1985-1995 Polaris All Models Snowmobile Service Repair Manual (Highly Detailed FSM, Preview)

CHAPTER 1 MODELS AND SPECIFICATIONS 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 O 1988 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .11-1 .12 Model Identification (1989) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 1989 Models .. . ... .. .. .. ... . ... .. ...... . .................... . ... .. .... 1.1 4-1.16 Model Identification ( 1990) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 7 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

•• 111 .... .... 0 )

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 12 1985 1985 MODEL DESIGNATION YEAR DESIGNATION--------- -., ENGINE DESIGNATION I oasl o917 MODEL DESIGNATION __________ _.! 1985 MODEL DESIGNATION NUMBERS (Chassis) 07 - Indy Trail, 400, 600 08 - Indy 600 SE 09- Sta.r 13- SS 14 - LongTrack 1985 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single FC 43 - EC44-2PM-2100-Twin FC 49 - EC44-2PM-Twin FC 57 - EC60PL-02-Three LC 59 - EC40PL-02-Tw in LC MODEL NUMBER MACHINE DESCRIPTION MODEL NUMBER 0850757 MACHINE DESCRIPTION 0850927 0851349 0850743 0850759 Star 244cc Single FC SS 432cc Twin FC Indy Trail 432cc Twin FC Indy 400 398oc Twin LC 0850847 0851449 Indy 600 596cc Three LC Indy 600 SE 597cc Three LC LongTrack 432cc Twin FC MODEL NO. SERIAL NO. MADE IN U.S.A. POLARIS PATENT NOTICE THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND S, ,ae REiit llREMENTS ANO CANADIAN FEDERAL MC - ~ICLE STANDARDS IN EFFECT ON THE DATE c.,. J FACTURE. MFD. DATE: Mid. by Polaris lndl>stries L.P. In Roseau, MN under one or more of the fOl l oWing patoots: U.S. Parents 3.605.511 3.533.66:? 3,613,811 3,580,647 3,613,810 3,605,510 3.483.766 3.MS.821 3.5:?5,412 Patented Canada 882,491ni 883,694/71 Canadian Rd. 34.573171 34,572171 J.867.991 4.793.950 5.038,881 S64.394n1 1,227, 823187 7072133 These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is permanently stamped into the tunnel. The model number is embossed on the decal. Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved model and serial numbers are located on the crankcase (intake side). 1., 8/94

MODELS AND SPECIFICATIONS 1985 Model Identification 600SE 0850857 Engine Type LC Triple Displacement (cc) 597 Bore x Stroke (mm) 65x 60 Carburetion!Throttle Body 3 Mikuni VM38SS Slide Oil Injected Standard Ignition COi Alternator Output 12V 120W Length (in.fem.) 106.251269.7 Width (in.fem.) 41.62/105.6 Height (in.fem.) 31.5179.9 Ski Stance (in.fem.) 36.5/92.7 Track Width (in.fem.) 1 5138.1 Track Length Overall (in.fem.) 1211307.1 Fuel Capacity (U.S. galJlmp. galJliters) 715.8126.5 Recommended Fuel 88 Octane Min. Front Suspension Coil Spring IFS Chrome Trailing Arms Brake Type Uquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights Temp Electric Start NIA Handwarmers Option Two-Up Seat NIA Backrest NIA Storage Rack Option Tow Hitch Option 8/94 1.2 600 400 Long Track 0850757 0850759 0851449 LC Triple LC Twin Fan Cooled Twin 597 398 432 65 x 60 65 x 60 67.62 x 60 3 Mikuni 2 Mikuni 1 Mikuni VM38SS Slide VM34SS Slide VM30SSSlide Standard Standard Standard COi COi COi 12V 120W 12V 120W 12V 120W 106.251269.7 106.25/269.7 120.251305.2 41.621105.6 41 .621105.6 40 /101.5 31.5/79.9 31.5/79.9 33183.7 36.5192.7 36.5192.7 31/78.7 15/38.1 15138.1 15/38.1 1211307.1 1211307.1 1481375.6 715.8126.5 715.8/26.5 5.414.5120 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Mono Leaf Liquid Cooled Liquid Cooled Mechanical Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Storage Rack Standard Standard Standard Standard Standard Option Standard Standard Standard Temp Temp NIA ·N IA NIA NIA Option Option Option N/A NIA NIA NIA NIA NIA Option Option Standard Option Option Standard

