1993 polaris rxl snowmobile service repair manual by 163048

CHAPTER 1 MODELS AND

PECIFICATIONS

Model Identification (1985) ................................ ........ ........... 1.1 1985 Models ......... .. . . ..... ...... .................... ............. . .. 1.2-1.3 Model Identification (1986) ....... .. .... .. . . . ......... .. .. .... .. . .. . ... . . . ... . 1.4 1986 Models ... .......... ... . ..... .............. . ... . .... . ... . ... ....... 1.5-1 .6 Model Identification (1987) .... .. ........... ... ... .......... . ............. ... . 1.7 1987 Models .. . .................... ... .. . . ..... ........... .. .... . . . . .. .. 1.8-1.9 Model Identification (1988) ........ . ........ .. .......... . ....... .. .. .... .. . .. 1.10 1988 Models ...... . .. . . .... ... ...... ... .. .... .. ..... ..... .. . ....... . .. 1.11-1.12 Model Identification (1989) ...... . ................ .. ........... .. ............ 1.13 1989 Models . . .... ..... ... . ............ . ... . ....... ... ... . .. . ... .. .... 1.14-1 .16 Model Identification (1 990) ....................... . ......... .. ............. .. 1.17

1990 Models ....... ... ....... . ..... . .... .... ............. ... ..... .. . . . 1.18-1.20 Model Identification (1991) .. ..... ...... ................ .. ................... 1.21 1991 Models .............................. .. ..... . ............ . .... . .. 1.22-1.24 Model Identification (1992) ....... ........ . .. ...................... .. .. . ..... 1.25 1992 Models ... . ... ... ........ .. . . . .... . . .......... . ... . ... . .......... 1.26-1 .29 Model Identification (1993) ... ......... .. .. . . . . .... .. ..... .... ..... . . . ... . ... 1.30 1993 Models ..... . . ... .. . ........ . . ... . .. ...... . ..... .... .... .. .. . .... 1.31-1.35 Model Identification (1994) ...... ..... ..... . ....... .... ...... . . .. ...... .. .. .. 1.36 1994 Models ....... ... ...... ... .... .... ..... ... ........ ... ..... . . ... .. 1.37-1 .42 Model Identification (1995) . . . ....... .... ... ................ ____ . . . . . . . . . . . .. 1.43 1995 Models .... .. .. .. ........ .... ..... ........ .... . ............. .. . . . 1.44-1.49

8/94

MODELS AND SPECIFICATIONS 1985 Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Refer to the first digits in the serial number for proper identification:

FIRST DIGITS

MODEL YEAR

1985

1985 MODEL DESIGNATION

YEAR DESIGNATION--------;=:;=::l;I:--:;-,

0 8

510

ENGINE DESIGNATION

MODEL DESIGNATION _ _ _ _ _ _ _ _ _ _-----'

1985 MODEL DESIGNATION NUMBERS (Chassis) .

1985 ENGINE DESIGNATION NUMBERS

07 - Indy Trail, 400, 600 08 - Indy 600 SE 09 - Star 13- SS 14 - LongTrack

27 43 49 57 59 -

EC25PS-Single FC EC44-2PM-2100-Twin FC EC44-2PM-Twin FC EC60PL-02-Three LC EC40PL-02-Twin LC

MODEL. NUMBER

MACHINE DESCRIPTION

MODEL NUMBER

MACHINE DESCRIPTION

0850927 0851349 0850743 0850759

Star 244cc Single FC SS 432cc Twin FC Indy Trail 432cc Twin FC Indy 400. 398cc Twin LC

0850757 0850847 0851449

Indy 600 596cc Three LC Indy 600 SE 597cc Three LC LongTrack 432cc Twin FC

MODEL NO.

MADE IN U.S.A.

POLRRIS PATENT NOTICE

SERIAL NO. TH IS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND S ,ATE REr'l 1 I1REMENTS AND o-ilCLE STANDARDS CANADIAN FEDERAL MC- IN EFFECT ON THE DATE C , J FACTURE.

MId. by Polaris Industries L.P. in Roseau , MN under one or more of the following patents: 3,533,662 3,613,811 U.S, Patents 3,605,511 3,580,647 3,613 ,810 3,605,510 3,483,766 3,545,821 3,525,412 Patented Canada 662,491n1 883,694n1 Canadian Rd, 34,573n1 34,572171

MFD. DATE:

3,867,991 4,793,950 5,038,881 864,394n1 1,227,823/87

7072133

These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is permanently stamped into the tunnel. The model number is embossed on the decal. Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved model and serial numbers are located on the crankcase (i ntake side).

" 1.1

8/94

MODELS AND SPECIFICATIONS 1985 Model Identification

600

400

Long Track

0850857

0850757

0850759

0851449

LC Triple

LC Twin

Fan Cooled Twin

597

398

432

65 x 60

67.62 x 60

3 Mikuni VM38SS Slide

2 Mikuni VM34SS Slide

1 Mikuni VM30SS Slide

Standard

COl

12V 120W

Length (in./cm.)

106.25/269.7

120.25/305.2

Width (in./cm.)

41 .62/105.6

41.62/105.6

41 .62/105.6

40/101.5

Height (in./cm.)

31.5/79.9

33/83.7

Ski Stance (in./cm.)

36.5/92.7

31/78.7

600SE Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output

Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gal./lmp. gal./liters) Recommended Fuel Front Suspension Brake Type Storage

15/38.1

121/307.1

148/375.6

7/5.8/26.5

5.4/4.5/20

88 Octane Min.

Coil Spring IFS Chrome Trailing Arms

Coil Spring IFS

Mono Leaf

Liquid Cooled Hydraulic Disc

Mechanical Disc

Rear of Seat

Rear of Seat Storage Rack

Speedometer

Standard

Tachometer

Standard

Option

Trip Odometer

Standard

Temp

N/A

Electric Start

N/A

Â· N/A

N/A

N/A Option

Accessory Lights Handwarmers

Option

Two-Up Seat

N/A

Backrest

N/A

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

8/94

1.2

MODELS AND SPECIFICATI ONS 1985 Model Identificati on .

Indy Trail

Star

0850743

0851349

0850927

Fan Cooled Twin

Fan Cooled Single

432

244

67.62 x 60

67.72 x 60

72 x 60

1 Mikuni VM34SS Slide

1 Mikuni VM30SS Slide

Standard

COl

12V 120W

12V 100W

Length (in.!cm.)

106.25/269.7

102/2 58.9

102/258.9

Width (in.!cm.)

41 .62/105.6

40/101. 5

40/101 .5

Height (in.!cm.)

31.5/83.7

33/83.7

Ski Stance (in.!cm.)

36.5/92.7

31/78.7

Track Width (in.!cm.)

15/38.1

Track Length Overall (in.!cm.)

121/307.1

120/304.6

108/274.1

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

7/5.8/26.5

6.8/5.7/25.7

5.414.5120

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Mono Leaf

Brake Type

Hydraulic Disc

Mechanical Disc

Engine Type Displacement (cc) Bore x Stroke (mm) Carl;>uretionfThrottle Body

Oil Injected Ignition Alternator Output

Rear of Seat

Speedometer

Standard

Option

Tachometer

Standard

Option

Trip Odometer

Standard

Option

N/A

Electric Start

Option

Handwarmers

Standard

Option

Two-Up Seat

N/A N/A

N/A N/A N/A N/A N/A N/A Option

Storage

Accessory Lights

Storage Rack

Option

N/A N/A N/A

Tow Hitch

Option

Backrest

1.3

8/94

MODELS AND SPECIFICATIONS Â·1986 Model Identification

SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Referto the first digits in the serial number for proper identification: FIRST DIGITS

MODEL YEAR

12 13

1985 1986

1986 MODEL DESIGNATION

YEAR DESIGNATIONI---

----;=::;::=lI:---=1

0 8

610

MODEL DESIGNATION _ _ _ _ _ _ _ _ _ _

ENGINE DESIGNATION

---'1

1986 MODEL DESIGNATION NUMBERS (Chassis)

1986 ENGINE DESIGNATION NUMBERS

07 08 09 13 14 -

27 31 33 49 57 -

59 - EC40PL-02-Twin LC 61 - EC50PM-01-Twin FC

Indy Trail, 400, 600 Indy 600 LE Star/Sprint 340 (ES) SS LongTrack

MODEL NO.

EC25PS-Single FC EC34-2PM-01 -Twin FC (ES) EC34-2PM-02-Twin FC EC44-2PM-5100-Twin FC EC60PL-02-Triple LC

MADE IN U.S.A.

SERIAL NO. THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQU IREMENTS AND CANADIAN FEDERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

PDLRRIS

PATENT NOTICE

Mfd. by Polaris Industries L.P. in Roseau. MN under one or more of the following patents: U.S. Patents 3.605.511 3.533.662 3,613,811 3,580.647 3,613,810 3,605,510 3,483,766 3,545,821 3,525,412 882,491171 883,694171 Patented Canada Canadian Rd. 34,573171 34,572171

MFD. DATE:

3,867,991 4,793,950 5,038,881 864,394171 1,227,823187

7072133

8/94

1.4

MODELS AND SPECIFICATIONS 1986 Model Identification

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition

Long Track

600 LE

600

400

0860857

0860757

0860759

0861449

LC Triple

LC Twin

Fan Cooled Twin

597

398

432

65 x 60

66.72 x 60

3 Mikuni VM38SS Slide

2 Mikuni VM34SS Slide

1 Mikuni VM30SS Slide

Standard

COl

12V 120W

Length (in./cm.)

106.25/269.7

120.25/305.2

Width (in./cm.)

41.62/105.6

41 .62/105.6

40/101.5

Height (in./cm.)

31.5/79.9

31 .5/79.9

33/83.7

Ski Stance (in./cm.)

36.5/92.7

31/78.7

Track Width (in./cm.)

15/38.1

Alternator Output

Track Length Overall (in./cm.)

121/307.1

148/375.6

Fuel Capacity (U .S. gaL/Imp. gaL/liters)

7/5.8/26.5

7.5/6.2/28

88 Octane Min.

Coil Spring IFS Chrome Trailing Arm

Coil Spring IFS

Mono Leaf

Liquid Cooled Hydraulic Disc

Mechanical Disc

Rear of Seat

Rear of Seat Storage Rack

Recommended Fuel Front Suspension Brake Type Storage Speedometer

Standard

Tachometer

Standard

Option

Trip Odometer

Standard

Temp

N/A

Electric Start

N/A

Handwarmers

Option

Two-Up Seat

N/A

Accessory Lights

- -

N/A

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

Backrest

1.5

8/94

MODELS AND SPECIFICATIONS 1986 Model Identification

o Engine Type

Indy Trail

Sprint

Sprint ES

Star

0860761

0861349

0860933

0860931

0860927

Fan Cooled Twin

Fan Cooled Single

488

432

339

244

Bore x Stroke (mm)

72 x 60

67.72 x 60

62 x 55.6

72 x 60

CarburetionfThrottle Body

2 Mikuni VM34SS Slide

1 Mikuni VM34SS Slide

2 Mikuni VM30SS Slide

1 Mikuni VM30SS Slide

Standard

Displacement (cc)

Oil Injected Ignition Alternator Output

COl

12V 120W

12V 100W

Length (in./cm.)

106.25/269.7

102/258.9

Width (in./cm.)

41.62/105.6

40/101.5

Height (in./cm.)

31 .5/79.9

33/83.7

Ski Stance (in./cm.)

36.5/92.7

31/78.7

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

121/307.1

120/304.6

108/274.1

Fuel Capacity (U.S. gal./l mp. gal./liters)

7/5 .8/26 .5

7.5/6.2/28

5.414 .5120

5.4/4.5/20

88 Octane Min.

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Mono Leaf

Brake Type

Hydraulic Disc

Mechanical Disc

Mechanical Disc Rear of Seat

Storage

Rear of Seat

Speedometer

Standard

Option

Standard

Option

Tachometer

Standard

Option

Standard

Option

Trip Odometer

Standard

Option

Standard

Option

N/A

Electric Start

Option

N/A N/A

Standard

Handwarmers

Standard

Option

Two-Up Seat

N/A N/A

N/A N/A N/A

N/A N/A N/A N/A N/A N/A

Option

Accessory Lights

Storage Rack

Option

N/A N/A N/A

Tow Hitch

Option

Backrest

8/94

1.6

MODELS AND SPECIFICATIONS 1987 Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Referto the first digits in the serial number for proper identification: FIRST DIGITS

MODEL YEAR

12 13 14

1985 1986 1987

1987 MODEL DESIGNATION YEAR DESIGNATIONI---------,:=:;:::J,I:--::l

0 8

710

ENGINE DESIGNATION

MODEL DESIGNATION _ _ _ _ _ _ __ _ _----'

1987 MODEL DESIGNATION NUMBERS (Chassis)

1987 ENGINE DESIGNATION NUMBERS

09 - Star/Sprint 340 (ES) 10- StarTrak 14 - LongTrack 15 - Long Track RLR 04 - Indy Sport 05 -Indy 133 SKS 07 - Indy Trail, 400, 600

27 31 33 49 57

59 - EC40PL-02-Twin LC 61 - EC50PM-01-Twin FC 62 - EC50PM-02-Twin FC ES

MODEL NO.

EC25PS-Single FC EC34-2PM-02-Twin FC ES EC34-2PM-01 -03-Twin FC EC44-2PM-5100-Twin FC EC60PL-02-Triple LC

MADE IN U.S.A.

