Download to read offline
![MODELS AND SPECIFICATIONS
1989 Model Identification
Sprint ES
0890931
Engine Type Fan Cooled Twin
Displacement (cc) 339
Bore x Stroke (mm) 62.3 x 55.6
CarburetionfThrottle Body 2 Mikuni
VM30SS Slide
Oil Injected Standard
Ignition COl
Alternator Output 12V 120W
Length (in.lcm.) 1021259.1
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
Track Length Overall (in.lcm.) 108/274.3
Fuel Capacity (U.S. gal./lmp. gal.lliters) 7.5/6.2128.1
Recommended Fuel 88 Octane Min.
Front Suspension Mono Leaf
Brake Type Mechanical Disc
Storage Rear of Seat
Speedometer Standard
Tachometer Option
Trip Odometer N/A
Accessory Lights N/A
Electric Start Standard
Handwarmers Option
Two-Up Seat N/A
Backrest Option
Storage Rack Option
Tow Hitch Option
Star
0890927
Fan Cooled Single
244
72 x 60
1 Mikuni
VM30SS Slide
Standard
COl
12V 100W
1021259.1
40/101.6
44.5/113
31/78.7
15/38.1
108/274.3
7.5/6.2/28.1
88 Octane Min.
Mono Leaf
Mechanical Disc
Rear of Seat
Option
Option
N/A
N/A
N/A
N/A
N/A
N/A
Option
Option
8/94 1.16
Long Track Star Trak
Reverse
0891549 0891027
Fan Cooled Twin Fan Cooled Single
432 244
67.72 x 60 72 x 60
2 Mikuni 1 Mikuni
VM34SSSiide VM30SS Slide
Standard Standard
COl COl
12V 120W 12V 100W
120.5/306.1 109/276.9
40/101.6 40/101.6
44.5/113 44.5/113
31/78.7 31/78.7
15/38.1 15/38.1
148/376 133/337.8
7.5/6.2128.1 7.5/6.2128.1
88 Octane Min. 88 Octane Min.
Mono Leaf Mono Leaf
Mechanical Disc Mechanical Disc
Rack/Rear of Seat Rack/Rear of Seat
Standard Standard
Option Option
N/A N/A
N/A N/A
N/A N/A
Option N/A
N/A N/A
N/A N/A
Standard Standard
Standard Standard
[]](https://image.slidesharecdn.com/1989polarislongtrackreversesnowmobileservicerepairmanual-180220120327/75/1989-polaris-long-track-reverse-snowmobile-service-repair-manual-17-2048.jpg)
![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.
8. 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.
9. 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
LOCATION --==-__---:':~~
INDICATORS
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.
8/94 2.6
SEWN SEAMS
TACK COVER
HERE SECOND
STAPLING CHANNEL
STAPLE HERE FIRST '
STAPLE
HERE SECOND
STAPLE HERE THIRD
STAPLE SEQUENCE ILL. 2](https://image.slidesharecdn.com/1989polarislongtrackreversesnowmobileservicerepairmanual-180220120327/75/1989-polaris-long-track-reverse-snowmobile-service-repair-manual-59-2048.jpg)
1989 polaris long track reverse snowmobile service repair manual
- 1. CHAPTER 1 MODELS ANDPECIFICATIONS 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 I 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
- 2. MODELS AND SPECIFICATIONS 1985Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine model year. Refer to the first digits inthe serial number for proper identification: FIRST DIGITS MODEL YEAR 12 1985 1985 MODEL DESIGNATION YEAR DESIGNATION--------;=:;=::l;I:--:;-, ENGINE DESIGNATION I 0 8 510 9 17 MODEL DESIGNATION __________-----' 1985 MODEL DESIGNATION NUMBERS (Chassis) . 07 - Indy Trail, 400, 600 08 - Indy 600 SE 09 - Star 13- SS 14 - LongTrack 1985 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single FC 43 - EC44-2PM-2100-Twin FC 49 - EC44-2PM-Twin FC 57 - EC60PL-02-Three LC 59 - 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. THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND S ,ATE REr'l1I1REMENTS AND CANADIAN FEDERAL MC- - o-ilCLE STANDARDS IN EFFECT ON THE DATE C, J FACTURE. MFD. DATE: MId. 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 Patented Canada 662,491n1 883,694n1 Canadian Rd, 34,573n1 34,572171 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 (intake side). 1.1 8/94 "
- 3. MODELS AND SPECIFICATIONS 1985Model Identification 600SE 0850857 Engine Type LC Triple Displacement (cc) 597 Bore x Stroke (mm) 65 x 60 CarburetionlThrottle Body 3 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 120W Length (in./cm.) 106.25/269.7 Width (in./cm.) 41 .62/105.6 Height (in./cm.) 31.5/79.9 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 121/307.1 Fuel Capacity (U.S. gal./lmp. gal./liters) 7/5.8/26.5 Recommended Fuel 88 Octane Min. Front Suspension Coil Spring IFS Chrome Trailing Arms Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights Temp Electric Start N/A Handwarmers Option Two-Up Seat N/A Backrest N/A Storage Rack Option Tow Hitch Option 8/94 1.2 600 0850757 LC Triple 597 65 x 60 3 Mikuni VM38SS Slide Standard COl 12V 120W 106.25/269.7 41.62/105.6 31.5/79.9 36.5/92.7 15/38.1 121/307.1 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 N/A N/A Option Option 400 Long Track 0850759 0851449 LC Twin Fan Cooled Twin 398 432 65 x 60 67.62 x 60 2 Mikuni 1 Mikuni VM34SS Slide VM30SS Slide Standard Standard COl COl 12V 120W 12V 120W 106.25/269.7 120.25/305.2 41 .62/105.6 40/101.5 31.5/79.9 33/83.7 36.5/92.7 31/78.7 15/38.1 15/38.1 121/307.1 148/375.6 7/5.8/26.5 5.4/4.5/20 88 Octane Min. 88 Octane Min. Coil Spring IFS Mono Leaf Liquid Cooled Mechanical Disc Hydraulic Disc Rear of Seat Rear of Seat Storage Rack Standard Standard Standard Option oStandard Standard Temp N/A N/A N/A Option Option N/A N/A N/A N/A Option Standard Option Standard
- 4. r Engine Type Displacement (cc) Borex Stroke (mm) Carl;>uretionfThrottle Body Oil Injected Ignition Alternator Output Length (in.!cm.) Width (in.!cm.) Height (in.!cm.) Ski Stance (in.!cm.) Track Width (in.!cm.) Track Length Overall (in.!cm.) Fuel Capacity (U.S. gal.llmp. gal./liters) Recommended Fuel Front Suspension Brake Type Storage Speedometer Tachometer G 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 VM34SS Slide VM30SS Slide Standard Standard Standard COl COl COl 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 31/78.7 15/38.1 15/38.1 15/38.1 121/307.1 120/304.6 108/274.1 7/5.8/26.5 6.8/5.7/25.7 5.414.5120 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 N/A N/A Option Option N/A Standard Option N/A N/A N/A N/A N/A N/A N/A Option N/A N/A Option Option Option 8/94
- 5. MODELS AND SPECIFICATIONS ·1986Model 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 12 13 MODEL YEAR 1985 1986 1986 MODEL DESIGNATION YEAR DESIGNATIONI--- - - ----;=::;::=lI:---=1 ENGINE DESIGNATION I 0 8 610 9 17 MODEL DESIGNATION _ _ _ _ _ _ _ _ _ _ ---'1 1986 MODEL DESIGNATION NUMBERS (Chassis) 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 FC 31 - EC34-2PM-01 -Twin FC (ES) 33 - EC34-2PM-02-Twin FC 49 - EC44-2PM-5100-Twin FC 57 - EC60PL-02-Triple LC 1986 ENGINE DESIGNATION NUMBERS 59 - EC40PL-02-Twin LC 61 - EC50PM-01-Twin FC MADE IN U.S.A. PDLRRIS PATENT NOTICE Mfd. by Polaris Industries L.P. 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 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: These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. 3,867,991 4,793,950 5,038,881 864,394171 1,227,823187 7072133 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). 8/94 1.4 ,, o
- 6. 600 LE 0860857 Engine TypeLC Triple Displacement (cc) 597 Bore x Stroke (mm) 65 x 60 CarburetionfThrottle Body 3 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 120W Length (in./cm.) 106.25/269.7 Width (in./cm.) 41.62/105.6 Height (in./cm.) 31.5/79.9 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 121/307.1 Fuel Capacity (U.S. gaL/Imp. gaL/liters) 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 N/A 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 COl COl COl 12V 120W 12V 120W 12V 120W 106.25/269.7 106.25/269.7 120.25/305.2 41 .62/105.6 41 .62/105.6 40/101.5 31.5/79.9 31 .5/79.9 33/83.7 36.5/92.7 36.5/92.7 31/78.7 15/38.1 15/38.1 15/38.1 121/307.1 121/307.1 148/375.6 7/5.8/26.5 7/5.8/26.5 7.5/6.2/28 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 N/A N/A N/A N/A Option Option Option N/A N/A N/A N/A N/A N/A Option Option Standard Option Option Standard 8/94
- 7. MODELS AND SPECIFICATIONS 1986Model 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 CarburetionfThrottle 2 Mikuni 1 Mikuni Body VM34SS Slide VM34SS Slide Oil Injected Standard Standard Ignition COl COl Alternator Output 12V 120W 12V 120W 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 15/38.1 Track Length Overall 121/307.1 120/304.6 (in./cm.) Fuel Capacity (U.S. 7/5.8/26.5 7.5/6.2/28 gal./lmp. 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 N/A N/A Electric Start Option Option Handwarmers Standard Option Two-Up Seat N/A N/A Backrest N/A N/A Storage Rack Option N/A Tow Hitch Option Option 8/94 1.6 oSprint 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 VM30SS Slide Standard Standard Standard COl COl COl 12V 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 33/83.7 33/83.7 31/78.7 31/78.7 31/78.7 15/38.1 15/38.1 15/38.1 108/274.1 108/274.1 108/274.1 5.414.5120 5.4/4.5/20 5.4/4.5/20 88 Octane Min. 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 N/A N/A N/A N/A Standard N/A Option Option N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Option Option Option
- 8. MODELS AND SPECIFICATIONS 1987Model 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 12 13 14 MODEL YEAR 1985 1986 1987 1987 MODEL DESIGNATION YEAR DESIGNATIONI---------,:=:;:::J,I:--::l ENGINE DESIGNATION I 0 8 710 9 17 MODEL DESIGNATION __________----' 1987 MODEL DESIGNATION NUMBERS (Chassis) 09 - Star/Sprint 340 (ES) 10- StarTrak 1987 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single FC 1987 ENGINE DESIGNATION NUMBERS 59 - EC40PL-02-Twin LC 61 - EC50PM-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 - EC50PM-02-Twin FC ES 15 - Long Track RLR 04 - Indy Sport 05 -Indy 133 SKS 07 - Indy 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: 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 883.694f71 Canadian Rd. 34.573f71 34.572f71 These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. 3.867.991 4.793.950 5.038.881 864.394171 1.227.823/87 7072133 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
