SKS 0950556 7041281 Hyd
XLT SKS PT 0950956 7041281 Hyd
XLT SP 0956756 7041386 Gas IFP
XLT Touring 0952857 7041281 Hyd
RXL 0956768 7041386 Gas IFP
RXL Touring 0950869 7041281 Hyd
Storm 0950782 7041281 Hyd
Storm SKS 0950582 7041281 Hyd
Storm SKS PT 0950982 7041281 Hyd
202#/in Var - 200# variable rate
SUSPENSIONS
Center Shock, Spring Chart
Shock Spnon Spring PN
Maker Oescrlpt on
Gabriel lS1#lin 704'127
Gabriel 181#ll n 7041127
Gabriel 181#lin 7041127
Gabriel 181#fin 7041140
Gabriel 161#/in 7041140
Gabriel 181 #lin 7041140
Gabriel 181 #lin 7041140
Gabriel 181#/i n 7041140
Fo'
202#/in Var 7041253
Fo'
202#/in Var 7041253
Gabrie! 181#/i n 7041140
Gabriel 181 #/in 7041140
Gabriel 181#/in 7041140
Gabriel 181#li n 7041140
Fo, 75/125#/in 7041351
Fo, 751125#li n 7041351
Gabriel 202#lin Var 7041289
Gabriel 202#/i n Var 7041289
Gabriel 181#/i n 7041140
CAUTION: Fox
T
" Shock orientation should be with the charge fitting in the ~ u p " position. If mounted incorrectly,
the fitting will catch the track drive lugs.
9.55
AICERED
11/95
SUSPENSIONS
1994 REAR SUSPENSION (REAR
Mod,lI Mod" PN Sho,k PN

I SIa,Li" Hyd
I SIa,Liio G1 0943127 Hyd
I'''''' Ulo
Hyd
I'''''' Lit, 0",,,
Hyd
I'''''' lrto GT
0943133 Hyd
I Span Hyd
'IR"Io')
r,.iI
,
II"",
II"", SKS
10941760 G" 'FP
G" 'FP
. G" 'FP
. ,Tau"",
WideT,ok GT

I Hyd
7041 I Hyd
500 EF'
SOO EF' SKS
Xl"
XlT SKS
S I G"
XlTSP
XlT Spoe'" X". I G .. 'FP
RXl
RXl SKS
I G" 'FP
S'rnm
Slo,m SKS
KEY: Hyd Hydraulic Standard Shock
Gas IFP - Gas Charged Inlernal Floating Piston, Fox Shock
Gas-Bag - Gas Fined Bag
NOTE: All pounds referred to in the spring description col umn are '0%
Optional Suspension Springs
I Shook M.ko, spn"1
Spring PH
,
I 10.393
I Gabriel
1
0
.
393
I G",",' 10.393
I Gabriel 10.393
I G.bri,' 10.393
I G.""" 1
0
.
393
I G."""
10.421
I G.""" 10.421
I G.bri" 0.406
G.bri,' >'421
G."""
>'421
G."""
0. 421
Fo, >'421
Fo, 0.421 , 249
Fo, 0.421 , 249
G",",' 0.421
G.bri" 0.421
G."""
0.468
G."""
0.468
G",",' 0.421
G.""" 0.42'
G."""
0.421
G."""
0.421
Fo, 0.421
F"
0.406
0.42'
F"
0.421
G."""
0.421