SER IAL NO. THIS VEHICLE CONFORMS TO ALL APPLICABLE u.s. FEDERAL AND STATE REQUIREMENTS AND CANADIAN FEDERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

PDLRRIS

PATENT NOTICE

Mfd . by Polaris Industries loP. in Roseau. MN under one or more of the following patents: 3.613.811 U.S. Patents 3.605.511 3.533.662 3.580.647 3.613 .810 3.605.510 3.483.766 3.545.821 3.525.412 Patented Canada 882,491171 883 .694f71 34.573f71 34.572f71 Canadian Rd.

MFD. DATE:

3.867.991 4.793.950 5.038.881 864.394171 1.227.823/87

7072133

These numbers shou ld 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) .

1.7

8/94

MODELS AND SPECIFICATIONS 1987 Model Identification

Indy 600

Indy 400 400SKS

Indy Trail Trail ES I SKS

Long Track LTR

0870757

0870759 0870559

0870761 0870762/0870561

0871449 0871549

LC Triple

LCTwin

Fan Cooled Twin

597

398

488

432

65 x 60

72 x 60

67.72 x 60

3 Mikuni VM38SS Slide

2 Mikuni VM34SS Slide

1 Mikuni VM30SS Slide

Standard

COl

Alternator Output

12V 120W

Length (in.lcm.)

109/276.6

109/276.6 113/286.8 SKS

120.25/305.2

Width (in.lcm.)

41 .62/105.6

41.62/105.6

41 .62/105.6

40/101.5

33/83.7

33/83.7 . 31/78.7

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition

33/83.7

Ski Stance (in.lcm.)

36.5/92.7

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

121/307.1

121/307.1 133.5/338.8

148/375.6

Fuel Capacity (U.S. gal./lmp. gal./liters)

7/5.8/26.5

7.5/6.2/28 88 Octane Min.

Height (in.lcm.)

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Mono Leaf

Brake Type

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Mechanical Disc

Rear of Seat

Storage

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Option

Trip Odometer

Standard

Accessory Lights

Temp

N/A

Electric Start

N/A

Option Standard ES

N/A

Handwarmers

Option

Standard

Option

Two-Up Seat

N/A

Backrest

N/A

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

8/94

1.8

MODELS AND SPECIFICATIONS 1987 Model Identification

Engine Type

Sprint Sprint ES

Star

Star Trak

0870433

08"10933 0870931

0870927

0871027

Fan Cooled Twin

Fan Cooled Single

339

244

62 x 55.6

72 x 60

2 Mikuni VM30SS Slide

1 Mikuni VM30SS Slide

Standard

COl

Alternator Output

12V 120W

12V 100W

Length (in./cm.)

109/276.6

1021258.9

102/258.9

109/276.9

Wid1h (in./cm.)

41.62/105.6

40/101.5

Height (in./cm.)

33/83.7

34/86.3

36.5/92.7

31 /78.7

31/78.7

Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition

Ski Stance (in./cm.) Track Width (in./cm.) Track Length Overall (in./cm.)

15/38.1

121/307.1

108/274.1

133.5/338.9

7/5.8/26.5

5.4/4.5/20

7.5/6 .2128

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Mono Leaf

Brake Type

Liquid Cooled Hydraulic Disc

Mechanical Disc

Rear of Seat

Standard

Option Sprint Standard ES

Option

Standard

Option

Option Sprint Standard ES

Option

Standard

Option Sprint Standard ES

Option

Standard

Fuel Capacity (U .S. gaL/Imp. gal./liters)

Indy Sport

Storage Speedometer Tachometer Trip Odometer

N/A

Electric Start

Option

Sprint ES Only

N/A

Handwarmers

Option

N/A

Two-Up Seat

N/A

Accessory Lights

Backrest

N/A

Storage Rack

Option

N/A

Standard

Tow Hitch

Option

1.9

8/94

MODELS AND SPECIFICATIONS 1988 Model Identification

SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Referto the first digits in the serial number for proper identification: FIRST DIGITS

MODEL YEAR

12 13 14 15

1985 1986 1987 1988

1988 MODEL DESIGNATION

YEAR DESIGNATIONI- - - - --

-;:::==ll~

8 810

MODEL DESIGNATION _ __ __ __ __

ENGINE DESIGNATION

---.JI

1988 MODEL DESIGNATION NUMBERS (Chassis)

1988 ENGINE DESIGNATION NUMBERS

09 - Star/Sprint (ES) 10 - StarTrak 15 - Long Track RLR 04 - Indy Sport 05 - Indy 133 SKS 06 - Indy Trail SP 07 - Indy Trail, 400, 650

27 31 33 49 58

59 - EC40PL-02-Twin LC 61 - EC50PM-01-Twin FC 62 - EC50PM-02-Twin FC ES

MODEL NO.

EC25PS-Single FC EC34-2PM-02-Twin FC ES EC34-2PM-01-03-Twin FC EC44-2PM-4100-Twin FC EC65PL-01-Triple LC

MADE IN U.S.A.

SERIAL NO. THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADIAN FEDERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

PDLRRIS

PATENT NOTICE

Mfd. by Polaris Industries L.P. in Roseau, MN under one or more of the following patents: U.S. Patents 3,605.511 3,533.662 3.613,811 3,580,647 3,613 ,810 3.605.510 3.525,412 3,483.766 3.545 .821 882.491 17 1 883,694171 Patented Canada Canadian Rd. 34,573171 34,572171

MFD. DATE:

3,867,991 4,793,950 5,038,881 864,39417t 1,227,823187

7072133

8/94

1.10

MODELS AND SPECIFICATIONS 1988 Model Identification

Engine Type Displacement (cc)

Indy 400 400SKS

Indy 400 Classic

Indy Trail, SP Deluxe, ES, SKS

0880758 0880558

0880759 0880559

0880859

0880761/08806611 0880262/08807621 0880561

LC Triple

LCTwin

LC Twin

Fan Cooled Twin

648

398

488

67.72 x 60

65 x 60

72 x 60

3 Mikuni VM38SS Slide

2 Mikuni VM34SS Slide

2 Mikuni VM34 SS Slide

Standard

COl

12V 120W

Length (in./cm.)

106.25/269.9 113/287 SKS

106.25/269.9

106.25/269.9 113/287 SKS

Width (in./cm.)

41 .62/105.7

41 .62/105 .7

41 .62/105.7

41.62/105.7 43.12/109.5 SP

Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output

Height (in./cm.)

42/106 .7

42/106.7

42/106 .7

42/106.7

Ski Stance (in./cm.)

36.5/92.7

36.5/92 .7

36.5/92.7

36.5/92.7 38/9 6.5 SP

Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gal./l mp. gal./liters)

Indy 650 Indy 650 SKS

15/38 .1

15/38.1

120.96/307.2 133.56/339.2 SKS

120.96/307.2 133.56/339 .2 SKS

120.96/307.2

121/307.1 133.56/339 .2 SKS

7.3/6.1/27.7

7.3/6.1 /27 .7

7 .3/6.1/27.7

7.3/6.1/27.7

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Brake Type

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Storage

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Trip Odometer

Standard

HighTemp Ind.

High Temp Ind.

Standard

N/A

Electric Start

N/A

Standard

Option Standard ESIDel

Handwarmers

Option

Standard

Two-Up Seat

Option

Option Standard Deluxe

Backrest

Option

Option Standard Deluxe

Storage Rack

Option

Tow Hitch

Option

Accessory Lights

1.11

8/94

MODELS AND SPECIFICATIONS 1988 Model Identification

Indy Sport

Engine Type

Star

Sprint

Long Track Reverse

Star Trak

0880433

0880931

0880927

0881549

0881027

Fan Cooled Twin

Fan Cooled Single

Fan Cooled Twin

Fan Cooled Single

339

244

432

244

Bore x Stroke (mm)

62 x 55.6

72 x 60

67.72 x 60

72 x 60

CarburetionfThrottle Body

2 Mikuni VM30SS Slide

1 Mikuni VM30SS Slide

2 Mikuni VM34SS Slide

1 Mikuni VM30SS Slide

Standard

COl

Displacement (cc)

Oil Injected Ignition

12V 120W

12V 100W

12V 120W

12V 100W

Length (in.!cm.)

106.25/269.9

1021259.1

102/259.1

120.5/306.1

109/276.9

Width (in.!cm.)

41 .621105.7

40/101 .6

40/101.6

Alternator Output

Height (in.!cm.)

42/106.7

44.5/113

44 .5/113

44.5/113

44.51113

Ski Stance (in.!cm.)

36.5/92.7

31/78.7

Track Width (in.!cm.)

15/38.1

Track Length Overall (in.!cm.)

120.96/307 .2

108/274.3

148/376

133/337.8

Fuel Capacity (U .S. gal./lmp. gal./liters)

7.3/6 .1 /27.7

7.5/6.2128.1

7.5/6.2/28.1

88 Octane Min.

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Mono Leaf

Brake Type

Hydraulic Disc

Mechanical Disc

Rear of Seat

Rack/Rear of Seat

Standard

Option

Standard

Option

Standard

N/A

N/A N/A

N/A N/A N/A N/A N/A N/A

Storage Speedometer Tachometer

Electric Start

Option

N/A N/A N/A

Handwarmers

Option

Two-Up Seat

N/A N/A

N/A N/A N/A N/A N/A N/A

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

Option

Trip Odometer Accessory Lights

Backrest

8/94

N/A

1.12

Neutral Ind.

N/A Option

MODELS AND SPECIFICATIONS 1989 Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Referto the first digits in the serial number for proper identification:

FIRST DIGITS

MODEL YEAR

12 13 14 15 16

1985 1986 1987 1988 1989

1989 MODEL DESIGNATION

YEAR DESIGNATION-----------;:=;:::JI~

0 8

910 9

MODEL DESIGNATION _ _ _ _ _ _ _ _ __

ENGINE DESIGNATION

-'1

1989 MODEL DESIGNATION NUMBERS (Chassis)

1989 ENGINE DESIGNATION NUMBERS

09 - Star/Sprint (ES) 10- StarTrak 15 - LongTrak LTR 01 - Indy Trail SuperTrak 02 - Indy Trail Deluxe 04 - Indy Sport 05 - Indy 133 SKS 06 - Indy Trail SP 07 - Indy 440, 500, 650 08 - Indy 500 Classic 24 Indy Sport GT

27 31 33 49 58

59 61 62 64 65

MODEL NO.

EC25PS-Single FC EC34-2PM-02-Twin FC ES EC34-2PM-01-03-Twin FC EC44-2PM-4100-Twin FC EC65PL-01-Triple LC

MADE IN U.S.A.

SERIAL NO. THIS VEHICLE CON FORMS TO ALL APP LICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADIAN FED ERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

PCLRRIS

EC40PL-02-Twin LC EC50PM-01 -Twin FC EC50PM-02-Twin FC ES EC50PL-01-Twin LC EC50P L-02-Twin LC ES

PATENT NOTICE

Mfd. by Polaris Industries L. P. in Roseau, MN under one or more of the following patents: U.S. Patents 3,605,51t 3,533,662 3,6t3,811 3,580,647 3,613,810 3,605,510 3,483,766 3,545,821 3,525,412 Paten ted Canada 882 ,491171 883 .694171 Canadian Rd. 34,573171 34 ,572171

MFD. DATE:

3,867,991 4,793,950 5,038,881 864,39417t 1,227,823/87

7072133

1.13

8/94

MODELS AND SPECIFICATIONS 1989 Model Identification

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition

Indy 650 Indy 650 SKS

Indy 500 500SKS

Indy 500 Classic

Indy 500 SP

0890758 0890558

0890764 0890564

0890865

0890664

LC Triple

LCTwin

648

488

67.72 x 60

72 x 60

3 Mikuni VM38SS Slide

2 Mikuni VM38SS Slide

Standard

COl

12V 120W

Length (in./cm.)

106.25/269.9 113/287 SKS

106.25/269.9

Width (in./cm.)

41.62/105.7

43.12/109.5

Height (in./cm.)

44/111.8

44/111 .8

44/111.8

42/106.7

Ski Stance (in./cm.)

36.5/92.7

38/96.5

Alternator Output

Track Width (in./cm.) Track Length Overall (in./cm.)

15/38.1

120.96/307.2 133.56/339.2 SKS

120.96/307.2

7.3/6.1 /27.7

7.3/6.1/27.7

7.3/6.1 /27.7

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Brake Type

Liquid Cooled Hydraulic Disc

Hydraulic Disc

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

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Storage

Standard

High Temp Ind.

Standard

N/A

Electric Start

N/A

Standard

N/A

Handwarmers

Standard

Option

Standard

Option

Two-Up Seat

Option

Backrest

Option

Storage Rack

Option

Tow Hitch

Option

Trip Odometer Accessory Lights

8/94

1.14

)

MODELS AND SPECIFICATIONS 1989 Model Identification

Engine Type Displacement (cc)

Indy 400

Indy Trail, SP Deluxe, ES, SKS

Indy Trail SuperTrak

Indy Sport

Indy Sport GT

0890759

0890761/0890661/ 0890262/0890762/ 0890561

0890161

0890433

0892433

LCTwin

Fan Cooled Twin

398

488

339

65 x 60

72 x 60

62.3 x 55.6

2 Mikuni VM34SS Slide

2 Mikuni VM30SS Slide

Standard

CDI

12V 120W

Length (in./cm.)

106.25/269.9

106.25/269.9 113/287 SKS

128/325.1

106.25/269.9

118/299.7

Width (in./cm.)

