Publication Numbers _ 1.1 -1 1b Service Bulletin Index By Bulletin Numbe r 1 2 -1 2c 1996 Service Bulletin Index By Model 1997 Service Bulletin Index By Model 1998 Service Bulletin Index By Model Service Videos ...... , . . ...... . . . .. . . . ...... . . 1.2d - 1.2h 1.2i -1 2j 1.2k - 1.21 1.3 1996 Model Identification I General Specification s 1.4 - 1.1 3 1997 Model Identification I General Specifications 1 .1 3a - 1 131 1998 Model Identification I General Specifications 1 13m - 1 13 u Paint Codes , . , ' , , , , , 1 14 -1.1 4 b Torque Specifications • .• 1.1 5 -1.1 6 Decimal Equivalents 1.17 Conversion Table .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 Tap Drill Charts. • 1.19 Glossary of Terms • •...... 1 20-1 .22 Service Tips • , • , • _ 1.2 3 Warranty Policy .. _ . . .. . , . . . . . . . . . . . . . . . . . . . . . 1.24 Special Tool Inf o rmation 1.25
CHAPTER 1 GENERAL INFORMATION
GENERAL INFORMATION Publication Numbers
1996 Publication Numbers
Model Model No. Indy Lite 0963433 Indy Lite Deluxe 0963431 Indy Lite GT 0963133 IndySport 0960443 Indy TranSport 0960143 IndySport Touring 0960243 Indy Super Sport 0960743 Indy440 LC 0962760 Indy 440 XCR 0961660 Indy 440 XCR SP 0961760 Indy WideTrak GT 0962061 Indy WideTrak LX 0962084 Indy Trail 0962761 Indy Trail Touring 0962262 Indy 500 0962764 Indy500 SKS 0962564 Indy 500 RMK 0962984 IndyClassic 0963865 Indy Classic Trg 0963365 Indy 500 EFI 0963774 Indy 500 EFI SKS 0962574 Indy 500 EFI RMK 0962974 Indy XLT 0966756 Indy XLT SKS 0960556 Indy XLT RMK 0960956 Indy XLT SP 0966676 Indy XLTTouring 0963357 Indy 600 XCR 0961676 Indy 600 XCR SP 0965677 Indy RXL 0966768 Indy Ultra SP 0960678 Indy Ultra SKS 0960578 Indy Ultra RMK 0960978 Indy Storm 0965782 Indy Storm SKS 0965582 IndyStorm RMK 0965982 Polaris Industries Inc. Owner's Parts Manual Manual 9913084 9913166 9913084 9913166 9913084 9913308 9913224 9913222 9913224 9913227 9913215 9913222 9913215 9913218 9913107 9913174 9913207 9913211 9913706 9913158 9913092 9913162 9913089 9913164 9913107 9913176 9913465 9913176 9913210 9913187 9913210 9913187 9913210 9913187 9913153 9913538 9913153 9913362 9913617 9913618 9913195 9913198 9913195 9913198 9913103 9913382 9913307 9913181 9913307 9913181 9913103 9913170 9913153 9913192 9913207 9913212 9913322 9913206 9913205 9913203 9913094 9913708 9913094 9913168 9913094 9913168 9913097 9913159 9913097 9913159 9913097 9913159 1.1
Parts Assembly Microfiche Instructions 9913167 9913085 9913167 9913088 9913309 9913087 9913223 9913220 9913228 9913225 9913223 9913221 9913219 9913216 9913175 9913172 9913213 9913208 9913336 9913338 9913163 9913093 9913165 9913090 9913177 9913110 9913177 9913109 9913188 9913185 9913188 9913185 9913188 9913189 9913539 9913184 9913363 9913154 9913619 9913196 9913199 9913310 9913199 9913200 9913383 9913178 9913182 9913466 9913182 9913179 9913171 9913105 9913193 9913190 9913214 9913209 9913311 9913323 9913204 9913201 9913707 9913194 9913169 9913095 9913169 9913183 9913160 9913098 9913160 9913101 9913160 9913101 11/95
GENERAL I NFORMATION
1997 Publication Numbers Model Model No. Indy Lite 0973433 Indy Lite Deluxe 0973431 Indy Lite GT 0973133 Indy Sport 0970443 Indy TranSport 0970143 Indy Sport Touring 0970243 Indy XCF 0971643 Indy Super Sport 0970761 Indy 440 LC 0972760 Indy 440 XC 0971760 Indy 440 XCR 0971660 Indy WideTrak GT 0972061 Indy WideTrak LX 0972065 Indy Trail 0972761 Indy Trail Touring 0972262 Indy Trail RMK 0970961 Indy 500 0972764 Indy 500 SKS 0972564 Indy 500 RMK 0972964 Indy Classic 0973865 Indy Classic Trg 0973365 Indy 500 EFI 0973774 Indy XLT 0976756 Indy XLT SKS 0970556 Indy XLT RMK 0970956 Indy XLT SP 0976676 Indy XLT Touring 0973357 Indy XLT LTD 0973756 Indy XLT SP LTD 0973776 Indy 600 XC 0971776 Indy 600 XCR 0975677 Indy 600 XCR SE H975677 Indy RXL 0976768 Indy Ullra 0976778 Indy Ultra SP 0970678 Indy Ullra SPX 0975678 Indy Ultra SPX SE H975678 Indy Ultra Touring 0975378 Indy 700 SKS 0970566 Indy 700 RMK 0970966 Indy 700 XC 0971766 Indy Storm 0975782 Indy Storm SE H975782 Indy Storm RMK 0975982 9/97 Owner 's Parts Parts Assembly Manual Manual Microfiche Instructions 9913748 9913827 9913828 9913749 9913748 9913827 9913828 9913750 9913740 9913825 9913826 9913742 9913688 9913767 9913768 9913687 9913696 9913829 9913830 9913697 9913699 9913767 9913768 9913702 9913661 9913861 9913862 9913662 9913763 9913764 9913765 9913766 9913934 9913835 9913836 9913837 9913755 9913787 9913788 9913754 9914006 9913789 9914472 9913791 9913816 9913817 9913818 9913819 9913821 9913822 9913823 9913824 9913709 9913831 9913832 9913710 9913705 9913831 9913832 9913704 9913647 9913833 9913834 9913648 9913709 9913839 9913840 9913735 9913841 9913839 9913840 9913735 9913841 9913839 9913840 9913844 9913845 9913846 9913847 9913848 9913732 9913849 9913850 9913737 9913753 9913842 9913843 9913751 9913713 9913769 9913770 9913714 9913761 9913769 9913770 9913762 9913761 9913769 9913770 9913771 9913774 9913775 9913776 9913777 9913732 9913772 9913773 9913733 9913658 9913779 9913780 9913659 9913658 9914007 9914008 9913659 9913755 9913793 9913794 9913758 9913795 9913796 9913797 9913798 9913795 9913796 9913797 9913798 9913851 9913852 9913853 9913854 9913804 9913805 9913806 9913807 ....../ 9913912 9913809 9913810 9913811 9913801 9913953 9913954 9913802 9913801 9913953 9913954 9913802 9913812 9913813 9913814 9913815 9913856 9913857 9913858 9913859 9913856 9913857 9913858 9913859 9914180 9914181 9914182 9914183 9913781 9913782 9913783 9913784 9913781 9913782 9913783 9913784 9913786 9913782 9913783 9913784 1 1a Polaris Industries Inc.