G."""
0.421
Although the snowmobile's suspension has the capability 01 providing the best ride possible, the following accessory
springs are available to better suit individual riding needs.
Oial and XC-l00 Suspensions: ITS Suspens;oos Wilh MOfe Preload:
-
Wire Dia. Spring Wits Dia.
7041246 0.406
T
7041335 0.406 Ughler
7041247
,-
7041336 0_
t
7041248 0.421 7041337 0.421
7041249 0.421 7041338 0.421
7041235 0.437 7041339 0.437
7041236 0.437 Heavier 7041340 0.437 Heavier
ITS SllSpIIflSlOOS: SpoI1 Type Suspensions:
SpO", Wire Dia. Spring Wire Oia.
7041276 ,.- Lighter 7041318 0.375 Lighter
7041277 0.406
t
7041319 0.375
t
7041273 0.421 7041119 0.393
704 1274 0.421 7041120 0.393
7041278 0.437 7041320 0.""
7041279 0.437 HeaVIer 7041321 0._ HeaVIer
8/94
9. 56
RIDE RED
1995 REAR SUSPENSION (REAR SHOCK)
SUSPENSIONS
Rear Shock, Spring Chart
Model Description Model PN Shock PH Shock Shock Maker S p r l n ~ Spring PH
Descripti on
StarLite 0953427 7041154 Hyd Gabriel
Indy Lite 0953433 7041 154 Hyd Gabriel
Indy Lile Deluxe 0953431 7041154 Hyd Gabriel
Indy Lite GT 0953133 704'154 Hyd Gabriel
Sport 0950443 7041154 Hyd Gabriel
Sport Touring 0950243 7041331 Gas-Bag Gabriel
Super Sport 0950743 7041237 Gas-Bag Gabriel
Trail 0952761 7041237 Gas-Bag Gabriel
Trail Deluxe 0952262 7041331 Gas-Sag Gabriel
440 Liquid Indy 0952760 7041237 Gas-Bag Gabriel
440 Liquid Indy SKS 0952560 7041331 Gas-Bag Gabriel
440 XCA 0951660 7041345 Gas IFP Fo,
600 XCA 0951676 7041345 Gas IFP
Fo'
Classic 0952865 7041237 Gas-Bag Gabriel
500 0952764 7041237 Gas-Bag Gabriel
WideTrak GT 0952061 7041290 Hyd Gabriel
WideTrak LX 0952064 7041280 Hyd Gabriel
500 EFI 0952774 7041237 Gas-Bag Gabriel
500 EFt SKS 0952574 7041331 Gas-Bag Gabriel
500 EFI SKS PT 0952974 7041237 Gas-Sag Gabriel
XLT 0950756 7041331 Gas-Sag Gabriel
XLT SKS 0950556 704133 1 Gas-Sag Gabriel
XLT SKS PT 0950956 7041331 Gas-Bag Gabriel
XLT SP 0956756 7041387 Gas IFP
Fo'
XLT Touring 0952857 7041392 Gas-Sag AFX Gabriel
RXL 0956768 7041387 Gas IFP Fo,
AXL Touring 0950869 7041331 Gas-Sag Gabriel
Storm 0950782 7041391 Gas-Sag Select Gabriel
Storm SKS 0950582 7041391 Gas-Bag Select Gabriel
Storm SKS PT 0950243 7041391 Gas-Sag Select Gabriel
Gas-Bag - Gas Filled Bag
Select - Gabriel Select Adjustable Shock
AFX - Gabriel Adjustable Shock
9.57
Description
0.393
0.393
0.393
0.393
0.393
0.421
0.421
0.406
0.421
0.406
0.421
0.421
0.421
0.421
0.421
0.468
0.468
0.421
0.42 1
0.421
0.421
0.421
0.421
0.406
0.421
0.406
0.421
0.421
0.421
0.421
RIDE RED
7041119& 120
7041119& 120
7041 119& 120
7041119& 120
7041 119& 120
7041248 & 249
7041248 & 249
7041246 & 247
7041248 & 249
7041246 & 247
7041248 & 249
7041248 & 249
7041248 & 249
7041248 & 249
7041248 & 249
7041239 & 240
7041239 & 240
704 1 248 & 249
7041248 & 249
7041248 & 249
7041248 & 249
7041248 & 249
7041248 & 249
7041394 & 395
7041248 & 249
7041394 & 395
7041248 & 249
7041248 & 249
7041248 & 249
7041248 & 249
8/94
SUSPENSIONS
Troubleshooting
Situation
l. Very stjff ride.
2. Top speed down and
snowmobile will nol
free wheel.
3. Heavy steering.
4. Will not turn. Too little
ski pressure.
5. Track ralchel ing.
6. Shock shafts bent,
leaky seals, iced up
shocks.
8/94
Probable Cause
1 . Spring rate too aggressive.
2. Front torque arm shock in most
upright position.
3. Bent or corroded shafts.
4. Suspension shocks froze up.
l. Incorrect track tension and
alignment.
2. Worn hi-fax.
1 . Front torque arm limiter strap too
short.
2. Rear suspension springs rate
adjusted too high.
3. Incorrect suspension to tunnel
mounting locations.
l. Worn ski skags.
2. Limiter strap adjusted too long.
3. Rear spring set too soft.
4. Suspension mounted in wrong
lunnel location.
l. Track too loose.
2. Drive sprockets not timed,
incorrectly positioned.
3. Frozen shock (not allowing
suspension to travel).
4. Dri ve lugs worn off (if ralcheting
occurs severely, drive lugs of track
or sprockets may be ruined).
5. The suspension mounting is too
high in the front vs. too low in the
rear.
6. Too many studs (track will be too
aggressive and spin drive
sprockets).
7. 141" track ratcheting in deep snow.
l. Shock pivot tubes overtighten.
9.58
Remedy
1. Use a lighter spring setting or
step down in wire diameter.
2. Move shock top mounting to
forward front torque arm bracket.
3. Remove and inspect shafts.
Replace bad shafts, clean and
lubricate.
4. Replace jf damage and/or
remove ice buildup.
l. Refer to MRM for proper track
alignment and tension.
2. Replace if wavy or grooved.
l. Lengthen front limiter strap.
2. Set rear springs at a softer rate.
3. Check MRM chart for proper
mounting locations.
l. Inspect and replace if b ~ d .
2. Shorten limiter strap to put more
weight on the skis.
3. Set springs at a higher rate.
4. Check MRM chart for proper
mounting locations.
l. Tighten track. See page 9. 10.
2. Remove drive shaft assembly
and correct sprocket alignment.
3. Bring Into healed area, thaw and
assure proper working condition.
4. Replace worn parts.
5. Correclly position as
recommended only.
6. Remove studs, replace track
andior sprockets if necessary.
7. Tighten front torque arm spring
tension.
1 . Torque to proper specs. Assure
that shocks pivot freely.
RIDE RED
SUSPENSIONS
Fox' Shocks (Welded Dome Only) - Maintenance
Changing oil on Fox'" Shocks is recommended annually and must be done when doing your season-end storage
preparation. This oil change must be done to avoid any chance of corrosion which could be caused by moisture
contamination.
When doing maintenance on Fox
n
.. Shocks, use the Gas Shock Recharging Kit PN 2200421. It consists of the
necessary valves, pressure gauge, and fittings to deflate and pressurize the shocks.
WARNING: Extreme caution should be observed while handling and working with high pressure service
equipment.
Care should be observed while handling the inflater needle and the pressure gauges. Maintain your equipment
and keep it in good condition. If injury should occur, consult your physician immediately.
Extreme cleanliness is of utmost importance during all
disassembly and reassembly operations to prevent any
dirt or foreign particles from getting in the shocks.
1. Position shock in a vise with the pressure valve at its
highest position.
2. Insert inflater needle to de-pressurize. The valve
must be at the highest position to avoid oil spraying
out.
3. After de-pressurization. unscrew the top and pull
shock rod and piston straight out to avoid seal or
valve damage. Be prepared to catch the piston ring.
It may fall off as you do this.
4. Dump oil out and rinse cylinder with a mechanic
solvent or equivalent and blow dry with compressed
air.
9.59
8/94
AICERED
SUSPENSIONS
Fox Shocks (Welded Dome Only) - Maintenance
5. Hold the reservoir so it is at about a 151030angle
from vertical. Pour oi l (PN 2870995) in slowly
against side of reservoir to avoid mixing air into the
oil.
6. The oi l should be 2 ~ (5 em) from lOp of cylinder.
Measure with cylinder in straight up position as
shown. Position cylinder at 15 to 30. Insert
piston, keeping the three closely spaced valve
holes to the high side to allow all ai r to escape.
Gently wiggle piston and rod to help disperse ai r.
Keep sliding piston in until it's submerged in oil.
1""o-- """lII-Oil Level - 2.00"
8/94
Welded Dome Front Shock (Emulsion) PN
7041266
Early Version
r I"O-- ...... II-Oit Level 0: 2.00"
Threaded Body Cap Front Shock (Emulsion) PN 7041266
9.60
RIDERED
SUSPENSIONS
Fox Shocks (Welded Dome Only) - Maintenance
7. Screw lOp back on shock and position shock with
the pressure valve in the highest position.
Pressurize shock to 200 psi with nitrogen.
B. As a final check, stroke the shock a full stroke.
CAUTION: Never stroke the shock before it's
pressurized. Damage to the shock will occur.
9. When reinstalling shock assemblies onto the
machine, torque only to required specifications
found in Sections 2 or 10. If the shock is over
tightened it will not pivot, resulting in damage to
shaft and seals.
9.61
8194
RIDE RED
SUSPENSIONS
Fox' Shocks (Welded Dome Only) - Maintenance
Rear Suspension Fox Shocks -IFP (Internal Floating Piston, Welded Dome Type)
1. Insert inflating needle into pressure valve to
de-pressurize shock.
2. With bottom of shock secured in a vise, unscrew
shaft bearing cap.
3. Using care, remove rod and piston by pulling
straight out so as not to damage any seals or valves.
4. Pour oil out.
5. Rinse cylinder with a cleaning solvent and blow dry
with compressed ai r.
6. Check height of IFP as shown. You may need to
adjust the height of the piston. If it is too high, insert
the inflating needle into the pressure valve. Using a
rod, push down on the piston to obtain the proper
height. If the piston is too low, screw the lop cap
back on and add nitrogen to raise the piston.
CAUTION: Never add nitrogen without the shaft
bearing cap installed.
8194 9.62
RICEREC
SUSPENSIONS
Fox Shocks - Maintenance
1992 Front Torque Arm (IFP) PN 7041254 and 1993 XCRlXLT Front Torque Arm (I FP) PN 7041294
II
~ ~
IFP Depth. 4. t 50"
""'-'
XCR Rear Shock (IFP) PN 704t267
I.. IFP Depth - 6.35" .1
NOTES:
1. Depths of Internal Floating Piston (IF?) are
measured to bottom of inside diameter.
2. Shocks are to be charged with nitrogen to 200
p.sj.
3. Only approved oil is PN 2870995.
9.63
AIDE RED
11195
SUSPENSIONS
7. With the IFP at its proper height, you can now add
the oil (PN 2870995). Position the shock al a 15to
30 angle and pour oil in slowly against side of
reservoir to avoid mixing ai r into the oi l. With oil level
at base of threads, insert rod and piston.
8. Keep shock body tilted at 15to 30and slide piston
in with the three closely spaced valve holes to the
high side. The center hole is an air bleed and will
allow air to bleed off. Gently wiggle rod and piston to
help disperse air. Keep sliding piston in until it's
submerged in oil. The oil level should now be to the
base of the threads. Have a clean shop cloth handy
to catch the oil which will seep out as the shock cap
is replaced.
9. Once cap has been tightened, pressurize shock to
200 psi with nitrogen.
10. As a final check, stroke the shock a full stroke to
check the IFP depth. CAUTION: Never stroke the
shock until it has been pressurized. Damage to the
shock will occur.
Troubleshooting
Erratic dampening or loss of dampening may be caused
by a pressure loss. To detect a leak at the cover O-Ring
or pressure valve, pressurize the shock to 200 psi and
submerge in water. Bubbles appearing around the
cover indicate a pressure leak.
NOTE: Always check for leaks after changing oil.
found in Chapters 2 or 10. If the shock is over
tightened it will not pivot. resulting in damage to
shaft and seals.
8194
9.64
RIDE RED
Changing oil on FOXHI Shocks is recommended
annually and must be done when performing your
season end storage preparation. This oil change is
necessary to avoid any chance of corrosion which could
be caused by moisture contamination.
When performing maintenance on FOXTW Shocks, use
the Gas Shock Recharging Kit (A) PN 2200421. It
consists of the necessary valves, pressure gauge, and
fittings to deflate and pressurize the shocks. Not
included with this kit is the Body Cap Tool (8) PN
2871071, which is needed to hold shock the body when
disassembling.
WARNING: Extreme caution should be observed while
handling and working with high pressure service
equipment. We strongly recommend you wear 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 your physician immediately.
dirt or foreign particles from getting into the shocks.
1. Thoroughly wash shocks in a parts washer or with
soap and water. Dry with compressed air to remove
sand, dirt, and other debris. Position and clamp
body cap of shock in soft jaws (aluminum) of vise.
2. Remove Allen screw from air valve located in body
cap. This shock has a needle type air valve. You will
need the FOXTW safety needle (Polaris PN 7052069)
from the recharging kit to de-pressurize the shock.
3. Install the de-pressurizing valve into the pressure
gauge fitting. Turn T-handle valve clockwise to
open spring valve.
4. Install safety needle into pressure gauge assembly.
With valve outlet pointed in a safe direction, insert
safety needle assembly into shock pressure valve.
Release nitrogen in a safe direction away from
everyone.
5. Depress safety pin and push valve assembly down,
inserting needle. When pressure gauge registers
zero, shock has been deflated.
6. Extend shock shaft by pulling up on shock eyelet.
Using a 1" (25 mm) wrench, unscrew shaft bearing
cap.
NOTE: If the body of the shock starts to unscrew from
the body cap, tighten and try again. To keep body from
turning, it may be necessary to use Body Cap Tool (PN
2871071) clamped lightly around body in soft jaws of
vise just above body cap.
9.65
SUSPENSIONS
Fox'" IFP Shock Maintenance (1993)
RIDE RED
8/94
SUSPENSIONS
Fox'" IFP Shock Maintenance (1993)
7. Pull shock rod and piston straight out to avoid seal
or valve damage. Be prepared to catch piston ring.
It may fall off as you do this.
8. Dispose of used oil properly in suitable container.
9. Rinse cylinder and piston assembly with mechanic
solvent or equivalent and blow dry with compressed
air. Set aside piston assembly for rei nstallation.
10. Using Body Cap Tool (PN 2871071), position tool
just below body cap and carefully tighten in soft jaws
of a vise.
CAUTION: Never apply heat to shock body without first
depressurizing shock and removing bearing cap and oil.
11. Lightly heat threaded area of body cap with a butane torch to loosen Loctite sealant. CAUTION: Do not over
heat. Damage to internal seals or personal injury could result.
12. Using a large adjustable wrench on the body cap, unscrew the body cap from the body. CAUTION: Parts are
hot. Use leather gloves to avoid burns.
13. Remove internal floating piston by pushing with handle of hammer against piston toward body cap end
(external threaded end). Be prepared to catch piston as it comes out.
14. Note location of Allen screw for reassembly in body tube. Remove Allen screw and O-Ring from center of
piston.
15. Carefully clean all parts thoroughly in a parts cleaner and dry with compressed air.
16. Inspect seals and shaft surface for any damage. NOTE: These parts may be purchased separately.
17. Loosen piston assembly to insure all old oil is removed and flushed from valves to prevent contamination of
new oIl.
Reassembly
1. Wrap flexible piston ring around dampening piston and reinstall into body. While holding body in your hand,
lightly tighten bearing cap into body with 1" (25 mm) wrench until bearing cap and O-Ring are seated.
2. Fully extend shaft.
3. Mount shaft eyelet in soft jaws of vise, body end up.
4. Slowly pour suspension fluid (PN 2870995) into the body of the shock until it comes within 2" (5.1 em) from the
top of the body.
5. Cup hand over open end of body, remove from vise and with a soft face hammer, strike shaft eyelet several
times to remove trapped air in piston valves.
6. Continue to fill body with fluid to within 3 / 4 ~ (1.9 em) from top of body.
2
Ref. # Part No. Q ~ . Description
1 1500005 1 Valve
2 1500004 2 O-Ring
6
3 7710424 1 Retaining Ring
4 5020617 1 Spring Retainer Body
5 1500003 2 O-Ring 5
_7
6 1500006 1 Piston Ring (Floating)
7 1500002 1 Piston Ring (Damping)
8 5020618 1 Spring Retainer, Slotted
8
8194
9.66
RIDE RED
SUSPENSIONS
Fox Shocks - Maintenance (1993)
1. To set the IFP, remove shock from vise, reposition and mount flats of bearing cap in soft jaws of vise with body
cap end up. Lightly tighten vise. CAUTION: 00 not overtighten vise or bearing may be crushed and
deformed.
2. Wrap IFP flexible piston ring around internal floating piston and insert piston into body, O-Ring first. Using 1"
(2.5 em) 0.0. x .780" (2 em) minimum 1.0. tubing, slowly position IFP to within .050" (. 1 em) of its specified
depth. Refer to illustration for IFP depth of appropriate shock.
3. Slowly bleed shock once more by pushing up and pulling down on shaft eyelet to fully extend shock shaft.
NOTE: Oil should squirt out of IF? bleed hole during this procedure. If oil does not come out bleed hole, add
more oil through bleed hole to bring shock to full capacity. Be sure to double check IFP depth after this
procedure. The IFP should be completely submerged in fluid at this point.
4. USing an 1/8" (.3 cm) Allen wrench, reinstall screw and O-Ring in center of piston and tighten.
5. No oil should be left on piston top. Pour out excess oil and wipe with a clean, dry, absorbent shop cloth to
remove any excess oil. Make sure no lint or other debris is left in piston area after removing excess oil. Again
verify IFP depth.
Model Used On Part Number IFP Depth
1993 XLT & XCR Front Ski LH 7041291 .728" (1 .85 cm) from piston surface to body edge
RH 7041292
1994-1995 440 XCR SP & 600 XCR 7041346 .728" (1.85 cm) from piston surface to body edge
1995 RXL Touring 7041346 .728" (1.85 cm) from piston surface to body edge
Front Shock (IFP)
.728"
Model Used On Part Number IFP Depth
1993 XCR Rear Suspension 7041295 .835" (2.12 cm) from piston surface to body edge
1993 XLT Rear Suspension 7041293 .835" (2.12 cm) from piston surface to body edge
1994440 XCR, XLT SP Rear Suspension 7041347 .835" (2.12 cm) from piston surface to body edge
1995440 XCR, 600 XCA 7041345 .835" (2.12 cm) from piston surface to body edge
Rear Shock (IFP)
o
.835"
9.67 RICE RED
11/95
SUSPENSIONS
12. Reinstall body cap and tighten by hand. Mount
shock with body cap end down in the soft jaws of a
vise. Torque bearing cap to 8-10 ft. Ibs.
(1.1Q..'.38 kglm). This will also tighten the body
into the body cap. CAUTION: 00 not over tighten
or damage to the bearing may result.
13. Using the Fox salety needle valve installed on the
pressure gauge assembly, pressurize with
nitrogen gas to 200 psi.
14. To test shock for smooth and consistent
dampening, place shock shaft eyelet on a hard
surface. Fully compress the shock and let it
return. Shock should offer obvious consistent
dampening, moving freely through both
compression and rebound strokes.
NOTE: The front torque arm shock is of the welded
dome type. Refer to 1992 Fox Shock section for
maintenance procedure.
15. When reinstalling front IFS shocks, be sure to
install and torque top eyelet mounting of shock
first. Pivot shock body into lower moun!.
Determine placement of lower mount spacers
(thick or thin) to prevent twist of shock and side
load.
NOTE: Do not overtighten shock mounting bolts.
Shocks must pivot at mounts. Torque only to required
specifications found in Sections 2 or 10.
Troubl eshooting
Erratic dampening or loss of dampening may be
caused by a pressure loss. To detect a leak at the
cover D-Ring or pressure valve, pressurize the shock
to 200 psi and submerge in water. Bubbles appearing
around the cover indicate a pressure leak.
NOTE: Always check for leaks after changing oil.
found in Sections 2 or 10. If the shock is over
tightened it will not pivot, resulting in damage to
shaft and seals.
8/94
9.68
RIDERED
SUSPENSIONS
Fox' IFP XTRA Shock - Rebuild (1994-1995)
Changing oil on Fox'''' Shocks is recommended annually and must be done when performing your season end
storage preparation. This oil change is necessary to avoid any chance of corrosion which could be caused by
moisture contamination.
When performing maintenance on Foxn., Shocks, use
the Gas Shock Recharging Kit (A) PN 220042 t. It
consists of the necessary valves. pressure gauge, and
2871071 , which is needed to hold shock the body when
disassembling.
shocks.
2. Remove Alien screw from air valve located in body
need the Fox
T
.. safety needle (Polaris PN 7052069)
3. Install t he de-pressurizing valve into the pressure
gauge fitting. Turn T-handle valve clockwise to open
spring valve.
Rel ease nitrogen in a safe direction away from
everyone.
9.69
RICEREC
8194
SUSPENSIONS
Fox'" IFP XTRA Shock - Rebuild (1994-1995)
Using a 1" (25 mm) wrench, unscrew shaft bearing
cap.
NOTE: If the body of the shock starts to unscrew from
the body cap, lighten and try again. To keep body from
turning, it may be necessary to use Body Cap Tool (PN
2871071) clamped lightly around body in soft jaws of
vise just above body cap.
7. Pull shock rod and piston straight out to avoid seal or
valve damage. NOTE: Be prepared to catch piston
ring since it may fall off as you do this.
8. Drain oil into a suitable container and dispose of
properly.
9. Rinse cylinder and piston assembly with solvent and
blow dry with compressed air.
10. Using Body Cap Tool (PN 2871071), position tool
just below body cap and carefully tighten in soft jaws
of a vise. Using a large adjustable wrench on the
body cap, unscrew the body cap from the body.
11. Remove internal floating piston by pushing with
handle of hammer against piston toward body cap
end (external threaded end). Be prepared to catch
piston as it comes out.
12. Note location of Allen screw for reassembly in body
tube. Remove All en screw and O-Ring from center
of piston.
13. Carefully clean aI/parts thoroughly in a parts cleaner
and dry with compressed air.
14. Inspect seals and shaft surface for any damage.
NOTE: These parts may be purchased separately.
15. Loosen piston assembly to insure all old oil is
removed and flushed from valves to prevent
contamination of new oil.
NOTE: Lightly oil flexible piston ring and O-Ring prior to
installation.
16. Reinstall IFP with flexible piston ring and O-Ring.
Position piston into body O-Ring from body cap end
fi rst (smooth 1.0. of body, no internal threads).
17. Reinstall body cap and hand tighten.
lB. Place in body clamps and vise. torque to 8-1 0 ft. Ibs.
(1.10-1.38 kg/m).
19. To set the IFP, mount body cap in vise and lightly
tighten. CAUTION: Do not overtighten as bushings
may be crushed.
20. Using a caliper or steel rule, check IFP depth. Use a
1" 0.0. x . 7 B O ~ 1.0. x 12" long piece of tubing
positioned in lFP cup to repOSition lFP.
8/94
9.70 RIDE RED
SUSPENSIONS
Fox'" IFP XTRA Shock - Rebuild (1994-1995)
Front Shock IIFPI
II
IFP Deplh = 4.150"
21. Slowly pour suspension fluid (PN 2870995) into the body of the shock. Refer to table for correct fluid amount.
NOTE: Pour slowly to minimize air bubbles in fluid. Ai r bubbles will cause shocks to fade over a period oflime.
22. Wrap IFP flexible piston ring onlo pi ston and carefully install shaft assembly.
23. Tighten bearing cap end to shock body. Torque to 8-10 ft. Ibs. (1.10-1.38 kglm).
24. lighten bleed screw on bearing cap.
25. Press shaft into shock body about 1/2 the stroke. AI this poinl strike the eyeret of the shaft with a soft face
hammer several times to dislodge any air trapped in piston assembly.
26. Install Fox
n
safety needle valve (Polaris PN 2200421 ) on pressure gauge assembly and pressurize with
nitrogen gas to 200 PSI. Shock shaft will extend while you are pressurizing shock.
27. Slowly open bleeder unlil all ai r is released and oil starts to appear out of bleeder. Tighten bleeder and
re-charge with nitrogen to 200 ft. Ibs. (27.6 kglm).
28. To test shock for smooth and consistent damping, place shock shaft eyelet on a hard surface. Fully compress
shock and let it return. Shock should offer obvious consistent damping, moving freely through both
IFS XTRA and Front Track XTRA Fox'" Shock
~ IFP Depth = 7. 75"
Moclel Used On Part Number IFP Depth (Initial) Suspension Fluid
XTAA IFS (Ski) 7041385 7.75- 165cc+' -lcc
XTAA Front Track 7041386 7.75- 165 cc+l-l cc
NOTE: IFP depth is measured from top edge of body housing (A) 10 inside cup of IFP (8).
9.71
RIDERED
8194
SUSPENSIONS
Fox' IFP XTRA Shock - Rebuild (1994-1995)
Rear XTRA Fox
n
.. Shock
Model Used On Part Number lFP Depth (Initial) Suspension Fluid
XTAA Rear Track 7041387 5.25" 108.2 cc +1- .25 cc
NOTE: To accurately measure cc quantities, we suggest using a syringe, such as may be purchased at a
veterinary supply house.
Rear Shock (IFP)
' - - - - - - - ~ ~ ~ ~ ( @
IFP Deplh _ 5.25"
29. When reinstalling front IFS shocks, be sure to install and torque top eyelet mounting of shock first. Pivot shock
body into lower mount.
CAUTION: When reinstalling shock assemblies onl o the machine, torque only to required specifications found in
Chapter 2 or 10. If the shock is over tightened it wi ll not pivot, resulting in damage to shaft and seals.
Troubleshooting
Erratic damping or loss of damping may be caused by a pressure loss. To detect a leak at the cover O Ring or
pressure valve. pressurize the shock to 200 PSI and submerge in water. Bubbles appearing around the cover
indicate a pressure leak.
Always check for leaks after changing oil.
8194
9.72
RIDERED
SUSPENSIONS
Fox' IFP XTRA Shock - Oil Change Only (1994-1995)
Changing oil on Fox"" Shocks is recommended annually and must be done when performing your season end
storage preparation. This oil change is necessary to avoid any chance of corrosion which could be caused by
moisture contamination.
When performing maintenance on FOX
TIII
Shocks, use
the Gas Shock Recharging Kit (A) PN 2200421. It
consists of the necessary valves, pressure gauge, and
2871071, which is needed to hold shock the body when
disassembling.
shocks.
2. Remove Allen screw from air valve located in body
need the FOXTW safety needle (Polaris PN 7052069)
3. Install the de-pressurizing valve into the pressure
gauge fitting. Turn T-handle valve clockwise to open
spring valve.
Release nitrogen in a safe direction away from
everyone.
Using a 1 H (25 mm) wrenCh, unscrew shaft bearing
cap.
9.73
8194
RIDE RED
SUSPENSIONS
Fox'" IFP XTRA Shock " Oil Change Onl y {1994-1995}
7. Pull shock rod and piston straight out to avoid seal or
valve damage. NOTE: Be prepared to catch piston
ring since it may fall off as you do this.
8. Drain oil into a suitable container and dispose of
property.
9, Rinse cylinder and piston assembly with solvent and
blow dry with compressed air.
10. To set the IFP, mount body cap in vise and lightly tighten. CAUTION: Do not overtighten as bushings may be
crushed.
11. Using a caliper or steel rule, check IFP depth. Use a , ,. 0.0. x . 7 8 0 ~ 1.0. x 12" long piece of lubingpositioned in
IFP cup to reposition IFP.
Front Shock (IFP)
IFP Depth = 4.150"
12. Slowly pour suspension fluid (PN 2870995) into the body of the shock. Refer to illustration for correct fluid
amount. NOTE: Pour slowly to minimize air bubbles in fluid. Air bubbles will cause shocks 10 fade over a
period of time.
13. Wrap IFP flexible piston ring onto piston and carefully install shaft assembly.
14. Tighten bearing cap end to shock body. Torque to 8-10 ft. Ibs. (1 .10-1.38 kg/m).
15. Tighten bleed screw on bearing cap.
16. Press shaft into shock body about 1/2 the stroke. At this point strike the eyelet of the shaft with a soft face
hammer several times to dislodge any air trapped in piston assembly.
17. Install Fox
rM
safety needle valve (Polaris PN 2200421) on pressure gauge assembly and pressurize with
nitrogen gas to 200 PSI. Shock shaft will extend while you are pressurizing shock.
18. Slowly open bleeder until all air is released and oil starts to appear out of bleeder. Tighten bleeder and
re-charge with nitrogen to 200 ft. Ibs. (27.6 kg/m).
19. To test shock for smooth and consistent damping, place shock shaft eyelet on a hard surface. Fully compress
shock and let it return. Shock should offer obvious consistent damping, moving freely through both
8/94
9.74
RIDE RED
SUSPENSIONS
Fox
T
IFP XTRA Shock - Oil Change Only (1994-1995)
IFS XTRA and Front XTRA Fox' Shock
IFP Depth ~ 7.75"
Model Used On Part Number IFP Depth (Initial) Suspension Fluid
XTRA IFS (Ski) 7041385 7.75" 165 cc +/-1 cc
XTRA Front Track 7041386 7.75" 165 cc +/-1 cc
NOTE: IFP depth is measured from top edge of body housing (A) to inside cup of IFP (8).
Rear XTRA Fox
Tloi
Shock
Model Used On Part Number IFP Depth (Initial) Suspension Fluid
XTRA Rear Track 704'387 5.25" 108.2 cc +/- .25 cc
NOTE: To accurately measure cc quantities, we suggest using a syringe, such as may be purchased al a
veterinary supply house.
IFP Depth = 5.25'"
20. When reinstalling front IFS shocks, be sure to install and torque top eyelet mounting of shock first. Pivot shock
body into lower mount.
CAUTION: When rei nstalling shock assemblies onto the machine, torque only to requi red specifications found in
Chapter 2 or 10. If the shock is over tightened it will not pivot, resulting in damage to shaft and seals.
Troubleshooting
Erratic damping or loss of damping may be caused by a pressure loss. To detect a leak al the cover O-Ring or
pressure valve, pressurize the shock 10 200 PSI and submerge in water. Bubbles appearing around Ihe cover
indicate a pressure leak.
Always check for leaks after changing oil.
9.75
8194
RIDE RED
-
SUSPENSIONS
Shock Valving
7041291 & 7041292 IFS I Front Ski Shocks
Compression Stack
Exira Light Ligtl1
:&
* *