Engine Type Displacement (cc) Bore x Stroke (mm) Carburetionff hrottle Body Oil Injected Ignition Alternator Output Length (in.fem.) Width (in.fem.) Height (in.fem.) Ski Stance (in.f em.) Track Width (in.f em.) Track Length Overall (in.fem.) Fuel Capacity (U.S. gal.limp. gal./liters) Recommended Fuel Front Suspension Brake Type Storage Speedometer Tachometer Trip Odometer Accessory Lights Electric Start Handwarmers Two-Up Seat Backrest Storage Rack Tow Hitch 1.3 MODELS AND SPECIFICATIONS 1985 Model Identification Indy Trail SS Star 0850743 0851349 0850927 Fan Cooled Twin Fan Cooled Twin Fan Cooled Single 432 432 244 67.62 x 60 67.72 x 60 72 x 60 1 Mikuni 1 Mikuni 1 Mikuni VM34SS Slide VM34SSS1ide VM30SS Slide Standard Standard Standard COi COi COi 12V 120W 12V 120W 12V 100W 106.25/269. 7 102/258.9 102/258.9 41.62/105.6 40/101.5 40 /101.5 31.5/83.7 33/83.7 33/83.7 36.5/92.7 31/78.7 31 178.7 15/38.1 15/38.1 15/38.1 121 /307.1 120 /304.6 108/274.1 7/5.8/26.5 6.815.7/25.7 5.4/4.5/20 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Mono Leaf Mono Leaf Hydraulic Disc Mechanical Disc Mechanical Disc Rear of Seat Rear of Seat Rear of Seat Standard Standard Option Standard Standard Option Standard Standard Option N/A NIA N/A Option Option N/A Standard Option N/A N/A NIA N/ A N/A N/ A N/A Option N/ A N/A Option Option Option 8/94 -

MODELS AND SPECIFICATIONS 1986 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 pr oper identification: FIRST DIGITS 12 13 MODEL YEAR 1985 1986 1986 MODEL DESIGNATION YEAR DESIGNATION '------- - - - -. 1 ENGINE DESIGNATION I a a 61 a 9 1 1 MODEL DESIGNATION ____ _ _____ ~I 1986 MODEL DESIGNATION NUMBERS IChassisl 07 - Indy Trail, 400, 600 08 - Indy 600 LE 09 - Star/Sprint 340 (ES) 13- SS 14 - LongTrack MODEL NO. SERIAL NO. 1986 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single EC 31 - EC34-2PM-01-Twin FC (ES) 33- EC34-2PM-02-Twin FC 49 - EC44-2PM-51 DO-Twin FC 57 - EC60PL-02-T riple LC 1986 ENGINE DESIGNATION NUMBERS 59 - EC40PL-02-Twin LC 61 - ECSOPM-01-Twin FC MADE IN U.S.A. PDLRRIS PATENT NOTICE Mfd.• by Polaris Industries LP . 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. in Roseau. MN under one or more ol lhe 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: These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. 3,867,991 4, 793,950 S.038,881 864,394171 1,227.823/87 7072133 The machine model and serial number identiflcatlon decal ls 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). 8/94 1.4