- 9. MODELS AND SPECIFICATIONS 1987Model Identification Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output Length (in.lcm.) Width (in.lcm.) Height (in.lcm.) Ski Stance (in.lcm.) Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gal./lmp. 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 Indy 600 0870757 LC Triple 597 65 x 60 3 Mikuni VM38SS Slide Standard COl 12V 120W 109/276.6 41 .62/105.6 33/83.7 36.5/92.7 15/38.1 121/307.1 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 N/A N/A Option Option 1.8 Indy 400 400SKS 0870759 0870559 LCTwin 398 65 x 60 2 Mikuni VM34SS Slide Standard COl 12V 120W 109/276.6 113/286.8 SKS 41.62/105.6 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 N/A N/A Option Option Indy Trail Long Track Trail ES I SKS LTR 0870761 0871449 0870762/0870561 0871549 Fan Cooled Twin Fan Cooled Twin 488 432 72 x 60 67.72 x 60 2 Mikuni 1 Mikuni VM34SS Slide VM30SS Slide Standard Standard COl COl 12V 120W 12V 120W 109/276.6 120.25/305.2 ., 113/286.8 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 N/A Option Standard Option Standard
- 10. Indy Sport 0870433 Engine TypeFan Cooled Twin Displacement (cc) 339 Bore x Stroke (mm) 62 x 55.6 CarburetionlThrottle Body 2 Mikuni VM30SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 120W Length (in./cm.) 109/276.6 Wid1h (in./cm.) 41.62/105.6 Height (in./cm.) 33/83.7 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 121/307.1 Fuel Capacity (U.S. gaL/Imp. gal./liters) 7/5.8/26.5 Recommended Fuel 88 Octane Min. Front Suspension Coil Spring IFS Brake Type Liquid Cooled Hydraulic Disc c Storage Rear of Seat Speedometer Standard Tachometer Option Trip Odometer Standard Accessory Lights N/A Electric Start Option Handwarmers Option Two-Up Seat N/A Backrest N/A Storage Rack Option Tow Hitch Option 1.9 MODELS AND SPECIFICATIONS 1987 Model Identification Sprint Star Star Trak Sprint ES 08"10933 0870927 0871027 0870931 Fan Cooled Twin Fan Cooled Single Fan Cooled Single 339 244 244 62 x 55.6 72 x 60 72 x 60 2 Mikuni 1 Mikuni 1 Mikuni VM30SS Slide VM30SS Slide VM30SS Slide Standard Standard Standard COl COl COl 12V 120W 12V 100W 12V 100W 1021258.9 102/258.9 109/276.9 40/101.5 40/101.5 40/101.5 33/83.7 33/83.7 34/86.3 31/78.7 31/78.7 31/78.7 15/38.1 15/38.1 15/38.1 108/274.1 108/274.1 133.5/338.9 5.4/4.5/20 5.4/4.5/20 7.5/6.2128 88 Octane Min. 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 Sprint Option Standard Standard ES Option Sprint Option Standard Standard ES Option Sprint Option Standard Standard ES N/A N/A N/A Sprint ES Only N/A N/A Option N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Standard Option Option Option 8/94 ,
- 11. MODELS AND SPECIFICATIONS 1988Model 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 12 13 14 15 MODEL YEAR 1985 1986 1987 1988 1988 MODEL DESIGNATION YEAR DESIGNATIONI- - - - -- - -;:::==ll~ ENGINE DESIGNATION I 0 8810 9 17 MODEL DESIGNATION _________ ---.JI 1988 MODEL DESIGNATION NUMBERS (Chassis) 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 MODEL NO. SERIAL NO. 1988 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single FC 31 - EC34-2PM-02-Twin FC ES 33 - EC34-2PM-01-03-Twin FC 49 - EC44-2PM-4100-Twin FC 58 - EC65PL-01-Triple LC 1988 ENGINE DESIGNATION NUMBERS 59 - EC40PL-02-Twin LC 61 - EC50PM-01-Twin FC 62 - EC50PM-02-Twin FC ES MADE IN U.S.A. PDLRRIS PATENT NOTICE Mfd. by Polaris Industries L.P. 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 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 882.491 171 883,694171 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 5,038,881 864,39417t 1,227,823187 7072133 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). 8/94 1.10 o
- 12. Indy 650 Indy 650SKS 0880758 0880558 Engine Type LC Triple Displacement (cc) 648 Bore x Stroke (mm) 67.72 x 60 CarburetionlThrottle Body 3 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 120W Length (in./cm.) 106.25/269.9 113/287 SKS Width (in./cm.) 41 .62/105.7 Height (in./cm.) 42/106.7 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38 .1 Track Length Overall (in./cm.) 120.96/307.2 133.56/339.2 SKS Fuel Capacity (U.S. gal./lmp. gal./liters) 7.3/6.1/27.7 Recommended Fuel 88 Octane Min. o Front Suspension Coil Spring IFS Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights HighTemp Ind. Electric Start N/A Handwarmers Option Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 1.11 MODELS AND SPECIFICATIONS 1988 Model Identification Indy 400 Indy 400 Indy Trail, SP 400SKS Classic Deluxe, ES, SKS 0880759 0880859 0880761/08806611 0880559 0880262/08807621 0880561 LCTwin LC Twin Fan Cooled Twin 398 398 488 65 x 60 65 x 60 72 x 60 2 Mikuni 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide VM34SS Slide Standard Standard Standard COl COl COl 12V 120W 12V 120W 12V 120W 106.25/269.9 106.25/269.9 106.25/269.9 113/287 SKS 113/287 SKS 41 .62/105.7 41 .62/105.7 41.62/105.7 43.12/109.5 SP 42/106.7 42/106.7 42/106.7 36.5/92.7 36.5/92.7 36.5/92.7 38/96.5 SP 15/38.1 15/38.1 15/38.1 120.96/307.2 120.96/307.2 121/307.1 133.56/339.2 SKS 133.56/339.2 SKS 7.3/6.1 /27 .7 7.3/6.1/27.7 7.3/6.1/27.7 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Coil Spring IFS Hydraulic Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Standard Standard Standard Standard Standard Standard Standard Standard Standard High Temp Ind. Standard N/A N/A Standard Option Standard ESIDel Option Standard Standard Option Option Option Standard Deluxe Option Option Option Standard Deluxe Option Option Option Option Option Option 8/94
- 13. MODELS AND SPECIFICATIONS 1988Model Identification Indy Sport Sprint 0880433 0880931 Engine Type Fan Cooled Twin Fan Cooled Twin Displacement (cc) 339 339 Bore x Stroke (mm) 62 x 55.6 62 x 55.6 CarburetionfThrottle 2 Mikuni 2 Mikuni Body VM30SS Slide VM30SS Slide Oil Injected Standard Standard Ignition COl COl Alternator Output 12V 120W 12V 120W Length (in.!cm.) 106.25/269.9 1021259.1 Width (in.!cm.) 41 .621105.7 40/101 .6 Height (in.!cm.) 42/106.7 44.5/113 Ski Stance (in.!cm.) 36.5/92.7 31/78.7 Track Width (in.!cm.) 15/38.1 15/38.1 Track Length Overall 120.96/307.2 108/274.3 (in.!cm.) Fuel Capacity (U.S. 7.3/6.1 /27.7 7.5/6.2128.1 gal./lmp. 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 Option Option Trip Odometer Standard N/A Accessory Lights N/A N/A Electric Start Option N/A Handwarmers Option Option Two-Up Seat N/A N/A Backrest N/A N/A Storage Rack Option Option Tow Hitch Option Option Star 0880927 Fan Cooled Single 244 72 x 60 1 Mikuni VM30SS Slide Standard COl 12V 100W 102/259.1 40/101.6 44.5/113 31/78.7 15/38.1 108/274.3 7.5/6.2128.1 88 Octane Min. Mono Leaf Mechanical Disc Rear of Seat Option Option N/A N/A N/A N/A N/A N/A Option Option 8/94 1.12 Long Track Star Trak Reverse 0881549 0881027 Fan Cooled Twin Fan Cooled Single 432 244 67.72 x 60 72 x 60 2 Mikuni 1 Mikuni VM34SS Slide VM30SS Slide Standard Standard COl COl 12V 120W 12V 100W 120.5/306.1 109/276.9 o40/101.6 40/101.6 44.5/113 44.51113 31/78.7 31/78.7 15/38.1 15/38.1 148/376 133/337.8 7.5/6.2/28.1 7.5/6.2/28.1 88 Octane Min. 88 Octane Min. Mono Leaf Mono Leaf Mechanical Disc Mechanical Disc Rack/Rear of Seat Rack/Rear of Seat Standard Standard Option Option oN/A N/A Neutral Ind. N/A N/A N/A Option N/A N/A N/A N/A N/A Standard Standard Standard Option
- 14. o MODELS AND SPECIFICATIONS 1989Model 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 12 13 14 15 16 MODEL YEAR 1985 1986 1987 1988 1989 1989 MODEL DESIGNATION YEAR DESIGNATION-----------;:=;:::JI~ ENGINE DESIGNATION I 0 8 910 9 17 MODEL DESIGNATION _ _________ -'1 1989 MODEL DESIGNATION NUMBERS (Chassis) 09 - Star/Sprint (ES) 10- StarTrak 1989 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single FC 1989 ENGINE DESIGNATION NUMBERS 59 - EC40PL-02-Twin LC 61 - EC50PM-01 -Twin FC 15 - LongTrak LTR 01 - Indy Trail SuperTrak 02 - Indy Trail Deluxe 31 - EC34-2PM-02-Twin FC ES 33 - EC34-2PM-01-03-Twin FC 49 - EC44-2PM-4100-Twin FC 58 - EC65PL-01-Triple LC 62 - EC50PM-02-Twin FC ES 64 - EC50PL-01-Twin LC 04 - Indy Sport 05 - Indy 133 SKS 06 - Indy Trail SP 07 - Indy 440, 500, 650 08 - Indy 500 Classic 24 Indy Sport GT 65 - EC50PL-02-Twin LC ES MODEL NO. MADE IN U.S.A. PCLRRIS 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: 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 Patented Canada 882,491171 883 .694171 Canadian Rd. 34,573171 34 ,572171 These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. 3,867,991 4,793,950 5,038,881 864,39417t 1,227,823/87 7072133 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). 1.13 8/94
- 15. MODELS AND SPECIFICATIONS 1989Model Identification Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output Length (in./cm.) Width (in./cm.) Height (in./cm.) Ski Stance (in./cm.) Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gal.llmp. 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 Indy 650 Indy 650 SKS 0890758 0890558 LC Triple 648 67.72 x 60 3 Mikuni VM38SS Slide Standard COl 12V 120W 106.25/269.9 113/287 SKS 41.62/105.7 44/111.8 36.5/92.7 15/38.1 120.96/307.2 133.56/339.2 SKS 7.3/6.1 /27.7 88 Octane Min. Coil Spring IFS Liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Standard High Temp Ind. N/A Standard Option Option Option Option 1.14 Indy 500 500SKS 0890764 0890564 LCTwin 488 72 x 60 2 Mikuni VM38SS Slide Standard COl 12V 120W 106.25/269.9 113/287 SKS 41.62/105.7 44/111 .8 36.5/92.7 15/38.1 120.96/307.2 133.56/339.2 SKS 7.3/6.1/27.7 88 Octane Min. Coil Spring IFS Hydraulic Disc Rear of Seat Standard Standard Standard High Temp Ind. N/A Option Option Option Option Option Indy 500 Indy 500 SP ) Classic 0890865 0890664 LCTwin LCTwin 488 488 72 x 60 72 x 60 2 Mikuni 2 Mikuni VM38SS Slide VM38SS Slide Standard Standard COl COl 12V 120W 12V 120W 106.25/269.9 106.25/269.9 41.62/105.7 43.12/109.5 44/111.8 42/106.7 36.5/92.7 38/96.5 15/38.1 15/38.1 120.96/307.2 120.96/307.2 7.3/6.1/27.7 7.3/6.1 /27.7 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Standard Standard Standard Standard oStandard Standard Standard N/A Standard N/A Standard Option Option Option Option Option Option Option Option Option
