2014-2016 Polaris Snowmobile Indy 550 Pro-Ride Service & Repair Manual

2014 - 2016 550 PRO-RIDE SNOWMOBILE SERVICE MANUAL PN 9925968

POLARIS® 2014-2016 550 PRO-RIDE Snowmobile Service Manual FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Polaris Master Service Dealer® technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service. We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual I Service Literature Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340. Publication Printed October 2015 {PN 9925968 R01) © Copyright 2015 Polaris Industries Inc. All infonnation contained within this publication is based on the latest product infonnation at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the infonnation presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: ~,~drum~ SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE provides key information by clarifying instructions. IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

2014-2016 550 PRO-RIDE Snowmobile Service Manual Chapter Summary CHAPTER 1: MODEL SPECIFICATIONS I GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE I EXHAUST CHAPTER4: FUELSYSTEM CHAPTER 5: FINAL DRIVE I BRAKE SYSTEMS CHAPTERS: PVTSYSTEM CHAPTER 7: STEERING I SUSPENSIONS CHAPTER 8: CHASSIS CHAPTER 9: BATTERY I ELECTRICAL SYSTEMS

TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Tone, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. REVISION INDEX: 2014- 2016 550 PRO-RIDE DATE ' CHANGES R01 10/01/15 Initial release

MODEL SPECIFICATIONS I GENERAL INFORMATION CHAPTER 1 MODEL SPECIFICATIONS I GENERAL INFORMATION VEHICLE IDENTIFICATION .................................................... . ........................ 1.2 MODEL NUMBER DESIGNATION ..................................................................... 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ............................................ 1.2 TUNNEL DECAL ...................................................................................... 1.2 MISC. INFORMATION .................................................................................... 1.3 2014 PUBLICATIONS ..................................................... . ............................ 1.3 2015 PUBLICATIONS ........................................... .. ..................................... 1.3 2016 PUBLICATIONS ... ... ............................................................................ 1.3 MODEL SPECIFICATIONS .............................................................................. 1.4 2014 550 INDY ........................................................................................ 1.4 2014 550 INDY 144 .............................. . ... ....... ....... . .. .... .... . ........................ 1.6 2014 550 INDY VOYAGER . ............................................................................ 1.8 2014 550 INDY LXT ................................................................................... 1.10 2014 550 INDY ADVENTURE X2 .................................................................... .. 1.12 2015 550 INDY ................................ .... ...... . ................ .. .......................... 1.14 2015 550 INDY 144 ................ . .................................................................. 1.16 2015 550 INDY VOYAGEUR 144 ............................. ... ...................................... 1.18 2015 550 INDY VOYAGEUR 155 .................................................................. . ... 1.20 2015 550 INDY LXT ................................................ . ............ .. .... ..... ........... 1.22 2015 550 INDY ADVENTURE 144 .................................................................... . 1.24 2015 550 INDY ADVENTURE 155 ..................................................................... 1.26 2016 550 INDY ................................................................................... . .. . 1.28 2016 550 INDY 144 ............... . ................................................................... 1.30 2016 550 INDY VOYAGEUR 144 .................................................................... .. 1.32 2016 550 INDY VOYAGEUR 155 ............................................................ .. ...... .. 1.34 2016 550 INDY LXT ................................................................................... 1.36 2016 550 INDY ADVENTURE 144 ..................................................................... 1.38 2016 550 INDY ADVENTURE 155 ..................................................................... 1.40 GENERAL INFORMATION ..................... .. .. . .................................................... 1.42 SPECIAL TOOLS ............................ . ........................................................ 1.42 CONVERSION TABLE ................................................................................ 1.43 STANDARD BOLT TORQUE SPECIFICATION ........................................................ 1.44 METRIC BOLT TORQUE SPECIFICATION ............................................................ 1.44 SAE TAP I DRILL SIZES . ................................................ . ....................... ... .. 1.45 METRIC TAP I DRILL SIZES ............................................ . ............................. 1.45 DECIMAL EQUIVALENTS ....................................... ... .... ... ......................... .. 1.46 FUEL I OIL PRE-MIX RATIOS ......................................................................... 1.46 SERVICE PRECAUTIONS ............................................................................ 1.47 9925968 R01 - 2014- 2016 550 PRO-RIDE Snowmobile Service Manual ©Copyright Polaris Industries Inc. 1.1