600 LE 0860857 Engine Type LC Triple Displacement (cc} 597 Bore x Stroke (mm) 65 x 60 Carburetionffhrottle Body 3 Mikuni VM38SS Slide Oil Injected Standard Ignition CDI Alternator Output 12V 120W Length (in.fem.} 106.25/269.7 Width (in./ cm.) 41.621105.6 Height (in.fem.} 31.5/79.9 Ski Stance (inJcm.) 36.5192.7 Track Width (in .f em.) 15/38.1 Track Length Overall (in.fem.) 121 /307.1 Fuel Capacity (U.S. gal.limp. galJliters) 7/5.8/26.5 Recommended Fuel 88 Octane Min. Front Suspension Coil Spring IFS Chrome Trailing Arm Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard - Accessory Lights Temp Electric Start NIA Handwarmers Option Two-Up Seat N/A Backrest N/A Storage Rack Option Tow Hitch Option 1.5 MODELS AND SPECIFICATIONS 1986 Model Identification 600 400 Long Track 0860757 0860759 0861449 LC Triple LC Twin Fan Cooled Twin 597 398 432 65 x 60 65 x 60 66.72 x 60 3 Mikuni 2 Mikuni 1 Mikuni VM38SS Slide VM34SS Slide VM30SS Slide Standard Standard Standard CDI CDI CDI 12V 120W 12V 120W 12V 120W 106.251269.7 106.25/269.7 , 20. 25/305.2 41.62/105.6 41.62/105.6 40/101.5 31.5/79.9 31 .5/79.9 33 183.7 36.5/92.7 36.5/92.7 3 1/78.7 15/38., 15/38.1 15/38.1 121 /307.1 1211307.1 148/375.6 7/5.8/26.5 7/5.8 /26.5 7.516.2/28 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Mono Leaf Liquid Cooled Liquid Cooled Mechanical Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Storage Rack Standard Standard Standard Standard Standard Option Standard Standard Standard Temp Temp NIA N/A NIA NIA Option Option Option N/A N/A NIA NIA N/A N IA Option Option Standard Option Option Standard 8/94

MODELS AND SPECIFICATIONS 1986 Model Identification Indy Trail SS 0860761 0861349 Engine Type Fan Cooled Twin Fan Cooled Twin Displacement (cc) 488 432 Bore x Stroke (mm) 72 x 60 67.72 x 60 Carburetion!Throttle 2 Mikuni 1 Mikuni Body VM34SS Sli de VM34SS Slide Oil Injected Standard Standard Ignition COi CDI Alternator Output 1 2V 120W 12V 120W Length (in.f em.) 106.25/269.7 102/258.9 Width 0n./ cm.) 41.62/105.6 40/101.5 Height (in.tern.) 3 1.5/79.9 33/83.7 Ski Stance (in.tern.) 36.5/ 92.7 3 1/78.7 Track Width (i n.t ern.) 15/38.1 15/ 38.1 Track Length Overall 121/307.1 120/304.6 (in.tern.) Fuel Capacity (U.S. 7/5.8126.5 7.516.2/28 gal./l mp. gal./liters) Recommended Fuel 88 Octane Min. 88 Octane Min Front Suspension Coil Spring IFS Mono Leaf Brake Type Hydraulic Disc Mechanical Disc Storage Rear of Seat Rear of Seat Speedometer Standard Standard Tachometer Standard Standard Trip Odometer Standard Standard Accessory Lights NIA NIA Electric Start Option Option Handwarmers Standard Option Two-Up Seat NIA NI A Backrest N/A NIA Stor a ge Rack Option NIA Tow Hitch Option Option 8/94 1.6 Sprint Sprint ES Star 0860933 0860931 0860927 Fan Cooled Twin Fan Cooled Twin Fan Cooled Single 339 339 244 62 x 55.6 62 x 55.6 72 x 60 2 Mikuni 2 Mikuni 1 Mikuni VM30SS Slide VM30SS Slide VM30SSSlide Standard Standard Standard CDI CDI CDI 12.V 120W 12V 120W 12V 100W 102/258.9 102/258.9 102/258.9 40/ 101.5 40/101.5 40/101.5 33/83.7 33 183.7 33 /83.7 31/78.7 31/78.7 31 /78.7 15/38.1 15138.1 15138.1 108/274.1 1081274.1 1081274.1 5.4/4.5120 5.414.5/20 5.4/4.5 120 88 Octane Miri . 88 Octane Min. 88 Octane Min. Mono Leaf Mono Leaf Mono Leaf Mechanical Disc Mechanical Disc Mechanical Disc Rear of Seat Rear of Seat Rear of Seat Option Standard Option Option Standard Option Option Standard Option NI A NIA NIA NIA Standard N/A Option Option NIA N/ A NIA NIA N/A N/A NIA N/A NIA NI A Option Option Option