*
*
;H; @ 1.00 x .OO6
*
2J:
@) 1.10 x .006
*

1.30" .006
o
1.30" .006
Rebound Slack
Hl0
1.25 x .008 0,.25)(.008
ZoB
@),.'0)( .008 @) 1. 10x .OO8
:l.:B
@ .80x .008 @ .80x .Ol0

@
.70 x .008 @ .70 x .010
Parts in box are standard valving .
Standard Valyjog

I .80 )('()08 1 @ .80LOW
1 1
: @ .90)( ,008 : @ .90 . 010
1
I 1,00 . 008 I *
1 1
I @) 1
i i
1
I 1.30)1 .008 I
1 1
1/ 0 1
*
*
1 1
1 T Piston"
1
G 1.25 . 010 :
*
@) 1.1011 .010 i
*
.8Ox .OO8 ! @ .80x .Ol0
.70)1 .008 \ @ .70x .Ol0
L- ________ J

Indicates the use of the standard valving washer in thi s positi on .
Extra Heavy
@
.80)( .010
@
.90;It .010
@ I.DO I( .010
@)1.10X.Ol0
*
*
*
@
@
.80 x .012
.70 I( .012
Note the direction of valve piston before disassembly. The side with three slots should face the shaft end.
Example: To increase rebound dampening from standard to heavy, remove the Flexl oc nut and replace washers
3-R (.60 x .006) with the .60 x .0tO, and 4-R (.70 x .006) with the .70 x .0tO washers. All other washers in the
rebound stack would remain the same. Reinstall the washer and Flexloc nut. Torque to 20 to 25 ft . Ibs.
NOTE: Remember to add rolling torque. Refer to shock assembly procedures in thi s section to complete
assembly.
8/94
9.76
AIDE RED
7Q41293 - Rear Shock
Compression Stack
Extra Light

*
ti<
@
.90)( .006
z,c
@ 1.10x.OO6
II
0,.30X.OO6
Rebound Stack
0,.30X.OO6
2Jl
@1.10)'..006
;Hl
@ 1.00 x .OO6
1-
*
Standard ValYing
Shaft End
@ .80x.Ol0
1 1
: @ .90dl08 : @.90x.Ol0
*
*
*
1
I 1.10x .008 I *
1 1
: *
I
i @-
1 1
8'30'006: @)1.30,008 i
*
* :1 :
1.1OLOO8
1
*
*
*
: @ 1.00X .008 : @,.OX.Ol0
: @ .90X.008 : @ .90)( .010
1 1
L _________ J
I=> Nul End
Parts in box are standard valvjog .
Indicates the use of the standard valving washer in this position .
SUSPENSIONS
Shock Valving
Extra Heayy
@ .80x.OlD
@.90X.Ol0
@1.10X.010
*
*
@1.10)( ,OlO
@1.00X.Ol0
@ .90X .010
9.77
RIDE RED
8194
SUSPENSIONS
Shock Valvlng
7041294 - Center Shock
Compressioo Stack
Extra Light l.igIll

.90 x .008
*
:loC @ 1.00x.OO8 @ 1.oox.008
20Q @,.,0X.008 @,.,0X.008
li@)
1.30 x.OO6
*
Rebound Stack
UlfZ\
@),.25X.008
20B
@,.ooX,008
*
;uJ
@
.90)( .OOB
*

* *
:;,a
* *
Parts in box are standard valving.
Standard Valvjog

r---- ----,
t ,..... .90 x .010 I
I \8-' I
I r--.. I
I 1.oox.010 I
:
1.10)1.010 I
*
*
*
@)130'Ooa : @)
o
I
I
I
-: Piston*-
I
I
0,."..0'0:
1.00X .Ol0 :
I
@ .90x .01O :
d-. II
'2J .80 )( .010
.d.. II
c...s:v .70 x.Q10
L ________ J

*
*
*
* Indicates the use of the standard valving washer in this position .
1.30 x.01O
.80x .01 2
.70x .012
Extra Heayy
.90x.012
@,.ooX.012
*
G
1.30)( .010
*
@,.00X.012
@ .90x.012
.80X.012
@ .70x.012
11195
9.78
RIDE RED
7041295 - Rear Shock
Standard Yalyjng

Compression Stack
Liobl l.igll1
r---------,
.80x.008 1 .80x.Ol0
1
,90X .008 : @ .90x .010
@ 1.00)( .008 : @ 1.00x.Ol 0
1. 10 x.008 i @,.'0X.Oto
50Q
* *

* *
00Q
* *
<oQ
* *
11<
0 ,.30 x ,006 0,.30X.008
1.30, .010: 0,.30' .Ooa
1
o JJ. 1
Piston"
Rebound Slack
I
0 '25 '008 ! 0,25'010 ! 0'25'00'
* : 1.10X.OO8 : @ 1.10x.Ol0
Hi
0
1.25 x .006
ZoB
*
Hi
* *
!Hi
* *
O:B
* *
O:B
* *
Parts in box are standard vaJving.
1
t '-SJ 1.00 x .008 I 1.00:w.: .010
1 1
: @ .90x.008 : @ ,90x.010
I .d-. 11 'c5'
I .80x .008 .80x.Ol0
11 .d-. I
!..S2J .70 x.OO8 I @ .70)( .010
L ________ J

SUSPENSIONS
Shock Valvlng
Extra Heayy
@ .BOx .Ol0
@ .90x.010
@1.00X.Ol0
@ 1.10x.Ol0
0,.30)( ,010
0,.25)(,010
@1.10X.010
@ 1.00x.Ol0
@ .90x.01O
@ .80x.Ol0
@ .70x .Ol0
9.79
RIDE RED
t t /95
SUSPENSIONS
Shock Valvlng
7041387 - Rear Shock XTRA
Standard Valyjog
ShattEnd
,--------,
Compression Slack
Exira Ught
.089 Orifice
Rebound Stack

1.25Ox .OO6
z,a

1.100 x .006
:Hi @ 1.oo0x.006
Hi
*
00Il
*
00Il
*
I .700 X ,006 ) *
I
I '2) .800 . 006 I
I
i \..2) .900 x .
006
1

1.00x .006
:@) 110,006
I
*
*
*
*
Exira Heayy
*
*
.90 x .012
1.00 x .012
*
ie!) 1.30)( .006 0,30X.0100,30X.Ol0
: .067 Onflce .067 Orifice
T Plston--
.081 Orifice
Orifice:
I I
0
'25
)( ,008 :
0
, 250X .010:
1.,00x .ooe : 1.100X.010 :
I
* I@ I
I 1.000 x .010 I
I I
*
*
*
I r--. I
I .900x .
010
I
I
I \QJ .8oox.010 I
I d-- I
I I...S:V .700 x .010 I
L ___ ___ __ J
Nul End
*
o 1.250x .012
*
1.250x .012
*
1.10 x .012
1.000 x ,012
*
@ .900)(.012
*
@ .800)(.012
*
, 1/95
9.80
RIDE RED
7041344 Center Shock
Compression Slack
Rebound Slack
Standard Yalving
~ Shaft End
r---------,
I @ .800x.01O i
I ~ I
I I2J .900 x .010 I
I@ I
I 1.00x.Ol0 I
I I
: 1.1DOx.OID I
I
: ~ :
~ \.3OOX.010:
I
I ~ :1
~ 1.3OOx.012
I
@- L PiS'OO
C!) 1.250x.010
1.1OOx.OlO
1.000:<: .010
@ .900x.OlO
I .8oox.01O I
I ~ I
I I..S:V .700 x .010 I
L _________ J
~ Nul End
SUSPENSIONS
Shock Valving
.067 Orifice
9.81
RIDE RED
8/94
SUSPENSIONS
Shock Valving
7041345 - Rear Shock
Compression Slack
Standard Valyjng
~ ShallEod
r---------,
: .800 l(.008
: @ .900 l( .008
: I ~
~ 1.000 ... 008
I I I ~
~ 1.1oox.008
I
: ~ l.30x .Ol0
I
I I
J::ielm'
G
*

@)

G
El!ll[a t l e a ~
1.250)( .010
*
1.250x .010
.800 x .008 @
.800)( .008
.900)( .010

.900 x .0lD
\.000)( .010
@)
1.000)1 .010
1.100)( .008

1.100)( .010
1.300)( .010
G 1.3(0)( .010
!@ - r Pisloo"
.067 Orifice
Rebound Stack
Parts in box are standard valviog .
I
I
01.300X,OIO:
I
@) 1.100)( .008 :
I
I
1.000 x ,008
1
I
.900:11 .006 1
I
I
.800 x ,006
1
L __ ______ J
~ NulEod
G