- 16. Indy 400 IndyTrail, SP Deluxe, ES, SKS 0890759 0890761/0890661/ 0890262/0890762/ 0890561 Engine Type LCTwin Fan Cooled Twin Displacement (cc) 398 488 Bore x Stroke (mm) 65 x 60 72 x 60 CarburetionlThrottle Body 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide Oil Injected Standard Standard Ignition CDI CDI Alternator Output 12V 120W 12V 120W Length (in./cm.) 106.25/269.9 106.25/269.9 113/287 SKS Width (in./cm.) 41 .62/105.7 41.62/105.7 43.12/109.5 SP Height (in./cm.) 44/111.8 42/106.7 45/114.3 Del Ski Stance (in./cm.) 36.5/92.7 36.5/92.7 38/96.5 SP Track Width (in./cm.) 15/38.1 15/38.1 Track Length Overall 120.96/307.2 120.96/307.2 (in./cm.) 133.56/339.2 SKS Fuel Capacity (U.S. 7.3/6.1/27.7 7.3/6.1/27.7 gal.llmp. gal.lliters) Recommended Fuel 88 Octane Min. 88 Octane Min. Front Suspension Coil Spring IFS Coil Spring IFS Brake Type Hydraulic Disc Hydraulic Disc Storage Rear of Seat Rear of Seat Speedometer Standard Standard Tachometer Standard Standard Trip Odometer Standard Standard Accessory Lights High Temp Ind. N/A Electric Start N/A Option Standard ES/Del Handwarmers Option Standard Two-Up Seat Option Option Standard Deluxe Backrest Option Option Standard Deluxe Storage Rack Option Option Tow Hitch Option Option 1.15 MODELS AND SPECIFICATIONS 1989 Model Identification Indy Trail Indy Sport Indy Sport GT SuperTrak 0890161 0890433 0892433 Fan Cooled Twin Fan Cooled Twin Fan Cooled Twin 488 339 339 72 x 60 62.3 x 55.6 62.3 x 55.6 2 Mikuni 2 Mikuni 2 Mikuni VM34SS Slide VM30SS Slide VM30SS Slide Standard Standard Standard CDI CDI CDI 12V 120W 12V 120W 12V 120W 128/325.1 106.25/269.9 118/299.7 41.62/105.7 41.62/105.7 41.62/105.7 45/114.3 42/106.7 45/114.3 36.5/92.7 36.5/92.7 36.5/92.7 15/38.1 15/38.1 15/38.1 156/396.2 120.96/307.2 141/358.1 7.3/6.1/27.7 7.3/6.1/27.7 7.3/6.1/27.7 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Coil Spring IFS Mechanical Disc Hydraulic Disc Hydraulic Disc Rack/Rear of Seat Rear of Seat Rack/Rear of Seat Standard Standard Standard Standard Option Option Standard Standard Standard N/A N/A N/A Opt!on Option Option Standard Option OlltiCh Standard Option Standard ~ Standard Option Standard Standard Option Standard Standard Option Standard 8/94
- 17. MODELS AND SPECIFICATIONS 1989Model Identification Sprint ES 0890931 Engine Type Fan Cooled Twin Displacement (cc) 339 Bore x Stroke (mm) 62.3 x 55.6 CarburetionfThrottle Body 2 Mikuni VM30SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 120W Length (in.lcm.) 1021259.1 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 Track Length Overall (in.lcm.) 108/274.3 Fuel Capacity (U.S. gal./lmp. gal.lliters) 7.5/6.2128.1 Recommended Fuel 88 Octane Min. Front Suspension Mono Leaf Brake Type Mechanical Disc Storage Rear of Seat Speedometer Standard Tachometer Option Trip Odometer N/A Accessory Lights N/A Electric Start Standard Handwarmers Option Two-Up Seat N/A Backrest Option Storage Rack Option Tow Hitch Option Star 0890927 Fan Cooled Single 244 72 x 60 1 Mikuni VM30SS Slide Standard COl 12V 100W 1021259.1 40/101.6 44.5/113 31/78.7 15/38.1 108/274.3 7.5/6.2/28.1 88 Octane Min. Mono Leaf Mechanical Disc Rear of Seat Option Option N/A N/A N/A N/A N/A N/A Option Option 8/94 1.16 Long Track Star Trak Reverse 0891549 0891027 Fan Cooled Twin Fan Cooled Single 432 244 67.72 x 60 72 x 60 2 Mikuni 1 Mikuni VM34SSSiide VM30SS Slide Standard Standard COl COl 12V 120W 12V 100W 120.5/306.1 109/276.9 40/101.6 40/101.6 44.5/113 44.5/113 31/78.7 31/78.7 15/38.1 15/38.1 148/376 133/337.8 7.5/6.2128.1 7.5/6.2128.1 88 Octane Min. 88 Octane Min. Mono Leaf Mono Leaf Mechanical Disc Mechanical Disc Rack/Rear of Seat Rack/Rear of Seat Standard Standard Option Option N/A N/A N/A N/A N/A N/A Option N/A N/A N/A N/A N/A Standard Standard Standard Standard []
- 18. MODELS AND SPECIFICATIONS 1990Model 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 12 13 14 15 16 17 MODEL YEAR 1985 1986 1987 1988 1989 1990 1990 MODEL DESIGNATION YEAR DESIGNATION-------~=:J.I____,_, ENGINE DESIGNATION I 0 9 01 0 9 17 MODEL DESIGNATION __________----- 1990 MODEL DESIGNATION NUMBERS (Chassis) 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 MODEL NO. SERIAL NO. 1990 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single FC 31 - EC34-2PM-02-Twin FC ES 33 - EC34-2PM-01-03-Twin FC 49 - EC44-2PM-41 OO-Twin FC 58 - EC65PL-01-Triple LC 1990 ENGINE DESIGNATION NUMBERS 59 - EC40PL-02-Twin LC 61 - EC50PM-01/02-Twin FC 62 - EC50PM-03-Twin FC ES 64 - EC50PL-01/03-Twin LC 65 - EC50PL-02-Twin LC MADE IN U,S,A. POLRRIS PATENT NOTICE 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 3,867,991 4,793,950 5,038,881 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. Patented Canada 882,491171 883,694171 Canadian Rd. 34,573171 34,572171 864,394171 1,227,823/87 MFD. DATE: 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). 1.17 8/94
- 19. MODELS AND SPECIFICATIONS 1990Model Identification Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output Length (in./cm.) Width (in./cm.) Height (in./cm.) Ski Stance (in./cm.) Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gal./lmp. 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 8/94 650 650 SKS 0900758 0900558 LC Triple 648 67.72 x 60 3 Mikuni VM38SS Slide Standard COl 12V 120W 106.25/269.9 113/287 SKS 41.62/105.7 44/111.8 36.5/92.7 15/38.1 120.96/307.2 133.56/339.2 SKS 7.3/6.1/27.7 88 Octane Min. Coil Spring IFS Liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Standard High Temp Ind. N/A Standard Option Option Option Option 1.18 500 500 Classic 500SP 500SKS 0900764 0900865 0900664 0900564 LC Twin LC Twin LC Twin 488 488 488 72 x 60 72 x60 72 x 60 2 Mikuni 2 Mikuni 2 Mikuni VM38SS Slide VM38SS Slide VM38SS Slide Standard Standard Standard COl COl COl 12V 200W 12V200W 12V 200W 106.25/269.9 106.25/269.9 106.25/269.9 113/287 SKS o41.62/105.7 41.62/105.7 43.12/109.5 44/111.8 44/111.8 42/106.7 36.5/92.7 36.5/92.7 38/96.5 15/38.1 15/38.1 15/38.1 120.96/307.2 120.96/307.2 120.96/307.2 133.56/339.2 SKS 7.3/6.1/27.7 7.3/6.1/27.7 7.3/6.1/27.7 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Coil Spring IFS Hydraulic Disc HydrauliC Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Standard Standard Standard Standard Standard Standard Standard Standard Standard High Temp Ind. Standard N/A Option Standard Option Option Standard Option Option Option Option Option Option Option Option Option Option Option Option Option
- 20. o c Indy 400Indy Trail Trail Deluxe 0900759 0900761 0900262 Engine Type LCTwin Fan Cooled Twin Displacement (cc) 398 488 Bore x Stroke (mm) 65 x 60 72 x 60 CarburetionlThrottle Body 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide Oil Injected Standard Standard Ignition COl COl Alternator Output 12V 200W 12V 200W Length (in./cm.) 106.25/269.9 106.25/269.9 113/287 Del Width (in./cm.) 41.621105.7 41.62/105.7 Height (in./cm.) 44/111.8 421106.7 45/114.3 Del Ski Stance (in./cm.) 36.5/92.7 36.5/92.7 Track Width (in./cm.) 15/38.1 15/38.1 Track Length Overall 120.96/307.2 120.96/307.2 (in./cm.) 133.56/339.2 Del Fuel Capacity (U.S. 7.3/6.1/27.7 11.25/9.4/42.6 gal./lmp. gal./liters) Recommended Fuel 88 Octane Min. 88 Octane Min. Front Suspension Coil Spring IFS Coil Spring IFS o Brake Type Hydraulic Disc Hydraulic Disc Storage Rear of Seat Rear of Seat Speedometer Standard Standard Tachometer Standard Standard Trip Odometer Standard Standard Accessory Lights High Temp Ind. N/A Electric Start N/A Option Standard Deluxe Handwarmers Option Standard Two-Up Seat Option Option Standard Deluxe Backrest Option Option Standard Deluxe Storage Rack Option Option Tow Hitch Option Option 1.19 MODELS AND SPECIFICATIONS 1990 Model Identification Indy Trail Indy Sport Indy Sport GT SuperTrak 0900161 0900433 0902433 Fan Cooled Twin Fan Cooled Twin Fan Cooled Twin 488 339 339 72 x 60 62.3 x 55.6 62.3 x 55.6 2 Mikuni 2 Mikuni 2 Mikuni VM34SS Slide VM30SS Slide VM30SS Slide Standard Standard Standard COl COl COl 12V 200W 12V 150W 12V 150W 128/325.1 106.25/269.9 118/299.7 41.62/105.7 41.62/105.7 41 .62/105.7 45/114.3 42/106.7 45/114.3 36.5/92.7 36.5/92.7 36.5/92.7 15/38.1 15/38.1 15/38.1 156/396.2 120.96/307.2 141/358.1 11.25/9.4/42.6 7.3/6.1/27.7 7.3/6.1/27.7 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Coil Spring IFS Hydraulic Disc Hydraulic Disc Hydraulic Disc Rack/Rear of Seat Rear of Seat Rack/Rear of Seat Standard Standard Standard Standard Option Option Standard Standard Standard N/A N/A N/A Option Option Option Standard Option Option Standard Option Standard Standard Option Option Standard Option Standard Standard Option Standard 8/94