MODEL SPECIFICATIONS I GENERAL INFORMATION VEHICLE IDENTIFICATION MODEL NUMBER DESIGNATION Example: S16BF6KSA ENGINE SIZE I MODIFIER\.;; s 6 B F 6 •=digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively .. = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION Example: SN1 CG8GSOG3000000 VEHICLE DESCRIPTORS TYPE ENGINE ENGINE SERIES CHECK MODEL SIZE ii,;;;i MODIFIER DIGIT YEAR* 1 4 5 6 7 8 9 10 s c G 8 G s 0 G *Model Year: A= 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016 TUNNEL DECAL 7th• K 8th. 9th .. s A The Tunnel Decal has the Model Number (1 ), VIN Number (2), and the Manufactured Date (3). These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. The machine model and VIN number identification decal is located on the right front side of the tunnel. The VIN (2) number is permanently stamped into the tunnel. The model number is embossed on the decal. 1.2 1 2 rn1s VEH ICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AN CANADA MOTOR VEHICLE SAFElY STANDARD IN EFFECT ON THE DATE OF MANUFACTURE. MFD. DATE:·------·- 3 PATENT NOTICE MM. by Polaris Industriei Inc .. In Roseau, MN under one or IDG("e of the roUowmg patents: U.S. Pa tl>nta 3,605,511 3,580,647 3 ,483 ,766 3 ,533 ,661. 3,545,821 3,605,510 3,.5:25, 412 3,613 ,810 3,867,9'1 4,793 ,950 5,038,881 5,172,675 5,090,386 5,050,564 5,050,559 5,048,503 5,056,482 5,0'9,813 5,074,271 5,1'1,531 3,613 ,8U Patmted CUlada 88'2,4 91171 883,694/71 864 ,3 94/71 Canadian Rd. 34,573/71 34,572/71 1,227 )123/ 87 7072133 9925968 R01 - 2014 - 2016 550 PRO-RIDE Snowmobile Service Manual ©Copyright Polaris Industries Inc.

MODEL SPECIFICATIONS I GENERAL INFORMATION MISC. INFORMATION 2014 PUBLICATIONS 550 INDY 550INDY144 550 INDY Voyager 550 INDY LXT 550 INDY Adventure X2 2015 PUBLICATIONS MODEL ·· ii'. ··:; .......•....•. 550 INDY 550INDY144 550 INDY Adventure 144 550 INDY Adventure 155 550 INDY LXT 550 INDY Voyageur 550 INDY Voyageur 155 2016 PUBLICATIONS MODEL A\!, ... ···· 550 INDY 550INDY144 550 INDY Adventure 144 550 INDY Adventure 155 550 INDY LXT 550 INDY Voyageur 144 550 INDY Voyageur 155 OWNER'S MANUAL: 9924264 9924266 9924284 ... / OWNER'S MANUAL 9925065 9925097 9925097 9925413 9925097 9925097 9925413 OWNER'S MANUAL 9925966 9925972 9925968 R01 - 2014 - 2016 550 PRO-RIDE Snowmobile Service Manual ©Copyright Polaris Industries Inc. PARTS BOOK 9924265 9924267 9924285 9924267 PARTS BOOK ................ 9925066 9925080 9925081 9925106 9925098 9925102 9925105 ·• PARTS BOOK •+' \\ &~.· 9925967 9925989 9925973 9925974 9925993 9925990 9925994 1.3