1997 Publication Numbers
,
1998 Publication Numbers
Model Model No. Supplement to Parts Book Owner 's Manual Indy Lite 0983433 9914185 9914186 Indy Lite Deluxe 0983431 9914185 9914186 Indy Lite Trg. 0983133 9914185 9914193 Indy Sport 0980443 9914281 9914205 Indy TranSport 0980143 9914281 9914282 Indy Super Sport 0980761 9914281 9914287 Indy Sport Trg. 0980243 9914281 9914205 Indy XCF 0981643 9914281 9914277 Indy 440 0982760 9914257 9914272 Indy 440 XCR 0981660 9914371 9914590 Indy Trail 0982761 9914257 9914258 Indy Trail Trg. 0982362 9914257 9914231 Indy Trail RMK 0980961 9914281 9914221 Indy 500 0982764 9914257 9914210 Indy 500 Classic 0983865 9914257 9914362 Indy 500 RMK 0982964 9914257 9914263 IndyClassic Trg. 0983365 9914247 9914248 IndyWideTrak LX 0982065 9914387 9914388 Indy XLT LTD 0983756 9914302 9914303 Indy XLT Classic 0983857 9914302 9914226 Indy XLT SP 0985776 9914215 9914216 Indy XLT Tr9. 0983357 9914302 9914253 Indy 600 XCR 0985677 9914339 9914316 Indy 700 XCR 0985678 9914339 9914311 Indy 600 RMK 0980958 9914371 9914463 Indy 700 RMK 0980966 9914371 9914372 Indy 600 XC 0981758 9914414 9914419 Indy 700 XC 0981766 9914414 9914415 Indy Storm 0985782 9914339 9914367 Indy Ultra 0986778 9914354 9914355 Indy Ultra Trg 0985378 9914339 9914340 1998 Snowmobile Owner's Manual (All) . PN 9914617 1998 Snowmobile Dealer Assembly Manual · PN 9913911 1998 Snowmobile Dealer Assembly Manual Update· PN 9914643 Polaris Industries Inc 1 1b
1998 Publication Numbers Parts Microfiche Assembly Manual Addendum 9914187 9914241 9914187 9914188 9914194 9914195 9914206 9914299 9914283 9914284 9914288 9914289 9914206 9914207 9914278 9914279 9914273 9914274 9914591 9914592 9914259 9914260 9914232 9914233 9914222 9914223 9914211 9914212 9914363 9914364 9914264 9914265 9914249 9914250 9914389 9914390 9914304 9914305 9914227 9914228 9914217 9914218 9914254 9914255 9914317 9914318 9914312 9914313 9914464 9914465 9914373 9914374 9914420 9914421 9914416 9914417 9914368 9914369 9914356 9914357 9914341 9914342 9197
GENERAL INFORMATION
GENERAL INFORMATION
1994 Storm (EC80PL01) Piston Replacement
1994 XCR 600 Piston Cracking, Fuel Pump Relocation, Carburetor Jetting
1995 XC R 600
1. Oil Delivery Line Routing for Magneto (RH) Cylinder
2 Choke Lever Breaking Due to Incorrect Inner Cable Length
1995 XCR 440 Cylinder Head a - Rings leaking
1994 XLT SP XTRA ,1995 XLT SP, RXL Show Machines - IFS Shock and Rear Suspens ion Replacement (on all listed models); Head Gasket Repla ce ment, Fuel Pump Relocation and Carburetor Main Jet Change on XLT Models Only
1995 XLT Tour ing Circuit Breaker Wire may Contact Exhaust Outlet
1. 1995 XCR 600 Front Bolt Installe d Incorrectly on Steering Drag Link
2. 1995 RXL Exhaust Manifold Flange Angle Incorrect
Bottom Chalncase Sprocket Washer Replacement (See Models Listed on Bulletin)
1995 XLT Tunnel Wear Strips in Wrong Holes
1995 XCR 600 Steering Stops Incorrect
1995 XLT Touring - Circuit breaker wire may contact exhaust outlet (Additional Serial #'s)
1995 XC R 440 SP - Reinforced rear torque arm available
1995 XCR 440 SP - Steering stop kit available
1995 XC R 550 - PTa end crankshaft failure
S-95-05 S-95-06
1995 RXL , X LT SP - Durability Im provement kit
1995 Indy 500 , 500 EFI, 500 EFI SKS , 500 EFI SKS PT, Classic, WideTrak LX - PTa end crankshaft failure
1995 440 and 440 SKS, Helix In Driven Clutch
1. 1995 RXL and XLT SP Reverse Gear Base Kit Information
2 All Models using Reverse Gear Base Kit PN 2871154 or PN 2870861 - Pin ion Shaft
Diameter
XLTa nd XCR Models with EC58PL02, 03 and E04 Eng ines - Coolant Leak at Spark Plug Cavity
1995 XC R 600 Coolant Line may Contact Brake Disc
1995 RXL and RXL Touring - Coolant Line may Contact Brake Disc
1995 X CR 440 SP XTRA-1 0 Scissor Stop Alignment
1-94-09 1-94- 10 1-94-11 1-95-01 1-95-02 1-95-03
1995 RXL and XLT SP - XT RA 12 Suspens ion Adjustments and General Information
1995 RXL and RXL Touring - Hesitation or Bog when Accelerating
All 1995 Models - Loose Rear Suspension Bolts.
All 1995 Models Except XCRs - Seat Stain Removal
1995 Storm/ Storm SKS - O il Supply Line May Kink Near Steering Post
1996 XLT SP - Wrong Fuel Octane Called Out On Spec ification Decal
1996 X LT - Front Muffler Damper Location
Polaris Industries Inc.