- 21. MODELS AND SPECIFICATIONS 1990Model Identification Sprint ES 0900931 Engine Type Fan Cooled Twin Displacement (cc) 339 Bore x Stroke (mm) 62.3 x 55.6 CarburetionlThrottle Body 2 Mikuni VM30SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 150W Length (in.lcm.) 102/259.1 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 Track Length Overall (in.lcm.) 108/274.3 Fuel Capacity (U.S. gal./lmp. gal./liters) 7.5/6.2/28.1 Recommended Fuel 88 Octane Min. Front Suspension Mono Leaf Brake Type Mechanical Disc Storage Rear of Seat Speedometer Standard Tachometer Option Trip Odometer N/A Accessory Lights N/A Electric Start Standard Handwarmers Option Two-Up Seat N/A Backrest Option Storage Rack Option Tow Hitch Option 8/94 1.20 Star 0900927 Fan Cooled Single 244 72 x 60 1 Mikuni VM30SS Slide Standard COl 12V 150W 102/259.1 40/101.6 44.5/113 31/78.7 15/38.1 108/274.3 7.5/6.2/28 88 Octane Min. Mono Leaf Mechanical Disc Rear of Seat Option Option N/A N/A N/A N/A N/A Option Option Option Star Trak WideTrak 0901027 0902064 Fan Cooled Single LCTwin 244 488 72 x 60 72 x 60 1 Mikuni 2 Mikuni VM30SS Slide VM38SS Slide Standard Standard COl COl 12V 150W 12V200W 109/276.9 128/325.1 40/101.6 41.62/105.7 44.5/113 49/1 24.4 31/78.7 36.5/92.7 15/38.1 15/38.1 133/337.8 156/396.2 7.5/6.2128 10/8.3/37.8 88 Octane Min. 88 Octane Min. Mono Leaf Coil Spring IFS Mechanical Disc Hydraulic Disc Rack/Rear of Seat Rack/Under Seat Standard Standard Option Standard N/A Standard N/A Temp/Rev N/A Option N/A Standard N/A Standard Option Standard Standard Standard Standard Standard
- 22. MODELS AND SPECIFICATIONS 1991Model Identification SERIAL NUMBER IDENTIFICATION The machine serial number may be used as an aid in identifying machine modelyear. Referto the first digits in the serial number for proper identification: FIRST DIGITS 12 13 14 15 16 17 18 MODEL YEAR 1985 1986 1987 1988 1989 1990 1991 1991 MODEL DESIGNATION YEAR DES IGNATION----------;=~I~ ENGINE DESIGNATION I 0 9 112 0 ~ 4 MODEL DESIGNATION ___ _ _ _ _ _ _ _ ----' 1991 MODEL DESIGNATION NUMBERS (Chassis) 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 MODEL NO. SERIAL NO. 1991 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single FC 31 - EC34-2PM-02-Twin FC ES 33 - EC34-2PM-01 -03-Twin FC 43 - EC44-3PM-01-Twin FC 49 - EC44-2PM-4100-Twin FC 58 - EC65PL-D1 -Triple LC 1991 ENGINE DESIGNATION NUMBERS 59 - EC40PL-02-Twin LC 61 - EC50PM-01/02-Twin FC 62 - EC50PM-03-Twin FC ES 64 - EC50PL-01 /03-Twin LC 65 - EC50PL-02-Twin LC 68 - EC65PL-03-Triple LC MADE IN U.S.A. P D LRR IS 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 3,867,991 4,793,950 5,038,881 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. Patented Canada 882,491n1 883,694nt Canadian Rd. 34,573nt 34,572n1 864,394nt 1,227,823/87 MFD. DATE: 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). 1.21 8/94
- 23. MODELS AND SPECIFICATIONS 1991Model Identification Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output Length (in.!cm.) Width (in.!cm.) Height (in.!cm.) Ski Stance (in.!cm.) Track Width (in.!cm.) Track Length Overall (in.!cm.) Fuel Capacity (U.S. gal./lmp. 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 8/94 650 RXL RXL SKS 0910758 0910768 0910568 LC Triple 648 67.72 x 60 3 Mikuni VM38SS Slide 3 46mm Throttle Bodies Standard COl 12V 120W 106.25/269.9 11 3/287 SKS 41 .62/105.7 44/11 1.8 36.5/92.7 38/96.5 RXL 15/38.1 120.96/307.2 133.56/339.2 SKS 12.16/10.6/46 88 Octane Min. Coil Spring IFS Liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Standard Temp/Oil/Acc/Hi Beam N/A Standard Option Option Option Option 1.22 500 500 Classic 500 SP 500SKS 0910764 0910865 0910664 0910564 LCTwin LC Twin LC Twin 488 488 488 72 x 60 72 x 60 72 x 60 2 Mikuni 2 Mikuni 2 Mikuni VM38SS Slide VM38SS Slide VM38SS Slide Standard Standard Standard COl COl COl o12V200W 12V 200W 12V 200W 106.25/269.9 106.25/269.9 106.25/269.9 113/287 SKS 41.62/105.7 41 .62/105.7 43.12/1 09.5 44/111.8 44/111.8 42/106.7 36.5/92.7 36.5/92.7 38/96.5 15/38.1 15/38.1 15/38.1 120.96/307.2 120.96/307.2 120.96/307.2 133.56/339.2 SKS 12.16/10.6/46 12.16/10.6/46 12.16/10.6/46 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Coil Spring IFS Hydraulic Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Standard Standard Standard Standard Standard Standard Standard Standard Standard Temp/Oil/Hi Beam Temp/Oil/Acc/Hi Temp/Oil/Hi Beam Beam Option Standard Option Option Standard Option Option Option Option Option Option Option Option Option Option Option Option Option
- 24. o 400 0910759 Engine Type LCTwin Displacement(cc) 398 Bore x Stroke (mm) 65 x 60 CarburetionlThrottle Body 2 Mikuni VM34SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 200W Length (in./cm.) 106.25/269.9 Width (in./cm.) 41.62/105.7 Height (in.lcm.) 44/111.8 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 120.96/307.2 Fuel Capacity (U.S. gaUlmp. gal./liters) 12.16/10.6/46 Recommended Fuel 88 Octane Min. Front Suspension Coil Spring IFS Brake Type Hydraulic Disc Storage Rear of Seat c Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights Temp/Oil/Hi Beam Electric Start Option Handwarmers Option Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 1.23 MODELS AND SPECIFICATIONS 1991 Model Identification Indy Trail Indy Sport Indy Sport GT Trail Deluxe 0910761 0910443 0912443 0910262 Fan Cooled Twin Fan Cooled Twin Fan Cooled Twin 488 432 432 72 x 60 67.72 x 60 67.72 x 60 2 Mikuni 2 Mikuni 2 Mikuni VM34SS Slide VM30SS Slide VM30SS Slide Standard Standard Standard COl COl COl 12V 200W 12V200W 12V 200W 106.25/269.9 106.25/269.9 118/299.7 41.62/105.7 41.62/105.7 41.62/105.7 42/106.7 42/106.7 45/114.3 45/114.3 Deluxe 36.5/92.7 36.5/92.7 36.5/92.7 15/38.1 15/38.1 15/38.1 120.96/307.2 120.96/307.2 141/358.1 12.16/10.6/46 7.3/6.1/27.7 7.3/6.1/27.7 88 Octane Min. 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Coil Spring IFS Hydraulic Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rack/Rear of Seat Standard Standard Standard Standard Option Option Standard Standard Standard Temp/OiliAcc/Hi Option Option Beam Option Option Option Standard Deluxe Standard Option Option Option Option Standard Standard Deluxe Option Option Option Standard Deluxe Option Option Standard Option Option Standard 8/94
- 25. MODELS AND SPECIFICATIONS 1991Model Identification Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output Length (in./cm.) Width (in./cm.) Height (in./cm.) Ski Stance (in./cm.) Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gal./lmp. gal./liters) Recommended Fuel Front Suspension Brake Type SuperTrak 0910161 Fan Cooled Twin 488 72 x 60 2 Mikuni VM34SS Slide Standard COl 12V 200W 128/325.1 41.62/105.7 45/114.3 36.5/92.7 15/38.1 156/396.2 12.16/10.6/46 88 Octane Min. Coil Spring IFS Hydraulic Disc Storage Rack/Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights Acc/Rev Electric Start Option Handwarmers Standard Two-Up Seat Standard Backrest Standard Storage Rack Standard Tow Hitch Standard 8/94 1.24 WideTrak 0912064 LCTwin 488 72 x 60 2 Mikuni VM38SS Slide Standard COl 12V 200W 128/325.1 41.62/105.7 49/124.4 36.5/92.7 15/38.1 156/396.2 10/8.3/37.8 88 Octane Min. Coil Spring IFS Hydraulic Disc Under Seat Standard Standard Standard Temp/Oil/Rev/Hi Beam Option Standard Standard Standard Standard Standard Indy Lite Star Lite 0913033 0913027 Fan Cooled Twin Fan Cooled Single 339 244 62.3/55.6 72 x 60 2 Mikuni 1 Mikuni VM30SS Slide VM30SS Slide Standard Standard COl COl 12V 150W 12V 150W 103/261 103/261 o37.9/96.3 37.9/96.3 46/116.8 46/116.8 36.5/92.7 36.5/92.7 15/38.1 15/38.1 116/294.6 116/294.6 7.66/6.4/29 7.66/6.4/29 88 Octane Min. 88 Octane Min. Coil Spring IFS Coil Spring IFS Mechanical Disc Mechanical Disc Top of Hood Top of Hood Rear of Seat Rear of Seat Standard Option N/A N/A N/A N/A N/A N/A Option N/A Option Option N/A N/A N/A N/A Option Option Option Option
- 26. MODELS AND SPECIFICATIONS 1992Model 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 15 16 17 18 19 MODEL YEAR 1985 1986 1987 1988 1989 1990 1991 1992 1992 MODEL DESIGNATION YEAR DESIGNATION--------;:::::::;:=:JI~ ENGINE DESIGNATION I 0 9 21 0 7 ~. 8 MODEL DESIGNATION _ _ _ _______----' 1992 MODEL DESIGNATION NUMBERS (Chassis) 09 - Star/Sprint (ES) 10- StarTrak 15 - LongTrak LTR 1992 ENGINE DESIGNATION NUMBERS 27 - EC25PS-Single FC 31 - EC34-2PM-02-Twin FC ES 33 - EC34-2PM-01-03-Twin FC 43 - EC44-3PM-01 -Twin FC 1992 ENGINE DESIGNATION NUMBERS 59 - EC40PL-02-Twin LC 60 - EC45PL-01/02-Twin LC 61 - EC50PM-01/02-Twin FC 62 - EC50PM-03-Twin FC01 - Indy Trail SuperTrak 02 - Indy Trail Deluxe 04 - Indy Sport 05 - Indy 133 SKS 49 - EC44-2PM-4100-Twin FC 58 - EC65PL-01 -Triple LC 64 - EC50PL-01/03/04-Twin LC 65 - EC50PL-02-Twin LC ES 68 - EC65PL-03-Triple LC 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 74 - EC50PL-07-Twin LC MODEL NO. MADE IN U.S.A. PCLFlRIS 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 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 Patented Canada 882,49tf71 883,694f71 Canadian Rd. 34,573f71 34,572f71 These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. 3,867,991 4,793,950 5,038,881 S64,394f71 1.227,823/87 7072133 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). 1.25 8/94
- 27. MODELS AND SPECIFICATIONS 1992Model Identification RXL RXLSKS 0920768 0920568 Engine Type LC Triple Displacement (ee) 648 Bore x Stroke (mm) 67.72 x 60 CarburetionlThrottle Body 3 Throttle Body 46 mm Butterfly Oil Injected Standard Ignition COl Alternator Output 12V 180W Length (in.!cm.) 106.25/269.9 113/287 SKS Width (in.!cm.) 43.12/109.5 41.62/1 05.7 SKS Height (in.!cm.) 38.5/97.7 44/111.7 SKS Ski Stance (in.!cm.) 38/96.4 36.5/92.7 SKS Track Width (in.!cm.) 15/38.1 Track Length Overall (in.!cm.) 121/307.1 133.5/338.9 SKS Fuel Capacity (U.S. gal./lmp. gal./liters) 11 .9/9.9/45 Recommended Fuel 88 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights OilITemp/AcclHi Beam Electric Start N/A Handwarmers Standard H/L Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 8/94 1.26 650 0920758 LC Triple 648 67.72 x 60 3 Mikuni VM38SS Slide Standard COl 12V 180W 106.25/269.9 41.62/105.7 44/111.7 36.5/92.7 15/38.1 121 /307.1 11.9/9.9/45 88 Octane Min. Parallel Link Trailing Arm IFS Liquid Cooled Hydraulic Disc Rear of Seat Standard Standard Standard OiIITemp/Acc/Hi Beam N/A Standard H/L Option Option Option Option Classic 500 SP EFI 500 SKS EFI 0920865 0920674 0920574 LC Twin LCTwin 488 488 72 x 60 72 x 60 2 Mikuni 2 Throttle Body VM38SS Slide 46 mm Butterfly Standard Standard COl COl 12V 200W 12V200W 113/287 106.25/269.9 SP 113/287 SKS 41.62/1 05.7 43.121109.5 SP 41.62/105.7 SKS 44/111.7 44/111.7 36.5/92.7 38/96.4 SP 36.5/92.7 SKS 15/38.1 15/38.1 133.5/338.9 121/307.1 133.5/338.9 SKS 11 .9/9.9/45 11.9/9.9/45 88 Octane Min. 88 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Standard Standard Standard Standard Standard Standard OiVTemp/Acc/Hi OilITemp/Hi Beam Beam Standard TBA Standard H/L Option Standard Option Standard Option Option Option Option Option o