41 .62/105.7

41.62/105.7 43.12/109.5 SP

41.62/105.7

Height (in./cm.)

44/111.8

42/106.7 45/114.3 Del

45/114.3

42/106.7

45/114 .3

Ski Stance (in./cm.)

36.5/92.7

36.5/92.7 38/96.5 SP

36.5/92.7

Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

120.96/307.2

120.96/307.2 133.56/339.2 SKS

156/396.2

120.96/307.2

141/358.1

Fuel Capacity (U.S. gal.llmp. gal.lliters)

7.3/6.1/27.7

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Brake Type

Hydraulic Disc

Mechanical Disc

Hydraulic Disc

Rear of Seat

Rack/Rear of Seat

Rear of Seat

Rack/Rear of Seat

Speedometer

Standard

Tachometer

Standard

Option

Trip Odometer

Standard

High Temp Ind.

N/A

Electric Start

N/A

Option Standard ES/Del

Opt!on

Option

Handwarmers

Option

Standard

Option

OlltiCh

Two-Up Seat

Option

Option Standard Deluxe

Standard

Option

Standard

Option Standard Deluxe

Standard

Option

Standard

Storage

Accessory Lights

Backrest

Option

Storage Rack

Option

Standard

Option

Standard

Tow Hitch

Option

Standard

Option

Standard

1.15

8/94

MODELS AND SPECIFICATIONS 1989 Model Identification

Star

Sprint ES

Engine Type

Long Track Reverse

Star Trak

0890931

0890927

0891549

0891027

Fan Cooled Twin

Fan Cooled Single

Fan Cooled Twin

Fan Cooled Single

339

244

432

244

62.3 x 55.6

72 x 60

67.72 x 60

72 x 60

2 Mikuni VM30SS Slide

1 Mikuni VM30SS Slide

2 Mikuni VM34SSSiide

1 Mikuni VM30SS Slide

Standard

COl

Alternator Output

12V 120W

12V 100W

12V 120W

12V 100W

Length (in.lcm.)

1021259.1

120.5/306.1

109/276.9

Width (in.lcm.)

40/101.6

Height (in.lcm.)

44.5/113

Ski Stance (in.lcm.)

31/78.7

Track Width (in.lcm.)

15/38.1

108/274.3

148/376

133/337.8

7.5/6.2128.1

7.5/6.2/28.1

7.5/6.2128.1

88 Octane Min.

Mono Leaf

Mechanical Disc

Rear of Seat

Rack/Rear of Seat

Standard

Option

Standard

Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition

Track Length Overall (in.lcm.) Fuel Capacity (U .S. gal./lmp. gal.lliters) Recommended Fuel Front Suspension Brake Type Storage Speedometer

Option

Trip Odometer

N/A

Accessory Lights

N/A

Electric Start

Standard

N/A

Handwarmers

Option

N/A

Option

N/A N/A

Tachometer

N/A

Backrest

Option

N/A

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

Two-Up Seat

8/94

1.16

[]

MODELS AND SPECIFICATIONS 1990 Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Referto the first digits in the serial number for proper identification: FIRST DIGITS

MODEL YEAR

12 13 14 15 16 17

1985 1986 1987 1988 1989 1990

1990 MODEL DESIGNATION

YEAR

DESIGNATION -------~=:J.I____,_,

0 9 01 0 9

ENGINE DESIGNATION

MODEL DESIGNATION _ __ _ _ _ _ _ _ _-----"

1990 MODEL DESIGNATION NUMBERS (Chassis)

1990 ENGINE DESIGNATION NUMBERS

09 - Star/Sprint (ES) 10 - StarTrak 15 - LongTrak LTR 01 - Indy Trail SuperTrak 02 - Indy Trail Deluxe 04 - Indy Sport 05 - Indy 133 SKS 06 - Indy Trail SP/500 SP 07 - Indy 440, 500, 650 08 - Indy 500 Classic 20 - WideTrak 24 Indy Sport GT

27 31 33 49 58 -

59 61 62 64 65 -

MODEL NO.

EC25PS-Single FC EC34-2PM-02-Twin FC ES EC34-2PM-01-03-Twin FC EC44-2PM-41 OO-Twin FC EC65PL-01-Triple LC

MADE IN U,S,A.

EC40PL-02-Twin LC EC50PM-01/02-Twin FC EC50PM-03-Twin FC ES EC50PL-01/03-Twin LC EC50PL-02-Twin LC

POLRRIS PATENT NOTICE

SERIAL NO. THIS VEHICLE CONFORMS TO ALL APPLICABLE U,S. FEDERAL AND STATE REQUIREMENTS AND CANADIAN FEDERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

Mfd. by Polaris Industries loP. in Roseau, MN under one or more of the following patents: U.S. Patents 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 Patented Canada 882,491171 883,694171 Canadian Rd. 34,573171 34 ,572171

MFD. DATE:

3,867,991 4,793,950 5,038,881 864,394171 1,227,823/87

7072133

1.17

8/94

MODELS AND SPECIFICATIONS 1990 Model Identification

650 650 SKS

500 500SKS

500 Classic

500SP

0900758 0900558

0900764 0900564

0900865

0900664

LC Triple

LC Twin

648

488

67.72 x 60

72 x 60

72 x60

72 x 60

3 Mikuni VM38SS Slide

2 Mikuni VM38SS Slide

Standard

COl

12V 120W

12V 200W

12V200W

12V 200W

Length (in./cm.)

106.25/269 .9 113/287 SKS

106.25/269.9 113/287 SKS

106.25/269.9

Width (in./cm.)

41.62/105.7

43.12/109.5

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output

Height (in./cm.)

44/111.8

42/106.7

Ski Stance (in./cm.)

36.5/92 .7

36.5/92.7

38/96.5

Track Width (in./cm.)

15/38.1

120.96/307.2 133.56/339.2 SKS

120.96/307.2

Track Length Overall (in./cm.)

7.3/6.1/27.7

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Brake Type

Liquid Cooled Hydraulic Disc

Hydraulic Disc

HydrauliC Disc

Hydraulic Disc

Rear of Seat

Fuel Capacity (U.S. gal./lmp. gal./liters)

Storage Speedometer

Standard

Tachometer

Standard

High Temp Ind.

Standard

N/A

Electric Start

N/A

Option

Standard

Option

Handwarmers

Standard

Option

Standard

Option

Two-Up Seat

Option

Backrest

Option

Storage Rack

Option

Tow Hitch

Option

Trip Odometer Accessory Lights

8/94

1.18

MODELS AND SPECIFICATIONS 1990 Model Identification

Indy 400

Indy Trail Trail Deluxe

Indy Trail SuperTrak

Indy Sport

Indy Sport GT

0900759

0900761 0900262

0900161

0900433

0902433

LCTwin

Fan Cooled Twin

398

488

339

65 x 60

72 x 60

62.3 x 55.6

2 Mikuni VM34SS Slide

2 Mikuni VM30SS Slide

Standard

COl

12V 200W

12V 150W

Length (in./cm.)

106.25/269.9

106.25/269.9 113/287 Del

128/325.1

106.25/269.9

118/299.7

Width (in./cm.)

41.621105.7

41.62/105.7

41 .62/105.7

Height (in./cm.)

44/111.8

421106.7

45/114.3

42/106.7

45/114.3

36.5/92.7

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output

45/114.3 Del Ski Stance (in./cm.)

36.5/92.7

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

120.96/307.2

120.96/307.2 133.56/339.2 Del

156/396.2

120.96/307.2

141/358.1

Fuel Capacity (U.S. gal./lmp. gal./liters)

7.3/6.1/27.7

11.25/9.4/42.6

7.3/6.1/27.7

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Brake Type

Hydraulic Disc

Rear of Seat

Rack/Rear of Seat

Rear of Seat

Rack/Rear of Seat Standard

Storage Speedometer

Standard

Tachometer

Standard

Option

Trip Odometer

Standard

Accessory Lights Electric Start

High Temp Ind.

N/A

Option Standard Deluxe

Option

Handwarmers

Option

Standard

Option

Two-Up Seat

Option

Option Standard Deluxe

Standard

Option

Standard

Backrest

Option

Option Standard Deluxe

Standard

Option

Storage Rack

Option

Standard

Option

Standard

Tow Hitch

Option

Standard

Option

Standard

1.19

8/94

MODELS AND SPECIFICATIONS 1990 Model Identification

Sprint ES

Star

Star Trak

WideTrak

0900931

0900927

0901027

0902064

Fan Cooled Twin

Fan Cooled Single

LCTwin

339

244

488

62.3 x 55.6

72 x 60

2 Mikuni VM30SS Slide

1 Mikuni VM30SS Slide

2 Mikuni VM38SS Slide

Standard

COl

Alternator Output

12V 150W

12V200W

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Length (in.lcm.)

102/259.1

109/276.9

128/325. 1

Width (in.lcm.)

40/101.6

41.62/105.7

Height (in.lcm.)

44.5/113

49/1 24.4

Ski Stance (in.lcm.)

31/78.7

36.5/92.7

Track Width (in.lcm.) Track Length Overall (in.lcm.) Fuel Capacity (U .S. gal./lmp. gal./liters) Recommended Fuel Front Suspension

15/38.1

108/274.3

133/337.8

156/396.2

7.5/6.2/28.1

7.5/6.2/28

7 .5/6.2128

10/8.3/37.8

88 Octane Min.

88 Octane Min. Coil Spring IFS

Mono Leaf

Mechanical Disc

Hydraulic Disc

Rear of Seat

Rack/Rear of Seat

Rack/Under Seat

Standard

Option

Standard

Option

Standard

Trip Odometer

N/A

Standard

Accessory Lights

N/A

Temp/Rev

Electric Start

Standard

N/A

Option

Handwarmers

Option

N/A

Standard

Two-Up Seat

N/A

Standard

Backrest

Option

Standard

Storage Rack

Option

Standard

Tow Hitch

Opti on

Option

Standard

Brake Type Storage Speedometer Tachometer

8/94

1.20

MODELS AND SPECIFICATIONS 1991 Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Referto the first digits in the serial number for proper identification: FIRST DIGITS

MODEL YEAR

12 13 14 15 16 17 18

1985 1986 1987 1988 1989 1990 1991

1991 MODEL DESIGNATION

YEAR DES IGNAT I ON----------;=~I~ 0 9 112 0

ENGINE DESIGNATION 4

MODEL DESIGNATION _ __ _ _ _ _ _ _ _ ----'

1991 MODEL DESIGNATION NUMBERS (Chassis)

1991 ENGINE DESIGNATION NU MBERS

1991 ENGINE DESIGNATION NUMBERS

09 - Star/Sprint (ES) 10- StarTrak 15 - LongTrak LTR 01 - Indy Trail SuperTrak 02 - Indy Trail Deluxe 04 - Indy Sport 05 -Indy 133 SKS 06 - Indy Trail SP/500 SP 07 - Indy 440, 500, 650 08 - Indy 500 Classic 20 - WideTrak 24 - Indy Sport GT 30 - StarLite/Lite

27 31 33 43 49 58 -

59 61 62 64 65 68

MODEL NO.

EC25PS-Single FC EC34-2PM-02-Twin FC ES EC34-2PM-01 -03-Twin FC EC44-3PM-01-Twin FC EC44-2PM-4100-Twin FC EC65PL-D1 -Triple LC

MADE IN U.S.A.

SERIAL NO. THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQU IREMENTS AND CANADIAN FEDERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

P D LRR IS

EC40PL-02-Twin LC EC50PM-01/02-Twin FC EC50PM-03-Twin FC ES EC50PL-01 /03-Twin LC EC50PL-02-Twin LC EC65PL-03-Triple LC

PATENT NOTICE

Mfd. by Polaris Industries L.P. in Roseau, MN under one or more of the following patents: U.S. Patents 3,605,5tt 3,533,662 3.613,811 3,580,647 3,613,810 3,605,510 3,483,766 3,545,821 3,525,412 Patented Canada 882,491n1 883,694nt Canadian Rd. 34,573nt 34,572n1

MFD. DATE :

3,867,991 4,793,950 5,038,881 864,394nt 1,227 ,823/87

7072133

These numbers shou ld be referred to in any correspondence reg arding warranty, service or repl acement 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) .

1.21

8/94

MODELS AND SPECIFICATIONS 1991 Model Identification

Engine Type

650 RXL RXL SKS

500 500SKS

500 Classic

500 SP

0910758 0910768 0910568

0910764 0910564

0910865

0910664

LC Triple

LCTwin

LC Twin

648

488

67.72 x 60

72 x 60

3 Mikuni VM38SS Slide 3 46mm Throttle Bodies

2 Mikuni VM38SS Slide

Standard

COl

12V 120W

12V200W

12V 200W

Length (in.!cm.)

106.25/269.9 11 3/287 SKS

106.25/269.9 113/287 SKS

106.25/269.9

Width (in.!cm.)

41 .62/105.7

41.62/105.7

41 .62/105.7

43.12/1 09.5

Height (in.!cm.)

44/11 1.8

44/111.8

42/106.7

Ski Stance (in.!cm.)

36.5/92.7 38/96.5 RXL

36.5/92.7

38/96.5

Track Width (in.!cm. )

15/38.1

120.96/307.2 133.56/339.2 SKS

120.96/307.2

Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body

Oil Injected Ignition Alternator Output

Track Length Overall (in.!cm.)