S-94-04 S-94-05 S-94-06 S-94-07 S-94-08 S-94-09
Bulletin Index Service Bulletins S-94-03
S- 94-10 S- 94-11 S-94-12 S-95-01 S-95-02 S-95-03 S-95-04
1-94-05 1-94-06 1-94-07 1-94-08
Information Bulletins 1-94-03 1-94-04
1-95-04 11/95
1.2
Se rv ic e Bu ll etin s
1994 Storm (EC80PL01) Piston Replacement
1994 XCR 600 Piston Cracking , Fuel Pump Relocation, Carburetor Jetting
1995 XCR 600
1_ Oil Delivery Line Routing for Magneto (RH) Cylinder
2_ Choke Lever Breaking Due to Incorrect Inner Cable Length
1995 XCR 440 Cylinder Head O-Rings leaking
1994 XLT SP XTRA, 1995 XLT SP, RXL Show Machines - IFS Shock and Rear Suspension
Rep lacement (on all listed models); Head Gasket Replacement , Fuel Pump Relocation and Carburetor Main Jet Change on XLT Models Only_
1995 XLT Touring Circuit Breaker Wire may Contact Exhaust Outlet
1. 1995 XCR 600 F ront Bolt Installed Incorrectly on Steering Drag Link
2_ 1995 RX L Exhaust Manifold Flange Angle Incorrect
Bottom Chaincase Sprocket Washer Replacement (See M ode ls Li s ted on Bulletin)
1995 XLT Tunnel Wear Strips in Wrong Holes
1995 XCR 600 Steering Stops Incorrect
1995 XLT Touring - Circuit breaker wire may contact exhaust outlet (Additional Serial #'s)
1995 XCR 440 SP - Reinforced rear torque arm available
1995 XCR 440 S P - Steering stop kit available
1995 XCR 550 - PTO end c rankshaft failure
1995 RXL, XLT SP - Durab i lity improvement kit
1995 Indy 500, 500 EFI , 500 EFI SKS, 500 EFI SKS PT, Classic, WideTrak LX - PTO end crankshaft failure
1996 Ultra - Recoil Hub Cracking on EC68PL-Ol Eng i nes
08
S-95-10 S-95-11 S-95-12 S-95-13 S- 95-14 S-95-15
S-95-16
S-95-17
S-95-18
S-96-01
S-96-02
S-96-03
S-96-04
S-96-05
S-96-06 S-96-07
Trail Touring - Wrong Pinion Gear Installed in some Trail Touri ng Chaincases
1996 Trail Touring - Throttle Cable End s May be Rever sed on Some Trail Touring Model s
1996 Ultra - Kinked Oil Lines
1996 XLT RMKlSKS and Sport Touring - Snow Skirts Cracking Around Mounting Boss
1996 WideTrak GT/ LX-Handl eba r Damage When Opening and Closing the Hood
1994 Storm/Storm SKS - Cooling System Update Kit
1995 Storm/Storm SKS - Cooling System Update KiVEng ine Upd ate Kit
1995 XLT SP (48" Stance)_ Trail, XLT SKS - Safety Alert - Fuel Tank Cracks
1996 Storm RMK - Head Gasket Change to Prevent Piston Damage
1996 Ultra SP - Low Oil Level in Water Pump Drive Gearcase
1996 Ultra SP, Ultra SKS, Ultra RMK - Exhaust Thermal Sensing System Testing
1996 XLT Touring, Classic Touring - Front To rque Arm Shaft Ret ention Kit
1996 Storm, Storm SKS , Storm RMK , 600 XCR SP - Sharp Edge o n Engin e Mount Plate May Damage Water Trap
1996 Storm (Euro) , Sto rm SKS, Storm RMK - Revis ed Ignition Timing Specification and Carbu retor Adjustment
1996 Storm , Storm SKS , Storm RMK - Mag ( RH ) Exhaust Pipe Support Bra cket Ma y Crack and Separate from Pipe
1996 XLT Tou ring , Classic , Classic To ur ing, 500 , 500 SKS , 500 RMK , 500 EFI , 500 EFI SKS , 500 EFI RMK , Tra il , Tra il Touri ng , 440 - Handlebar Welds Missing or Incomplete
199 4 Storm , Storm SKS. 1995 Storm, Storm SKS - Coo lant Tank Expansion May Impair Brake Operation
1995 Trail, XLT SP (48" Stance), XLT SKS - Cracked Fuel Tanks; Reminder to perform Safety Alert S-95-15
GENERAL INFORMATION Bull etin Ind ex - By Num be r
S-94-03 S-94-04 S-94-05 S-94
S-94-07 S-94-08 S-94-09 S-94-10 S-94-11 S-94-12 S-95-01 S-95-02 S-95-03 S-95-04 S-95-05 S-95-06 S-95-07 S-95-
S-95-09
-06
Polaris Industries Inc 1. 2a 9/97
S-97-03
S-97-04
S-97-05
S-97-05R
S-97-06
S-97-07
1996 XLT Touring , Classic Touring - Increased Rear Handwarmer Heat
1996 Ultra RMK - Improved Running Quality and Snowmobility
1996 Ultra SP, Ultra SKS, Ultra RMK, 600 XCR, Storm, Storm SKS, Storm RMK - Impro ved Clutch Alignment
1997 440 XC - Front Track Shock Reservoir Clamps Installed Incorrectly
1997500 RMK - Incorrect Throttle Lever
1996 RMK Models - Ski Replacement Program
1997 Lite Dlx .; Trail Trng. ; Classic Trng .; XLT Trng. ; Ultra Trng. ; WideTrak LX - Loose Starter Ring Gear Screws
1997 Ultra Touring - Aluminum Tape On Speedometer Cable May Contact Battery
1997 XLT LTD SP - Inc o rrect Main Jets Installed In Carburetors
1997 Ultra ; Ultra SP (and Euro Models) - Oil Supply Line May Kink Below Oil Filter
1997 Sorm, Storm SE, Storm RMK - Coolant Check Valve I Filter Assembly Installed Incorrectly
1997 Ultra Touring - Hood Interference With Reverse Cable
1997 700 RMK - Insufficient Clearance Between Exhaust Pipe And Ho od
1997 XLT RMK - Rich Condition I Poor Fuel Economy
1997 440 XCR - Fuel Line And Water Trap Abrasi o n
1997 WideTrak GT/ LX (Including European) - Transmissi on Oil Leaks I Transmission Hard To Shift
1997 440 XCR - Cracked Or Broken CDI Wires
1997 700 SKS, RMK - Coolant Hose May Contact Recoil Housing
1997 WideTrak LX , GT - Transmission Not Engaging Or Sticking In Gear
Safety Alert - 1997 440 XC, XCF - Pitman Ann Weld Failure
Safety Alert - REVISED - Refer to S-97 -05R Below
Safety Alert - 1997 CRC Models and 1998 Show Machines (Refer to Bulletin For Specific Mode ls)
Pitman Arm Weld Failure
1997 440 XCR - Engine Update Options
1997700 XC, SKS , RMK - Durability Improvement Kit For Oil Pump and CDI Mod ule
1. Oil Tank Fittings Leaking on: 1994 Indy Lite, Lite GT, Lite Deluxe , StarLite, StarLite GT
2 Indic ator Lights that Pop out of Console on 1994 500 EFI
Rear Torsion Springs may Rub Against Track Carrier Wheel
- 12
Carburetor Jetting Recommendations for Kit PN 2200509
Water Traps on 1994 600 XCR, 400 XCR SP, StarLite, StarLite GT
1. 1994 Storm, Storm SKS may Enc o unter a Rich Condition on Ro ugh Terrain
2. 1994600 XCR Carburetor May Rub Against Torque Stop Mounting Bracket
1995 440 and 440 SKS , Helix In Driven Clutch
1. 1995 RXL and XLT SP Reverse Gear Base Kit Information
2. All Models using Reverse Gear Base Kit PN 287 11 54 or PN 2870861 - Pini on Shaft Diameter
XLT and XCR Mode ls w ith EC58PL02, 03 and E04 Eng ines - Coolant Leak at Spark Plug Cavity
1995 XCR 600 Coolant Line may Contact Brake Disc
1995 RXL and RXL Touring - Coolant Line may Contact Brake Disc
1995 XCR 440 SP XTRA-1 0 Scissor Stop Alignment
1995 RXL and XLT SP - XTRA 12 Suspension Adjustments and General Information
1995 RXL and RXL Touring - Hesitati o n or Bog when Accelerating
All 1995 Model s - Loo se Rear Suspension Bolts.