MODELS AND SPECIFICATIONS 1987 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 12 13 14 MODEL YEAR 1985 1986 1987 1 987 MODEL DESIGNATION YEAR DESIGNATION 1 --------~1 ENGINE DESIGNATION I a a 11 o 9 j 1 MODEL DESIGNATION _ _________ ~I 1987 MODEL DESIGNATION NUMBERS !Chassis) 09 - Star/Sprint 340 (ES) 10 - StarTrak 1987 ENGINE DESIGNATION NUMBERS 27 - EC26PS-Single FC 1987 ENGINE DESIGNATION NUMBERS 59- EC40PL-02-Twin LC 61 - ECSOPM-01-Twin FC 14 - LongTrack 31 - EC34-2PM-02-Twin FC ES 33 - EC34-2PM-01-03-Twin FC 49 - EC44-2PM-5100-Twin FC 57 - EC60PL-02-Triple LC 62 - ECSOPM-02-Twin FC ES 15 - Long Track RLR 04 - Indy Sport 05 - Indy 133 SKS 07 - lndy Trail, 400, 600 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. MFD. DATE: Mid. by Polaris lndustrfes LP. 1n Roseau. MN under one 0< more of lhe following pa1en1s: U.S. Palents 3,605,5H 3.533,002 3.G13,6i1 3,580.647 3.613.610 3.604,510 3.463.766 3.5'15.821 3.525.412 Patented Canada 882.491171 883.094/71 Canadian Rd. 34.573171 34.5721 71 These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. :i.SS7,991 4, 793,950 5,038.881 86-1.394(11 1.227 .823187 7072 133 The machine model and serial number identification decal ts 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 Identificati on Engine Type Displacement (cc) Bore x Stroke (mm) Carburetionffhrottle Body Oil Injected Ignition Alternator Output Length (in.fem.) Width (in.fem.) Height (in.fem.) Ski Stance (in.fem.) Track Width (in.fem.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gal.limp. gal./ liters) Recommended Fuel Front Suspension Brake Type Storage Speedometer Tachometer Trip Odometer Accessory Lights Electric Start Handwarmers Two-Up Seat Backrest Storage Rack Tow Hitch 8/94 lndy600 0870757 LC Triple 597 65 x 60 3 Mikuni VM38SS Slide Standard CDI 12V 120W 109/276.6 41.621105.6 33/83.7 36.5/92.7 15/38.1 121 /307.1 7/5.8/26.5 88 Octane Min. Coil Spring I FS Liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Standard Temp N/A Option NIA N/A Option Option 1.8 Indy 400 400 SKS 0870759 0870559 LC Twin 398 65 x 60 2 Mikuni VM34SS Slide Standard CDI 12V 120W 109/276.6 11 3/286.8 SKS 41.621105.6 33/83.7 36.5/92.7 15/38.1 121/307.1 133.5/338.8 7/5.8/26.5 88 Octane Min. Coil Spring IFS Liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Standard Temp N/A Option NIA N/A Option Option Indy Trail Long Track Trail ES I SKS LTR 0870761 0871449 087076210870561 0871549 Fan Cooled Twin Fan Cooled Twin 488 432 72 x60 67.72 x 60 2 Mikuni 1 Mikuni VM34SS Slide VM30SS Slide Standard Standard CDI COi 12V 120W 12V 120W 109/276.6 120.25/305.2 11 3/286.8 SKS 41.62/105.6 40/101 .5 33/83.7 33/83.7 36.5/92.7 31/78.7 15/38.1 15/38. 1 121 /307.1 148/375.6 133.5/338.8 7/5.8/26.5 7.5/6.2/28 88 Octane Min. 88 Octane Min. Coil Spring IFS Mono Leaf Hydraulic Disc Mechanical Disc Rear of Seat Rear of Seat Standard Standard Standard Option Standard Standard N/A N/A Option N/A Standard ES Standard Option N /A N/A N/A NIA Option Standard Option Standard

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1985-1995 Polaris All Models Snowmobile Service Repair Manual (Highly Detailed FSM, Preview)

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