12.16/10.6/46

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Brake Type

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Hydraulic Disc Rear of Seat

Fuel Capacity (U.S. gal./lmp. gal./liters)

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Storage

Standard

Temp/Oil/Acc/Hi Beam

Temp/Oil/Hi Beam

Temp/Oil/Acc/Hi Beam

Temp/Oil/Hi Beam

Electric Start

N/A

Option

Standard

Option

Handwarmers

Standard

Option

Standard

Option

Two-Up Seat

Option

Backrest

Option

Storage Rack

Option

Trip Odometer Accessory Lights

Tow Hitch

8/94

1.22

MODELS AND SPECIFICATIONS 1991 Model Identification

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition

Indy Trail Trail Deluxe

Indy Sport

Indy Sport GT

0910759

0910761 0910262

0910443

0912443

LCTwin

Fan Cooled Twin

398

488

432

65 x 60

72 x 60

67.72 x 60

2 Mikuni VM34SS Slide

2 Mikuni VM30SS Slide

Standard

COl

COl 12V 200W

12V 200W

12V200W

Length (in./cm.)

106.25/269.9

118/299 .7

Width (in./cm.)

41.62/105.7

Height (in.lcm.)

44/111.8

42/106.7 45/114 .3 Deluxe

42/106.7

45/114.3

Ski Stance (in./cm.)

36.5/92.7

Alternator Output

Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gaUlmp. gal./liters)

400

15/38.1

120.96/307.2

141/358.1

12.16/10.6/46

7.3/6.1/27.7

7 .3/6.1/27.7

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Brake Type

Hydraulic Disc

Rear of Seat

Rack/Rear of Seat

Storage Speedometer

Standard

Tachometer

Standard

Option

Trip Odometer

Standard

Temp/Oil/Hi Beam

Temp/OiliAcc/Hi Beam

Option

Electric Start

Option

Option Standard Deluxe

Option

Handwarmers

Option

Standard

Option

Two-Up Seat

Option

Option Standard Deluxe

Option

Standard

Backrest

Option

Option Standard Deluxe

Option

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

Accessory Lights

1.23

8/94

MODELS AND SPECIFICATIONS 1991 Model Identification

Engine Type Displacement (cc)

SuperTrak

WideTrak

Indy Lite

Star Lite

0910161

0912064

0913033

0913027

Fan Cooled Twin

LCTwin

Fan Cooled Twin

Fan Cooled Single

488

339

244

72 x 60

62.3/55.6

72 x 60

2 Mikuni VM34SS Slide

2 Mikuni VM38SS Slide

2 Mikuni VM30SS Slide

1 Mikuni VM30SS Slide

Standard

COl

Alternator Output

12V 200W

12V 150W

Length (in./cm.)

128/325.1

103/261

Width (in./cm.)

41.62/105.7

37.9/96.3

Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition

Height (in./cm.)

45/114.3

49/124.4

46/116.8

Ski Stance (in./cm.)

36.5/92.7

Track Width (in./cm.) Track Length Overall (in./cm.)

15/38.1

156/396.2

116/294.6

12.16/10.6/46

10/8.3/37.8

7.66/6.4/29

Recommended Fuel

88 Octane Min.

Front Suspension

Coil Spring IFS

Brake Type

Hydraulic Disc

Mechanical Disc

Rack/Rear of Seat

Under Seat

Top of Hood Rear of Seat

Speedometer

Standard

Option

Tachometer

Standard

N/A

Trip Odometer

Standard

N/A

Accessory Lights

Acc/Rev

Temp/Oil/Rev/Hi Beam

N/A

Electric Start

Option

N/A

Fuel Capacity (U.S. gal./lmp. gal./liters)

Storage

Handwarmers

Standard

Option

Two-Up Seat

Standard

N/A

Backrest

Standard

N/A

Storage Rack

Standard

Option

Tow Hitch

Standard

Option

8/94

1.24

MODELS AND SPECIFICATIONS 1992 Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Refer to the first digits in the serial number for proper identification: FIRST DIGITS

MODEL YEAR

12 13 14 15 16 17 18 19

1985 1986 1987 1988 1989 1990 1991 1992

1992 MODEL DESIGN ATION

YEAR DESIGNATION--------;:::::::;:=:JI~

0 9

0 7

ENGINE DESIGNATION 8

MODEL DESIGNATION _ _ _ _ _ _ _ _ _ _----'

1992 MODEL DESIGNATION NUMBERS (Chassis)

1992 ENGINE DESIGNATION NUMBERS

09 - Star/Sprint (ES) 10- StarTrak 15 - LongTrak LTR 01 - Indy Trail SuperTrak 02 - Indy Trail Deluxe 04 - Indy Sport 05 - Indy 133 SKS 06 - Indy Trail SP/500 SP 07 - Indy 440, 500, 650 08 - Indy 500 Classic 17 - Indy 440 XCR 20 - WideTrak 24 - Indy Sport GT 30 - StarLite/Lite

27 31 33 43 49 58

59 60 61 62 64 65 68 74 -

MODEL NO.

EC25PS-Single FC EC34-2PM-02-Twin FC ES EC34-2PM-01-03-Twin FC EC44-3PM-01 -Twin FC EC44-2PM-4100-Twin FC EC65PL-01 -Triple LC

MADE IN U.S.A.

EC40PL-02-Twin LC EC45PL-01/02-Twin LC EC50PM-01/02-Twin FC EC50PM-03-Twin FC EC50PL-01/03/04-Twin LC EC50PL-02-Twin LC ES EC65PL-03-Triple LC EC50PL-07-Twin LC

PCLFlRIS PATENT NOTIC E

SERIAL NO. THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADIAN FEDERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTU RE.

MId. by Polaris Industries L.P. in Roseau, MN under one or more 01the following patents: U.S. Patents 3,605,511 3,533,662 3,613.811 3,580,647 3,613,810 3,605,510 3,483,766 3.545,821 3,525,412 883,694f71 Patented Canada 882,49tf71 Canadian Rd. 34 ,573f71 34,572f71

MFD. DATE:

3,867,991 4,793,950 5,038,881 S64,394f71 1.227,823/87

7072133

1.25

8/94

MODELS AND SPECIFICATIONS 1992 Model Identification

RXL RXLSKS

650

Classic

500 SP EFI 500 SKS EFI

0920768 0920568

0920758

0920865

0920674 0920574

LC Triple

LC Twin

LCTwin

648

488

67.72 x 60

72 x 60

3 Throttle Body 46 mm Butterfly

3 Mikuni VM38SS Slide

2 Mikuni VM38SS Slide

2 Throttle Body 46 mm Butterfly

Standard

COl

12V 180W

12V 200W

12V200W

Length (in.!cm.)

106.25/269.9 113/287 SKS

106.25/269.9

113/287

106.25/269.9 SP 113/287 SKS

Width (in.!cm.)

43.12/109.5 41.62/1 05.7 SKS

41.62/105.7

41.62/1 05.7

43.121109.5 SP 41.62/105.7 SKS

Height (in.!cm.)

38.5/97.7 44/111.7 SKS

44/111.7

Ski Stance (in.!cm.)

38/96.4 36.5/92.7 SKS

36.5/92.7

38/96.4 SP 36.5/92.7 SKS

Engine Type Displacement (ee) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output

Track Width (in.!cm.) Track Length Overall (in.!cm.) Fuel Capacity (U .S. gal./lmp. gal./liters)

15/38.1

121/307.1 133.5/338.9 SKS

121 /307.1

133.5/338.9

121/307.1 133.5/338.9 SKS

11 .9/9.9/45

11.9/9.9/45

11 .9/9.9/45

11.9/9.9/45

Recommended Fuel

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Brake Type

Rear of Seat

Speedometer

Storage

Standard

Tachometer

Standard

Trip Odometer

Standard

OilITemp/AcclHi Beam

OiIITemp/Acc/Hi Beam

OiVTemp/Acc/Hi Beam

OilITemp/Hi Beam

Accessory Lights Electric Start

N/A

Standard

TBA

Handwarmers

Standard H/L

Option

Two-Up Seat

Option

Standard

Option

Backrest

Option

Standard

Option

Storage Rack

Option

Tow Hitch

Option

8/94

1.26

MODELS AND SPECIFICATIONS 1992 Model Identification

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected

500

WideTrak

440 XCR

440

0920764

0922064

0921760

0920760

LC Twin

LCTwin

488

432

72 x 60

67.72 x 60

2 Mikuni VM38SS Slide

2 Mikuni VM34SS Slide

Standard

COl

12V 200W

Length (in./cm.)

106.25/269.9

128/324.9

106.25/269.9

Width (in./cm.)

41.62/105.7

41 .62/105.7

43.12/109.5

41.62/105.7

Height (in./cm.)

44/111.7

49/124.4

38.5/97.7

44/11 1.7

Ski Stance (in./cm.)

36.5/92.7

38/96.4

36.5/92.7

Track Width (in./cm.)

15/38.1

20/50.8

15/38.1

Track Length Overall (in./cm.)

121/307.1

156/396

121/307.1

Fuel Capacity (U.S. gal./lmp. gaL/liters)

11 .9/9.9/45

10/8.3/38

7.3/6.1/28

11 .9/9.9/45

Recommended Fuel

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Parallel Link Trailing Arm IFS Gas Shock

Parallel Link Trailing Arm IFS

Hydraulic Disc

Mechanical Disc

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Rear of Seat

Under Seat Storage Rack

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Trip Odometer

Standard

Oil/Temp/Hi Beam

Oil/Temp/Rev/Hi Beam

Temp/Acc Hi Beam

Oil/Temp Hi Beam

Electric Start

Option

Ignition Alternator Output

Brake Type Storage

Accessory Lights

Handwarmers

Option

Single Heat

Std. H/L

Option

Two-Up Seat

Option

Standard

Option

Backrest

Option

Standard

Option

Storage Rack

Option

Standard

Option

Tow Hitch

Option

Standard

Option

127

8/94

MODELS AND SPECIFICATIONS 1992 Model Identification

Engine Type Displacement (cc)

SuperTrak

Trail Deluxe

Trail

Sport GT

0920161

0920262

0920761

0922443

Fan Cooled Twin

488

432

488 72 x 60

72 x 60

67.72 x 60

2 Mikuni VM34SS Slide

Standard

COl

Alternator Output

12V 200W

12V200W

12V 200W

Length (in.!cm.)

128/324.9

113/287

106.25/269.9

118/299 .5

Width (in.!cm.)

41.62/105.7

41 .62/105.7

Height (in.!cm.)

45/114.2

45/114 .2

44/111.7

45/114.2

Ski Stance (in.!cm.)

36.5/9 2.7

36.5/92.7

36 .5/92.7

Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition

Track Width (in.!cm.)

15/38.1

Track Length Overall (in.!cm.)

156/396

133.5/338.9

120.96/307.1

141/358

11.9/9 .9/45

11.9/9.9/45

11.919.9145

7.3/6.1/28

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

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Brake Type

Mechanical Disc

Hydraulic Disc

Rear of Seat Storage Rack

Rear of Seat

Rear of Seat Storage Rack Standard

Storage Speedometer

Standard

Tachometer

Standard

Option

Trip Odometer

Standard

RevlOil/ Hi BearnlAcc

Oil/AcclHi Beam

N/A

Electric Start

Option

Standard

Option

Handwarmers

Single Heat

Option

Two-Up Seat

Standard

Option

Standard

Backrest

Standard

Option

Standard

Storage Rack

Standard

Option

Standard

Tow Hitch

Standard

Option

Standard

Accessory Lights

8/94

1.28

MODELS AND SPECIFICATIONS 1992 Model Identification

Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output

Indy Lite GT

Indy Lite Lite Delu xe

Star Lite

0920443

0923133

0923033 0923231

0923027

Fan Cooled Twin

Fan Cooled Single

432

339

244

67.72 x 60

62.3x55.6

72 x 60

2 Mikuni VM34SS Slide

2 Mikuni VM30SS Slide

1 Mikuni VM30SS Slide

Standard

CDI

12V 200W

12V 150W

Length (in./cm.)

106.25/269.9

11 ?/292

103/261

Width (in./cm.)

41.62/105.7

37:9/96.2

37.9/96.2

Height (in./cm.)

44/111.7

48/121.8

46/116 .7

46/116.7

Ski Stance (in./cm .)

36.5/92 .7

36.5/92.7

15/38.1

Track Width (in./cm.)

15/38. 1

15/38.1

Track Length Overall (in./cm.)

121 /307.1

133.5/338.9

116/294.4

Fuel Capacity (U.S. gal./lmp. gal./liters)

7.3/6.1/28

7.7/6.4/29

Recomme nded Fuel

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Hydraulic Disc

Mechanical Disc

Rear of Seat

Standard

Option

N/A

Standard

Option

Brake Type

Sport 440

Storage Speedometer Tachometer Trip Odometer Accessory Lights

N/A

Electric Start

Option

Option Lite Standard Deluxe

N/A

Handwarmers

Option

Option Lite Single Heat Deluxe

Option

Two-Up Seat

Option

Standard

N/A

Backrest

Option

N/A

Storage Rack

Option

Standard

N/A

Tow Hitch

Option

Standard

Option

1_29

8/94

MODELS AND SPECIFICATIONS 1993 Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year, Referto the first digits in the serial number for proper identification: FIRST DIGITS

MODEL YEAR

12 13 14 15 16 17 18 19 20

1985 1986 1987 1988 1989 1990 1991 1992 1993

1993 MODEL DESIGNATION

YEAR D ES I G NATIONI-------------;==~ I ~

0 9

MODEL DESIGNATION _ _ _ _ _ __ _ _ _

2 7

ENGINE DESIGNATION

--1

1993 MODEL DESIGNATION NUMBERS (Chassis)

1993 ENGINE DESIGNATION NUMBERS

02 04 05 06 07 08 17 20 25 27 31 34 -

27 31 33 43 60 61

64 65 67 68 70 74

Indy Trail Deluxe Indy Sport 440,500 EFI, XLT, RXL (SKS) 500 EFI, XLT SP Indy Trail, 440, XLT, RXL Classic/Classic Touring 440 XCR WideTrak Storm (SKS) Storm Indy Lite GT/StarLite GT Indy Lite Deluxe/StarLite

MODEL NO.