All 1995 M ode ls Except XCRs - Seat Stain Removal
1.2b Polaris Industries Inc
Bulletin Index - By Number Service Bulletins, Cont. S-96-08 S-96-09 -5 -96-10
GENERAL INFORMATION
S-96 11 S- 96-12
S-96-13 S-96-14 S-96-15 S-96-16 S-96-17 S-96-18 S-96-19 S-96-20 S-96-21 S-96-22 S-96-23 S-97-01 S-97-02
1-93-10 1-93-11
1-94-01 1-94
1-94-03 1-94-04 1-94-05 1-94-06 1-94-07 1-94-08 1-94-09 1-94-10 1-94-11 1-95-01 9/97
Information Bulletins
1-93
-02
1996 XLT SP - Wrong Fuel Octane Called Out On Specification Decal
1996 XLT - Front Muffler Damper Location
1995 XLT Touring - Revised Ca rburetor Jetting for Low Elevat ion
1995 Indy 500 and 1995 Classic - Revised Carburetor Jetting for Low Elevation
1996 XLT RMK , 500 RMK , 500 EFI RMK - 19 Tooth Top Sprocket Required for Reverse Kit Ins tallation
1996 Ultra RMK - Carburetor Jetting and Fue l Recommendat ion for Operation Below 6000 ft. (1800 meters)
1996 Ultra RMK - Kinked Coolant Hose
1996 XLT Touring / Classic Touring - Nut Serts " Missing from Back Rest Brackets
1996 Storm (Euro), Storm SKS , Storm RMK - Main Wire Harness/ Brake Light Wire Harness Position
1996 600 XCR SP, Ultra, Ul t ra SKS , Ultra RMK - Sharp Edge on Hardware Mounting Bracket
1996 XLT, XLT SP, XLT SKS , XLT RMK, XLT Touring, 600 XCR, and European ModelsRestricted Coolant Filter
1996 All Models with P-85 Driven Clutch - Bogging or Belt Slippage
1996 XLT RMK , Ultra RMK, 500 RMK , 500 EF I RMK - Optional Setup f or Deep Snow Perlormance
1996 Storm, Ultra SP, 600 XCR SP, 600 XCR , 500 Carb, Trail, 440 XCR SP, 440 XCR, 440 , Super Sport - Loose Front Torque Arm Bolts
1996500 ,500 SKS (Euro), 500 RMK , ClaSSiC, Classic Touring (Euro) - Ho se Clamp Tabs May
Damage Coolant Line
1996 600 XCR SP, Ultra RMK - Improved H igh Elevation Perlormance
1996600 XCR SP - Improved Low End Pertormance at Low Elevations (0-3000 ft /0-900 m)
1996 All Models with XTRA-10 Rear Suspension - Loose Track Carrier Wheel Lock Collar
1996 Ultra SP, SKS, RMK - Cracked Exhaust Pipes
1996 XLT (All) and 600 XCR - Extended Warranty On 1996 EC58PL Engines
1996 XLT Touring, Classic Touring - Slide Rail Beam Repair Kit
1996 440 and 500cc Liquid Twins (Except 440 XCR and 440 XCR SP) - Oil In Fue l Pump Impulse Line
1997 XLT RMK - Incorrect Information On Specification Deca l
All Models With CRC Front Suspension - Steering Alignment During Setup
1997600 XC, XCR, SE; Ultra SPX , SPX SE - Incorrect IFS Shock Spring Pre-l oad
1997 Super Sp o rt; 600 XC - Nose Cone Decal Placement
1997 600 XCR SE; Ultras (All) - Pinched Fuel Line
1997 XLT LTD , LTD SP; RXL ; Storm, SE, RMK - 15 Wide Reverse Gear Kit In sta llation
1997 Classic Touri ng - Incorrect Tors ion Bar
1997 Storm (All Including European M odels) - Tight Belt-To-Sheave Clearance
1997600 XCR, SE ; Ultra S PX , SPX SE; (And All Euro Models ) - Poor PTO Exhaust Pipe Fit
1997 700 RMK ; SKS - Revised Oil Injection Pump Bleeding Procedure
1996 600 XCR SP; Ultras ; Storms - Recommendations For 1996 High Perlormance Models
1997 WideTrak LX - Coolant Hose And CDI Wire Routing
1997 Ultra SPX (Inc luding SE and Euro Mode ls) - PTO Oil Line Guide Clamp Positi on
1997 600 XCR, XCR SE; Ultra SPX, SPX SE ; (In clud ing Euro Models ) - Oil Line Damage At Fitting
1997 700 XC, SKS , RMK - Carburetor Calibration Changes
GENERAL INFORMATION Bu ll etin Index - By Number Inform atio n Bullet ins , Co nt. 1·95-02 1995 Storm/Storm SKS - Oi l Supply Line May Kink Near Steering Post '1-95-03 1-95-04 1-95-05 1-95-06 1-95-07 1-95-08 1-95-09 1-95-10 '1-96 -01 1-96 -02 1-96-03 1-96-04 1-96-05 - 1-96-06 1-96-07 '-1-96-08 1-96-09 - 1-96-10 1-96-11 - 1-96- 12 1-96-13 1-96-14 1-96-15
"--'
1-96-21 1-96-22 1-96 -23 1-96-24 1-96-25 1-96-26 1-96-27 1-96-28 1-96-29
1-96-16 1-96-17 1-96-18
1-96-19 1-96-20
Polaris Industries Inc. 1 2c 9/97
GENERAL I NFORMATI ON B
Notes
Imp roved Cl utc h A li g nm ent
Coolant Tank Expansio n
Exhaus t Pipe support Bracket May Crack
Rev ised Timing an d Carb uretor 8pecs.
8harp Edge On E ngine Mount
False Oil Level
Pisto n Fai lu re At Partia l Th rott le
Loose Whee l Lock Collars
Loose Front Torq u e Arm Bolts
Bogging or Belt slippage
Main Harness/Brake Light Harness Posi t ion
Heavy 8teering
Im proved Clutc h Alignment
Coo lant Tank Expansion
Exhaust Pipe support Bracket May Crack
Revised Timing and Carburetor 8pecs
8harp Edge On En gine Mount
Fa lse Oil Level
P is t on Failure At Partial Thrott le
Loose Wheel Lock Collars
Bogging or Belt slippage
Main Harness/ Brake Light Harness Position
Heavy 8teering
Aluminum Ski Rep lacement Program
Im proved Clutch A li gnment
Coolant Tank Expansion
Exhaust Pipe support Bracket May Crack
Revised Timing and Carburetor Specs
Sha rp Edge On Engine Mount
False Oil Level
Head Gasket Replacement
Loose Wheel Lock Collars
Bogging or Belt slippage
Main Harness/Brake Light Harness Position
Heavy Steering
Improved Clutch Alignmen t
Coolant Tank ExpanSion
False Oil Level
Exhaust Thermal Sensing 8ystem
Low Oi l Level In Water Pump Drive Gearcase
Kinked Oil Lines
Cracked Exhaust Pipes
Loose Whee l Lock Collars
- 1996 By Model 1996 Mode l Bulletin # 1996 In dy 8 torm 8 - 96 - 10 8 - 96 -06 8-96-04 8-96-03 8-96-02 8-95-22 8-95 -1 9 1-96-10 1-96-06 1-96-04 1-96 -01 1- 95 -13 1996 Indy 8torm 8K8 8-96 - 10 8 -96 - 06 8-96-04 8-96-03 8-96-02 8-95-22 8-95-19 1-96-10 1-96-04 1-96-01 1-95-13 1996 Indy 8torm RMK 8-96-13 8-96-10 8-96-06 5-96-04 5-96 -03 8-96-02 5-95-22 8 -95-16 1-96-10 1-96-04 1-96-0 1 1-95- 13 1996 Indy Ultra 8P 5 -96-10 8-96-06 8-95-22 8 -95-18 5-95-1 7 5-95- 10 1-96-11 1-96 - 10
Type Service 8afety Service Service Service Service Serv ice In f o Info In fo Info Info Service 8afety Service Service Service Service Service Info Info Info Info Service Service Safety Service Serv ice Service Service Service Info Info Info Info Service Safety Service Service Service Service Info Info
ulletin Index
9197
1.2d
Polaris
Inc.