- 28. o 500 0920764 Engine Type LCTwin Displacement (cc) 488 Bore x Stroke (mm) 72 x 60 CarburetionlThrottle Body 2 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 200W Length (in./cm.) 106.25/269.9 Width (in./cm.) 41.62/105.7 Height (in./cm.) 44/111.7 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 121/307.1 Fuel Capacity (U.S. gal./lmp. gaL/liters) 11 .9/9.9/45 Recommended Fuel 88 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights Oil/Temp/Hi Beam Electric Start Option Handwarmers Option Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 127 MODELS AND SPECIFICATIONS 1992 Model Identification WideTrak 440 XCR 440 0922064 0921760 0920760 LCTwin LCTwin LCTwin 488 432 432 72 x 60 67.72 x 60 67.72 x 60 2 Mikuni 2 Mikuni 2 Mikuni VM38SS Slide VM38SS Slide VM34SS Slide Standard Standard Standard COl COl COl 12V 200W 12V 200W 12V 200W 128/324.9 106.25/269.9 106.25/269.9 41 .62/105.7 43.12/109.5 41.62/105.7 49/124.4 38.5/97.7 44/11 1.7 36.5/92.7 38/96.4 36.5/92.7 20/50.8 15/38.1 15/38.1 156/396 121/307.1 121/307.1 10/8.3/38 7.3/6.1/28 11 .9/9.9/45 88 Octane Min. 88 Octane Min. 88 Octane Min. Parallel Link Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Gas Shock Mechanical Disc Liquid Cooled Hydraulic Disc Hydraulic Disc Under Seat Rear of Seat Rear of Seat Storage Rack Standard Standard Standard Standard Standard Standard Standard Standard Standard Oil/Temp/Rev/Hi Temp/Acc Oil/Temp Beam Hi Beam Hi Beam Option Option Option Single Heat Std. H/L Option Standard Option Option Standard Option Option Standard Option Option Standard Option Option 8/94
- 29. MODELS AND SPECIFICATIONS 1992Model Identification Engine Type Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output Length (in.!cm.) Width (in.!cm.) Height (in.!cm.) Ski Stance (in.!cm.) Track Width (in.!cm.) Track Length Overall (in.!cm.) Fuel Capacity (U.S. gal.llmp. 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 SuperTrak 0920161 Fan Cooled Twin 488 72 x 60 2 Mikuni VM34SS Slide Standard COl 12V 200W 128/324.9 41.62/105.7 45/114.2 36.5/92.7 15/38.1 156/396 11.9/9.9/45 88 Octane Min. Parallel Link Trailing Arm IFS Mechanical Disc Rear of Seat Storage Rack Standard Standard Standard RevlOil/ Hi BearnlAcc Option Single Heat Standard Standard Standard Standard 1.28 Trail Deluxe 0920262 Fan Cooled Twin 488 72 x 60 2 Mikuni VM34SS Slide Standard COl 12V200W 113/287 41.62/105.7 45/114.2 36.5/92.7 15/38.1 133.5/338.9 11.9/9.9/45 88 Octane Min. Parallel Link Trailing Arm IFS Hydraulic Disc Rear of Seat Standard Standard Standard Oil/AcclHi Beam Standard Single Heat Standard Standard Option Option o Trail Sport GT 0920761 0922443 Fan Cooled Twin Fan Cooled Twin 488 432 72 x 60 67.72 x 60 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide Standard Standard COl COl 12V 200W 12V 200W 106.25/269.9 118/299.5 o41.62/105.7 41 .62/105.7 44/111.7 45/114.2 36.5/92.7 36.5/92.7 15/38.1 15/38.1 120.96/307.1 141/358 11.919.9145 7.3/6.1/28 88 Octane Min. 88 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Storage Rack Standard Standard Standard Option Standard Standard Oil/AcclHi Beam N/A Option Option Single Heat Option Option Standard Option Standard Option Standard Option Standard
- 30. Sport 440 0920443 Engine TypeFan Cooled Twin Displacement (cc) 432 Bore x Stroke (mm) 67.72 x 60 CarburetionlThrottle Body 2 Mikuni VM34SS Slide Oil Injected Standard Ignition CDI Alternator Output 12V 200W Length (in./cm.) 106.25/269.9 Width (in./cm.) 41.62/105.7 Height (in./cm.) 44/111.7 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 121/307.1 Fuel Capacity (U.S. gal./lmp. gal./liters) 7.3/6.1/28 Recommended Fuel 88 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Hydraulic Disc Storage Rear of Seat c Speedometer Standard Tachometer Option Trip Odometer Standard Accessory Lights N/A Electric Start Option Handwarmers Option Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 1_29 MODELS AND SPECIFICATIONS 1992 Model Identification Indy Lite GT Indy Lite Star Lite Lite Deluxe 0923133 0923033 0923027 0923231 Fan Cooled Twin Fan Cooled Twin Fan Cooled Single 339 339 244 62.3x55.6 62.3x55.6 72 x 60 2 Mikuni 2 Mikuni 1 Mikuni VM30SS Slide VM30SS Slide VM30SS Slide Standard Standard Standard CDI CDI CDI 12V 150W 12V 150W 12V 150W 11 ?/292 103/261 103/261 37:9/96.2 37.9/96.2 37.9/96.2 48/121.8 46/116.7 46/116.7 36.5/92.7 36.5/92.7 36.5/92.7 15/38.1 15/38.1 15/38.1 133.5/338.9 116/294.4 116/294.4 7.7/6.4/29 7.7/6.4/29 7.7/6.4/29 88 Octane Min. 88 Octane Min. 88 Octane Min. Parallel Link Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Mechanical Disc Mechanical Disc Mechanical Disc Rear of Seat Rear of Seat Rear of Seat Standard Standard Option N/A N/A N/A Standard Standard Option N/A N/A N/A Option Option Lite N/A Standard Deluxe Option Option Lite Option Single Heat Deluxe Standard N/A N/A Option N/A N/A Standard N/A N/A Standard Option Option 8/94
- 31. MODELS AND SPECIFICATIONS 1993Model 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 12 13 14 15 16 17 18 19 20 MODEL YEAR 1985 1986 1987 1988 1989 1990 1991 1992 1993 1993 MODEL DESIGNATION YEAR D ES IG NATIONI-------------;==~I ~ ENGINE DESIGNATION I 0 9 31 2 7 10 MODEL DESIGNATION _ _ _ _ ___ _ _ _ --1 1993 MODEL DESIGNATION NUMBERS (Chassis) 02 - Indy Trail Deluxe 04 - Indy Sport 1993 ENGINE DESIGNATION NUMBERS 27 - EC25PS-07-Single FC 31 - EC34-2PM-02-Twin FC ES 33 - EC34-2PM-04-Twin FC 1993 ENGINE DESIGNATION NUMBERS 64 - EC50PL-04/06-Twin LC 65 - EC50PL-05-Twin LC ES 67 - EC58PL-01 -Triple LC05 - 440,500 EFI, XLT, RXL (SKS) 06 - 500 EFI, XLT SP 07 - Indy Trail, 440, XLT, RXL 08 - Classic/Classic Touring 17 - 440 XCR 43 - EC44-3PM-01-Twin FC 60 - EC45PL-01/02-Twin LC 68 - EC65PL-05-Triple LC (EFI) 70 - EC75PL-01 -Triple LC 61 - EC50PM-01 -Twin FC 74 - EC50PL-07-Twin LC (EFI) 20 - WideTrak 25 - Storm (SKS) 27 - Storm 31 - Indy Lite GT/StarLite GT 34 - Indy Lite Deluxe/StarLite 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 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 These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. 3,867,991 4,793,950 5,038,881 864,394171 1,227,823187 7072133 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). 8/94 1.30
- 32. o c Storm Storm SKS 0932770 0932570 EngineType LC Triple Engine Model Number EC75PL-01 Displacement (cc) 744 Bore x Stroke (mm) 69.72 x 65 CarburetionfThrottle Body 3 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 170W Length (in./cm.) 106.25/269.9 113/287 SKS Wid1h (in./cm.) 43.12/109.5 41.62/105.7 SKS Height (in./cm.) 38.5/97.7 44/111.7 SKS Ski Stance (in./cm.) 38/96.4 36.5/92.7 SKS Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 121/307.1 133.5/338.9 SKS Fuel Capacity (U.S. gal./lmp. gal./liters) 10.7/8.9/40.5 Recommended Fuel 90 Octane Min. c Front Suspension Parallel Link Trailing Arm IFS Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights Oil/BrakefTemp/Acc /Hi Beam Electric Start N/A HandwarmersfThumbwarmer Std/Std Two-Up Seat N/A o Backrest Option Storage Rack Option Tow Hitch Option 1.31 MODELS AND SPECIFICATIONS 1993 Model Identification RXL XLT XLT SKS RXL SKS XLTSP 0930768 0930767 0930567 0930568 0930667 LCTriple LC Triple LC Triple EC65PL-05 EC58PL-01 EC58PL-01 648 579 579 67.72 x 60 64 x 60 64 x 60 3 Throttle Body 3 Mikuni 3 Mikuni 46mm VM34SS Slide VM34SS Slide Standard Standard Standard COl COl COl 12V 180W 12V 170W 12V 170W 106.25/269.9 106.25/269.9 113/287 113/287 SKS 43.12/109.5 43.12/109.5 41 .62/105.7 41 .62/105.7 SKS 38.5/97.7 44/111.7 44/111 .7 44/111.7 SKS 38.5/97.7 38/96.4 38/96.4 36.5/92.7 36.5/92.7 SKS 15/38.1 15/38.1 15/38.1 121/307.1 121/307.1 133.5/338.9 133.5/338.9 SKS 11.9/9.9/45 11.9/9.9/45 11 .9/9.9/45 88 Octane Min. 88 Octane Min. 88 Octane Min. Parallel Link Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Liquid Cooled Hydraulic Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Standard Standard Standard Standard Standard Standard Standard Standard Standard Oil/BrakefTemp/Acc OillBrakefTemp/ Oil/BrakefTemp/ /Hi Beam Acc/Hi Beam Acc/Hi Beam N/A TBA TBA Std/N/A Std/Std Std/Std Option Option Option Option Option Option Option Option Option Option Option Option 1). 8/94
- 33. MODELS AND SPECIFICATIONS 1993Model Identification Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) Carburetionrrhrottle Body Oil Injected Ignition Alternator Output Length (in.lcm.) Width (in.lcm.) Height (in.lcm.) Ski Stance (in.lcm.) Track Width (in.lcm.) Track Length Overall (inkm.) Fuel Capacity (U.S. gal.llmp. gal./liters) Recommended Fuel Front Suspension Brake Type Storage Speedometer Tachometer Trip Odometer Accessory Lights Electric Start Handwarmersrrhumbwarmer Two-Up Seat Backrest Storage Rack Tow Hitch 8/94 500 EFI 500 SKS EFI 0930674 0930574 LCTwin EC50PL-07 488 72 x 60 2 Throttle Body 46mm Standard COl 12V200W 106.25/269.9 11 3/287 SKS 43.12/109.5 41.62/105.7 SKS 44/111.7 38/96.4 36.5/92.7 SKS 15/38.1 121/307.1 133.5/338.9 SKS 11.9/9.9/45 88 Octane Min. Parallel Link Trailing Arm IFS Hydraulic Disc Rear of Seat Standard Standard Standard OillBrakerremp/ Acc/Batt/Hi Beam Option Std/Std N/A Option Option Option 1.32 Classic 0930864 LCTwin EC50PL-04 488 72 x 60 2 Mikuni VM38SS Slide Standard COl 12V 200W 106.25/269.9 43.12/109.5 44/111.7 38/96.4 15/38.1 121/307.1 11.9/9.9/45 88 Octane Min. Parallel Link Trailing Arm IFS Hydraulic Disc Rear of Seat Standard Standard Standard OillBrakerremp/ Acc/Hi Beam Option Std/Std Option Option Option Option o Classic WideTrak Touring 0930865 0932064 LC Twin LCTwin EC50PL-05 EC50PL-06 488 488 72 x 60 72 x 60 2 Mikuni 2 Mikuni VM38SS Slide VM34SS Slide Standard Standard COl COl 12V 200W 12V 200W 113/287 128/324.9 41.62/105.7 41 .62/1 05.7 44/111.7 49/124.4 36.5/92.7 36.5/92.7 15/38.1 20/50.8 133.5/338.9 156/396 11.9/9.9/45 10/8.3/38 88 Octane Min. 88 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Hydraulic Disc Mechanical Disc Rear of Seat Under Seat oStorage Rack Standard Standard Standard Standard Standard Standard OillBrakerremp/ Oilrremp/Rev/ Acc/Hi Beam Hi Beam Standard Option Std/Std Std/Option Standard Standard Standard Standard oOption Standard Option Standard