*
*

1.250 x .010
G 1.250x.01O
l.1(Xh .010

1.100x .01O
@)
.900 x .012
*
.700 l( .008

.700 x .OO8
Note the direction of valve piston before disassembly. The side with three slols should face the shaft end.
8194
9.82
RIDERED
Standard Valyjog
ShaftEnd
Extra Light
r--------,
1.25Ox.Ol0 1.250)(.010 J @ .700 . 008 :
I
* I .800 x .008
:I @
.900 x .010
*
7041346 -IFS Shock
Compression Slack
*
*
I::I.elm:
*
*
*
*

\...:::.J 1.00 X .010
1.1ooX.008 1. ,00 . 0OB : 1.10x.Ol0
I
*
*
*
SUSPENSIONS
Shock Valving
Exira Heavy
*
*
@
.90 x .012

1.00)( .012
*
0,.3(0)(.008
* Ie 1.30)(.010 0,.30)( .010 0
1.30 x .010
Rebound Stack

1.2501 .008
1.100 x .008
;Hl

1.000 x .008
!loB
@
.900)( .008
o,a
*
lioB
*
G 1.25)(.008

@
*
*
1.100x.OO8
1.000 )( .008
.9(0)( .008
Parts in box are standard vall/lng .
I
i@----..!. :piston ..
I
I
o 1.250X,010:
1.100" ,010
l.ooox.OIO
@ .9OOx .010
.800 . 008
*
*
*
*
.078 Orifice
Optional Orifice .081
.800)( .012
o 1.OOOx.012
.900 . 012
.800x .012
.7oox .012
*
@ .700)( .012
Nut End
*
Indicates the use of the standard valvjog washer in this position .
.. Note the direction of valve piston before disassembly. The si de with three slols should face the shaft end.
9.83
RIDERED
8194
SUSPENSIONS
Shock Valving
7041347 - Rear Shock 1994 XCR
Compressioo Stack
Rebound Slack
Standard Yalyjog
~ ShaftEod
r- ------- ,
I .d-- I
I I...S) .800 .. . 008 I
I ~ I
I ~ .900x.OO8 I
I I
I A---, I
I ~ 1.000)(.008
1
let> I
I I
I 1.1oox.008
1
I I
I ~ I
I ~ 1.3Ox .010 1
I I
i ~ - i
l ~ TPistan"
I
I
0,250X,OlO:
I
1.,00X .008:
I
I
.900 II: ,008
1
I
.800 x .0081
I
I
.700)( ,008
1
L ________ ..l
~ NutEod
Indicates the use of the standard valving washer in thi s position .
Note the direction of valve piston before di sassembly. The side with three slots should face the shaft end.
8194
9.84
AICERED
7041385 - IFS Shock XTRA
Compressioo Stack
Extra Light
*

@
.800 1t.OO6
.900 x .OO6
*

@
.800)( .006
.900 x .OO6
@ 1.000 x .006 @ 1.000)( .006

1,1oox.006
*
0,300X .OO6
*
SUSPENSIONS
Shock Valvl ng
Standard Valyjng

r------- -, Extra Heayy
.700 x .008: * *
@800.008: *
.800 x .010
.900X.008: * @ .900x .010
,.000X.008: * @ l .oox .Ol0
,.,ooX,OOS : 1.1oox.Ol0 1. 100:cOIO
1.300 . 008: 0'.30 . 01001.300 .. 010
I I
: I
.1 Piston" .078 Orifice
Rebound Slack
: I
10,250 . 006 0'.250 . 006 :0 '.250 . 00.:
2:B 1. 100x.OO6 1. 100)( .006 : 1. ,00X.OO8:
I
I r:--.. I
I l.ooox.OO8 I
:1 ,.--.. :
.900)( .0081
: @ .600)(,0081
I I
I !..S:V .700)( .0081
L ___ __ ___ J
Nut End
1.000)( .006
*

.900 x .006
*

.BOO x .006
*
*
*
.700)( .006
* o 1.250x.Ol0
1.100 . 010 1.100 x .010
*
*
*
*
*
*
* *
Indicates the use of the standard valving washer in this position.
,. Note the direction of valve piston before disassembly. The side with three slots should face the shaft end.
9.85
RICERED
11195
-
SUSPENSIONS
Shock Valving
7041386 - Center Shock XTRA
Compression Slack
Extra Ught
Standard Valviog
dJv
Shaft End
r --------'
I @:> .700 I( .0061
I I
I .800' .006
1
I
I r--. .900 , .006:
I
I
I 1.ooox.006
1
10 I
: 1.100 1.0061
*
*
*
@

1.000 x .008
1.100 x .008
Extra Heavy
*
@
@
@

.800 x .010
.900 )(.010
1.00 x .010
1.100 x .010
I I
: 1.300>.006: 01.300' .008 01.300..010
: I
.089 Orifice
Rebound Stack
1@_ 1 .07Borlflce
I 0 ..L Piston"
I I
I .078 orifice :
0810nflce
Hl0 o 1.25Ox .OO8
2ll

1.1OOx.OO8
:loB
@
1.000:.:: .008
<loB
@
.900 x .008
1cl1
@ .800 x .008
lHl
*
I I
1.25)( 012 1
I
1.100'.010: @) 1.250,.012 :
* I
*
*
*
1.100x.0101
:
1.000)( .01 1
: @ .9OOX ,OlO:
I do-. I
I '8:V .800 :.::.0101
L ________ J
Nul End
Indicates the use of the standard valving washer in Ihis position .
*
*