Industries
GENERAL INFORMATION
Bulletin Index - 1996 By Model
Notes
L oose Front Torque Arm Bo lts
Bogging or Bell s lippage
Sharp Ed ge on Mounting Brackel
Heavy Stee ring
I mproved C l utch Alignmenl
Coo lant Tank Expansion
False Oi l Level
Exha ust Thermal Sensing Sys lem
Kinked Oil Lines
Cracked E xhaust Pipes
Loose Wheel L o ck Collars
Bogging or Bell s lippa ge
Sha rp Edg e on Mounting Brac ket
Heavy Steering
Aluminum Ski Repla ce ment Prog ram
Improved C lutch Alignment
Improved Running Quality & Snowmobili t y
Coolant Tank Expans ion
False Oil L evel
Exhaust Th ermal Sensing Sys tem
Kinked Oil Lines
Recoil Hub Cracking
Cracked Exhaust Pipes
L oose Wheel Lock Collars
Improv ed H igh Elevation P e rtormance
Optional Setup tor Deep Snow Pertormance
Bogging or Bell s lippage
Sharp Edg e on Mounting Bracket
Improved Snowmobility In Deep Snow
Heavy Steering
Kinked Coolant Hose
Ca rb & Fu e l Recomm e ndations for High Alt.
Bogging or Belt Slippage
Heavy Steering
Improved Clutch Alignment
Coo lant Tank Exp a n s io n
Sharp Edge On Engine Mount
F alse O il Level
L oose Wheel Lo c k Co llars
Improved Low End Performance-Low Alt.
Improv ed High Alt. Performance
Loose Front Torque Arm Bolts
Bogging o r Belt slippage
Model Bulletin # Type 1996 Indy Ultra SP, (ca nt. ) 1-96-06 In to 1-96-04 Info 1-96-02 Info 1-95-13 In fo 1996 Indy Ultra SKS S-96- 1 0 Service S-96-06 Safety S-95-22 Service S-95 -1 8 Service S-95-10 Service 1-96 -11 Info 1-96-10 Info 1-96-04 Into 1-96-02 Inlo 1-95-13 I nfo 1996 Indy Ultra RMK S-96-13 Service S-96-10 Service S-96-09 Service S-96-06 Satety S-95-22 Serv ice S -95-1 8 Serv ice S-95-10 Service S-95-07 Service 1-96-11 Into 1- 96- 10 Into 1-96-08 In fo 1- 96-05 In fo 1-96-04 In to 1-96-02 I nto 1-95-15 Info 1-95-13 In to 1-95-09 Into 1-95 -08 Into 1996 RXL 1-96-04 Info 1-95-13 Into 1996600 XCR SP S-96-10 Service S-96-06 Satety S-96-02 Service S-95-22 Service 1- 96-10 I nto 1-96-09 Into 1- 96 -08 Into 1-96-06 In to 1-96-04 Into Polaris Industrie s Inc 1 2e
1996
9/97
GENERAL INFORMATION
Notes
Sharp Edge o n Mounting Bracket
Heavy Steering
Se tup Recommendations
Extended Warranty on 1996 EC5BPL Engines
Loose Wheel Lock Collars
Loose Front Torque Arm Bolts
Bogging o r Belt s l ippage
Restricted Coolant Filter
Heavy Steering
Aluminum Ski Replacement Program
Snow Skirts Cracking Around Mounting Boss
Extend ed Warranty on 1996 EC5BPL Engines
Loose Wheel Lock Collars
Optional Setup for Deep Snow Performance
Bogging or Belt slippage
Restricted Coolant Filter
Heavy Steering
19 Tooth Top Sprocket For Reverse Kit
Extended Warranty on 1996 EC5BPL Engines
Bogging or Belt slippage
Restricted Coolant Filter
Heavy Steering
Wrong Octane Ca llout on Specification Decal
Snow Skirts Crack in g Around Mounting Boss
Extended Warranty on 1996 EC5BPL Engines
Loose Wheel Lock Collars
Bogging or Bell slippage
Restricted Cool ani Filter
Heavy St eering
Extended Warranty on 1996 EC5BPL Engines
Bogging or Bell slippage
Restricted Coolant Filter
Heavy Steering
Front Muffler Damper Installation Location
Increased Rear Ha ndwarmer Heat
Handle Bar Welds Missing or Incomp lete
Front Torque Arm Shaft Retent io n Kit
Slide Rai l Beam Repair Kit
Extend e d Warranty on 1996 EC5BPL Engines
Bogging or Belt slippage
Restri c ted Coolant Filter
Heavy Steering
Nut Sert™ Mi ssIng From Back R est Bra cket Po/arts
Bulletin Index -1996 By Model 1996 Model Bulletin # 1996600 XCR SP (cant.) 1-96-02 1-95-13 1-95-1 1 1996600 XCR 1-96-12 1-96-10 1-96-06 1-96-04 1-96-03 1-95-13 1996 Indy XLT RMK S-96-13 S-95-11 1- 96- 12 1- 96 - 10 1-96-05 1-9 6-04 1-96-03 1-95-13 1-95-07 1996 XLT SP 1-96-12 1-96-04 1-96-03 1-95-13 1-95-03 1996 XLT SKS S-95- 11 1- 96-12 1-96-10 1- 96-04 1- 96-03 1-95-13 1996 XLT 1-96-12 1- 96-04 1-96-03 1-95-13 1-95-04 1996 XLT Touring S-96-0B S-96;05 S-96-01 1-9 6- 13 1-96-12 1-9 6-0 4 1-96-03 1-95-13 1-9 5- 10 9/97 Type Info Info Info Info Info In f o Inf o Info Info Service Service Inf o Info Info Info Inf o Info Inf o Inf o Inf o Info Info Info Service Info Info Inf o Info Info Inf o Info Info Inf o Info Service Safety Service Info Info Inf o Info In fo In f o 1 .21
Industrtes In c.