EC25PS-07-Single FC EC34-2PM-02-Twin FC ES EC34-2PM-04-Twin FC EC44-3PM-01-Twin FC EC45PL-01/02-Twin LC EC50PM-01 -Twin FC

MADE IN U.S.A.

EC50PL-04/06-Twin LC EC50PL-05-Twin LC ES EC58PL-01 -Triple LC EC65PL-05-Triple LC (EFI) EC75PL-01 -Triple LC EC50PL-07-Twin LC (EFI)

PDLRRIS PATENT NOTICE

SERIAL NO. THIS VEHICLE CON FORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADIAN FEDERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

MId. by Polaris Industries loP. in Roseau, MN under one or more of the following patents: U.S. Patents 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 Patented Canada 882,491171 883,694171 Canadian Rd. 34,573171 34,572171

MFD . DATE:

3,867,991 4,793,950 5,038,881 864,394171 1,227,823187

7072133

8/94

1.30

MODELS AND SPECIFICATIONS 1993 Model Identification

c Engine Type Engine Model Number Displacement (cc)

XLT XLTSP

XLT SKS

0932770 0932570

0930768 0930568

0930767 0930667

0930567

LC Triple EC75PL-01

LCTriple EC65PL-05

LC Triple EC58PL-01

744

648

579

67.72 x 60

64 x 60

3 Mikuni VM38SS Slide

3 Throttle Body 46mm

3 Mikuni VM34SS Slide

Standard

COl

12V 170W

12V 180W

12V 170W

Length (in./cm.)

106.25/269.9 113/287 SKS

106.25/269.9

113/287

Wid1h (in./cm.)

43.12/109.5 41.62/ 105.7 SKS

43.12/109.5 41 .62/105.7 SKS

43.12/109.5

41 .62/105.7

Height (in./cm.)

38.5/97.7 44/111.7 SKS

44/111.7 38.5/97.7

44/111 .7

Ski Stance (in./cm.)

38/96.4 36.5/92.7 SKS

38/96.4

36.5/92.7

Track Width (in./cm.)

15/38.1

121/307.1 133.5/338.9 SKS

121/307.1

133.5/338.9

CarburetionfThrottle Body Oil Injected Ignition Alternator Output

Track Length Overall (in./cm.) Fuel Capacity (U.S. gal./lmp. gal./liters)

10.7/8.9/40.5

11.9/9.9/45

11 .9/9.9/45

Recommended Fuel

90 Octane Min.

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Brake Type Storage

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Trip Odometer

Standard

Oil/BrakefTemp/Acc /Hi Beam

OillBrakefTemp/ Acc/Hi Beam

Oil/BrakefTemp/ Acc/Hi Beam

Accessory Lights Electric Start HandwarmersfThumbwarmer

RXL RXL SKS

69.72 x 65

Bore x Stroke (mm)

Storm Storm SKS

Two-Up Seat

N/A

TBA

Std/Std

Std/N/A

Std/Std

N/A

Option

Backrest

Option

Storage Rack

Option

Tow Hitch

Option

Option 1)".

1.31

8/94

MODELS AND SPECIFICATIONS 1993 Model Identification

Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) Carburetionrrhrottle Body Oil Injected Ignition

500 EFI 500 SKS EFI

Classic

Classic Touring

WideTrak

0930674 0930574

0930864

0930865

0932064

LCTwin EC50PL-07

LCTwin EC50PL-04

LC Twin EC50PL-05

LCTwin EC50PL-06

488

72 x 60

2 Throttle Body 46mm

2 Mikuni VM38SS Slide

2 Mikuni VM34SS Slide

Standard

CO l

COl

12V200W

12V 200W

Length (in.lcm.)

106.25/269.9 11 3/287 SKS

106.25/269.9

113/287

128/324.9

Width (in.lcm.)

43.12/109.5 41.62/105.7 SKS

43.12/109.5

41.62/105.7

41 .62/1 05.7

Height (in.lcm.)

44/111.7

49/124.4

38/96.4 36.5/92.7 SKS

38/96.4

36.5/92.7

Alternator Output

Ski Stance (in.lcm.)

15/38.1

20/50.8

121/307.1 133.5/338.9 SKS

121/307.1

133.5/338.9

156/396

11.9/9.9/45

10/8.3/38

Recommended Fuel

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Hydraulic Disc

Mechanical Disc

Rear of Seat

Under Seat Storage Rack

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

Brake Type Storage Speedometer

Standard

Tachometer

Standard

Trip Odometer

Standard

OillBrakerremp/ Acc/Batt/Hi Beam

OillBrakerremp/ Acc/Hi Beam

Oilrremp/Rev/ Hi Beam

Electric Start

Option

Standard

Option

Handwarmersrrhumbwarmer

Std/Std

Std/Option

N/A

Option

Standard

Backrest

Option

Standard

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

Accessory Lights

Two-Up Seat

8/94

1.32

MODELS AND SPECIFICATIONS 1993 Model Identification

Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected

440 XC R

440 440 SKS

Trail

Trail Deluxe

0931760

0930760 0930560

0930761

0930243

LC Twin EC45PL-01

LCTwin EC45PL-02

Fan Cooled Twin EC50PM-01

Fan Cooled Twin EC44-3PM-01

432

488

432

67.72 x 60

72 x 60

67.72 x 60

2 Mikuni VM38SS Slide

2 Mikuni VM34SS Slide

Standard

COl

12V 200W

12V200W

12V 200W

Length (in.!cm.)

106.25/269.9

106.25/269.9 113/287 SKS

106.25/269.9

113/287

Width (in.!cm.)

43.12/109.5

43.12/109.5 41 .62/105.7 SKS

43.12/109.5

41 .62/105.7

Height (in.!cm.)

38.5/97.7

44/111.7

45/114.2

38/96.4

38/96.4 36.5/92.7 SKS

38/96.4

36.5/92.7

Ignition Alternator Output

Ski Stance (in.!cm.) Track Width (in.!cm.) Track Length Overall (in.!cm.) Fuel Capacity (U.S. gaUlmp. gaUliters)

15/38.1

15/38. 1

15/38.1

15/38. 1

121/307.1

121/307.1 133.5/338.9 SKS

121/307.1

133.5/338.9

7.3/6.1/28

11.9/9.9/45

11 .9/9.9/45

Recommended Fuel

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Brake Type

Rear of Seat

Speedometer

Storage

Standard

Tachometer

Standard

Option

Trip Odometer

Standard

BrakefTemp/Acc Hi Beam

Oil/BrakefTemp/ Acc/Hi Beam

Oil/Brake/ Acc/Hi Beam

Accessory Lights Electric Start

Option

HandwarmersfThumbwarmer

Std/Std

Std/Option

Two-Up Seat

Option

Standard

Backrest

Option

Standard

Storage Rack

Option

Tow Hitch

Option

1.33

8/94

MODELS AND SPECIFICATIONS 1993 Model Identification

) Sport 440 Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output

Indy Lite GT

Lite Deluxe

Indy Lite

0930443

0933133

0933431

0933433

Fan Cooled Twin EC44-3PM-01

Fan Cooled Twin EC34-2PM-04

Fan Cooled Twin EC34-2PM-02

Fan Cooled Twin EC34-2PM-04

432

339

67.72 x 60

62 .3/55.6

62.3/55.6

2 Mikuni VM34SS Slide

2 Mikuni VM30SS Slide

Standard

COl

12V 200W

12V 150W

Length (in./cm. )

106.25/269.9

115/292

105/267

Width (in./cm.)

41.62/105.7

37.9/96.2

Height (in./cm.)

44/ 111 .7

48/121.8

46/116.7

Ski Stance (in./cm.)

36.5/92.7

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

121/307.1

133.5/338.9

121/307.1

Fuel Capacity (U.S. gal./lmp. gal./liters)

11.9/9.9/45

8/6.7/30

Recommended Fuel

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Hydraulic Disc

Mechanical Disc

Rear of Seat

Standard

Option

N/A

Standard

Acc

N/A

Brake Type Storage Speedometer Tachometer Trip Odometer Accessory Lights Electric Start

Option

Standard

Option

Std/Option

Option/Option

Std/Option

Option/Option

Two-Up Seat

Option

Standard

N/A

Backrest

Option

N/A

Storage Rack

Option

Standard

TBA

Tow Hitch

Option

Standard

Option

HandwarmerslThumbwarmer

8/94

1.34

N/A N/A

MODELS AND SPECIFICATIONS 1993 Model Identification

c Indy StarLite GT Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output

Indy Star Lite

0933127

0933427

Fan Cooled Single EC25PS-07

244

72 x 60

1 Mikuni VM30SS Slide

Standard

COl

12V 150W

Length (in./cm.)

11 5/292

105/267

Width (in./cm.)

37.9/96.2

Height (in./cm.)

48/121.8

46/116.7

Ski Stance (in./cm.)

36.5/92.7

Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gaL/Imp. gaL/liters)

15/38.1

133.5/338.9

121/307.1

8/6.7/30

Recommended Fuel

88 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Brake Type

Mechanical Disc

Rear of Seat

Option

N/A

Storage Speedometer Tachometer Trip Odometer

Option

Accessory Lights

N/A

Electric Start

N/A

Option/Option

Standard

N/A

HandwarmersfThumbwarmer Two-Up Seat Backrest Storage Rack Tow Hitch

Option

N/A

Standard

TBA

Option

( 1.35

8/94

MODELS AND SPECIFICATIONS 1994 Model Identification SERIAL NUM BE R IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Referto the first digits in the serial number for proper identification: FIRST DIGITS 12 13 14 15 16 17 18 19 20 22

MODEL YEAR 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1994 MODEL DESIGNATION

YEAR DESIGNATIONI--------;:::~I:__:l 0 9 41 0 7

ENGINE DESIGNATION

MODEL DESIGNATION _ _ _ _ _ _ _ _ _ _--'

1994 MODEL DESIGNATION NUMBERS (Chassis) 02 - Sport SKS, Trail Deluxe 04 - Sport 05 - XLT SKS, Storm SKS 06 - XLT SP 07 - Super Sport,Trail, RXL, XLT, Storm 08 - RXL Touring 17 - 440 XCR 20 - WideTrak GT/LX 25 - 440 Indy SKS, 500 EFI SKS 27 - 440 Indy, 500 EFI 28 - Classic, Classic Touring 31 - Indy Lite GT, StarLite Gt 34 - Indy Lite, Lite Deluxe, StarLite

1994 ENGINE DESIGNATION NUMBERS 27 - EC25PS-07-Single FC 31 - EC34-2PM-02-Twin FC (ES) 33 - EC34-2PM-04-Twin FC 43 - EC44-3PM-01 -Twin FC 60 - EC45P L-01/02- Twin LC (A) 61 - EC50PM-01/03-Twin FC (B) 62 - EC50PM-02-Twin FC (ES)

1994 ENGINE DESIGNATION NUMBERS 64 - EC50PL-06-Twin LC 65 - EC50PL-05-Twin LC 67 - EC58PL-01-Triple LC 68 - EC65PL-05-Triple LC (EFI) 69 - EC65PL-06-Triple LC (EFI ES) 74 - EC50PL-07-Twin LC (EFI) 75 - EC50PL-08-Twin LC (EFI ES) 82 - EC80PL-01 Triple LC

KEY: (A) = Carb 38 mm vs 34 mm (B) = Jetting - Timing - Piston Length (ES) = Electric Start (EFI) = Electronic Fuel Injection (EFI ES) = Electronic Fuel Injection with Electric Start MODEL NO.

MADE IN U.S.A.

PDLRRIS PATENT NOTICE

SERIAL NO. THIS VEHICLE CONFORMS TO ALL APPLICABLE U.s. FEDERAL AND STATE REQUIREMENTS AND CANADIAN FEDERAL MOTOR VEHICLE STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE.

MId. by Polaris Industries L.P. in Roseau . MN under one or more of the following patents: 3,605,511 3.533,662 3,613,811 U.S. Patents 3,580,647 3,613,810 3,605,510 3,483,766 3,545,821 3,525,412 Patented Canada 882,491 171 883,694171 Canadian Rd. 34,573171 34,572171

MFD. DATE:

3.867,991 4,793,950 5,038,881 864 ,394/71 1 ,227,823187

7072133

8/94

1.36

MODELS AND SPECIFICATIONS 1994 Model Identification

o Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected

RX L RXL Touring

XLT XLTSP

XLT SKS

0940782 0940582

0940768 0940869

0940767 0940667

0940567

LC Triple EC80PL-01

LC Triple EC65PL-05/06

LC Triple EC58PL-01

794

648

579

72 x 65

67.72 x 60

64 x 60

3 Mikuni VM38SS Slide

3 Throttle Body 46mm

3 Mikuni VM34SS Slide

Standard

COl

12V 180W

12V 170W

Length (in.!cm.)

106.25/269.9 113/287 SKS

106.25/269.9 113/287 Touring

106.25/269.9

113/287

Width (in.!cm.)