@
1.100 x .012
1.000 x .012
.900 x .012
.800 x .012
.078 Orifice
@
@
1.250)( .015
1.250 x .015
1.100 x .012
1.000 x .012
.900)( .012
.800 x .010
8194
9.86
RIDE RED
SUSPENSIONS
Additional Fox Shock Hardware
earl ~ Q , Descrjption Ead. ~ Q . Description
7052069 .. Charging Needle 1500018 ... Screw, #10-24 x 3/8", Fox PN 204-1024-03
5020616 ... Spacer, Shock, Narrow, .160" (.4 em) 1500019 . . . Screw, #8-32 x 1/4", Fox PN 204-0832-25
5020612 ... Bushing, 1.34" (3.4 em) long 1500020 .... O-Ring, Outer, Fox PN 201-2218-00
5020613 ... Bushing, 1.16" (2.9 em) Long 1500021 .... O-Ring, Inner, Fox PN 201-2112-00
5020615 Spacer, Shock, Wide, .320" (.8 em) 1500022 ... O-Ring, DRlm, Outer, Fox PN 201-2008-00
5020622 .. Spacer, Shock, .640" (1.6 em) 1500023 ... O-Ring, Outer, Fox PN 201-2012-00
5020623 Bushing, Shock, 2.07" (5.3 em) 1500024 .... Wiper. Clear, Outer, Fox PN 202-0500-00
7710424 Ring, Retaining, External, 1.625" (4.1 em) 1500025 .... Wiper, Black, Inner, Fox PN 202-0052-00
5020617 .... Retainer, Spring, Body 1500026 .... Valve, Shock. Fox PN 214-3125-10
5020618 Retainer, Spring, Slotted 1500027 .... Valve, Shock, Fox PN 214-3110-10
1500002 ... Piston, Ring Dampening, FOX PN 23-6300 1500028 .... Valve, Shock, Fox PN 214-3080-08
1500003 .... O-Ring, FOX PN 01-2129 1500029 .... Valve, Shock, Fox PN 214-3070-08
1500004 .... O-Ring, FOX PN 012218 1500030 .... Valve, Shock, Fox PN 2143130-08
1500005 ... Valve, FOX PN 05-111 003A 1500031 Valve, Shock, Fox PN 214-3110-08
5020639 Spacer, Shock, .190" (.5 em) Wide 1500032 .... Valve, Shock, Fox PN 214-3100-08
5020640 ... . Bushing, 1.24" (3.1 em) long 1500033 ... . Valve, Shock, Fox PN 214-3090-08
1500006 .... Piston Ring, Floating, FOX PN 23-6200 1500034 ... Body, Shock, Fox PN 560-0744-00
543135S .... Spacer, Shock, 112" (1.3 em) lowering Kit 1500035 .... Shaft, Fox PN 650-0745-00
5431356 .... Spacer, Shock, 1/4" (.6 em) lowering Kit 1500036 .... Eyelet, "G" Eye, Fox PN 711-SPS1-Gl
7041293 .... Shock, Gas, Rear, XlT or ITS IS00037 .... Valve, Shock, Fox PN 214-3130-10
7041294 ... Shock, Gas, Middle IS00038 .... Eyelet, "A" Eye, Fox PN 711-S015-Al
7041291 .... Shock, Gas, IFS IFP lH 1500039 ... Body, Shock, D-E-S, Fox PN S60-2498-00
7041292 .... Shock, Gas, IFS IFP RH 1S0OO40 ... Shaft, Fox PN 650-0S35-00
7041295 .... Shock, Gas, Rear, XCR or Dial Adjust IS0oo41 .... Bearing, W/DU, Fox PN 812-0509-01
5431540 .... Bushing, Shock .. 220 Poly/IFS Toward 1500042 .... Piston, PM, Fox PN 213-3067- 14
Rear Body End and 2 Rod 1S00043 .... Piston, IFP, WlDome, Fox PN 231-3145-50
5431542 ... Bushing, Shock, .340 Poly/Rear Shock IS00044 .... Valve, Shock, Fox PN 214-3070-10
XlT Body End 1S00045 .... Valve, Shock, Fox PN 214-3100-10
5431541 .... Bushing, Shock, .260 Poly/Center Shock IS00046 .... Valve, Shock, Fox PN 214-3090-10
Both Ends 1S00047 ... Valve, Shock, Fox PN 214-3080-10
5431543 .. Bushing, Shock, .400 Poly/IFS Toward IS00048 .... Valve, Shock, Fox PN 214-3100-06
Front Body End IS00049 .... Valve, Shock, Fox PN 214-3110-06
5431544 ... Bushing, Shock, .675 Poly/XCR Rear IS000S0 .. . . Valve, Shock, Fox PN 214-3125-06
1500007 .. Body, Shock, Fox PN 560-063800 IS00051 .... Valve, Shock, Fox PN 214-3125-08
1500008 .. Shaft, Fox PN 650-0680-00 IS00052 .... Valve, Shock, Fox PN 214-3130-06
1500009 .. Bearing, W/DU, Fox PN 812-0511-01 IS00053 .... Valve, Shock, Fox PN 214-3090-06
1500010 .. Piston, PM, Fox PN 213-0314-00 IS00054 .. Valve, Shock, Fox PN 214-3080-06
1500011 .. Piston, IFP, Fox PN 231-3145-00 1500055 .. Valve, Shock, Fox PN 214-3070-06
1500012 .... Cap, Body, MI #1, Fox PN 335-0701-00 1500056 .. Valve, Shock. Fox PN 214-3070-12
1500013 .. Eyelet, Fox PN711-5765-01 1500057 .. Valve, Shock, Fox PN 214-3080-12
1500014 ... Asm., Air Valve, Fox PN B05-FAV2-o0 1500058 .... Valve, Shock, Fox PN 214-3090-12
1500015 .. Bushing, Backup, Fox PN 218-3620-93 1500059 .... Valve, Shock, Fox PN 214-3100-12
1500016 ... Nut, lock, 3/8-24, Fox PN 204-0324-00 IS0oo60 . . . . Valve, Shock, Fox PN 214-3110-12
1500017 ... Plale, Top Out, Fox PN 217-3112-93 1500061 .... Valve, Shock, Fox PN 214-3125-06
1500062 .... Valve, Shock, Fox PN 214-3130-10
Fox, Regist ered Trademark of FOX Shox
9.87
RIDE RED
8/94
CHAPTER 10
TOOLS AND PUBLICATIONS
How to Handle a Service Complaint ............ ........... . .... .... . . .
Service Ti ps .... . ............................ .......................
10.1
10.2
Recommended Shop Supplies/Accessories ........ .. . ...... ........ ..... 10.3
Decimal Equivalents ..... . .... .. .............. .. ........................ 10.3
Standard Torque Specifications ....... .. . ............. ....... .......... 10.4
Torque Deviation List .... . .... . ....... .. ........................... 10.4-10.5
MetriC Equivalents .. . ........ . ...... .. .... ........... . .... .......... 10.5
Extended Storage ............ . . . ...... .. .. .. . ...... .. .. . ... ...... 10.6- 10.8
General Troubleshooting .................... .. ....... . .. . . . ..... 10.9-10. 10
Special Service Tools . . ............... . . .......... . . . . . . .... 10.11-10.23
1993 Technical Service Publications . ..... . . . . .. .. . .. . .. . ....... .. . ... ....... 10.24
1994 Technical Service Publications .... . . . ....... .. .... . . . . .. .. . . .......... 10.25
1995 Technical Service Publications ....... . .. . .. . .... . ..... . .. .. .. . ......... 10.26
Service and Information Bulletins .......... . .... . .. .. .................. 10.27-10.31
Glossary of Terms. . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . .. . . . . . . . . .. . . .. 10.32-10.34
Trademarks . .... . .. . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 10.34
warranty Policy . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10.3510.36
RIDE RED
8/94
-.
TOOLS I PUBLICATIONS
How to Handle a Service Complaint
Even the best service center will occasionally need to deal with a disgruntled customer. Here are some tips on how
to handle a service complaint:
REMAIN CALM AND LISTEN unlil thecustomer has finished talking. This gives the customer the courtesy they
deserve. It helps them to feel you really care about their problem. Also, by laking the time to lislen, you give
yourself a chance to think and to prepare to solve the problem.
ASK, " WHAT WOULD YOU LIKE ME TO DO?". By asking the cuslomerwhat t hey expect, you will catch them
off guard. II they feel you are genuinely trying to help them, they will be more agreeable to your suggestions. Often
a customer will call simply to "blow off steam", never really expecting anyone to do anything.
YOUR TONE OF VOICE is very important. Be calm. Always be courteous. Do not speak too Quickly. Resist the
temptation to use humor or sarcasm. Friendly comments will help to defuse tension.
DEFUSE ANGER by listening to the customer and empathizing. Don't debate the facts, jump to conclusions. or
make hasty admissions, decisions orconcessions before all of the facts are known. Allow yourself time to make a
thorough investigation. Apologize and acknowledge the customer's anger. Be calm and respectful. The
customer is not angry with you, but with the product.
COMPLY with the customer's wishes if they are reasonable and within accepted policy guidelines.
RESOLVE COMPLAINTS QUICKLY after you and the customer have reached a decision. Don't make the
customer feel they are being talked into something.
IF YOU CAN'T do what the customer wishes, or if you haven't had enough time to thoroughly review the
problem, tell them you will resolve the problem as quickly as possible. Tell them you are concerned with the
problem, but that you need to look into the matter further to see what options are available. Take their telephone
number and CALL THEM BACK!
KEEP THE CUSTOMER INFORMED of your progress. If there is no progress, tell them that as well. No
communication leaves the customer feeling that nothing is being done and that nobody cares. This impression
can be easily cleared up if a service representative who knows the situation and what is happening can truthfully
relate the facts to the customer.
DO NOT IGNORE A COMPLAINT in the hope that it will go away. It won't. Every customer's concern or
complaint is important.
A dealer's image is often reflected in how customer complaints are handled. The fact that you cared enough to
listen and were willing to try to solve their problem can mean the difference between losing a customer or keeping
them, their friends and their relatives as customers.
All complaints must be addressed within your own policies and guidelines. Anyone handling customer service
relationships should be familiar with these policies.
8/94
RIDE RED
Service Tips
In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this
manual, thoroughly familiarizing him/herself with procedures before beginning. Pictures and illustrations have
been included with the text as an aid. Notes, cautions and warnings have also been included for clarification of text
and safety concerns. However, a knowledge of mechanical theory, tool use and shop procedures is necessary to
perform the service work safety and satisfactorily. Use only genuine Polaris service parts.
&. Cleanliness of parts andlools 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.
A Watch for sharp edges which can cause personal injury, particularly in the area of the tunnet. Protect hands
with gloves when working with sharp components.
A If difficulty is encountered in removing or installing a component, look to see if a cause forthe difficulty can be
found. If it is necessary to lap the part into place, use a soft face hammer and tap lightly.
A Some of the fasteners in the snowmobile were install ed with locking agents. Use of impact drivers or
wrenches will help avoid damage to fasteners.
&. Always follow torque specifications as outlined Ihroughoutthis 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, followi ng the method and sequence indicated in this manual, tighten evenly to the speci fied torque value.
When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before
removing them.
&. If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces
around the gasket are clean and smooth in order to avoid leaks.
A Some procedures wilt 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 wi th 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.
8/94
10.2
RIDE RED
Recommended Shop Supplies/Accessories
Description part Number
Ammco 3880 Honing Oil .. .. . .... . . . . ...... 2870588
Chaincase Oil - One Gallon . . . . . . . . . . . . . . . . .. 2870464
Chaincase Oil Pump ............................. 2870465
Low Temp Grease - 14 1/2 Oz. Cartridge .. ... . . .... . 2870577
Clutch and Choke Cable Lubri cant . . ............... 2870510
Fuel System Deicer (Isopropyl) ............ . . . . . . . .. . 2870505
Locti!e Primer T - 6 Oz. Aerosol ...... _ .............. 2870585
Loctite RC 680 - tOce Retaining Compound . ......... 2870584
Loctite 515 Gasket Elimi nator - SOce Tube ...... . . . .. . 2870587
l octite/Chisel Gasket Remover - 18 Oz. .. . . . . . . . . . . . . 2870601
Metal Polish - 8 Oz. . . . . . . . . . . . . . . . . . . . . . . . . . .. 2870632
DOT 3 Brake Fluid .. .... .. . ............... .. ...... 2870990
Fogging Oil .. .. ... .. .. .... . ............. . . . ...... 2870791
Corrosion Resistant Di electric Grease ........ ...... 2871027
Fox Shock Oil .. . . .. . ....... ............... . . ...... 2870995
High Speed, High Temp Bearing Grease ...... ...... 2870616
Decimal Equival ents
1/64 ................. 0156
1/32 ..... ....... 0312 ... 1 mm =
3/64 ................. 0469
1/16 . ...... 0625
5/64 ................. 0781 ... 2 mm =
3/32 . .. .. ....... 0938
................ 1094 ...
1/8 .. 1250
9/64 . . ....... . ....... 1406
5/32 ........ .... 1563 . .. 4 mm =
11 /64 .... ...... 1719
3/16 ...... . 1875 ... 5 mm =
13/64 ................ 2031
7/32 .. .. ........ 2188
15/64 ................ 2344 . .. 6 mm =
1/4 .. 25
17/64 ........ ....... .2656 ... 7 mm =
9/32 ............ 2813
19/64 ... ....... 2969
5/16 .. . .... 3125 ... 8 mm =
21 /64 ................ 3281
11/32 ........... 3438 ... 9 mm =
23/64 ...... ... ....... 3594
3/8 .. 375
25/64 ... . ........ . 3906 ... 10 mm = .3937"
13/32 . ... ...... .4063
27/64 ................ 4219 ... 11 mm::
7/16 . ..... .4375
29/64 ............... .4531
15/32 .......... .4688 ... 12 mm =
31/64 ... .. ...... 4844
1/2 .. 5 . .. .. . 13 mm = .5118
10.3
8/94
RIDE RED
Standard Torque Specifications
The following torque speci ficati ons are to be used as a general guideline. There are exceptions in the steering,
suspension, and engine areas. Always consult the torque deviation chart aruilhe specific manual section for
torque values of fasteners.
0
Q
0
Bolt Si ze Threads/In Grade 2 Grade 5 Grade 8
#10
#10
(MMfThread)
Torque jn. Ibs. (kgl m)
24 ......... . ... 27 (.31) ............... 43 (.50) ...... . ....... 60 (.69)
32 ...... . ..... 31 (.36) .......... 49 (.56) .............. 68 (.78)
Torgue tt. lbs. lkglm)*
1M ~ .. 5 ~ 8 (1.1 ) ............... 12 (1.6)
1M n 6 ~ 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)
112 13 ............. 50 (6.9) .............. . 75 (10.4) ............. 110 (15.2)
112 20 ............. 55 (7.6) .... .... .. 90 (12.4) ............. 120 (16.6)
To convert ft . Ibs. to kglm multiply foot pounds by .138.
To convert kglm to N/m move the decimal 10 the right one poSition.
Torque Deviation Li st
Due to the special grade bolts and nuts required for specific applications, observe the following torque values in
the areas specified.
Bolt Size Area Where Used Torque Minjmum-Maxlmum
7/16 ... .. Center Steering Block (Top) ........ . .. ...... 35-40 ft. Ibs. (4.83-5.52 kg/m)
112 ...... Center Steering Bl ock (Bottom) ............... 40-50 ft. Ibs. (5.52-6.9 kglm)
1/2 ..... . Center Steering Block (Center) ............... 55-60 ft. Ibs. (7.59-8.28 kg/m)
318 ...... Shock (Top& Bottom) ....................... 28-30 ft. lbs. (3.86-4.1 4 kglm)
3/8 ... . .. Radius Rod to Trailing Arm (Top & Bottom) ..... 28-30 ft . Ibs. (3.86-4.14 kglm)
3/8 ...... Drag Link (Center Frog to Steering Post) .... .. 28-30 ft. Ibs. (3.86-4. 14 kg/m)
318 .... .. Tie Rod to Steering Arm ..................... 28-30 ft . Ibs. (3.85-4. 14 kg/m)
318 ...... Tie Rod to Steering Frog .. .... ...... ....... .. 28-30 ft. Ibs. (3.86-4.14 kg/m)
7116 ..... Trailing Arm to Support ........... .. ... .. .. 40-45 ft . Ibs. (5.52-6.21 kglm)
5/16 ..... Steeri ng Post to Bulkhead .......... .. ..... 15-17 ft.lbs. (2.07-2.35 kg/m)
114 ...... Hoop to Bulkhead ................ ... ... . ... 6-8 ft . Ibs. (.83-1.1 0 kglm)
1/4 . . .... Upper Steering Bracket to Hoop . . . .... . . .. .. 8-10 ft . Ibs. (1.10- 1.38 kglm)
5/16 ..... Flangette .... .. ........ .. .................. 15-17 ft. Ibs. (2.07-2.35 kglm)
3/8 ...... Chaincase to Tunnel .... .. ..... .. .. . ........ 28-30 ft . Ibs. (3.86-4.14 kglm)
3/8 ...... Pinion Shaft Cover ............... .. ...... 17-20 ft . Ibs. (2.35-2.76 kglm)
3/8 .. .... Brake Caliper to Chaincase .... .. . ....... 28-30 ft . Ibs. (3.86-4.14 kglm)
t/4 .. .... Brake to Handlebar ............. . .. . ...... 8-10 ft. Ibs. (1.10-1 .38 kglm)
1/4 ...... Handlebar Block .. . . ... . . ...... . .. .. ...... 8-10 ft. Ibs. (1.10- 1.38 kglm)
1/4 ...... Oil Tank to Hoop .... ...... ... . . . . . . ...... 4-6 ft. lbs. (.S5-.83 kglm)
t/4 ...... Coolant Tank to Hoop ........ .. .. .. .. . . .... . 4-6 ft. Ibs. (.55-.83 kglm)
5/16 ..... Driven Cl utch to Shaft ........ . .. ... .. . ...... 15-17 ft. Ibs. (2.07-2.35 kglm)
7/1 6 ..... Driven Clutch to Engine ...... . . .. . . ........ 45-50 ft. Ibs. (6.21-6.9 kglm)
7/16 ..... Engine Mount to Chassis ........ . ... . . . .... 45-50 ft. Ibs. (6.21-6.9 kglm)
7/16 .... . Engine Mount to Engine ... ..... ............ 44-48 ft . Ibs. (6.07-6.62 kg/m)
8/94
10.4
RIDE RED
Torque Deviation List, Cont.
Bolt Size Area Where Used Torgue Minimum-Maximum
10-24 .... Regulator .................................. 38-43 in. Ibs. (.43-.49 kglm)
1/4 Side Panel to Nosepan Brace. Rubber Washer. 4-6 in. Ibs. (.05-.07 kg/m)
114 Side Panel to Nosepan, Well Nut.... . ... 4-6 in. Ibs. (.05-.07 kg/m)
114 Air Silencer ............. . ... 4-6 in. Ibs. (.05-.07 kg/m)
318 Set Screw to Throttle Block .. . . ... 30-35 in. Ibs (.35-.40 kg/m)
3/8 Weld Rod Suspension ....................... 10-12 ft. Ibs. (1.38-1.66 kglm)
Rubber Motor Mount Nuts. Low Flex .......... 15-18 ft. Ibs. (2.07-2.48 kglm)
Rubber Motor Mount Nuts, High Flex .......... 25-30 ft. Ibs. (3.45-4.14 kglm)
Manifold Nuts .... ........ .. 13-17 ft. Ibs. (1.79*2.35 kglm)
Ignition Switch to Plastic Console. . . . . ... 20--25 in. Ibs. (.23*.29 kglm)
Ignition Switch to Aluminum Console ...... ... . 50--55 in. Ibs. (.57*.63 kglm)
Choke to Plastic Console .................... 20--25 in. Ibs. (.23-.29 kglm)
Lock Collar Set Screws ...................... 70--80 in. Ibs. (.8 -.92 kg/m)
Conversion Table
ft. Ibs. x 12 '" in.lbs.
in.lbs. x .0833 '" ft. Ibs.
ft . Ibs. x .1383 = kg/m
in.lbs. x .0115 .. kg/m
kglm x 7.233 z: ft. Ibs.
kglm x 86.796 = in.lbs.
kglm x 10 = N-m
in. x 25.4 . mm
mm x .03937 = in.
in. x 2.54 .em
lb. x .454 '" kg
kg x 2.2046 lb.
mile x 1.6 =km
km x .6214 ,.,mile
gal x 3.7853 "" liters
quart x .9463 '"' liters
cc x .0610 = cu. inch
cc x .02816 '"' oz. (Imp.)
cc x .03381 = oz. (U.S.)
cu. in. x 16.39 = cc
liter x 28.16 = oz. (Imp.)
liter x 33.81 = oz. (U.S.)
liter x .8799 = qt. (Imp.)
liter x 1.0567 = q1. (U.S.)
C to of: 9 (OC + 40) + 5-40 = OF
OF to C: 5 (OF + 40) + 9-40 '" C
10.5
RIDE RED
8/94
Extended Storage
Extended storage of a snowmobile requires preventative measures to aid against deterioration and to prolong the
useful life of many components.
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. Be sure thaI corrosive salt and acids are removed from
surfaces before beginning preservation with waxes and rust inhibitors (grease, oi l or paint).