GENERAL INFORMATION
Bullet in I ndex - 1996 By Mode l
Notes
Handle Bar Welds Missing or Incomp lete
Oi l In Fuel Pump Impu lse Line
Hose Clamp Tab May Damage Coolant Line
Bogging or Belt slippage
Heavy Steering
Increased R ear Handwarmer Heat
H and le Bar We l ds Missing or Incomple te
Front To rque Arm S haft Rete ntion Kit
Oil In Fuel Pump Impulse Line
Slide Rail Beam Repair Kit
Hose Clamp Tab May Damage Coolant Line
Bogging or Belt slippage
Heavy Steering
Nut Sert'" Missing From Back Rest Bracket
Aluminum Ski Rep lacement Program
Han d le Bar Welds Missing or Incomplete
O il In Fue l Pump Impu lse Line
Loose Wheel Lock Collars
Hose Clamp Tab May Damage Coolant Line
Opt io nal Setup for Deep Snow Performance
Bogging or Belt slippage
Heavy Steering
19 Tooth Top Sprocket Required For Reverse Kit
Aluminum Ski Replacement Program
Handle Bar Welds Missing or Incomplete
Loose Wheel Lock Collars
Optional Setup for Deep Snow Performance
Bogging or Belt slippage
Heavy Steering
19 Tooth Top Sprocket Required For Reverse Kit
Handle Bar Welds Missing or Incomplete
Loose Wheel Lock Collars
Bogging or Belt slippage
Heavy Steering
Handle Bar Welds Missing or Incomplete
O il In Fuel Pump Impulse Line
Loose Wheel Lock Collars
Hose Clamp Tab May Damage Coolant Line
Loose Fronl Torque Arm Bolts
Bogging or Belt slippage
Heavy Steering
Handle Bar Welds Missing or Incomplete
0,1 In Fuel Pump Impulse Line 9;97
1996 Mo d el Bu ll etin # Type 1996 Indy Classic S-96-05 Safety 1- 96-14 Info 1-96-07 Info 1-96-04 Info 1-95-13 Info 1996 Classic Touring S-96-08 Service S-96-05 Safety S -96-01 Service 1-96-14 Info 1-96-13 Info 1-96-07 Info 1-96-04 Info 1-95-13 Info 1-95-10 Info 1996 Indy 500 RMK S-96-13 Service S -96-05 Safety 1-96-14 Info 1-96-10 Info 1-96-07 Info 1-96-05 Info 1-96-04 Info 1-95-13 Info 1-95-07 Info 1996 Indy 500 EFI RMK S-96-13 Service S-96-05 Safety 1-96-10 Info 1-96-05 Info 1-96-04 Info 1-95 - 13 Info 1-95-07 Info 1996 Indy 500 EFIISKS S-96-05 Safety (SKS Only) 1-96-10 Info 1-96-04 Info 1-95-13 Info 1996 Indy 500 S-96-05 Safety 1-96-14 Info 1-96-10 Info 1-96-07 Info 1-96-06 Info 1-96-04 Info 1-95-13 Info 1996 Indy 500 SKS S-96-05 Safety 1-96-14 Info Polaris Industries Inc. 1.2g
GENERAL INFORMAT ION
or Belt slippage
Info Heavy Steering
Info Loose Wheel Lock Collars
Info L oose Front Torque Arm Bolts
Info Bogging or Belt slippage
Info Heavy Stee ring
Service Loose Shock Eyelet On Fox Shocks
fo Loose Whee l Lock Collars
fo L oose Front Torque Arm Bolts
Bogging or Belt s lippage Info Jett ing and Clutching For Improved Perf
Heavy Steering Info Exhaust Pipe May Contact Hood
Safety Handle Bar Welds M issing or Incomplete
Info Loose Wheel Lock Collars
Info Oil In Fuel Pump Impu lse Line
In f o Loose Front Torque A rm Bolt s
Info Bogging or Belt s l ippage
In fo Heavy Steering
Service Hand lebar Damage When Opening Hood
Info Bogging or Belt s lippage
Info Oil In Fuel Pump Impulse Line
Safety Handle Bar Welds Missing or In co mplete
Info Loose Wheel Lock Collars
Info Loose Front Torque Arm Bolts
Info Bogging or Belt slippage
Info Heavy Steering
Safety Handle Bar Welds Missing or Incomplet e
Service Thrott le Cable Ends May Be Reversed
Service Wrong Pinion Gear In Chaincase
Info Loose Wheel Lock Collars
Info Bogging or Belt slippage
Info Heav y Steering
Info Loose Wheel Lock Collars
Info Loose Fronl Torque Arm Bolts
Info
Heavy Steering
Service Snow Skirts Cracking Around Moun ling Boss
Info Loose Whee l Loc k Collars
Info Heavy Steering
Info Heavy Sleering 1
Bulletin Index - 1996 By Mode l 1996 Mode l Bu ll etin # 1996 Indy 500 SKS (c ont. ) 1-96-10 1-96 -07 1-96-04 1 - 95 - 13 1996 Indy 440 XCR 1-96- 10 1-96-06 1-96-04 1-95-13 1996 Indy 440 XCR SP S-95- 20 1-96-10 1-96 -06 1-96-04 1-95-14 1-95 - 13 1-95-12 1996 Ind y 440 S-96-05 1-96-10 1-96-14 1 - 96-06 1-96-04 1-95-1 3 1996 Indy Widetrak GTI LX S-95-12 1-96-04 (LX Only) 1-96-14 1996 Indy Trail S-96-05 1-96 - 10 1-96-06 1-96-04 1-95- 13 1996 Indy Trail Touring S-96-05 S-95-09 S-95-08 1-96-10 1-96-04 1-95-13 1996 Indy Super Sport 1-96-10 1-96-06 1-95 - 13 1996 Indy Sport Touring S -95-11 1-96- 10 1-95-13 1996 Sport and Liles 1-95-13 9197 Type Notes Info Loose Wheel Lock Co ll ars Info H ose Clamp Tab May Damage Coolant Line Info Bogging
In
In
Info
Info
2 h
Polaris Industries Inc.
GENERAL INFORMATION
Installed Incorrec tl y
Pitman Arm We l d Failure and Pitman Arm to Steering Rack Bolt Replacement
Alert - Refer to 5-97-05B
Service Coolant Hose May Co ntact Recoi l Hou si ng
Info Re vised Oil Pump Bleeding Procedure
Servjce Insuffi c ient Clearance Between Exhaust Pipe and Hood
Info Carburetor Calibrat ion Changes
Service Durability Improvemen t Kit fo r Oi l Pump and COl
Alert Pitman Arm Weld Failure and Pitman A rm to Steering Rack Bolt Repla cemen t
,J!lert - Refer to 5-97- 05B
Service Pitman Arm Weld Failure and Pitman Arm to Steering Rack Bolt Replacement
,J!ler1 - to S-IH-QliR
Service Oil Suppl y Line May Kink Be l ow Filter
Service Hood Interference With Reve rse Cab le
Serv ice Aluminum Tape On Speedometer Cable May Contact Battery
Service Electric Start - Loose Starter Ring Gear Screws
Service Oil Supp ly Line May Kink Below Filter
A/fl d Pitman Arm Weld Failure and Pitman Arm to Steering Rack Bolt Rep lacement
Safetll. Alflrt - Refer to 5- 97-05R
Alert Pitman Arm Weld Failure and Pi tm an Arm to Steering Rack Bolt Replacement - to S-97-05R
Service Rich Condition I Po or Fuel Economy
Service Incorrect Main Jets Installed In Carburetors
Service Electric Start - Loo se S tart er Ring Gear Sc rews
Service A lum inum Sk i Repl ace ment Program
Service Inco rrect Throttle Leve r
1997 Model Bulletin # 1997 Storm I SE S-96-1 8 1997 Storm RMK S-96-18 1997700 (S KS and RMK) S-97-0SR S- 97-0S S-97-02 1-96-24 (RMK Only) 5-96-20 All 700s (XCISKSIRMK) 1-96-29 S-97-07 1997 Ultra SPx/SE S-97-0SR S-97-0S 1997 Ultra SP (Euro) S-97-0SR S-97-0S S-96-17 1997 Ultra Touring S -96-19 S -96 -1 S S-96-14 1997 Ultra (Euro) S-96-17 1997 RXL 1997 600 XCR I SE S-97-0SR S -97-0S 1997600 XC S-97-0SR S- 97 -0S 1997 XLT RMK S- 96-21 1997 XLT LTD I LTD SP S-96-16 1997 XLT Touri ng S-96-14 1997 XLT SP 1997 XLT SKS 1997 XLT 1997500 EFI 1997500 UC 1997500 RMK S-96-13 S-96-12 1997500 SKS Polaris Industries Inc. Type Serv ice Service ,J!hld Notes
Bulletin Index - 1997 By Model Coolant Check Valve I Filter Assembly In sta ll ed Inc o rr ec tl y Coolant Check Valve I Filter Assembly
1.2 i 9 197
Service El ect ri c S tart - Loose S tarter Ring Gea r Screws
Service El ect ric Start - Loose Starter Ring Gear Screws
Service Transmission Not Engaging or Sticking In Gear
Service Tran sm ission Oil Lea ks I Hard To ShiH
Service Transmission N ot En gaging or St icking In Gear
Serv ic e Transmission Oil Leaks I Hard To ShiH
Service El ect ri c Start - Loose Starter Ring Gear Sc rew
Serv ice Engin e Kit opt ions
Serv ice Cracked or Broken CO l Wires
Serv ice Fuel Line And Water Trap Abrasion
Pitman Arm Weld Failure
Service Front Tr ack Shock Reservoir Clamps Ins talled In correc tl y
Safetk'. Pitman Arm Weld Failure
Service Electric Start - Loose Starte r Ring Gear Screws
Serv ice Electric - Loose Starter Ring Gear Screws
Bulletin Index -1997 By Model 1997 Model Bulletin # 1997 Cl ass ic S-96 -1 4 1997 Class ic Touring S-96- 14 1997 Widetrak GT S-97-0 3 S-96-23 1997 Wid etrak LX S-97-03 S-96-23 S-96-14 1997440 XCR S- 97-06 S-97-01 S-96-22 1997440 XC S-97-04 S-96-1 1 1997 440 UC 1997 XCF S-97-04 1997 Trai l Touring S-96-14 1997 Trai l 1997 Sport 1997 Super Sport 1997 Sport Touring 1997 Transport 1997 lite 1997 lite Deluxe S-96-14 1997 Lite GT 9/97 Type Notes
GENERAL INFORMATION
1 2j Polaris Industries Inc.