- 34. 440 XCR 0931760 Engine TypeLC Twin Engine Model Number EC45PL-01 Displacement (cc) 432 Bore x Stroke (mm) 67.72 x 60 CarburetionfThrottle Body 2 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 200W Length (in.!cm.) 106.25/269.9 Width (in.!cm.) 43.12/109.5 Height (in.!cm.) 38.5/97.7 Ski Stance (in.!cm.) 38/96.4 Track Width (in.!cm.) 15/38.1 Track Length Overall (in.!cm.) 121/307.1 Fuel Capacity (U.S. gaUlmp. gaUliters) 7.3/6.1/28 Recommended Fuel 88 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Trip Odometer Standard Accessory Lights BrakefTemp/Acc Hi Beam Electric Start Option HandwarmersfThumbwarmer Std/Std Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 1.33 MODELS AND SPECIFICATIONS 1993 Model Identification 440 Trail Trail Deluxe 440 SKS 0930760 0930761 0930243 0930560 LCTwin Fan Cooled Twin Fan Cooled Twin EC45PL-02 EC50PM-01 EC44-3PM-01 432 488 432 67.72 x 60 72 x 60 67.72 x 60 2 Mikuni 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide VM34SS Slide Standard Standard Standard COl COl COl 12V 200W 12V200W 12V 200W 106.25/269.9 106.25/269.9 113/287 113/287 SKS 43.12/109.5 43.12/109.5 41 .62/105.7 41 .62/105.7 SKS 44/111.7 44/111.7 45/114.2 38/96.4 38/96.4 36.5/92.7 36.5/92.7 SKS 15/38. 1 15/38.1 15/38.1 121/307.1 121/307.1 133.5/338.9 133.5/338.9 SKS 11.9/9.9/45 11 .9/9.9/45 11 .9/9.9/45 88 Octane Min. 88 Octane Min. 88 Octane Min. Parallel Link Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Hydraulic Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Standard Standard Standard Standard Standard Option Standard Standard Standard Oil/BrakefTemp/ Oil/Brake/ Oil/Brake/ Acc/Hi Beam Acc/Hi Beam Acc/Hi Beam Option Option Option Std/Std Std/Option Std/Option Option Option Standard Option Option Standard Option Option Option Option Option Option 8/94
- 35. MODELS AND SPECIFICATIONS 1993Model Identification Sport 440 0930443 Engine Type Fan Cooled Twin Engine Model Number EC44-3PM-01 Displacement (cc) 432 Bore x Stroke (mm) 67.72 x 60 CarburetionlThrottle Body 2 Mikuni VM34SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 200W Length (in./cm.) 106.25/269.9 Width (in./cm.) 41.62/105.7 Height (in./cm.) 44/111 .7 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 121/307.1 Fuel Capacity (U.S. gal./lmp. gal./liters) 11.9/9.9/45 Recommended Fuel 88 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Option Trip Odometer Standard Accessory Lights Acc Electric Start Option HandwarmerslThumbwarmer Std/Option Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 8/94 1.34 Indy Lite GT 0933133 Fan Cooled Twin EC34-2PM-04 339 62.3/55.6 2 Mikuni VM30SS Slide Standard COl 12V 150W 115/292 37.9/96.2 48/121.8 36.5/92.7 15/38.1 133.5/338.9 8/6.7/30 88 Octane Min. Parallel Link Trailing Arm IFS Mechanical Disc Rear of Seat Standard N/A Standard N/A Option Option/Option Standard Option Standard Standard ) Lite Deluxe Indy Lite 0933431 0933433 Fan Cooled Twin Fan Cooled Twin EC34-2PM-02 EC34-2PM-04 339 339 62.3/55.6 62.3/55.6 2 Mikuni 2 Mikuni VM30SS Slide VM30SS Slide Standard Standard COl COl 12V 150W 12V 150W 105/267 105/267 37.9/96.2 37.9/96.2 46/116.7 46/116.7 36.5/92.7 36.5/92.7 15/38.1 15/38.1 121/307.1 121/307.1 8/6.7/30 8/6.7/30 88 Octane Min. 88 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Mechanical Disc Mechanical Disc Rear of Seat Rear of Seat Standard Standard N/A N/A Standard Standard N/A N/A Standard Option Std/Option Option/Option N/A / N/A N/A N/A TBA TBA Option Option
- 36. c Indy StarLite GT 0933127 EngineType Fan Cooled Single Engine Model Number EC25PS-07 Displacement (cc) 244 Bore x Stroke (mm) 72 x 60 CarburetionfThrottle Body 1 Mikuni VM30SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 150W Length (in./cm.) 11 5/292 Width (in./cm.) 37.9/96.2 Height (in./cm.) 48/121.8 Ski Stance (in./cm.) 36.5/92.7 Track Width (in./cm.) 15/38.1 Track Length Overall (in./cm.) 133.5/338.9 Fuel Capacity (U.S. gaL/Imp. gaL/liters) 8/6.7/30 Recommended Fuel 88 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Mechanical Disc Storage Rear of Seat Speedometer Option Tachometer N/A Trip Odometer Option Accessory Lights N/A Electric Start N/A HandwarmersfThumbwarmer Option/Option Two-Up Seat Standard Backrest Option Storage Rack Standard Tow Hitch Option ( 1.35 MODELS AND SPECIFICATIONS 1993 Model Identification Indy StarLite 0933427 Fan Cooled Single EC25PS-07 244 72 x 60 1 Mikuni VM30SS Slide Standard COl 12V 150W 105/267 37.9/96.2 46/116.7 36.5/92.7 15/38.1 121/307.1 8/6.7/30 88 Octane Min. Parallel Link Trailing Arm IFS Mechanical Disc Rear of Seat Option N/A Option N/A N/A Option/Option N/A N/A TBA Option 8/94
- 37. MODELS AND SPECIFICATIONS 1994Model Identification SERIAL NUMBER IDENTIFICATION The machine serialnumber 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 ENGINE DESIGNATION I 0 9 410 7 12 MODEL DESIGNATION __________--' 1994 MODEL DESIGNATION NUMBERS (Chassis) 02 - Sport SKS, Trail Deluxe 04 - Sport 1994 ENGINE DESIGNATION NUMBERS 27 - EC25PS-07-Single FC 31 - EC34-2PM-02-Twin FC (ES) 33 - EC34-2PM-04-Twin FC 1994 ENGINE DESIGNATION NUMBERS 64 - EC50PL-06-Twin LC 65 - EC50PL-05-Twin LC 67 - EC58PL-01-Triple LC05 - XLT SKS, Storm SKS 06 - XLT SP 43 - EC44-3PM-01 -Twin FC 68 - EC65PL-05-Triple LC (EFI) 07 - Super Sport,Trail, RXL, XLT, Storm 08 - RXL Touring 60 - EC45PL-01/02- Twin LC (A) 61 - EC50PM-01/03-Twin FC (B) 62 - EC50PM-02-Twin FC (ES) 69 - EC65PL-06-Triple LC (EFI ES) 74 - EC50PL-07-Twin LC (EFI) 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 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 75 - EC50PL-08-Twin LC (EFI ES) 82 - EC80PL-01 Triple LC MODEL NO. PATENT NOTICE MADE IN U.S.A. PDLRRIS 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 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 Patented Canada 882,491 171 883,694171 Canadian Rd. 34,573171 34,572171 These numbers should be referred to in any correspondence regarding warranty, service or replacement parts. 3.867,991 4,793,950 5,038,881 864,394/71 1,227,823187 7072133 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). 8/94 1.36 o
- 38. o Engine Type Engine ModelNumber Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output Length (in.!cm.) Width (in.!cm.) Height (in.!cm.) Ski Stance (in.!cm.) Track Width (in.!cm.) Track Length Overall (in.!cm.) Fuel Capacity (U.S. gal.llmp. gal.lliters) Recommended Fuel o Front Suspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights Electric Start HandwarmersIThumbwarmer Two-Up Seat Backrest Storage Rack Tow Hitch Storm Storm SKS 0940782 0940582 LC Triple EC80PL-01 794 72 x 65 MODELS AND SPECIFICATIONS 1994 Model Identification RXL XLT XLT SKS RXL Touring XLTSP 0940768 0940767 0940567 0940869 0940667 LC Triple LC Triple LC Triple EC65PL-05/06 EC58PL-01 EC58PL-01 648 579 579 67.72 x 60 64 x 60 64 x 60 3 Mikuni 3 Throttle Body 46mm 3 Mikuni 3 Mikuni VM38SS Slide VM34SS Slide VM34SS Slide Standard Standard Standard Standard COl COl COl COl 12V 180W 12V 180W 12V 170W 12V 170W 106.25/269.9 106.25/269.9 106.25/269.9 113/287 113/287 SKS 113/287 Touring 45.5/115.6 45.5/115.6 45.5/115.6 43.5/110.5 43.5/110.5 SKS 38.5/97.8 38.5/97.8 44/111.8 44/111.8 44/111 .8 SKS 44/111.8 Touring 38.5/97.8 SP 40/1 01 .6 40/101.6 40/101.6 38/96.5 38/96.5 SKS 15/38.1 15/38.1 15/38.1 15/38.1 121/307.3 121/307.3 121/307.3 133.5/339.1 133.5/339.1 SKS 133.5/339.1 Touring 10.7/8.9/40.5 10.7/8.9/40.5 10.7/8.9/40.5 10.7/8.9/40.5 90 Octane Min. 87 Octane Min. 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Liquid Cooled Liquid Cooled Hydraulic Disc Hydraulic Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Rear of Seat Standard Standard Standard Standard Standard Standard Standard Standard Option Standard Option Option Oil/Brake Oil/Brake Oil/Brake Oil/Brake Temp/Acc Temp/Acc Temp/Acc Temp/Acc High Beam High Beam High Beam High Beam N/A Touring Option Option Hi-Lo/Std Hi-Lo/NA Hi-Lo/Std Hi-Lo/Std N/A Option Option Option Option Option Option Option Option Option Option Option Option Option Option Option 1.37 8/94