45.5/115.6 43.5/110.5 SKS

45.5/115.6

43.5/110.5

Height (in.!cm.)

38.5/97.8 44/111 .8 SKS

38.5/97.8 44/111.8 Touring

44/111.8 38.5/97.8 SP

44/11 1.8

Ski Stance (in.!cm.)

40/1 01 .6 38/96.5 SKS

40/101.6

38/96.5

Track Width (in.!cm.)

15/38.1

Track Length Overall (in.!cm.)

121 /307.3 133.5/339.1 SKS

121/307.3 133.5/339.1 Touring

121/307.3

133.5/339.1

10.7/8.9/40.5

Recommended Fuel

90 Octane Min.

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Hydraulic Disc Rear of Seat

Ignition Alternator Output

Fuel Capacity (U.S. gal.llmp. gal.lliters)

Storm Storm SKS

Brake Type Storage

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Option

Standard

Option

Oil/Brake Temp/Acc High Beam

N/A

Touring

Option

Hi-Lo/Std

Hi-Lo/NA

Hi-Lo/Std

N/A

Option

Backrest

Option

Storage Rack

Option

Tow Hitch

Option

Electric Fuel Gauge Accessory Lights

Electric Start HandwarmersIThumbwarmer Two-Up Seat

1.37

8/94

MODELS AND SPECIFICATIONS 1994 Model Identification

Engine Type Engine Model Number Displacement (ee) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output

XLT Special XTRA

500 EFI 500 EFI SKS

Classic

Classic Touring

0946767

0942774 0942574

0942865

0942875

LC Triple EC58PL-03

LCTwin EC50PL-07

LCTwin EC50PL-05

LCTwin EC50PL-08

596

488

65 x 60

72 x 60

3 Mikuni VM34SS Slide

2 Throttle Body 46mm

2 Mikuni VM38SS Slide

2 Mikuni VM38SSSiide

Standard

COl

12V 170W

12V 250W

12V200W

12V 250W

Length (in./cm.)

106.25/269.9

107/271.8 113/287 SKS

107/271.8

113/287

Width (in./cm.)

49/124.5

45.5/115.6 43.5/110.5 SKS

45.5/115.6

Height (in./cm.)

47/119.4

46/116.8

Ski Stance (in./cm.)

38/96.5

40/101.6 38/96.5 SKS

40/101 .6

40/101.6

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

121/307.3

121/307.3 133.5/339.1 SKS

121/307.3

133.5/339.1

10.7/8.9/40.5

Recommended Fuel

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Hydraulic Disc

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Option

Standard

Oil/Brake Temp/Acc High Beam

Oil/BrakefTemp Acc/Batt High Beam

Oil/Brake Temp/Acc High Beam

Oil/BrakefTemp Acc/Batt High Beam

Fuel Capacity (U.S. gas'/Imp. gaL/liters)

Brake Type Storage

Electric Fuel Gauge Accessory Lights

Electric Start HandwarmersfThumbwarmer

Option

Standard

Hi-Lo/Std

Two-Up Seat

Option

Standard

Backrest

Option

Standard

Storage Rack

Option

Tow Hitch

Option

8/94

1.38

MODELS AND SPECIFICATIONS 1994 Model Identification

WideTrak GT

600XCR

440 XCR

0942064

0942061

0941667

0941760

LCTwin EC50PL-06

Fan Twin EC50PM-03

LCTwin EC58PL-02

LC Twin EC45PL-01

WideTrak LX Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected

488

596

432

72 x 60

65 x 60

67.72 x 60

2 Mikuni VM34SS Slide

3 Mikuni VM38SS Slide

2 Mikuni VM38SS Slide

Standard

COl

Alternator Output

12V 200W

12V 170W

12V200W

Length (in.!cm.)

128/325.1

121.5/308.6

106.25/269.9

Width (in.!cm.)

43.5/110.5

45.5/115.6

45.5/11 5.6

Height (in.!cm.)

49/124.5

38.5/97.8

38/96.5

41/104.1

40/101.6

Ignition

Ski Stance (in.!cm.) Track Width (in.!cm.)

20/50.8

15/38.1

Track Length Overall (in.!cm.)

156/396.2

141/358.1

121/307.3

Fuel Capacity (U.S. gas.!l mp. gal.lliters)

10/8.3/38

10/8.3/37.8

10.7/8.9/40.5

Recommended Fuel

87 Octane Min.

91 Octane Min.

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Brake Type

Mechanical Disc

Liquid Cooled Hydraulic Disc

Under Seat Storage Rack

Under Seat

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Option

Standard

N/A

Option

OilfTemp Rev High Beam

Rev/Acc Oil High Beam

Oil/Brake Temp/Acc High Beam

Storage

Electric Fuel Gauge Accessory Lights

Electric Start HandwarmersfThumbwarmer

Option

Single Heat/Std

Hi-Lo/Std

Two-Up Seat

Standard

N/A

Option

Backrest

Standard

N/A

Option

Storage Rack

Standard

N/A

Option

Tow Hitch

Standard

N/A

Option

1.39

8/94

MODELS AND SPECIFICATIONS 1994 Model Identification

440XCR SP

440 Indy 440 Indy SKS

Trail Deluxe

Trail

0941660

0942760 0942560

0940262

0940761

LCTwin EC45PL-03

LC Twin EC45PL-02

Fan Twin EC50PM-02

Fan Twin EC50PM-01

439

432

488

68.25 x 60

67.72 x 60

72 x 60

2 Mikuni VM38SS Slide

2 Mikuni VM34SS Slide

Standard

COl

12V 200W

12V200W

Length (in./cm.)

106.25/269.9

107/271.8 113/287 SKS

113/287

106.25/269.9

Width (in./cm.)

45.5/115.6

45.5/115.6 43.5/110.5 SKS

45.5/115.6

45.5/115 .6

Height (in./cm.)

38.5/97.8

46/116 .8

45/114.3

44/111.8

Ski Stance (in./cm.)

41/104.1

40/10 1.6 38/96.5 SKS

40/101.6

Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) Carburetionrrhrottle Body Oil Injected Ignition Alternator Output

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

121/307.3

121/307.3 133.5/339.1 SKS

133.5/339.1

121/307.3

Fuel Capacity (U.S. gas'/Imp. gal.!liters)

10.7/8.9/40 .5

10.7/8.9/40.5

Recommended Fuel

91 Octane Min.

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Brake Type

Rear of Seat

Speedometer

Standard

Tachometer

Standard

Option

Standard

Option

Oil/Brake

Oil/Brake TemplAcc High Beam

Oil/Brake Acc High Beam

Storage

Electric Fuel Gauge Accessory Lights

TemplAcc High Beam Electric Start Handwarmersrrhumbwarmer Two-Up Seat Backrest Storage Rack Tow Hitch

8/94

Option

Standard

Option

Hi-Lo/Std

Single Heat/Std

N/A N/A N/A N/A

Option

Standard

Option

Standard

Option

1.40 ,.

MODELS AND SPECIFICATIONS 1994 Model Identification

Super Sport

Sport SportSKS

Indy Lite Deluxe

Indy Lite GT

0940743

0940443 0940243

0943431

0943133

Fan Twin EC44-3PM-01

Fan Twin EC34-2PM-02

Fan Twin EC34-2PM-04

432

339

67.72 x 60

62.3 x 55.6

2 Mikuni VM34SS Slide

2 Mikuni VM30SS Slide

Standard

COl

12V 200W

12V200W

12V 150W

Length (in.lcm.)

106.25/269.9

106.25/269.9 113/287 SKS

105/266.7

11 5/292.1

Width (in.lcm.)

45.5/115.6

43.5/110.5

42.5/108

Height (in.lcm.)

38.5/97.8

44/111 .8 45/114.3 SKS

44/111 .8

48/121.9

Ski Stance (in.lcm.)

40/101.6

38/96.5

37/94

Track Width (in.lcm.)

15/38.1

121/307.3

121/307.3 133.5/339.1 SKS

121/307.3

133.5/339.1

10.7/8.9/40.5

8/6.7/30.3

Recommended Fuel

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Parallel Link Trai ling Arm IFS

Parallel Link Trailing Arm IFS

Hydraulic Disc

Mechanical Disc

Rear of Seat

Rear of Seat Top of Hood

Speedometer

Standard

Tachometer

Standard

Option

N/A

Option

N/A

Oil/Brake Acc High Beam

Oil/Acc

Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) Carburetionrrhrottle Body Oil Injected Ignition Alternator Output

Track Length Overall (in.lcm.) Fuel Capacity (U.S. gas.ll mp. gal.lliters)

Brake Type Storage

Electric Fuel Gauge Accessory Lights

Option

Standard

Option

Single Heat/Std

Single Heat Std

Single Heat/Std

Option

Option Standard SKS

N/A

Standard

Option Standard SKS

N/A

Standard

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

Electric Start Handwarmersrrhumbwarmer Two-Up Seat Backrest

1.41

8/94

MODELS AND SPECIFICATIONS 1994 Model Identification

StarLite GT Engine Type Engine Model Number

StarLite

Indy Lite

0943127

0943427

0943433

Fan Single EC25PS-07

Fan Twin EC34-2PM-04

244

339

Displacement (cc)

72 x 60

62.3 x 55.6

1 Mikuni VM30SS Slide

2 Mikuni VM30SS Slide

Standard

COl

Alternator Output

12V 150W

Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected

Ignition

Length (in.lcm.)

115/292.1

105/266.7

Width (in.lcm.)

42.5/108

Height (in.lcm.)

48/1 21.9

44/111.8

Ski Stance (in.lcm.)

37194

37/94

Track Width (in.lcm.)

15138.1

15/38.1

133.5/339.1

121/307.3

121 /307.3

Track Length Overall (in.lcm.)

8/6 .7/30.3

8/6.7/30.3

8/6. 7/30.3

Recommended Fuel

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Brake Type

Mechanical Disc

Rear of Seat Top of Hood

Fuel Capacity (U.S. gas.llmp. gaUliters)

Storage

Option

Standard

Tachometer

N/A

Electric Fuel Gauge

N/A

Accessory Lights

N/A

Speedometer

N/A

Option

Option/Option

OptionlOption

Two-Up Seat

Standard

N/A

Backrest

Standard

N/A

Storage Rack

Standard

Option

Tow Hitch

Standard

Option

Electric Start HandwarmersfThumbwarmer

8/94

1.42

MODELS AND SPECIFICATIONS 1995 Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Refer to the first digits in the serial number for proper identification: MODEL YEAR FIRST DIGITS FIRST DIGITS MODEL YEAR 1991 18 12 1985 19 1992 13 1986 20 1993 14 1987 1994 22 15 1988 1995 23 16 1989 17 1990

1995 MODEL DESIGNATION YEAR DESIGNATION-

MODEL DESIGNATION

- --

---,

r--

1995 1995 ENGINE DESIGNATION MODEL DESIGNATION NUMBERS NUMBERS (Chassis) 27 - EC25PS07 02 - Sport Touring 33 - EC34-2PM02lE02 04 - Sport 43 - EC44-3PM01/02 05 - XLT SKS, Storm SKS 60 - EC45PL02/03 07 - Super Sport, XLT, Storm 61 - EC50PM03/E04/04 08 - RXL Touring 62 - EC50PME04/04 20 - WideTrak GT/LX 56 - EC58PL03 25 - 440 Indy SKS, 500 EFI SKS 27 - 440 Indy, 500 EFI, Indy Trail, Indy 500 28 - Classic, XLT Touring 31 - Indy Lite GT 34 - Indy Lite, Lite Deluxe, Star Lite 22 - Indy Trail Deluxe 16 - Indy 440 XCR, Indy 600 XCR 29 - Indy 500 EFI SKS (paddle track) 67 - Indy XLT Special, RXL 09 - Indy XLT SKS (paddle track), Storm SKS (paddle track)

MODEL NO.

MADE IN U.S.A.

SERIAL NO. THiS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADiAN FEDERAL MOTOR VEHICLE STANÂ· DARDS IN EFFECT ON THE DATE OF MANUFACTURE.

ENGINE DESIGNATION Refer to Engine Section for more detailed information

1995 ENGINE DESIGNATION NUMBERS 64 - EC50PL06/E04/04 65 - EC50PL05/E04/04 67 - EC58PL01 E04 68 - EC65PL05/E05 69 - EC65PL05/E05 74 - EC50PL07 76 - EC58PL02 82 - EC80PL01

PATENT NOTICE

PDLRRIS

Mfd. by Polaris Industries L.P. in Roseau, MN under one or more of the following patents: Patented Canada U.S. Patents

3,605,511 3,580,647 3,483,766 3,533,662 3,545,821 3,605,510 3,525,412

MFD. DATE:

3,613,810 3,867,991 4,793,950 5,038,881 5,172,675 5,090,386 5,050,564

5,050,559 5,048,503 5,056,482 5,099,813 5,074,271 5,191,531 3,613,811

882,491n1 883,694f71 864,394n1

Canadian Rd.

34,573n1 34,572f71 1,227,823187 7072133

1.43

8/94

MODELS AND SPECIFICATIONS 1995 Model Identification

Engine Type Engine Model Number

Storm Storm SKS/PT

RXL Touring

RXL

XLT XLTSP

0950782 0950582 0950982

0950869

0956768

0950756 0956756

LC Triple EC80PL01

LC Triple EC65PLE05

LC Triple EC65PL05

LC Triple EC58PL03

794

648

597

72 x 65

67.72 x 60

65 x 60

3 Mikuni VM38SS Slide

3 Throttle Body 46mm

3 Mikuni VM34SS Slide

Standard

COl

12V 170W

12V 180W

12V 170W

Length (in./cm.)