1998 Model
Notes
Pitman Arm Weld Failure And Pitman Arm to Stee ri ng Rack Bolt Replacement
- Refer To S-9 7- 05R
Pitma n A rm Weld Failure And Pitman Arm to Stee ri ng Rack Bolt Replacement
- Refer To S -97- 05.R
Pitman Arm Weld Fai l ure And Pitman Arm to Steering Rack Bolt Replacement
t. l gd - Refer To S -97-Q5 R
Pit man Arm Weld Fai l ure And Pitman Arm to Steering Rack Bolt Replacement
Algrt - Rgfer To fi.-fl7-Q5B
ll&.d Pi t man Arm Weld Failure And Pitman Arm to Steering Rack Bolt Replacement
t. le d - Refer [0 S -fl7-Q5B
LX
Storm
700
700
600
600
Classic
Widetrak
Trail Trail
Trail
700 XC
XCR
RMK U ltra U lt ra Tou ring 600 XC
XCR
RMK XLT SP XLT Ltd XLT C l assic XLTTou ring SOO SOO RMK C lassic
Touring
Touring
RMK 440
Sport Super
Sport Touring Transport Lite Lite
Lite Touring Polaris Industries Inc. Bulletin # S-97-0SR S-97- 0S S-97-0SR S-97-0S S-97-0SR S-97-0S S-97-0SR S-97-0S S-97 -0SR S-97-0S Type Alert t.l gd Aled t. /ert
- 1998
4 40 XCR XCF
Sport
De l uxe
GENERAL INFORMATION Bulletin Index
By Model
1 .2k 9[97
Service Videos P",d NumQer Description 9914394 Advanced Carburetion 9912776 Fuel System Diagnostics 9913987 Polaris Variable Transm issions 9914171 Customer Service 9912996 Magnum 4 Stroke Int roduction 9913278 Charging System Diagnost ics 9913533 Ignition System Diagnostics 9913684 Snowmobile Suspension Service Polaris Industries In c. 1.3 GENERAL INFORMATION Service Videos 9/97
GENERAL INFORMATION
1996 Model Identification
SERIAL NUMBER IDENTIFICATION
The machineserial number may be used as an aid In identifying machine model year. Refertothe first digits in the seria l number for proper
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 rig ht 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 numb ers be called out. Laser engraved model and serial numbers are located on the crankcase (intake side).
Identification:
MODEL
YEAR DESIGNATlm'i-l-----------, ,---- ENGINE DESIGNATION MODEL DESIGNATION 1996 MODEL DESIGNATION NUMBERS (Chassis) 01 - Indy TranSport 02 - Indy Sport Tour ing 04 - Indy Sport 05 - Indy XLT SKS , Ultra SKS 06 - Indy Ultra SP 07 - Indy Super Sport, XLT, Storm 09 - Indy XLT RMK , Ultra RMK 16 - Indy 440 XCR, 600 XCR 20 -I ndy WideTrak GT/ LX 22 - Indy Trail Touring 25 - Indy 500 EEl SKS, 500 SKS 27 - Indy 440, Trail , 500 29 - Indy 500 RMK, 500 EEl RMK 31 - Indy Lit e GT 33 -Indy Classic Touring, XLT Touring 34 -Indy Lite, Lite Deluxe 37 - Indy 500 EEl 38 - Indy Classic 55 - Indy Storm SKS 56 - Indy 600 XCR SP 57 - Indy Storm 59 - Indy Storm RMK 66 -Indy XLT SP 67 - Indy XLT, RXL MODEL NO V.l. N. NO .
ENGINE DESIGNATION NUMBERS 33 - EC34-2PM02 43 - EC44-3PM01 , PM02 60 - EC45PL07, PL08, PL06 61 - EC50PM03, PM04 62 - EC50PM04 56 - EC58PL03, PL07 57 - EC58PLE05 64 - EC50PL11, PL15 , PLE12 65 - EC50PLE11, PL14 68 - EC65PL05 74 - EC50PL13 76 - EC58PL02 77 - EC59PL01 78 - EC68PL01 , PL04 82 - EC80PL05, PL04 31 - EC34-2PME02 MADE IN U.S.A. POLRRIS
info rmation PATENT NOTICE MId. by Polaris Indu8U'le, Inc: In ROMtU, MN under one or mol1l of the fol lowing patents: THIS VEHICLE CONFORMS TO ALL APPLICABLE U,S. FEDERAL AND STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE U S. Patents 3,805,511 3,1580,&47 3,483,785 3 ,1533,1582 3,1545,821 3,105,510 3,525,412 3,613,810 3,867,i91 4,n3,i50 11,038,881 5, 172,6711 5,OiO,38e 5,050,584 5,050,5&9 5,048,503 5 ,0515,482 5,0i9,813 5,074,211 5,1tl,531 3,813,811 PatenWC! canada 882,491nl 883,894(71 884.394n1 Caned Ian Rd. MFO. DATE: 34,573171 1,227,823187 7072133
EIRST DIGITS 26 MODEL YEA R 1996 1996
DESIGNATION
1996
Refer to Engine Section for more detailed
11/95 1.4 Polaris Industries Inc.