- 39. MODELS AND SPECIFICATIONS 1994Model Identification XLT Special XTRA 0946767 Engine Type LC Triple Engine Model Number EC58PL-03 Displacement (ee) 596 Bore x Stroke (mm) 65 x 60 CarburetionfThrottle Body 3 Mikuni VM34SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 170W Length (in./cm.) 106.25/269.9 Width (in./cm.) 49/124.5 Height (in./cm.) 47/119.4 Ski Stance (in./cm.) 38/96.5 Track Width (in./cm.) 15/38.1 Track Length Overall 121/307.3 (in./cm.) Fuel Capacity (U.S. gas'/Imp. gaL/liters) 10.7/8.9/40.5 Recommended Fuel 87 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Electric Fuel Gauge Option Accessory Lights Oil/Brake Temp/Acc High Beam Electric Start Option HandwarmersfThumbwarmer Hi-Lo/Std Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 8/94 500 EFI 500 EFI SKS 0942774 0942574 LCTwin EC50PL-07 488 72 x 60 2 Throttle Body 46mm Standard COl 12V 250W 107/271.8 113/287 SKS 45.5/115.6 43.5/110.5 SKS 46/116.8 40/101.6 38/96.5 SKS 15/38.1 121/307.3 133.5/339.1 SKS 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS Hydraulic Disc Rear of Seat Standard Standard Option Oil/BrakefTemp Acc/Batt High Beam Option Hi-Lo/Std Option Option Option Option 1.38 o Classic Classic r) Touring 0942865 0942875 LCTwin LCTwin EC50PL-05 EC50PL-08 488 488 72 x 60 72 x 60 2 Mikuni 2 Mikuni VM38SS Slide VM38SSSiide Standard Standard COl COl 12V200W 12V 250W 107/271.8 113/287 45.5/115.6 45.5/115.6 46/116.8 46/116.8 40/101 .6 40/101.6 15/38.1 15/38.1 121/307.3 133.5/339.1 10.7/8.9/40.5 10.7/8.9/40.5 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Standard Standard Standard Standard Standard Standard Oil/Brake Oil/BrakefTemp Temp/Acc Acc/Batt High Beam High Beam Option Standard Hi-Lo/Std Hi-Lo/Std Option Standard Option Standard Option Option Option Option
- 40. WideTrak LX WideTrakGT 0942064 0942061 Engine Type LCTwin Fan Twin Engine Model Number EC50PL-06 EC50PM-03 Displacement (cc) 488 488 Bore x Stroke (mm) 72 x 60 72 x 60 CarburetionfThrottle Body 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide Oil Injected Standard Standard Ignition COl COl Alternator Output 12V 200W 12V 200W Length (in.!cm.) 128/325.1 121.5/308.6 Width (in.!cm.) 43.5/110.5 43.5/110.5 Height (in.!cm.) 49/124.5 49/124.5 Ski Stance (in.!cm.) 38/96.5 38/96.5 Track Width (in.!cm.) 20/50.8 20/50.8 Track Length Overall 156/396.2 141/358.1 (in.!cm.) Fuel Capacity (U.S. gas.!lmp. 10/8.3/38 10/8.3/37.8 gal.lliters) Recommended Fuel 87 Octane Min. 87 Octane Min. Front Suspension Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Brake Type Mechanical Disc Mechanical Disc Storage Under Seat Under Seat Storage Rack Speedometer Standard Standard Tachometer Standard Option Electric Fuel Gauge N/A N/A Accessory Lights OilfTemp Rev/Acc Rev Oil High Beam High Beam Electric Start Option Option HandwarmersfThumbwarmer Single Heat/Std Single Heat/Std Two-Up Seat Standard Standard Backrest Standard Standard Storage Rack Standard Standard Tow Hitch Standard Standard 1.39 MODELS AND SPECIFICATIONS 1994 Model Identification 600XCR 440 XCR 0941667 0941760 LCTwin LC Twin EC58PL-02 EC45PL-01 596 432 65 x 60 67.72 x 60 3 Mikuni 2 Mikuni VM38SS Slide VM38SS Slide Standard Standard COl COl 12V 170W 12V200W 106.25/269.9 106.25/269.9 45.5/115.6 45.5/11 5.6 38.5/97.8 38.5/97.8 41/104.1 40/101.6 15/38.1 15/38.1 121/307.3 121/307.3 10.7/8.9/40.5 10.7/8.9/40.5 91 Octane Min. 87 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Liquid Cooled Liquid Cooled Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Standard Standard Standard Standard Option Option Oil/Brake Oil/Brake Temp/Acc Temp/Acc High Beam High Beam Option Option Hi-Lo/Std Hi-Lo/Std N/A Option N/A Option N/A Option N/A Option 8/94
- 41. MODELS AND SPECIFICATIONS 1994Model Identification 440XCR SP 0941660 Engine Type LCTwin Engine Model Number EC45PL-03 Displacement (cc) 439 Bore x Stroke (mm) 68.25 x 60 Carburetionrrhrottle Body 2 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 200W Length (in./cm.) 106.25/269.9 Width (in./cm.) 45.5/115.6 Height (in./cm.) 38.5/97.8 Ski Stance (in./cm.) 41/104.1 Track Width (in./cm.) 15/38.1 Track Length Overall 121/307.3 (in./cm.) Fuel Capacity (U.S. gas'/Imp. gal.!liters) 10.7/8.9/40.5 Recommended Fuel 91 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Electric Fuel Gauge Option Accessory Lights Oil/Brake TemplAcc High Beam Electric Start Option Handwarmersrrhumbwarmer Hi-Lo/Std Two-Up Seat N/A Backrest N/A Storage Rack N/A Tow Hitch N/A 8/94 1.40 , . 440 Indy 440 Indy SKS 0942760 0942560 LC Twin EC45PL-02 432 67.72 x 60 2 Mikuni VM34SS Slide Standard COl 12V 200W 107/271.8 113/287 SKS 45.5/115.6 43.5/110.5 SKS 46/116 .8 40/10 1.6 38/96.5 SKS 15/38.1 121/307.3 133.5/339.1 SKS 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS Hydraulic Disc Rear of Seat Standard Standard Option Oil/Brake TemplAcc High Beam Option Hi-Lo/Std Option Option Option Option Trail Deluxe Trail 0940262 0940761 Fan Twin Fan Twin EC50PM-02 EC50PM-01 488 488 72 x 60 72 x 60 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide Standard Standard COl COl 12V200W 12V200W 113/287 106.25/269.9 45.5/115.6 45.5/115.6 45/114.3 44/111.8 40/101.6 40/101.6 15/38.1 15/38.1 133.5/339.1 121/307.3 10.7/8.9/40.5 10.7/8.9/40.5 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Standard Standard Option Standard Option Option Oil/Brake Oil/Brake Acc Acc High Beam High Beam Standard Option Single Heat/Std Single Heat/Std Standard Option Standard Standard Option Option Option Option
- 42. Super Sport 0940743 Engine TypeFan Twin Engine Model Number EC44-3PM-01 Displacement (cc) 432 Bore x Stroke (mm) 67.72 x 60 Carburetionrrhrottle Body 2 Mikuni VM34SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 200W Length (in.lcm.) 106.25/269.9 Width (in.lcm.) 45.5/115.6 Height (in.lcm.) 38.5/97.8 Ski Stance (in.lcm.) 40/101.6 Track Width (in.lcm.) 15/38.1 Track Length Overall (in.lcm.) 121/307.3 Fuel Capacity (U.S. gas.llmp. gal.lliters) 10.7/8.9/40.5 Recommended Fuel 87 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Electric Fuel Gauge Option Accessory Lights Oil/Brake Acc High Beam Electric Start Option Handwarmersrrhumbwarmer Single Heat/Std Two-Up Seat Option Backrest Standard Storage Rack Option Tow Hitch Option 1.41 MODELS AND SPECIFICATIONS 1994 Model Identification Sport Indy Lite Indy Lite GT SportSKS Deluxe 0940443 0943431 0943133 0940243 Fan Twin Fan Twin Fan Twin EC44-3PM-01 EC34-2PM-02 EC34-2PM-04 432 339 339 67.72 x 60 62.3 x 55.6 62.3 x 55.6 2 Mikuni 2 Mikuni 2 Mikuni VM34SS Slide VM30SS Slide VM30SS Slide Standard Standard Standard COl COl COl 12V200W 12V 150W 12V 150W 106.25/269.9 105/266.7 11 5/292.1 113/287 SKS 43.5/110.5 42.5/108 42.5/108 44/111 .8 44/111 .8 48/121.9 45/114.3 SKS 38/96.5 37/94 37/94 15/38.1 15/38.1 15/38.1 121/307.3 121/307.3 133.5/339.1 133.5/339.1 SKS 10.7/8.9/40.5 8/6.7/30.3 8/6.7/30.3 87 Octane Min. 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Hydraulic Disc Mechanical Disc Mechanical Disc Rear of Seat Rear of Seat Rear of Seat Top of Hood Top of Hood Standard Standard Standard Option N/A N/A Option N/A N/A Oil/Brake Oil/Acc Oil/Acc Acc High Beam Option Standard Option Single Heat Std Single Heat/Std Single Heat/Std Option N/A Standard Standard SKS Option N/A Standard Standard SKS Option Option Standard Option Option Standard 8/94
- 43. MODELS AND SPECIFICATIONS 1994Model Identification Engine Type Engine Model Number Displacement (cc) Bore x Stroke (mm) CarburetionfThrottle Body Oil Injected Ignition Alternator Output Length (in.lcm.) Width (in.lcm.) Height (in.lcm.) Ski Stance (in.lcm.) Track Width (in.lcm.) Track Length Overall (in.lcm.) Fuel Capacity (U.S. gas.llmp. gaUliters) Recommended Fuel Front Suspension Brake Type Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights Electric Start HandwarmersfThumbwarmer Two-Up Seat Backrest Storage Rack Tow Hitch 8/94 . StarLite GT 0943127 Fan Single EC25PS-07 244 72 x 60 1 Mikuni VM30SS Slide Standard COl 12V 150W 115/292.1 42.5/108 48/1 21.9 37194 15138.1 133.5/339.1 8/6.7/30.3 87 Octane Min. Parallel Link Trailing Arm IFS Mechanical Disc Rear of Seat Top of Hood Option N/A N/A N/A N/A Option/Option Standard Standard Standard Standard 1.42 StarLite Indy Lite 0943427 0943433 Fan Single Fan Twin EC25PS-07 EC34-2PM-04 244 339 72 x 60 62.3 x 55.6 1 Mikuni 2 Mikuni VM30SS Slide VM30SS Slide Standard Standard COl COl 12V 150W 12V 150W 105/266.7 105/266.7 42.5/108 42.5/108 44/111.8 44/111.8 37/94 37/94 15/38.1 15/38.1 121/307.3 121 /307.3 8/6.7/30.3 8/6.7/30.3 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Mechanical Disc Mechanical Disc Rear of Seat Rear of Seat Top of Hood Top of Hood Option Standard N/A N/A N/A N/A N/A N/A N/A Option OptionlOption OptionlOption N/A N/A N/A N/A Option Option Option Option
- 44. MODELS AND SPECIFICATIONS 1995Model 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 FIRST DIGITS 18 MODEL YEAR 1991 13 1986 19 1992 14 1987 20 1993 15 1988 22 1994 16 1989 23 1995 17 1990 1995 MODEL DESIGNATION YEAR DESIGNATION- - - - -- - ---, r-- - - - ENGINE DESIGNATION o~MODEL DESIGNATION 1995 MODEL DESIGNATION NUMBERS (Chassis) 02 - Sport Touring 04 - Sport 05 - XLT SKS, Storm SKS 07 - Super Sport, XLT, Storm 08 - RXL Touring 20 - WideTrak GT/LX 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, StarLite 22 - Indy Trail Deluxe 16 - Indy 440 XCR, Indy 600 XCR 29 - Indy 500 EFI SKS (paddle track) 67 - Indy XLT Special, RXL 1995 ENGINE DESIGNATION NUMBERS 27 - EC25PS07 33 - EC34-2PM02lE02 43 - EC44-3PM01/02 60 - EC45PL02/03 61 - EC50PM03/E04/04 62 - EC50PME04/04 56 - EC58PL03 09 - Indy XLT SKS (paddle track), Storm SKS (paddle track) MODEL NO. MADE IN U.S.A. PDLRRIS 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 SERIAL NO. Mfd. by Polaris Industries L.P. in Roseau, MN under one or more of the following patents: THiS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL AND STATE REQUIREMENTS AND CANADiAN FEDERAL MOTOR VEHICLE STAN· DARDS IN EFFECT ON THE DATE OF MANUFAC- TURE. MFD. DATE: U.S. Patents 3,605,511 3,580,647 3,483,766 3,533,662 3,545,821 3,605,510 3,525,412 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 Patented Canada 882,491n1 883,694f71 864,394n1 Canadian Rd. 34,573n1 34,572f71 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). 1.43 8/94