106.25/269.9 113/287 SKS

113/287

106.25/269.9

Width (in./cm.)

45.5/115.6 43.5/110.5 SKS

45.5/11 5.6

49/124.46

45.5/11 5.6 49/124.46 SP

Height (in./cm.)

38.5/97.8 44/111.8 SKS

45/ 114.3

43/109.22

44/111.8 43/1 09.22 SP

40/101.6

40/101 .6

43.5/11 0.49

40/101.6 43.5/1 10.49 SP

Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output

Ski Stance (in./cm.)

38/96.5 SKS Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

121/307.3 133.5/339.1 SKS

133.5/339.1

121/307.3

10.7/8.9/40.5

Recommended Fuel

90 Octane Min.

87 Octane Min.

Front SuspenSion

Parallel Link Trailing Arm IFS

Non-Parallel Link Trailing Arm IFS

Parallel Link Trailing Arm IFS Non-Parallel LinkTrailing Arm IFSSP

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Rear of Seat Toolbox Footrest

Speedometer

Standard

Tachometer

Standard

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

Brake Type Storage

Electric Fuel Gauge Accessory Lights

Electric Start

Option

Standard

Option

Oil/Brake Temp/Ace High Beam

Oil/Brake Temp/Acc High Beam

N/A

Standard

Option

Hi-Lo/Std

Hi-Lo/Option

Hi-Lo/Std

Two-Up Seat

Option

Standard

Option

Backrest

Option

Standard

Option

Storage Rack

Option

Tow Hitch

Option

TBA

Option TBA SP

HandwarmersIThumbwarmer

8/94

1.44

MODELS AND SPECIFICATIONS 1995 Model Identification

Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected

XlTTouring

600 XCR

500

0950556 0950956

0952857

0951676

0952764

t;c Triple EC58PL03

LC Triple EC58PLE04

LC Triple EC58PL02

LC Twin EC50PL04

597

488

65 x 60

72 x 60

3 Mikuni VM34SS Slide

3 Mikuni VM38AL Slide

2 Mikuni VM38SS Slide

Standard

COl

CO l

COl

12V 170W

12V200W

Length (in./cm.)

113/287

106.25/269.87

107/271.8

Width (in./cm.)

43.5/110.5

45.5/115.57

45.5/115.6

Height (in./cm.)

44/111.8

46/116.84

40/101.6

40/101.6 40/101 .6

Ignition Alternator Output

Ski Stance (in./cm.)

38/96.5

40/101 .6

40/101.6

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

133.5/339.1

121/307.3

10.7/8.9/40.5

9.5/8.9/40.5

10.7/8.9/40.5

Recommended Fuel

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Parallel Link Trailing Arm IFS w/shock

Hydraulic Disc

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Rear of Seat Toolbox Footrest

Rear of Seat Toolbox Under Hood

Rear of Seat

Rear of Seat Toolbox

Speedometer

Standard

Tachometer

Standard

Option

Standard

N/A

Option

Oil/Brake Temp/Acc High Beam

Option

Standard

N/A

Option

Hi-Lo/Std

Hi-Lo/S.td

Two-Up Seat

Option

Standard

Option

Fuel Capacity (U.S. gas'/Imp. gal./liters)

Brake Type

XlT SKS/PT

Storage

Electric Fuel Gauge Accessory Lights

Electric Start HandwarmerslThumbwarmer

Backrest

Option

Standard

Option

Storage Rack

Option

Tow Hitch

Option

1.45

8/94

MODELS AND SPECIFICATIONS 1995 Model Identification

Engine Type Engine Model Number

Classic

500 EFI 500 EFI SKS/PT

WideTrak LX

WideTrak GT

0952865

0952774 0952574 0952974

0952064

0952061

LCTwin EC50PLE04

LCTwin EC50PL07

LCTwin EC50PL06

Fan Twin EC50PM03

488

72 x 60

2 Mikuni VM38SS Slide

2 Throttle Body 46mm

2 Mikuni VM34SS Slide

Standard

COl

Alternator Output

12V 200W

12V 250W

12V200W

12V 200W

Length (in.!cm.)

107/271.8

107/271.8 113/287 SKS

128/325.1

121.5/308.6

Width (in.!cm.)

45.5/115.6

45.5/115.6 43.5/110.5 SKS

43.5/110.5

Height (in.!cm.)

44/111.76

49/124.5

Ski Stance (in.!cm.)

40/101.6

40/101 .6 38/96.5 SKS

38/96.5

Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition

Track Width (in.!cm.)

15/38.1

20/50.8

Track Length Overall (in.!cm.)

121/307.3

121/307.3 133.5/339.1 SKS

156/396.2

141/358.1

10.7/8.9/40.5

10/8.3/38

10/8.3/37.8

Recommended Fuel

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Hydraulic Disc

Mechanical

Rear of Seat Toolbox Under Hood

Under Seat Storage Rack

Under Seat

Fuel Capacity (U.S. gas.!lmp. gal./liters)

Brake Type Storage Speedometer

Standard

Tachometer

Standard

Option

Electric Fuel Gauge

Standard

Option

N/A

Oil/Brake Temp/Ace High Beam

Oil/BrakefTemp Ace/Batt High Beam

OilfTemp Rev High Beam

Rev/Acc Oil High Beam

Accessory Lights

Electric Start

Standard

Option

HandwarmersfThumbwarmer

Hi-Lo/Std

Single Heat/Std

Two-Up Seat

Option

Standard

Backrest

Option

Standard

Standard Standard Standard

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

8/94

1-46

MODELS AND SPECIFICATIONS 1995 Model Identification

Engine Type Engine Model Number

440XCR

440 Indy 440lndySKS

Trail Deluxe

Trail

0951660

0952760 0952560

0952262

0952761

Fan Twin EC50PME04

Fan Twin EC50PM04

488

LCTwin EC45PL05

LCTwin 1' } EC45PL02

439

432

68.25 x 60

67.72 x 60

72 x 60

2 Mikuni VM34SS Slide

Standard

COl

12V 200W

12V200W

Length (inJcm.)

106.25/269.9

107/271.8 113/287 SKS

113/287

107/271 .78

Width (inJcm.)

45.5/115.6

45.5/115.6 43.5/110.5 SKS

45.5/115.6

45.5/1 15.6

Height (inJcm.)

38.5/97.8

44/111 .76

46/116.84

44/111 .8

Ski Stance (inJcm.)

41/104.14

40/101.6 38/96.5 SKS

40/101.6

Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output

Track Width (inJcm.)

15/38.1

Track Length Overall (inJcm.)

121/307.3

121/307.3 133.5/339.1 SKS

133.5/339.1

121/307.3

Fuel Capacity (U.S. gasJlmp. gaL/liters)

9.5/8.9/40.5

10.7/8.9/40.5

Recommended Fuel

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS w/shock

Parallel Link Trailing Arm IFS

Liquid Cooled Hydraulic Disc

Hydraulic Disc

Rear of Seat

Rear of Seat Toolbox

Speedometer

Standard

Tachometer

Standard

Option

Standard

Brake Type Storage

Electric Fuel Gauge Accessory Lights

Electric Start HandwarmersIThumbwarmer Two-Up Seat

N/A

Option

Oil/Brake Temp/Acc High Beam

OiVBrake Temp/Acc High Beam

OiVBrake Acc High Beam

Oil/Brake Acc High Beam

N/A

Option

Standard

Option

Hi-Lo/Std

Option

Standard

Option

Backrest

Option

Standard

Option

Storage Rack

Option

Tow Hitch

Option

1.47

8/94

MODELS AND SPECIFICATIONS 1995 Model Identification

Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition

Super Sport

Sport Sport Touring

Indy Lite Deluxe

Indy Lite GT

0950743

0950443 0950243

0953431

0953133

Fan Twin EC44-3PM02

Fan Twin EC44-3PM01

Fan Twin EC34-2PME02

Fan Twin EC34-2PM02

432

339

67.72 x 60

62.3 x 55.6

2 Mikuni VM34SS Slide

2 Mikuni VM30SS Slide

Standard

COl

12V200W

12V 200W

12V 150W

Length (in./cm.)

106.25/269.9

106.25/269.9 113/287 Touring

105/266.7

11 5/292.1

Width (in.!cm.)

45.5/115.6

43.5/110.5

42.5/108

42.5/1 08

Height (in.!cm. )

38.5/97. 8

44/111.8 45/114.3 Touri ng

44/111.8

48/121.9

Ski Stance (in.!cm.)

41 /1 04.14

38/96.5

37/94

Track Width (in.!cm.)

15/38.1

121/307.3

121/307.3 . 133.5/339.1 Touring

121 /307.3

133.5/339.1

Alternator Output

Track Length Overall (in.!cm.)

10.7/8.9/40.5

8/6.7/30.3

Recommended Fuel

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Hydraulic Disc

Mechanical Disc

Rear of Seat Toolbox Footrest

Rear of Seat Top of Hood

Speedometer

Standard

Tachometer

Standard

Option

N/A

Option

N/A

Oil/Brake Acc High Beam

Oil/Acc

Option

Standard

Option

Single Heat/Std

Single Heat/Std Single Heat/Acc Touring

Single Heat/Std

Two-Up Seat

Option

Option Standard Touring

N/A

Standard

Backrest

Option

Option Standard Touring

N/A

Standard

Storage Rack

Option

Standard

Tow Hitch

Option

Standard

Fuel Capacity (U.S. gas.!lmp. gal./liters)

Brake Type Storage

Electric Fuel Gauge Accessory Lights

Electric Start HandwarmersfThumbwarmer

8/94

1.48

MODELS AND SPECIFICATIONS 1995 Model Identification

Indy Lite Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected

0953433

0953427

Fan Twin EC34-2PM02

Fan Single EC25PS07

339

244

62.3 x 55.6

72 x 60

2 Mikuni VM30SS Slide

1 Mikuni VM30SS Slide

Standard

COl

CO l

Alternator Output

12V 150W

Ignition

Length (in./cm.)

105/266.7

Width (in./cm.)

42.5/1 08

42.5/108

Height (in./cm.)

44/111.8

Ski Stance (in./cm.)

37/94

Track Width (in./cm.)

15/38.1

Track Length Overall (in./cm.)

121/307.3

Fuel Capacity (U.S. gas'/Imp. gal./liters)

8/6.7/30.3

Recommended Fuel

87 Octane Min.

Front Suspension

Parallel Link Trailing Arm IFS

Brake Type

Mechanical Disc

Rear of Seat Top of Hood

Storage

StarLite

Standard

Option

Tachometer

N/A

Electric Fuel Gauge

N/A

Accessory Lights

N/A

Speedometer

Electric Start HandwarmerslThumbwarmer Two-Up Seat

Option

N/A

Option/Option

N/A

Storage Rack

Option

Tow Hitch

Option

Backrest

1.49

8/94

o ,

ac:zI

CHAPTER 2 BODY AND STEERING

Summer Storage ......................... .. ....... ............ ........... 2.1-2.2 Gas Tank and Seat Removal - Cutlass SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 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 ABS Nosepan - Care, Cleaning and Repair ................................. 2.9-2.10 Nosepan Replacement Procedure (1994 Indy 440/SKS, 500 EFI/SKS, Classic/Touring) . . . . . . . . . . . . . . . . . . . .. 2. 11 RIM Mettonâ&#x201E;¢ Part Repair ..... . ................. . ..................... .. .. . . 2.12 Fiberglass Repair ......................... . .......................... . . .... 2. 13 Hood and Nosepan Adjustment (1994 Indy 440/SKS, 500 EFI/SKS, Classic/Touring) .......... . . ... ..... . 2.13 Steering - Conventional Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.14 Steering - IFS - Independent Front Suspension - 1985 to Current ..... .. .......... 2.15 IFS Adjustable Torsion Bar . . ............................... .. . . ............. 2. 16 1994 Shock and Spring Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 7 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 ..... ....... ......... . .................. . ...... . ....... . 2.24 Ski Spindle Bushing Replacement - Handlebar Torque and Sequence ........ .. .. 2.25 Ski Skag Removal - Conventional Type .. . .. . .. . ......... .. ........... ....... . 2.26 Ski Skag Removal-IFS and EZ Steer Type ................. . ..... ... .. .. ..... 2.27 1994 Model Seat Lengths ......... . ........... .. . .. .... .. ...... . .. ..... . ... . 2.28 1995 Model Seat Lengths .............. . .. .................... . ............. 2.29 1993 Paint Codes .. .. . .................... . .... . .......... . . .... . .. ........ 2.30 1994 Paint Codes ........ .. .. ................... . .. ....... .... .......... . .. 2.31 1995 Paint Codes .. ............ . .. .. ........... . ... . .............. .. .. . .... 2.32

8/93

BODY AND STEERING Summer Storage Cleaning And Preservation Of Hood, Chassis And Trim Proper storage starts by cleaning, washing and waxing the hood, chassis, upholstery and plastiC parts. Clean and touch up with paint any rusted or bare metal surfaces. Ensure that all corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil, or paint) . If the machine is equipped with 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 ru st 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 model Indys.) Loosen driven clutch retaining bolt and pull clutch outward to expose bearing. Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal. Push clutch back on shaft and replace clutch retaining bolt. Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal. Lubricate both front ski pivots at bushings and spindles. See 111.1 and 2.