The machine should be stored indoors, out of direct sunlight and covered with a fabric snowmobile cover. Plastic
tarp can cause condensation to form and damage some snowmobile components.
Controls and Linkage
All bushings, spindle shafts and tie rod ends should be coaled with a light coal of oil or grease. Throttle controls
and cables should be lubricated wilh Polaris cable lubricant (PN 2870510).
Bearings
To prevent corrosion which will destroy the bearings, always grease jackshaft and driveshaft clutch side bearings
with a high quality bearing grease.
Electrical Connections
Separate electrical connector blocks and clean corrosive buildup from connectors. Lubricate or pack connector
blocks with Polaris corrosion resistant dielectric grease (PN 2871044) and re-connect. Replace worn or frayed
electrical wire and connectors.
Battery
Whenever the snowmobile is placed in storage for one month or more, the battery should be removed, charged to
proper level, and stored in a cool dry place. Or use Polaris Battery TenderTt.! battery charger.
Clutch and Drive System
Remove drive belt and store in cool dry location. Lubricate sheave faces, shaft and ramps of drive and driven
clutches with a light coal of oil or Polaris Clutch and Cable lubricant (PN 2870510).
Front Suspension
To minimize fatigue on the front shocks and springs, it is recommended that the fronl end of the machine be safely
bl ocked off the ground, removing tension from the shocks and springs.
Track and Suspension
Under normal conditions moderate track tension should be maintained during summer storage. The rear of the
machine should be supported off the ground 10 allow free hanging of the track.
Engine and Carburetor
Proper off season preparation of the engine and fuel system is vital to the prevention of rust and corrosion
formation on precision engine parts during storage.
We recommend adding 10 oz. of fuel conditioner/stabilizer such as Gold Eagle brand STABIL (Polaris PN
2870652) to the gas tank and topping off with fresh fuel.
Fog the engine wilh Polaris Fogging Oil (PN 2870791) following recommended procedures indicated on the can.
8194
10.6
RIDE RED
Extended Storage (continued)
Lubrication
lubricate the following fittings with Polaris low temperature grease (PN 2870577).
1. Spindles, left and right. The front end of the machine should be raised to permit better grease entry
into the spindle area.
2. Steering post support bracket (aerosol lubricant).
3. Rear suspension pivot shafts.
4. Remove (12) radius rod end bushings. Clean, inspect, lubricate and reinstall. Torque radius rod bolts
to 25 ft. Ibs.
5. Lubricate both front ski pivots at grease zerk with low temperature grease.
6. Loosen driven clutch retaining bolt and pull clutch outward to expose jackshaft bearing. Use a point
type grease gun fitting to inject grease through hole in flangelle into bearing until grease purges out
inside or outside bearing seal. Push clutch back on shaft and replace clutch retaining bolt.
7. Inject grease into fil1ing on speedometer drive adaptor until grease purges out inside or outside
bearing seal.
Fall Tune Up
Obtaining maximum performance and use from a snowmobile requires proper care and preparation. Whenever
inspection reveals worn or damaged parts, replacement is necessary.
Battery
Charge and test the battery before replacing it in the machine.
Track and Suspension
Check track tension and alignment and adjust if needed. Rotate track by hand to check for any possible damage.
Carefully examine track along entire length of each rod, bending and inspecting for breakage. Check for loose
nuts and bolts on suspension system. If any loose bolts are found on the rail beam, apply Loctite 262 and torque to
25 to 30 ft. Ibs.
Steering Arm and Ti e Rod Ends
Check steering arm and tie rod ends for play or looseness and adjust as needed.
Fasteners
Inspect and tighten all fasteners to recommend torque specs.
Clutc h and Drive System
Inspect drive belt for wear, cracks and tears. If worn or damaged, replace with new belt. Install drive belt.
Spark Plugs
Inspect spark plugs and connections. Clean or replace as needed.
Controls and Li nkage
Inspect all wires and cables for wear. Replace as needed. Lubricate throttle and choke controls and cables with
Polaris cable lubricant. Be sure all cables and wires are routed away from hot or moving parts.
Bearings
To prevent corrosion which will destroy the bearings, always grease jackshaft and driveshaft clutch side bearings
with a high quality bearing grease.
10.7
RIDE RED
8/94
Extended Storage (continued)
Lubrication
Lubricate the following fittings with Polaris low temperature grease (PN 2870577).
1. Spindles, left and right. The front end of the machine should be raised to permit better grease entry
into the spindle area.
2. Steering post support bracket (aerosol lubricant).
3. Rear suspension pivot shafts.
4. Remove (12) radius rod end bushings. Clean, inspect, lubricate and reinstall. Torque radius rod bolts
to 25 ft. Ibs.
5. Lubricate both front ski pivots at grease zerk with low temperature grease.
6. Loosen driven clutch retaining bolt and pull clutch outward to expose jackshaft bearing. Use a point
type grease gun fitting to inject grease through hole in flangette into bearing untit grease purges out
inside or outside bearing seal. Push clutch back on shaft and replace clutch retaining bolt.
7. Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside
bearing seal.
Hoses
Examine all fuel and coolant hoses for cracks, stiffness or deterioration. Replace as needed.
Brakes
Check master cylinder reservoir to make sure it contains the correct amount of fluid. Fill only with Polaris DOT 3
high temperature brake fluid. Check brake pads for wear and replace as needed. Check brake lever travel.
Fluids
Check coolant level and fill with correct coolant mixture as requi red. To insure the coolant maintains its ability to
protect the engine, it is recommended that the system be completely drained every two years and a fresh SO/50
mixture of and water be added.
Inspect chaincase for leaks. Check oil level and add Polaris chaincase oil as needed.
Check oil reservoir and fill with Polaris brand oil.
Emergency Shut Off Switch
Test operation of emergency shut off switch.
Throttle Safety Switch
Test operation of throl1le safety switch.
lights and Indicators
Check for proper operation of all lights, indicator lights and gauges.
8/94
10.8
RIDE RED
\
PROBLEM PROBABLE CAUSE
Machine Fails to Move Clutch Jammed
Track Jammed
Chaincase Sprocket or
Chain Jammed or Broken
Drive Bell Turns Over Wrong Belt for Application
Clutch Alignment out of
Spec
Engine Mount Broken or
Loose
Erratic Engine Operating Drive Clutch Binding
RPM During Acceleration
or Load Variations
Driven Clutch Malfunction
Harsh Drive Clutch Drive Bell Worn or Too
Engagement Narrow
Excessive BelU
Sheave Clearance
Noi se in Drive System Broken Drive Clutch
Components
Bearing Failure/Chaincase,
Jackshaft or Front Drive
Shaft
Drive Chain Loose or Worn,
Sprocket Teeth Broken
Drive Belt Surface Flat
Spots
10.9
General Troubleshooting
SOLUTION
Belt twisted, spring broken, weights stuck,
lubricated.
Foreign object caught or hi-fax melted to track
clips due to lack of proper lubrication.
Chain is loose or broken. Chain lightener is
loose.
Replace.
Adjust alignment offset.
Inspect/adjust or replace.
a. Disassembly of drive clutch required to inspect
shift weights for wear and free operation.
b. Clean and polish stationary shaft hub.
a. Replace ramp buttons.
b. Inspect movable for excessive bushing
clearance/replace.
Replace.
Perform belt/sheave clearance adjustment with
engagement spacers.
Check manual.
Check manual.
Inspect/adjust or replace.
Inspect/replace.
8194
RIDE RED
General Troubleshooting
PROBLEM PROBABLE CAUSE
Engine Does Seized Engine
Not Turn
Hydrostatic Lock (Fuel has entered
crankcase while vehicle was standing or
being transported)
Engine Turns Faulty Ignition
Over But Fails
to Start
No Fuel to Engine
Flooded Engine (Normal situation
caused by too much choking)
Poor Engine Compression
Engine Does Wire Connections
Not Start
(Electric Models)
Engine Lacks Fouled or Defective Spark Plug
Power
Carburetor and Fuel Pump
Fuel Filter (Loss of high RPM power)
Engine Faull y Plug(s)
Continually
Backfires
Carburetor
8/94
10. 10
SOLUTION
Direct result of poor lubrication or inadequate
fuel supply.
Drain plug(s) located on lower crankcase for
emergency draini ng.
Replace spark plug(s). If engine still fails to
start check for spark.
8. Check tank level and fill up with correct
fuel-oil mixture.
b. Ice in fuel line, fitter, or pump. On the
standard Polaris carburetor. the choke will not
function with the throttle depressed. See
second item under "Probable Cause" of
"Engine Continually
Hold throttle open, crank engine several times.
It may be necessary to change plugs. Plugs
may operat e satisfactori ly when dried out.
Running 100 lean a mixture. Too small main jet
will cause seizure resulting in loss of power.
Check manual.
Change and test operati on.
There is no adjustment that will change power
output.
Check fuel filter flow. Disconnect hose and
drain about 112 cup. Fuel flow should be
steady and encompass the entire diameter of
fuel line. If not, replace fitter.
Change Plug(s)
Dirt or ice in fuel system. (De-icer should be
added to fuel at all times for assurance against
fuel line icing).
RIDE RED
Ski Alignment Bar
For spindle alignment primarily on IFS models
Al ignment Bar Specifications:
Material: C-1018
Diameter: .623"-.625"
Length: 42"
Not available through Polaris
Fluke 73 Analog/Digital Multiteste,
Tests all electrical circuits and components.
PN 2870659
Ignition Timing Dial Indicator
0-1" Range
Indicates piston BTDC position for timing all engines.
PN 2870459
Mity VacH.I
The Mity Vac
Tl
!! is a multi purpose pressure/vacuum
test tool.
PN 2870975
10.1 1
TOOLS / PUBLICATIONS
Special Service Tools
8/94
RIDE RED
Pressure Gauge
This is a fuel system pressure tester designed to be
used on fuel injected machines.
PN 2870982
Camoplast Clip Tool
This tool is used for installation of track guides and
clips on Camoplast tracks.
NOTE: This tool is not for use on other tracks.
PN 2871041
Select Monitor
This is a required service tool for AXL-EFI diagnostic
checks; it provides quick and easy checks of various
sensor and system functions on fuel injected
machines.
PN 2870969
Strap Wrench
Aids in the removal and installation of fl ywheels, drive
clutches and other cylindrical objects which need
holding or turning.
PN 2870336
Replacement Strap
PN 2870389
Bl94
10. 12
RIDE RED
Chain Wrench
Holds flywheel puller an 3 cylinder engines and aids in
removal and installation of drive clutches, etc.
PN 2870203
Piston Pin Puller
Removes piston pins on all engines.
PN 2870386
Piston Support Block
Supports piston and prevents piston skirt damage
during cylinder installation on all engines.
PN 2870390
Ammco Model 3950 Cylinder Hone
Rigid cylinder hone for de-glazing and truing heat
distorted cylinders.
1 7/8"" 2 3/4" Range (4.8" 7cm)
PN 2870303
10.13
8/94
RIDE RED
Replacement Ammco Hone Stone Sets
Cylinder Hone Slone Set SId. Fine (Ammco No.
3952) - PN 2870305
Cylinder Hone Stone Set Std. Coarse (Ammeo No.
3951) - PN 2870304
Cylinder Hone Slone Set 0.5. Fine (Ammeo No.
3954)- PN 2870307
Cylinder Hone Stone Set 0.5. Coarse (Ammeo No.
3953) - PN 2870306
O.S. Stone Sets Range 2 112" - 3 31B" (6.4 - B.6cm)
Ammco 3880 Honing Oil
Improves hone operation and prevents stone loading.
PN 2870588
Crankshaft Alignment Kit
Used for checking and straightening crankshafts on
all Polaris engines.
PN 2870569
Uni-Syn Gauge
Used to synchronize carburetor air flow on multi
carburetor engines.
PN 2870509
8/94
10. t4
RIDERED
Jackshaft Installation Tool
This is a required tool for 1991 to present Indys; used
to prevent damage to chaincase upper oil seal.
PN 2870974
Drive Clutch Spider Button Remover
Removes tight spider buttons easily.
PN 2870985
T Handle Drive Clutch Puller
Quick aluminum drive clutch removal for most models.
PN 2870506
Steel Drive Clutch Puller
For 1965-72 Steel Clutches.
PN 2870030
Aluminum Clutch Puller
For Models Without Nosepan Access Hole.
PN 2870130
Drive Clutch Holding Fixture
All Models
PN 2870547
Replacement Holding Tabs
Used for disassembly of all aluminum drive clutches.
PN 5130518
10. 15
8/94
RIDE RED
Drive Clutch Spider Nut Driver
For removal and installation of drive clutch spider jam
nut on high performance models.
PN 2870338
Spider Removal Tool
Fits all aluminum drive clutch spiders. For removal
and relorquing of spider.
PN 2870341
Spider Roller Centering Punch
PN 2870401
Shift Weight Spring Pin Punch
PN 2870402
Shift Weight/Roller Pin Punch
PN 2870507
Roller Pin Gauge Block
Used during removal and installation of spider roller
pins in standard aluminum drive clutches.
PN 2870310
8/94
10.1 6
RIDE RED
518" Offset Clutch Alignment Tool
Establishes correct 5/8" (1.6cm) drive/driven clutch
offset and alignment.
PN 2870426
P-90 Version Drive Clutch Alignment Tool
PN 2870914
NOTE: PN 2870426 and PN 2870914 are 1he
alignment toots for use a.tle.r initial break in. Not for
use at setup and pre-delivery inspection.
9116" Offset Clutch Alignment Tool
Establishes correct 9/ 16" (1.4cm) drive/driven clutch
offset and alignment.
PN 2870161
Drive Clutch Bore Tapered Reamer
Cleans up all drive clutch bore tapers to ensure proper
fit to engine crankshaft.
PN 2870576
Jackshaft Alignment Tool
Ensures correct jackshaft bearing alignment during
chaincase installation.
PN 2870399
10.17
8/94
RIDE RED
Suspension Compression Tool
Assists with necessary compression of rear
suspension springs and shocks to permit tunnel
mounting bolt installation.
PN 2870354
IOL Track Clipping Tool
Used for installation of track clips on other than
Camoplast tracks.
PN 2870380
Replacement Allen head guide bolt
PN 7515461
Shock Absorber Spring Compression Tool
PN 2870623
COl Strobe Timing Light
High intensity strobe, works on all types 01 ignition
systems including the difficult to time 3 cylinders.
Self contained.
Requires no outside power source.
(Two "0" cell batteries included.)
PN 2870630
8/94
10.18
RIDE RED
Carburetor Synchronizing Manometer
Accurate synchronization of multi carbureted engines
which are equipped with vacuum spigots.
PN 2870672
Transmission Seal/Bearing Driver
For installing bearings and case seals during
transmission gearcase overhaul.
PN 2870702
Gas Shock Recharging Kit
Contains atl the necessary components and
instructions to recharge Polaris gas fi tl ed suspension
shock absorbers.
PN 2200421
Piston Wrist Pin Keeper Installation Tool
Used to install C-clip style retainer.
PN 2870773
10. 19
8/94
RIDE RED
TOOLS / PUBLICATIONS
Engine Cylinder Compression Gauge
PN 2870852
Hi Speed/Hi-Temp Bearing Grease
Special10,QOO RPM rated bearing grease.
PN 2870616
Master Cylinder Service Tool Kit
Used to remove and install master cylinder internal
components.
PN 2870962
Electrical AntiCorrosive Lubricant
Use on all electrical connections to prevent corrosion
and high resistance, especiall y on EFt systems.
PN 2871044
8/94
10.20
RIDE RED
Clutch Compression Tool
Supercedes 2870984
This clutch compression tool will work on all models
including 1994 with side panels.
PN 28711 73
Driven Clutch Puller
Used to remove splined driven clutch from jackshaft.
PN 2871056
Spanner Wrench
Shock absorber cam preload adjustment tool.
PN 2870872
Clutch Bushing Replacement Tool Kit
Removes and installs all bushings on drive and driven
clutches.
PN 2871025
10.21
: . = = ~ J oj , oJ __
o
8/94
RIDE RED
Rolierl Pin Installer
Drive clutch spider roller and pin installation 1001.
PN 2870910
Fox Shock Needle
Used for pressurizing Fox Shock.
PN 7052069
Battery Hydrometer
Accurate small battery specific gravity hydrometer.
PN 2870836
Fox Shock Absorber Body Block Tool
Safely holds Fox Shock body during rebuilding
without damage.
PN 2871071
8/94
10.22
RIDE RED
Flywheel Puller
For all 3 bolt pattern flywheels.
Items in square are for watercraft only.
PN 2871043
Flywheel Puller
Removes all 4 bott pattern flywheels.
PN 2870159
Tunnel Rivet Tool
Installs rivets in tunnel. Includes anvil and striker.
PN 2871188
10.23
-
-
_ Special Service Tools
RIDE RED
8/94
1993 Technical Service Publications
MODEL
Trail
Sport
440
Classic
XLT
RXL
RXL SKS
500 EFI
500 EFI SKS
Trail Deluxe
440 SKS
Classic Touring
Storm SKS
XLT SKS
WideTrak
StarLite
Lite
Lite Deluxe
StarLite GT
Lite GT
XLTSP
440 XCR
Storm
Part Number
9911193
9911340
9912121
9912363
9912364
9912264
9912265
8194
MODEL NO. OWNER'S PARTS PARTS ASSEMBLY
MANUAL MANUAL MICROFICHE INSTRUCTIONS
0930761 9911243 9912322 9912352 9912244
0930443 9911243 9912294 9912350 9912244
0930760 9911243 9912293 9912349 9912244
0930864 9911243 9912295 9912351 9912244
0930767 9911243 9912301 9912358 9912244
0930768 9912249 9912299 9912357 9912250
0930568 9912249 9912299 9912357 9912250
0930674 9912249 9912296 9912353 9912250
0930574 9912249 9912296 9912353 9912250
0930243 9912257 9912322 9912352 9912370
0930560 9912257 9912293 9912349 9912244
0930865 9912257 9912295 9912351 9912370
0932570 9912257 9912304 9912361 9912371
0930567 9912257 9912301 9912358 9912244
0932064 9912257 9912298 9912356 9912245
0933427 9912235 9912297 9912354 9912239
0933433 9912235 9912297 9912354 9912239
0933431 9912235 9912297 9912354 9912239
0933127 9912235 9912323 9912355 9912384
0933133 9912235 9912323 9912355 9912384
0930667 9912282 9912301 9912358 9912341
0931760 9912282 9912302 9912359 9912341
0932770 9912282 9912303 9912360 9912371
Description
Master Repair Manual Replacement Empty Binder (5 Hole)
Snowmobile Master Repair Manual Vol. 1 (1972- 1991) Includes Binder
Snowmobile Master Repair Manual Vol. 2 (1985-1992) Includes Binder
1993 Master Repair Manual Update
1993 Snowmobile Technical Service Data Watlchart Packet
Maintenance Inspection Form, 150 Mile (Pkg. of 25)
Maintenance Inspection Form, 1000 Mile (Pkg. of 25)
10.24 RIDE RED