MODEL SPECIFICATIONS I GENERAL INFORMATION MODEL SPECIFICATIONS 2014 550 INDY Model Numbers: S14CB5BSA/S14CB5BSL International Model Number: S14CB5BEL GENERAi! • g >\(;[' /'?;&]! . ({ ITEM ·······. <n VALUE .. .. .. . Width (in/cm) 48 / 122 Length (in/cm) 114 / 289 Height (in/cm) 48 / 122 Estimated Dry Weight 422/191 .4 (lb/kg) Fuel (Gallons I Liters) 11.5 / 43.5 Oil (Quarts I Liters) 3.05 / 2.89 Brake Fluid DOT4 Drive Belt Part Number 3211154 Width (inches I cm) 1.29 / 3.27 Side Angle 28° Circumference (inches I cm) 42.48 / 107.9 Center Distance (inches I cm) 10.63 (27) Chaincase Top Gear (Stock) 18 Bottom Gear (Stock) 42 Chain (Stock) 72 Gear Lube Polaris Synthetic Capacity (oz I ml) 9.0 / 266 Reverse PERC ENGINE ,ct:·· # < ·•·•·:,; { ITEM ;\; , +E> ..• ......... .• VALUE t+ Engine Type Fuji Fan-Cooled I Piston Port with Reed Assist Induction Model Number EC55PM13 Displacement I # Cylinders 544cc/ 2 Bore (inches/mm) 2.87 / 73.0 Stroke (inches/mm) 2.56 /65.0 Piston to Cylinder Clearance .0039 - .0053 / 0.10 -0 .135 (inches/mm) Installed Ring Gap .016 - .022 / 0.406- 0.558 (inches I mm) 1.4 ENGINE Operating RPM ±200 7000 Idle RPM ±200 1700 Engagement RPM ±200 3800 Piston Mark 5ML CARBURETOR SETTINGS ;;,;, •rt . jjj;. ,;:;,'.'>.]ii ...•. ·:;; ITEM ll di!j(i•V,w!• . l\tA'I I~~ ,,,,,, ·•''" Y• i\t~+> [\ Type Mikuni VM34SS Main Jet 220 Pilot Jet 45 Jet Needle I Clip Position 6BGY48/4 Needle Jet Q-0 (480) Throttle Gap (Under Cutaway) (in/mm) .275 I 6.98 Drill Bit Size I or J Cutaway 3.0 Valve Seat 1.5 Viton Pilot Air Jet 2.5 Air Screw (Tums Out) 1.5 Tums Out (Fixed) Fuel Octane (R+M/2) (Minimum) 87 Non-Oxygenated (Recommended) 89 Oxygenated ELECTRICAL x "+ .· .. ·· ··;;.. ·\;;il,y .JY.t'h··· •· k •' .,;\''\•!!.%~ \f ,, ••••••••••••·••• '"' ITEM' Alternator Output Operating Voltage Watts@ 13.5 Vdc (Total) Ignition Timing Spark Plug Gap in.(mm) Spark Plug CDI Marking Flywheel Marking TRACK .. ITEM Width - Inches (cm) Length - Inches (cm) Lug Height- Inches (cm) Domestic Intemational Track Tension Sag- Inches (cm) FRONT SUSPENSION ITEM Suspension Type Shocks IFS Spring Rate lbs/in (N/mm) VALUE i\ 13.5 -14 .5 Vdc 280 @ 4000 RPM 15°±1 .5°@ 1600 RPM 14° ± 1.5°@ 6500 RPM .028 (0.70) NGK BR9ES CU7276 FP9318 .. #, Hii .... ; .. ) . ..,y:·• VALUE 15 (51) 121 (396) .91/ (2.31) - Shockwave 1.352 (3.43) - Cobra 718- 1-1/8 (2.2-2.9) PRO RIDE (Fixed Camber) RydeFX MPV 100 (17.5) 9925968 R01 - 2014 - 2016 550 PRO-RIDE Snowmobile Service Manual ©Copyright Polaris Industries Inc.

2014-2016 Polaris Snowmobile Indy 550 Pro-Ride Service & Repair Manual

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