Grease

Ski Spindle

~ndW /

Ings ~

Jackshaft Bearing

III. 1

(W Grease

Driveshaft Bearing

Use Polaris Fogging Oil (PN 2870791) on shock absorber shafts to help prevent corrosion.

_M o

Under normal conditions moderate track tension should be maintained during summer storage. Rubber track tension should be maintained at the prescribed normal operating tension specified in this manual. The rear of the machine should be supported off the ground to allow free hanging of track.

III. 2

2.1

Located on left side of machine (clutch side)

8/94

BODY AND STEERING Summer Storage Engine And Carburetor The fuel tank, fuel lines and carburetor should be completely drained of gasoline. To eliminate any fuel remaining in the carburetor, run the engine until it stops. Support front of snowmobile so engine is level or tilted slightly rearward. Remove spark plug(s) . Rotate piston to BDC and pour approximately two ounces (16 ml) Polaris oil into the cylinder. NOTE: Allow ample time for oil to flow from top of piston down transfer ports and onto crankshaft bearings before proceeding to next cylinder. Turn engine over several times to insure coverage of piston rings, cylinder walls and crankshaft bearings. See photo at right. 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.

EFt Storage Considerations Add fuel conditioner/stabilizer and fi ll tank as described above. Fog engine. If machine is to be stored for one month or longer, fill and charge battery monthly using Polaris 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 the fue l.

Standard Torque Specifications Refer to pages 10.4-10.5 for a complete list of standard torque specifications, and torque deviations.

8/94

2.2

BODY AND STEERING Gas Tank and Seat Removal -Cutlass SS Be sure the fuel tank is emptied before beginning the removal procedure.

WARNING

Gasoline is extremely flammable and explosive under certain conditions .

.&.. Do not smoke or allow open flames or sparks in or near the area where 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. .&.. 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.

Removal 1.

Remove the two 1/4 x 1" screws from the rear underside of the tunnel.

Disconnect the seat wire harness at the tank and remove the seat.

Remove the six 10-24 x 5/8" bolts (A) securing the console to the chassis. See photo at right.

Remove the fuel line from the fuel pump.

Locate tank vent line on upper left front side of tank. Cut line from its fitting. CAUTION: Do not attempt to pull the line off as damage to the vent fitting may result.

Roll the front and rear tank hold-down springs off the tank.

Disconnect the fuel gauge sight line, both top and bottom, from the right front side of the tank.

Remove the fuel cap.

Lift the console Slightly and remove the tank.

10. Reverse procedure for reinstallation.

2.3

8/94

BODY AND STEERING Gas Tank and Seat Removal- Indy Models 1.

Remove tank cover by disconnecting snaps.

Remove vent line at front LH side of tank.

Remove gas cap and rubber grommet.

Remove air silencer box.

Disconnect fuel line from fuel pump and plug line to prevent fuel spillage from tank. See photo at right.

WARNING: Gasoline is extremely flammable and explosive under certain conditions. Do not smoke or allow open flames or sparks in or near the area where work is being performed. If you should get gasoline in your eyes or if you should swallow gasoline, see your doctor immediately. If you should spill gasoline on your skin or clothing, immediately wash if off with soap and water and change clothing. Prolonged exposure to petroleum based products may cause paint failures. Always protect finished surfaces and wipe up any spills immediately. 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.

Slide seat rearward enough to gain access to taillight connector at RH side of fuel tank. Unplug connector. Slide seat off machine and set aside.

10. Fuel tank can now be removed from chassis by disconnecting two springs at center of fuel tank.

One Piece Fuel Tank/Seat Removal Procedure (1994 440/SKS, 500 EFIISKS, ClassicI Touring) 1.

Remove front tank retaining spring located behind driven clutch area.

Remove fuel cap and grommet.

Remove fuel lines.

If machine is equipped with gauges, unplug gauge wires.

Remove two bolts in tool box.

DisconnecUaillight wiring.

Remove two console bolts attaching console to tunnel.

Remove two console bolts located under hood.

Remove fuel cap and lift console up. Replace fuel cap.

10. Lift up at rear of seat and slide out.

8/94

2.4 ,

BODY AND STEERING

Seat Cover Replacement (Plastic Base) 1.

Remove seat cushion assembly as outlined 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 "0" ring buckle which secures the center hold down strap. Push the "0" ring through the slot in the tool box and carefully pull it through the foam cushion.

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.

Place the seat foam on the seat base assembly as shown in III. 1.

Drape the seat cover over the seat foam.

Insert and pull the two seat bucket hold down straps, attached to the seat cover, through the two holes in the seat foam and the routed-out holes located in the storage box area on the plastic seat base. HINT: A stiff wire attached to the 3 bar slide on the hold down strap will aid in this process. NOTE: Use the rear two holes for a longer length seat and the forward two holes for the standard length seat.

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SEAT BUCKET HOLD DOWN STRAP

FOR USE WITH LONG SEAT STORAGE BOX AREA

PLASTIC SEAT BASE ILL. 1

2.5

8/94

BODY AND STEERING

Seat Cover Replacement (Plastic Base) 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. 1A.

CAUTION: Apply staples 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.

Using a staple gun, tack each side of the vinyl cover in place using two staples. If cover has a Polaris emblem carefully align emblem with bottom edge of seat. This will help ensure that the cover is positioned properly.

Align the two sewn seams located at the rear of the seat cover with the two back corners of the seat base. See III. 1. Pull the vinyl tight and tack the seat cover to the plastic seat base in each corner. Use two or three staples per corner.

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

SEWN SEAMS TACK COVER HERE SECOND

LOCATION --==-_ _---:>"'<:~~ INDICATORS

STAPLING CHANNEL

ILL. 1

11. Staple the remainder of the unattached seat cover to the plastic seat base as shown in III. 1. HINT: Always staple between two existing staples and follow this procedure until the seat cover is completely stapled to the seat base. See III. 2. 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.

STAPLE HERE FIRST '

STAPLE HERE SECOND

STAPLE HERE THIRD

STAPLE SEQUENCE

8/94

2.6

ILL. 2

])

BODY AND STEERING Seat Cover Replacement (Plastic Base) 1995 Models With Grommets In Tool Flap 13. Close tool 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 flap. 15. Using twist lock as a template, drill two .160/1 to .164/1 holes through vinyl and seat base. 16. Rivet twist lock to seat base using rivets provided.

All Models 17. Trim excess vinyl from the bottom around the back of the seat area only after a satisfactory fit is obtained. See III. 1, page 2.6 .

18. Reinstall seat by reversing disassembly steps as they apply to your particular model.

Seat Covering Instructions â&#x20AC;˘

OneiTwo Piece Seat and Tank PN 9912521

â&#x20AC;˘

1994-1995 XCR 440 SP, XCR 600 PN 9912842

Taillight Assembly Replacement 1.

After removal of seat cover, drill out three rivets from the top of the taillight.

Remove the taillight assembly and wire harness.

Install new taillight assembly and rivet into place.

Connect taillight wire harness. NOTE: Taillight harness wires must be routed away from any possible contact with seat cover staples to prevent electrical shorts.

Pull the seat cover tightly and evenly into position and re-staple to the seat pan .

Inspect cover for a wrinkle-free finish before reinstalling on the snowmobile.

2.7

8/94

BODY AND STEERING Decal Removal and Installation Decal Removal 1.

Before removing old decal, it is important to note its position by marking it in several locations. 2. Remove old decal completely. NOTE: A small amount of solvent will aid in removing the old decal. 3. Depending on year and model, the decals may be UV based or solvent based. If heat will not remove decal, gently buff area with a mild abrasive. Use 3M Scotch Briteâ&#x201E;˘ Graphics Removal Discs (3M PN 048011-16855), with a No.1 Roloc 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 will be installed using a solution of mild soap (such as dishwashing liquid) and clean water. NOTE: Use approximately four ounces soap to one gallon water.

Decal Installation 1. Apply a solution of mild soap mixed with clean water to th e area where the new decal is to be applied. Do not wipe off. 2. Carefully remove decal backing and apply new decal. 3. If decal does not have a pre-mask, apply additional soapy water solution to top of decal after it is in position. 4.

Holding decal in position , remove all trapped air and soapy water solution from under decal using a clean, soft rubber squeegee to prevent scratching of decal surface. If decal has a pre-mask, carefully remove . .

NOTE: If the decal being applied needs to be stretched around a radius, follow these recommendations:

6. 7.

Fasten a straight edge to tail end of decal. Pull or stretch remaining portion of decal around radius and into position. NOTE: A small amount of heat applied to the decal will aid in forming it to the radius. The mass of the decal which was secured in previous steps will hold it in position while pulling.

8. Again, apply soapy water solution to top of decal and remove trapped air using a clean, soft rubber squeegee. Use care to prevent scratching the 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

(

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, wiping 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 household 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 Dirt and 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 will 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 lightly buffing 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. ty'iaterials required include: Fiberglass cloth; ASS pipe cement (NOTE: Several types of plumbing cement are available. Se sure to use one which is for either ASS or PVC and ASS material. Do not use cement labeled "for PVC only'?; Polaris blue ASS touch up paint (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.

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 .

Separate edges of crack slightly and fill void with cement. Press edges together, clamp in place, and wipe excess cement from outside of pan.

Liberally coat inside surface of pan with cement, covering approximately 1 1/2" (38 mm) on either side of the fracture.

Lay fiberg lass cloth over fracture.

Wearing rubber gloves, work cloth into pan using a squeegee or your fingers. NOTE: ASS cement is a solvent cement which dissolves the outer surface of the nosepan. The cement and cloth will change color as this happens.

2.9

8/94

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.

Lightly sand 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 replace ment ABS nosepan, the following procedures must be closely observed to ensure correct fit to the frame and maximum strength. ABS material is not rigid . Consequently, it must be installed in such a manner that it can expand or contract with temperature changes. 1.

Remove damaged nosepan by drilling out rivet heads. Engine mountings and other mountings attached to the forward part of the machine should be removed for ease of installation.

The following aluminum rivets must be used to attach nosepan: â&#x20AC;˘

PN 7621448, 3/16 x .652, Quantity requ ired - 7

â&#x20AC;˘

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 7621448). See illustration below. All remaining holes require 3/16 x .527" rivets (PN 7621403).

Make sure there is 1/4" (.6 cm) clearance around the exhaust outlet.

Install foil (PN 5810108) in the same location as the original part.

Rivet PN 7621448

@ 8

Rivet PN 7621403

8/94

2.10

BODY AND STEERING Nosepan Replacement Procedure (1994/1995 Indy 440/SKS, 500 EFI/SKS, Classic/Touring, Trail/Deluxe, XLT Touring) IMPORTANT: When installing a replacement nosepan, this rivet sequence must be followed correctly in order to ensure proper nosepan and body panel fit. NOTE: The rivet for polyethylene nosepans is PN 7621467. NOTE: Rivet holes 14 through 19 may require drilling into the bulkhead. Circled rivet numbers 1, 2, 5 and 6 are locating holes used for proper alignment.

Âˇ24

NOTE: 1. When transfer drilling holes do not force pan into a position which is not uniform with the other side. (Use the same method to drill both sides)

Rivet holes across from one another in unison.

2 .11

8/94

BODY AND STEERING RIM Metton Part Repair 1M

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. TM

The patch kit can be obtained from your local automotive parts house. It is suitable for repair of 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: Heat, 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 (SMC) , 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, wh ich can be repaired either with a two part repair kit or by hot air type plastic welding.

8/94

2.12

BODY AND STEERING Fiberglass Repair and Hood Adjustment Fiberglass Repair

;1 - - - - - - - - -...,

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 cm) back from patch area on inside of part. 3.

Apply masking tape to outside of part to form a mold.

Mix enough polyester resin and catalyst to complete the repair, following instructions for resin being used.

Apply resin to inside of patch area using a disposable paint brush.

Lay in small pieces of shredded fiberglass matt. Use the paint brush to force air bubbles out. Add more resin and move matt around. NOTE: Pieces of matt between 1" to 2" (2.5 to 5 cm) square work best.

Keep adding matt and resin until patch area is filled up to the original thickness.

Let resin cure thoroughly.

Remove masking tape from outside of repair.

/ I

, -- ----...,1 I I I I

I I I I I

II I I

- -- I I I I I

I HOOd~ I1

I I

I Upper I Hinge L

'-'

I _ _ _ _ _ _ _ _ _ ..l Hood and Hinge need not be flush

III. 1

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.

III. 2

Hood Adjustment Sequence (New Style 1994 to Current) 1.

Check to see that hood and upper hood hinge are properly aligned. To adjust, loosen nuts (A) and align properly. Tighten nuts. See III. 1.

With hood open, loosen nut (8). See III. 1.

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.

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-tighten one nut per hinge. Close hood and recheck alignment. .

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 illustration. 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 wil l result in improper adjustment. See III. 2. 2.13 8/94

BODY AND STEERING Steering - Conventional Front Suspension Steering 1. .

With the handlebars in the straight ahead position, skis should be parallel at points A and 8. Skis must not toe in. 1\

CAUTION: The steering assembly should be checked whenever a machine comes in for tune-up or repair.

=-~....r--'=-

lbl

11- -~.P -

- /,-

II B

Steering Removal NOTE: To retain proper ski alignment, the spindle and steering arm should be marked. 1.

Remove steering arm bolt (A).

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 tie rod end bearings, they should be replaced as a complete unit.

Remove spindle from body.

CAUTION: If spindles are cracked or bent they must be replaced. NOTE: Spindles should be lubricated annually to insure proper steering.

8/94

2.14

151

II 1\

II /I

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