MODEL
440
Sport
Super Sport
Sport SKS
Classic
Trail Deluxe
Classic Touring
Indy Lile
500 EFI
Indy U1. GT
Indy Lite Oeluxe
440 SKS
Trail
Starlite
Slarlite GT
Widetrak LX
Widetrak GT
SOD EFI SKS
XLT
RXL Touring
RXL
XLT SP
XLT Special Xtra
XLT SKS
Storm SKS
Storm
440 XCR
440 XCR SP
600 XCR
part Number
9911 193
991 1340
9912121
9912591
MODEL OWNER'S PARTS PARTS ASSEMBLY
NO, MANUAL MANUAL MICROFICHE INSTRUCTIONS
0942760 9912387 9912495 9912507 9912528
0940443 9912490 9912505 9912516 9912534
0940743 9912490 9912743 9912775 9912635
0940243 9912491 9912505 9912516 9912637
0942865 9912387 9912496 9912508 9912526
0940262 9912491 9912497 9912509 9912636
0942875 9912492 9912496 9912508 9912527
0943433 9912493 9912499 9912511 9912532
0942774 9912492 9912498 9912510 9912525
0943133 9912493 9912501 9912512 9912533
0943431 9912493 9912499 9912511 9912532
0942560 9912387 9912495 9912507 9912528
0940761 9912490 9912497 9912509 9912535
0943427 9912493 9912499 9912511 9912532
0943127 9912493 9912501 991251 2 9912533
0942064 9912491 9912504 9912515 9912530
0942061 9912491 991261 1 9912612 9912531
0942574 9912492 9912498 9912510 9912525
0940767 9912490 9912502 9912513 9912522
0940869 9912492 9912506 9912517 9912523
0940768 9912492 9912506 9912517 9912658
0940667 9912494 9912502 9912513 9912522
0946767 9912819 9912711 9912715 9912707
0940567 9912491 9912502 9912513 9912522
0940582 9912491 9912503 9912514 9912524
0940782 9912494 9912503 9912514 9912524
0941760 9912494 9912518 9912519 9912529
0941660 9912603 9912708 9912712 9912706
0941667 9912811 9912709 9912713 9912706
Description
Snowmobile Masler Repair Manual Vol . 1 (1972- 1991) Includes Binder
Snowmobile Master Repair Manual Vol . 2 (1985- 1992) Includes Binder
1994 Snowmobile Service Technical Update Package (Includes 1994 Master Repair
Manual Update and Wallchart)
10.25
AICERED
8/94
MODEL
lite
lite Deluxe
Ule GT
StarUte
Sport
Super Sport
Sport SKS
Trail
Trail Deluxe
440 LC
440 SKS
500 Carb
Classic
XLT Touring
500 EFI
500 SKS
500 SKS PT
XLT
XLT SKS
XLT SKS PT
XLT SP
WideTrak LX
WideTrak GT
RXL Touring
RXL
Storm
Storm SKS
Storm SKS PT
440XCR
600XCR
Part Number
991 11 93
991 1340
9912121
9912719
8194
MODEL NO. OWNER' S PARTS PARTS ASSEMBLY
MANUAL MANUAL MICROFICHE INSTRUCTIONS
0953433 991 2814 9912890 9912891 991 2815
0953431 9912814 9912890 9912891 991281 7
0953133 9912814 9912892 9912893 9912820
0953427 9912814 9912890 9912891 9912823
0950443 9912804 9912882 9912883 9912805
0950743 9912804 9912888 9912889 9912844
0950243 9912804 9912882 9912883 9912846
0952761 991 2807 9912886 991 2887 9912840
0952262 9912807 9912886 9912887 9912849
0952760 9912807 9912903 9912904 9912808
0952560 9912807 9912903 9912904 9912812
0952764 9912807 9912919 9912920 9912921
0952865 9912882 9912907 9912908 9912863
0952857 9912862 9912917 9912918 9912864
0952774 9912837 9912905 9912906 9912879
0952574 9912837 9912905 9912906 991 2880
0952974 9912837 9912905 9912906 9912880
0950756 9912818 9912884 9912885 9912833
0950556 9912818 9912884 9912885 9912833
0950956 9912818 9912884 9912885 9912883
0956756 9913060 9913076 9913077 9912877
0952064 9912857 9912894 9912895 9912859
0952061 991 2858 9912896 9912897 9912860
0950869 9912837 9912898 9912899 9912878
0956768 9913061 9913078 9913079 9912838
0950782 9912853 9912901 9912902 9912854
0950582 9912853 9912901 9912902 9912855
0950982 9912853 9912901 9912902 9912855
0951660 9912867 991291 1 9912912 9912869
0951656 9912867 9912913 991291 4 9912870
Descriptjon
1995 Snowmobile Service Technical U ~ a t e Package (Includes 1995 Master Repair
Manual Update and Walichart)
10.26
AICERED
Technical Service Printed Materials
1990 Service Bulletins
P-90-01
8-90-01
8-9(}-02
8-9(}-03
8-90-04
8-90-05
1990 Indy 400 and 500 Rear Suspension Shock Absorber
1990 Indy 400, 500 and 650 Carburetor Airbox Intake Chimney Foam
1990 Indy Brake Master Cylinder Sight Glass
1990 Star, SlarTrak Carburetor Main Jet
1990 Indy 400 and 500 Voltage Regulator
1990 Sport/Sport GT pogO System Driven Clutch Snap Ring Retainer
1990 Information Bulletins
1-90-01 1990 Pre-delivery Topics
1-9(}-02 1989 Indy 650 Water Pump
1-9(}-03 1990 WideTrak Rear Tunnel Extension Mounting Holes
1-9(}-04 1. 1990650 RXL EFt Guidelines
2. Reverse Chaincase Kit Information
1-9(}-05 1990 Indy 500 and 400 Service Recommendations
1. Engine Ignition Timing
2. Spark Plug Fouling
1-90-06 1. Reverse Gear Kit Assembly Part Number Breakdown
2. PN 2870905 Hood Screen Kit
1-9(}-07 High Elevation Clutching for Indy 650
1991 Indy Trail Brake Hose
Steering Post Attaching Bolt Tightness on 1991 Indy 500 SKS Snowmobiles
Under Hood Heat Deflection Kit Indy SOD Snowmobiles
Indy 500 Drive Clutch Rebuild Kit PN 2200386
1991 RXL Handlebar Engine Stop Switch PN 4110109
1991 RXL and 650 Indy Models Drive Clutch Service/Adj .
1990 RXL Snowmobile Emergency Engine Shut Off Switch
1991 RXL Disc Brake Caliper Alignment and Cooler Hose Modification
1991 StarLite Engine Failure Correction Action
1991 Indy Lite Muffler Clearance
1991 Indy Lite, StarLi te and Lite GT Fuel and Oi l Tank Vent Line
1991 Indy 400 XC Upper Steering Post Bracket Bushing
1991 Indy Lite GT - Muffler, Speedometer Cable, Drive Clutch
8-91-02
8-91-03
8-91-04
8-91-05
8-91-06
8-91-07
8-91-08
8-91-09
8-91-10
8-91-11
8-91-12
8-91-13
8-91-14
8-91-15
8-91-16
Carburetion Changes on 1991 Indy 500 Machines Manufactured with Engines
1991 RXURXL 8K8
1991 Indy Lite Pi lot Production X913033
Drive Clutch BelUSheave Clearance Adjustment
10.27
8/94
RIDE RED
,
1-9 ' -0'
1-9'-02
1-91-03
1-91-04
1-91-05
1-91-06
1-91-07
1-91-08
1-9'-09
1-9'-'0
Bl94
1. 1991 StarUte Fuel line
2. 1991 WideTrak Track Adjustment Bolt
3. Thumbwarmer
RXL EFt Tuning TIps
1. Idle Adjustment
2. Select Monitor
3. Acceleration Clutch Tuni ng
1. Indy Brake Caliper/Disc Alignment
2. Indy Chaincase Reverse Kit Cover
3. Diagnosing Indy Chaincase Leakage
1. Later 1991 Indy 400 and SOD Ignition Timing
All 1991 WideTrak and Indy 400XC Ignition Timing
2. 1991 Indy 400XC Jetting Information and Jet Needle "E" Clip Location Change
3. Indy 500 ECSOPL-04/05 Main Jet Recommendation
1. 1991 RXL SKS Front Limiter Strap on Rear Suspension
2. 1991 RXL Muffler to Manifold Leakage
3.1991 Indy 500 Drive Clutch Setup/Procedure
4. COl BoxiFlywheel ldentification Setup
1. Improved Greaseable Transmission Input Shaft Coupler Kit for WideTrak. SuperTrak.
and longTrak Reverse Models
2. Hood Screen Kit Usage
3. Indy lite and lite GT Air Intake Door for Deep Snow Operation
1991 RXl Erratic Behavior and Seizures
1. 1991 Fuel Tank Cap Gasket
2. Recoil Starter Rope Guide
3. Indy lite Handling Adjustments
1991 650 Indy Carburetor Idle Adjustment
1991 RXl EFI System Adjustments (0-3000 ft . elevation)
1. ECU Replacement Chip
2. EFI System Diagnostic Checks
10.28
RIDE RED
5-92-01
8-92-02
8-92-03
8-92-04
8-92-05
92-XlT
1992 XCR Handwarmer Wi ring
1992 EFI Fuel Pump Wire Connector
1992 Indy 440 Cold Engine Driveaway Lean Carburetion Condition
1992 Indy 500 SPX Track Suspension Wheels
1992 Indy Lite GT Drive Clutch Shift WeighVSpring Change for Operation Below 6000 ft.
Elevation
1992 Indy 500 XlT
1. Rear Suspension Limiter Straps, Front Shock and IFS Shock Adjustment Setting Changes
2. Carburetion Adjustments to Stabilize Idle RPM
1-92-01
1-92-02
1-92-03
1-92-04
1-92-05
1-92-06
1-92-07
1-92-08
High Performance Bearing Kit PN 2200422
Snowmobile Drive Clutch Replacement Numbers Information
1. Snowmobile Chaincase Reverse Kit Application Data
2. EFI Secondary Fuel Filter Flow
3. Kinked Fuel, Oil and Vent Lines
1. Indy Li te Deluxe Handlebar Heater Wires
2. Select Monitor Cartridge for SOO SP
1. 1992 Indy Lite Performance Tips
2. PN 3211061 High Performance Indy Drive Belt
3. Dealer Maintenance Inspection Forms
4. PN 2200356 Under Hood Heat Deflection Kit
1992 Indy Hydraulic Brake Caliper/Disc Float Inspection Procedure
1. Engine Torque Stop Adjustment
2. 1992 WideTrak and SuperTrak Jackshaft Driven Side Bearing Snap Ring
3. 1992500 SPX Battery and Temperature Light Wires Misconnected
1. Hi/Lo Range Transmission Chai n Adjustment Revision for all WideTrak and SuperTrak
2. EFI System Fuel Filter Service
3. Recoil Starter Engagement Problems
10.29
RIDE RED
8194