Indy Lite Indy Lite Deluxe
GENERAL INFORMATION
1996 Model Identification
Indy
0963433 0963431 Engine Type Fan Twin Fan Twin Engine Model Number EC34-2PM02 EC34-2PM02 Displacement (ee) 339 339 Bore x Stroke (mm) 62.3 x 55.6 62.3 x 55.6 CarouretionfThrotlle Body 2 Mlkuni 2 Mikuni VM30SS Slide VM30SSSIIde Oil Injected Standard Standard Ignition CDI CDI Alternator Output 12V 150W 12V 150W Length (in.lcm.) 1051266.7 105/2 66.7 Width (in1cm.) 42.5/ 108 42.51108 Height (in1cm.) 44 / 111.8 44/111.8 Ski Stance (i n .icm.) 37194 37194 Track Width (in1cm.) 15/ 38 1 15/38.1 Track Length Overall (in.icm.) 121/307 3 121/307.3 Fuel Capacity (U.S. gas l imp. gal./liters) 816.7/30.3 8/6.7/30.3 Recommended Fuel 87 Octane Min. 87 Octane Min. Front Suspension Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Rear Suspension Standard Standard Brake Type Mechanical Disc Mechanical Disc Storage Rear of Seat Rear of Seat Topol Hood Topol Hood Speedometer Standard Standard Tachometer N/ A N/A Electric Fuel Gauge N/ A NlA Aceessory Lights N/A Oil/Ace Electric Start Option Standard HandwarmersfThumbwarmer OptiOn/Option Single HeaUStd Seat Standard Lite Standard Lite Storage Rack Option Option Tow Hitch Option Option Polaris Industries Inc. 1.5
Lite
0963133 0960443 Fan Twin Fan Twin EC34-2PM02 EC44-3PM01 339 432 62.3 x 55.6 67.72 x 60 2 Mikuni 2 Mikuni VM30SS Slide VM34SS Slide Standard Standard CDI CDI 12V 150W 12V200W 1151292.1 106.251269.9 42.51108 43.51110.5 481121.9 44 / 111.8 37/94 38196.5 15138.1 15/38.1 133.5/339.1 121/307.3 8/ 6.7/ 30.3 10.7/8.9/40.5 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Standard Standard Mechanical Disc Hydraulic Disc Rear 01 Seat Rear of Seat Top 01 Hood Toolbox Footrest Standard Standard N/ A Option N/ A Option Oil/Ace OiliBrake Ace High Beam Option Option Single Heat/Std Single HeaUStd 2 Up Lite Standard Standard Option Standard Option 11 195
GT Indy Sport
GENERAL INFORMATION 1996 Model Identification
Indy Super Sport
Indy Indy 440 LC Sport Touring
Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionfThrottie Body Oil Injected Ignition Alternator Output Length (in.lcm.) Width (inJcm.) Height (i n .lcm.) Ski Stance (in.lcm.) Track Width (i n Jcm.) Track Length Overall (in.lcm.) Fuel Capacity (U.S. gas.llmp. gal.llite",) Recommendec Fuel Front Suspension Rear Suspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory lights Electric Start HandwarmersfThumbwarmer Seat Storage Rack Tow Hitch 11/95 Indy TranSport 0960143 Fan Twin EC44-3PMOI 432 67.72 x 60 2 Mikuni VM34SS Slide Standard COl 12V 200W I I 3/287 43.51110.5 45/114.3 38/96.5 15/38 I 141/358. I 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS Standard Hydraulic Disc Rear of Seat Toolbox Footrest Standard Option Option O i VBrake Acc High Beam Option Single HeaVAce 2 Up Option Option
0960743 Fan Twin EC44-3PM02 432 67.72 x 60 2 Mikuni VM34SS Slide Standard COl 12V200W 106.251269.9 45.5/115.6 38.5/97.8 411104.14 15/38. I 121/307.3 10.7/8 9/40.5 88 Octane Min Parallel Link Trailing Arm IFS XTRA 10 Hydraulic Disc Rear 01 Seat Toolbox Footrest Standard Standard Option OiVBrake Ace High Beam Option Single HeaVStd Standard Option O ption 1.6
0960243 0962760 Fan Twin LC Twin EC44-3PMOI EC45PL09 432 432 67.72 x 60 67.72 x 60 2 Mikunl 2 Mikuni VM34SS Slide VM34SS Slide Standard Standard COl COl 12V 200W 12V 200W 1131287 1081274.3 43.51110.5 46.5/118. I 50/127 46 /1 18.1 38/96.5 41 1104.14 15138. I 15/38. I 133.5/339. I 121 /3 07.3 10.7/8 .9 /40.5 10.7/8.9/40.5 87 Octane Min 87 Octane Min. Parallel Link Parallel Link Trailing Arrn IFS Trailing Arm IFS XTRA 10 XTRA 10 Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Toolbox Footrest Toolbox Standard Standard Option Standard Option Option Oi l/ Brake OiVBrake Ace Temp High Beam High Beam Option Option Single HeaVAcc Hi-Lo/Std 2 Up Short Option Option Option Option Polaris
Inc
Industries
Indy 440 XCR Indy 440XCRSP
GENERAL INFORMATION
1996 Model Identification
Indy
0961660 0961760 Engine Type LCTwln LCTwin Engine Model Number EC45PL07 EC45PL08 Displacement (ee) 439 439 Bore x Stroke (mm) 68 25 x 60 68.25 x 60 CarburetlonfTh rottJe Body 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide Oi l Injected Standard Standard Ignition COl COl Alternator Output 12V200W 12V200W Length (in.lcm.) 1091276 8 109/276.8 Width (in Jcm .) 46 51118.1 46.5/11 8.1 Height (in.lcm.) 38.5197.8 TBA Ski Stance (in.lcm.) 41/104 14 41 / 104 .1 4 Track Width (inJcm.) 15/ 38 1 15/38.1 Track Length Overall (i n Jcm.) 121/307.3 121/307.3 Fuel Capacity (U S. gas .ll mp. gal.niters) 9 .5/8 9 / 40.5 9.5 /8.9 / 40.5 Recommended Fuel 91 Octane Min. 91 Octane Min Front Suspension CRC CRC Rear Suspension XTRA 10 XTRA 10 Brake Type liquid Cooled TBA Hydraulic Disc Storage Rear of Seat Rear of Seat Speedometer Standard Option Tachometer Standard Standard Electric Fuel Gauge N/ A N/A Accessory Lights OiV8rake OiVBrake Temp/Acc Temp/Ace High Beam High Beam Electric Start Option Option HandwarmersfThumbwarmer Hi-Lo/ Std Hi-Lo/Std Seat 2 pc I Knee Pad 2 pc I Knee Pad Storage Rack Option Option Tow Hitch Option Option Polaris Industries Inc . 1.7
096276 1 0962262 Fan Twin Fan Twin EC50PM04 EC50PME04 488 488 72 x 60 72 x 60 2 Mikun i 2 Mikuni VM34SS Slide VM34SS Slide Standard Standard COl COl 12V 200W 12V 200W 114 / 289 5 1221309.8 46.51118.1 46.5/118/1 46/116.8 481121 9 41 /1 04 .14 41/104 14 15/38.1 15/38.1 121/307 3 133.5/339.1 10.718.9/40.5 10.7/8 9/40 5 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS XTRA 10 XTRA10 Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Toolbo x Toolbox Standard Standard Standard Option Option Option OiVB rake OiV8rake High Beam Hig h Beam Option Standard Hi-Lo/ Std Hi -Lo /S td Long 2 Up Option Option Option Option 11/95
Trail Indy Trail Touring
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