-------------------- ---
5-93-01
8-93-02
5-93-03
5-93-04
5-93-05
5-93-06
8-93-07
5-93-08
5-93-09
5-93-10
5-93-11
8-93-12
5-93-13
5-93- 14
5-93-15
5-93-16
5-93-17
5-93-18
5-93-19
5-93-20
5-93-21
Incorrect Dimension Thrust Washer Installed on 1993 Indy Classic Touring Snowmobil es and
Current Accessory Reverse Kit PN 2870861
1993 WideTrak Airbox Intake Foam Duct Incorrect
Incorrect Heat Range Spark Plugs Installed on Some 1993 Indy XCR Model Snowmobiles
Under Hood Heal Deflection Kit PN 2200356 for 1993 Indy XLT and Indy 500 Snowmobiles
ThroHle Cable Junction Block Kit PN 2200470
Fuel Filter l ocation on Some 1993 Indy Storms and Indy SKS
1993 Indy Storm and Indy SKS Performance and Durability Improvements
1993 Storm Low End Improvement Kit
1. Base Gasket Replacement Procedure for EC58PL-Ql Engines
2. Warranty Notice
1. Handwarmer, wire harness modification.
2. Temp-Battery indicator warning lamp wire placement
WideTrak LX Exhaust Boot
Possible Fuel Leak at Electric Fuel Gauge Sender Ground Wire Screw
Handwarmers Have Only Low Heat and Indicator Does Not Ught in High Position
Inadequate Antifreeze/Coolant Strength
Loose Handlebar Grips
Chaincase Washers Misplaced or Missing
RXL and RXL Touring Kinked Surge Tank Vent Une
1. Storm and Storm SKS Air entering Oil Une
2. Storm and Storm SKS Vibration Through Running Boards
RXL Touring Improperly Routed Battery Cable
600 XCR Steering Binding or Locking
Loose Handlebar Grips
1-93-01
1-93-02
1-93-03
1-93-04
8194
Electric Start Kits PN 2870863 and PN 2870656
1993 XCR Removable Snow Filter on Air Box Chimney
1993 Indy Storm/Indy Storm SKS Cooling System Inspections and Possible Modifications
Use of Oxygenated Fuels in Polari s Snowmobiles
10.30
RICEREC
1-93-{)S
1-93-06
1-93-07
1-93-08
1-93-09
1-93-10
1-93-11
1-93-12
1. 1993 SKS Moders: Deep Snow Performance
2.1993 XLT: Engine Misfire
3. 1993 All Models: Throttle Lever Does Not Always Hit Safety Switch Pin and Can Cause
Engine Starting Problems
4. 1993 Indy Lite Deluxe Model 0933431: Recoil Rope May Contact Oil Line and Eventually
Wear Through line.
5. 1993 Indy Storm Clutching Options for Various Types of Driving Conditions
,. EC58PL-Ol Engines with Failed Cylinder Base Gaskets
2. EC58PL-Ol Service Tips
3. All EC50PL and EC50PM Engines That Experience PTO End Bearing Failures
New Crate Handling Procedures
Defective Key Switches
Improved Transfer Suspension (ITS) Kits
1. Oil Tank Fittings Leaking on 1994 Indy Lite/StarLite
2. Indicator Lights That Pop Out of Console on 1994 500 EFI
Rear Torsion Springs May Rub Against Track Carrier Wheel
Carburetor Jetting Recommendation for Storm and Storm SKS Performance Kit
S-94-o1 1. RXL Touring Top Chaincase Sprocket Cotter Pin Missing or Loose
2. Lite GT Wrong Lever on Brake Block
S-94-02 Fuel Leaks at Carburetor Water Trap Drain Plug
1-94-01
1-94-02
1. Water and sediment may not drain from carburetor float bowl into sediment tube (water trap).
2. Cooling system leak at water pump
3. Cooling system leak at center extrusion.
4. Oil line from oil pump to engine kinked on PTa (LH) side.
5. Excessive fuel consumption, lack of power and poor throttle response .
6. Kinked fuel tank vent line at fuel tank.
7. Rear view mirrors do not have full adjustment range.
1. Some 1994 Storm and Storm SKS models may encounter a rich condition when
operated on rough terrain.
2. PTa (LH) carburetor may rub against the torque stop mounting bracket on 1994600
XCR.
10.31
RIDE RED
8/94
Glossary of Terms
AC$: Alternalorcontrol system. The main relay for the 1993500 EFt system. Rectifies AC alternator voltage to DC for
battery chargi ng, and triggers the ECU with DC for start up.
ACV: Alternating current voltage.
Ai r Gap Spark Test: A good check for ignition voltage and general ignition system condil ion. Spark should arc 3/8" (1
em) minimum from end of high tension lead to ground. Several tests are avai lable.
Alternator: Electrical generator producing voltage alternating current.
BTDC; Before top 'dead center.
COl : Capacitor discharge ignition. Ignition system which stores \/oltage generated by the stator plate exciter coi l in a
capacitor or condenser (in COl box) . At the proper moment a .... oltage generated by the stator plale pulser coil closes an
electronic switch (thyristor) in the COl box and al lows the voltage in the capacitor to discharge into the primary windings
of the ignition coit.
Center Distance: Distance between center of crankshaft and center of driven cl utch 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 wilt stay nearly straight as it moves along the clutch
face.
Clutch Weights: Three levers in the drive clutch which relative to their weight. profile and engine RPM cause the drive
clutch to close. .
Coli : A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic
current passes through it.
Condenser/Capacitor: A storage reservoi r for electricity. used in both E.T. and COl systems.
Crankshaft Run-Out: Run-out or ubend" 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 cm).
DCV: Direct current voltage.
Delonatlon: The spontaneous ignition of the unbumed fueVai r mixture after normal spark ignition. Piston looks
"hammered" through. rough appearance around hole. Possible causes; 1) too high a compression ratio for the fuel
octane; 2) low octane fuel; 3) over-advanced ignition timing.
Dial Bore Gauge: A cyli nder measuring instrument which uses a dial indicator. Good for showing taper and
out-of-round in the cylinder bore.
Dropping Resistor: Component in an EFI system which reduces input (battery) voltage to approximately 5 volts.
ECU: Electronic Control Module. In an EFI System. the component which monitors all data from sensors in the system,
and electronicall y adjusts injector duration accordingly.
Effective Compression Ratio: Compression ratio measured from after the piston closes the exhaust port.
Electrical Open: Open circuit. An electrical ci rcui t which isn't complete. (i.e. poor connections or broken wire at hi-Io
beam switch resulting in loss of headlights.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended
component. (i.e. a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake
!;ghls) .
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
E.T. Ignition: Energy transfer ignition. Magneto type ignition system usi ng an external igni tion coil.
fJ- Flat Head 801t: 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 di rection.
Fuel Pressure Regulator: Mechanical device in an EFI system which regulates fuel pressure in the distribution
manifold by returning excess fuel to the tank.
Fuel Rail: The fuel distribution manifold for the injectors in an EFI system.
8/94
10.32
RICE RED
g: Gram. Unit of weight in the metric system.
Glossary of Terms (continued)
Head Volume: Cylinder head capacity in ce, 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 comers trimmed
to close tolerances. Recommended for general commercial applications.
HI-Fax: Trademark of Himont Advanced Materials. The special slide malerial which fits onto the bottom of the
suspension rails.
High Tension Wire: The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug.
Hol ed Pist on: 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.
Igniti on Genliratlng Coil : Exciter coi l, primary charge coil. Stator plate coil which generates primary ignition voltage.
CDI system uses one ignition generating coil. Twin cylinder E.T. ignition systems use two ignition generating coils. Coil
is mounted at the top of the stator plate.
Inch Pound: In. lb. 12 in. Ibs. = 1 ft. lb.
Kg/cm2: Kilograms per square centimeter.
Keystone Ri ng: A piston ring with bevel on upper inside surface.
Kil ogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
L Ring: A wide face piston ring with an nLn shaped cross section. Leg of "Ln 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.
Lighti ng Coil : Large coil mounted at the bottom of the stator plate. Generates voltage for lights, battery charging, etc.
mm: Millimeter. Unit of length in the metric system. 1 mm ... D40n.
Magneti c 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.
No. 1 Cylinder: Cylinder on flywheel side of engine.
No.2 Cylinder: Cylinder on PTO side of engine.
Ohm: The unit of electrical resistance opposing current flow.
Ow Oval Head Screw: Fully specified as "oval countersunk
n
, this head is identical to the standartl flat head, but
possesses a rounded upper sur1ace for attractiveness of design .
Pan Head Screw: Provides a low, targe diameter head, but with characteristically high outer edges atong the
outer edge of the head where driving action is most effective. Slightly different head contour when supplied with Phillips
Recess. See dotted tine.
Pist on Clearance: Total distance between piston and cyl inder wall.
Piston Erosion: Piston dome melts. Usually occurs at the exhaust port area. Possible causes: 1) lean fuellair mixture;
2) improper spark plug heat range.
Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston looks
melted at area of damage. Possible causes: 1) too hot a spark plug; 2) spark plug not properly torqued; 3) uglowing"
piece of head gasket, metal burr or carbon in the combustion chamber; 4) lean fuellair mixture.
Pri mary Ci rcuit: 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 stat or plate to the small primary winding in the ignition coit.
In the COl system the parts include the exciter coil , the trigger coil, the wires from stator plate to COl box and to the low
resistance primary windings in the ignition coil.
Primary Clutch: Drive clutch on engine.
Pri mary Compression: Pressure built up in the crankcase of a two stroke engine.
10.33 8/94
RIDE RED
Glossary of Terms (continued)
psI.: Pounds per square inch.
R & R: Remove and replace.
RFI : Radio frequency interference. Caused by high voltage from the ignition system. There are special plug caps and
spark plugs to help eliminate this problem. Required in Canada.
RPM: Revolutions per minute.
Relay Colis: Electromagnetic device in an EFI system which controls circuit connection with input from another circuit.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to
heat.
Right Side: Always referred to based on normal operating position of the driver.
~ Round Head Screw: The familiar head most universally used for general application.
underhead bearing surface and finished appearance are characteristic of this head.
Running Time: Ignition timing when fully advanced or at specified RPM.
Good slot depth, ample
Secondary Ci rcuit: 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 Pi ston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the pis.ton onto the cylinder
wall . Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck
piston rings.
Select Monitor: Diagnostic tool which provides static and dynamic displays of the-function of critical components in an
EFI system. It also has the capabi lity to display the contents of the ECU memory.
Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 314" (2 em) reach plugs.
Stati c Timing: Ignition timing when engine is at zero RPM.
Stator Pl ate: The plate mounted under the flywheel supporting the primary ignition components and lighting coil.
Surge Tank: The fill tank in the liquid cooling system.
TOC: Top dead center. Piston's most outward travel from crankshaft.
Throttl e Body: The air flow metering device in an EFI system.
Transfer: The movement of fueVair from the crankcase to the combustion chamber in a two stroke engine.
Tri gger Coil : Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in COl
systems. Small coil mounted at the top of the stator plate next to the ignition generating coil.
V Regulator: Voltage regulator. Maintains maximum lighting coil output at approx. 14.5 ACV as engine RPM
increases.
Vent uri: An area of ai r constriction. A venturi is used in carburetors to speed up ai r 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 etectromotive force. Measured by a voltmeter in parallel with the
circuit.
Watt: Unit of electrical power. Watts. amperes x volts.
Trademarks
PolariS acknowledges the following products mentioned in this manual;
Loctite, Regi stered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Hi-Fax, Trademark of Himont Advanced Materials
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vae, Registered Trademark of Neward Enterprises, Inc.
Camoplast, Registered Trademark of Camoplast, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
8194
10.34
RICEREC
LIMITED WARRANTY
Warranty Policy
Polaris Industries L.P., 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, gives a ONE YEAR
LI MITED WARRANTY on all components of the Polaris Snowmobiles against defects in material or workmanship.
This warranty begins on the date of purchase.
A warranty registration must be completed by your dealer and submitted to Polaris by the dealer prior to the time
you attempt to obtain any service under this warranty. Be sure that you receive your copy of the Warranty
Registration from your dealer, as this is your entitlement to warranty repairs. UNLESS YOUR SNOWMOBILE IS
REGISTERED WITH POLARIS, NO WARRANTY COVERAGE WILL BE ALLOWED.
The warranty on the Polaris snowmobile is transferrable during the warranty period for a fee of 525. This fee must
be paid to the transferring dealer at the time of transfer. Transfer of warranty on snowmobi les that were purchased
under the snow check program must receive prior approval of the warranty department.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by you dealer and submitted to Polaris
within ten days. Upon receipt of this registration Polaris will record the registration for warranty. No verification of
registration will be sent to you as your copy of the Warranty Registration Form will be your warranty entitlement. If
you have not signed the original registration and received the "customer copy," please contact your dealer
immediately. No warranty will be authorized unless your snowmobile is registered.
Initial dealer preparation and set-up of your snowmobile is very important in ensuring trouble-free operation.
Purchasing a machine in the crate or without proper dealer set-up wi ll void your warranty coverage.
WARRANTY COVERAGE AND EXCLUSIONS;
LIMITATIONS OF WARRANTIES AND REMEDIES
This warrantY, covers all parts and components except:
1. Light Bulbs
2. Spark Plugs
3. Brake Pads
4. SuspenSions Slides and Ski Wear Bars
5. Drive Belts
This warranty also covers labor charges relating to repair or replacement of defective parts which are covered by
this warranty.
This warranty covers only failures due to defects in material or workmanship. This warranty does not cover
accidental damage, normal wear and tear, abuse (such as operation in areas without adequate snow coverage) or
improper handling. This warranty also does not cover any snowmobile that has been altered structurally,
neglected, improperly maintained, used for raCing, or used for purposes other than for which it was manufactured;
or for any damages which occur during trailer tranSit, or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, tearing or
puncturing of upholstery material, or corrosion of defects in parts or components of the snowmobile. the warranty
also does not cover damage to snowmobiles due to fire, explosion or any other cause beyond Polaris' control.
10.35
AIDE RED
8194
Warranty Policy
The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any
defective materials, components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF
ANY DESCRIP]:ION, WHETHER ARISING OUT OF WARRANTY (INCLUDING ANY IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) OR ANY OTHER CONTRACT,
NEGLIGENCE OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of
incidental or consequential damages or implied warranties, so the above limitation or exclusion may not apply to
you, if inconsistent with controlli ng state law.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) IF UNEXCLUDABLE UNDER
CONTROLLING STATE LAW ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD.
POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some
state do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if
inconsistent with controll ing state law.
HOW TO OBTAIN WARRANTY SERVICE
After you have purchased your snowmobi le, your dealer should send the Warranty Registration Form to Polaris. If
your snowmobile requires warranty service, you must take it to a current Polaris Servicing Dealer. When
requesting warranly service, you must present your copy of the Warranty Registration Form to the dealer. (THE
COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) Polaris suggests
that you use your original selling dealer; however, you may use any current Polaris Servicing Dealer to perform
warranty service.
If you have questions or problems you cannot resolve with your dealer, please contact Polari s directl y at the
address given on the preceding page (Attn: Warranty ServiceDepartment).
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
tf any of the above terms are void because of stale or federal law, all other warranty terms will remain in effect.
8/94
10.36
RIDE RED

Polaris 1985-1995

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Polaris 1985-1995

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CHAPTER 1

MODELS AND SPECIFICATIONS

__ "" 1IIIrnT UfllI

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