- 45. MODELS AND SPECIFICATIONS 1995Model Identification Storm Storm SKS/PT 0950782 0950582 0950982 Engine Type LC Triple Engine Model Number EC80PL01 Displacement (cc) 794 Bore x Stroke (mm) 72 x 65 CarburetionfThrottle Body 3 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 170W Length (in./cm.) 106.25/269.9 113/287 SKS Width (in./cm.) 45.5/115.6 43.5/110.5 SKS Height (in./cm.) 38.5/97.8 44/111.8 SKS Ski Stance (in./cm.) 40/101.6 38/96.5 SKS Track Width (in./cm.) 15/38.1 Track Length Overall 121/307.3 (in./cm.) 133.5/339.1 SKS Fuel Capacity (U.S. gal.llmp. gal./liters) 10.7/8.9/40.5 Recommended Fuel 90 Octane Min. Front SuspenSion Parallel Link Trailing Arm IFS Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Toolbox Footrest Speedometer Standard Tachometer Standard Electric Fuel Gauge Option Accessory Lights Oil/Brake Temp/Ace High Beam Electric Start N/A HandwarmersIThumbwarmer Hi-Lo/Std Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 8/94 RXL Touring 0950869 LC Triple EC65PLE05 648 67.72 x 60 3 Throttle Body 46mm Standard COl 12V 180W 113/287 45.5/11 5.6 45/114.3 40/101 .6 15/38.1 133.5/339.1 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS Liquid Cooled Hydraulic Disc Rear of Seat Toolbox Footrest Standard Standard Standard Oil/Brake Temp/Ace High Beam Standard Hi-Lo/Option Standard Standard Option Option 1.44 RXL XLT XLTSP 0956768 0950756 0956756 oLC Triple LC Triple EC65PL05 EC58PL03 648 597 67.72 x 60 65 x 60 3 Throttle Body 3 Mikuni 46mm VM34SS Slide Standard Standard COl COl 12V 180W 12V 170W 106.25/269.9 106.25/269.9 49/124.46 45.5/11 5.6 49/124.46 SP 43/109.22 44/111.8 43/1 09.22 SP 43.5/11 0.49 40/101.6 43.5/1 10.49 SP 15/38.1 15/38.1 121/307.3 121/307.3 10.7/8.9/40.5 10.7/8.9/40.5 87 Octane Min. 87 Octane Min. Non-Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Non-Parallel LinkTrailing Arm IFSSP Liquid Cooled Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Toolbox Footrest Toolbox Footrest Standard Standard Standard Standard Standard Option Oil/Brake Oil/Brake Temp/Acc Temp/Acc High Beam High Beam Option Option Hi-Lo/Option Hi-Lo/Std Option Option Option Option Option Option TBA Option TBA SP
- 46. Engine Type Engine ModelNumber Displacement (cc) Bore x Stroke (mm) CarburetionlThrottle Body Oil Injected Ignition Alternator Output Length (in./cm.) Width (in./cm.) Height (in./cm.) Ski Stance (in./cm.) Track Width (in./cm.) Track Length Overall (in./cm.) Fuel Capacity (U.S. gas'/Imp. gal./liters) Recommended Fuel Front Suspension Brake Type c Storage Speedometer Tachometer Electric Fuel Gauge Accessory Lights Electric Start HandwarmerslThumbwarmer Two-Up Seat Backrest Storage Rack Tow Hitch XlT SKS/PT 0950556 0950956 t;c Triple EC58PL03 597 65 x 60 3 Mikuni VM34SS Slide Standard COl 12V 170W 113/287 43.5/110.5 44/111.8 38/96.5 15/38.1 133.5/339.1 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS Hydraulic Disc Rear of Seat MODELS AND SPECIFICATIONS 1995 Model Identification XlTTouring 600 XCR 500 0952857 0951676 0952764 LC Triple LC Triple LC Twin EC58PLE04 EC58PL02 EC50PL04 597 597 488 65 x 60 65 x 60 72 x 60 3 Mikuni 3 Mikuni 2 Mikuni VM34SS Slide VM38AL Slide VM38SS Slide Standard Standard Standard COl COl COl 12V 170W 12V 170W 12V200W 113/287 106.25/269.87 107/271.8 45.5/115.57 45.5/115.57 45.5/115.6 46/116.84 40/101.6 40/101.6 40/101 .6 40/101.6 40/101 .6 15/38.1 15/38.1 15/38.1 133.5/339.1 121/307.3 121/307.3 10.7/8.9/40.5 9.5/8.9/40.5 10.7/8.9/40.5 87 Octane Min. 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS w/shock w/shock Hydraulic Disc Liquid Cooled Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Toolbox Footrest Toolbox Under Hood Toolbox Standard Standard Standard Standard Standard Standard Standard Standard Option Standard N/A Option Oil/Brake Oil/Brake Oil/Brake Oil/Brake Temp/Acc Temp/Acc Temp/Acc Temp/Acc High Beam High Beam High Beam High Beam Option Standard N/A Option Hi-Lo/Std Hi-Lo/Std Hi-Lo/Std Hi-Lo/S.td Option Standard Option Option Option Standard Option Option Option Option Option Option Option Option Option Option 1.45 8/94
- 47. MODELS AND SPECIFICATIONS 1995Model Identification Classic 0952865 Engine Type LCTwin Engine Model Number EC50PLE04 Displacement (cc) 488 Bore x Stroke (mm) 72 x 60 CarburetionfThrottle Body 2 Mikuni VM38SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 200W Length (in.!cm.) 107/271.8 Width (in.!cm.) 45.5/115.6 Height (in.!cm.) 44/111.76 Ski Stance (in.!cm.) 40/101.6 Track Width (in.!cm.) 15/38.1 Track Length Overall 121/307.3 (in.!cm.) Fuel Capacity (U.S. gas.!lmp. 10.7/8.9/40.5 gal./liters) Recommended Fuel 87 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Hydraulic Disc Storage Rear of Seat Toolbox Under Hood Speedometer Standard Tachometer Standard Electric Fuel Gauge Standard Accessory Lights Oil/Brake Temp/Ace High Beam Electric Start Standard HandwarmersfThumbwarmer Hi-Lo/Std Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 8/94 500 EFI 500 EFI SKS/PT 0952774 0952574 0952974 LCTwin EC50PL07 488 72 x 60 2 Throttle Body 46mm Standard COl 12V 250W 107/271.8 113/287 SKS 45.5/115.6 43.5/110.5 SKS 44/111.76 40/101 .6 38/96.5 SKS 15/38.1 121/307.3 133.5/339.1 SKS 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS Hydraulic Disc Rear of Seat Toolbox Under Hood Standard Standard Option Oil/BrakefTemp Ace/Batt High Beam Option Hi-Lo/Std Option Option Option Option 1-46 WideTrak LX WideTrak GT 0952064 0952061 LCTwin Fan Twin EC50PL06 EC50PM03 488 488 72 x 60 72 x 60 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide Standard Standard COl COl 12V200W 12V 200W 128/325.1 121.5/308.6 43.5/110.5 43.5/110.5 49/124.5 49/124.5 38/96.5 38/96.5 20/50.8 20/50.8 156/396.2 141/358.1 10/8.3/38 10/8.3/37.8 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Mechanical Mechanical Under Seat Under Seat Storage Rack Standard Standard Standard Option N/A N/A OilfTemp Rev/Acc Rev Oil High Beam High Beam Option Option Single Heat/Std Single Heat/Std Standard Standard Standard Standard Standard Standard Standard Standard
- 48. 440XCR 0951660 Engine Type LCTwin EngineModel Number EC45PL05 Displacement (cc) 439 Bore x Stroke (mm) 68.25 x 60 CarburetionlThrottle Body 2 Mikuni VM34SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 200W Length (inJcm.) 106.25/269.9 Width (inJcm.) 45.5/115.6 Height (inJcm.) 38.5/97.8 Ski Stance (inJcm.) 41/104.14 Track Width (inJcm.) 15/38.1 Track Length Overall 121/307.3 (inJcm.) Fuel Capacity (U.S. gasJlmp. gaL/liters) 9.5/8.9/40.5 Recommended Fuel 87 Octane Min. Front Suspension Parallel Link Trailing Arm IFS w/shock Brake Type Liquid Cooled Hydraulic Disc Storage Rear of Seat Speedometer Standard Tachometer Standard Electric Fuel Gauge N/A Accessory Lights Oil/Brake Temp/Acc High Beam Electric Start N/A HandwarmersIThumbwarmer Hi-Lo/Std Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 1.47 MODELS AND SPECIFICATIONS 1995 Model Identification 440 Indy Trail Deluxe Trail 440lndySKS 0952760 0952262 0952761 0952560 LCTwin 1'} Fan Twin Fan Twin EC45PL02 EC50PME04 EC50PM04 432 488 488 67.72 x 60 72 x 60 72 x 60 2 Mikuni 2 Mikuni 2 Mikuni VM34SS Slide VM34SS Slide VM34SS Slide Standard Standard Standard COl COl COl 12V 200W 12V200W 12V200W 107/271.8 113/287 107/271 .78 113/287 SKS 45.5/115.6 45.5/115.6 45.5/1 15.6 43.5/110.5 SKS 44/111 .76 46/116.84 44/111 .8 40/101.6 40/101.6 40/101.6 38/96.5 SKS 15/38.1 15/38.1 15/38.1 121/307.3 133.5/339.1 121/307.3 133.5/339.1 SKS 10.7/8.9/40.5 10.7/8.9/40.5 10.7/8.9/40.5 87 Octane Min. 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Trailing Arm IFS Hydraulic Disc Hydraulic Disc Hydraulic Disc Rear of Seat Rear of Seat Rear of Seat Toolbox Toolbox Toolbox Standard Standard Standard Standard Option Standard Option Option Option OiVBrake OiVBrake Oil/Brake Temp/Acc Acc Acc High Beam High Beam High Beam Option Standard Option Hi-Lo/Std Hi-Lo/Std Hi-Lo/Std Option Standard Option Option Standard Option Option Option Option Option Option Option 8/94
- 49. MODELS AND SPECIFICATIONS 1995Model Identification Super Sport 0950743 Engine Type Fan Twin Engine Model Number EC44-3PM02 Displacement (cc) 432 Bore x Stroke (mm) 67.72 x 60 CarburetionfThrottle Body 2 Mikuni VM34SS Slide Oil Injected Standard Ignition COl Alternator Output 12V200W Length (in./cm.) 106.25/269.9 Width (in.!cm.) 45.5/115.6 Height (in.!cm.) 38.5/97.8 Ski Stance (in.!cm.) 41 /1 04.14 Track Width (in.!cm.) 15/38.1 Track Length Overall (in.!cm.) 121/307.3 Fuel Capacity (U.S. gas.!lmp. gal./liters) 10.7/8.9/40.5 Recommended Fuel 87 Octane Min. Front Suspension Parallel Link Trailing Arm IFS Brake Type Hydraulic Disc Storage Rear of Seat Toolbox Footrest Speedometer Standard Tachometer Standard Electric Fuel Gauge Option Accessory Lights Oil/Brake Acc High Beam Electric Start Option HandwarmersfThumbwarmer Single Heat/Std Two-Up Seat Option Backrest Option Storage Rack Option Tow Hitch Option 8/94 Sport Sport Touring 0950443 0950243 Fan Twin EC44-3PM01 432 67.72 x 60 2 Mikuni VM34SS Slide Standard COl 12V 200W 106.25/269.9 113/287 Touring 43.5/110.5 44/111.8 45/114.3 Touring 38/96.5 15/38.1 121/307.3 . 133.5/339.1 Touring 10.7/8.9/40.5 87 Octane Min. Parallel Link Trailing Arm IFS Hydraulic Disc Rear of Seat Toolbox Footrest Standard Option Option Oil/Brake Acc High Beam Option Single Heat/Std Single Heat/Acc Touring Option Standard Touring Option Standard Touring Option Option 1.48 o Indy Lite Indy Lite GT Deluxe 0953431 0953133 Fan Twin Fan Twin EC34-2PME02 EC34-2PM02 339 339 62.3 x 55.6 62.3 x 55.6 2 Mikuni 2 Mikuni VM30SS Slide VM30SS Slide Standard Standard COl COl 12V 150W 12V 150W 105/266.7 11 5/292.1 42.5/108 42.5/1 08 44/111.8 48/121.9 37/94 37/94 15/38.1 15/38.1 121/307.3 133.5/339.1 8/6.7/30.3 8/6.7/30.3 87 Octane Min. 87 Octane Min. Parallel Link Parallel Link Trailing Arm IFS Trailing Arm IFS Mechanical Disc Mechanical Disc Rear of Seat Rear of Seat Top of Hood Top of Hood Standard Standard N/A N/A N/A N/A Oil/Acc Oil/Acc Standard Option Single Heat/Std Single Heat/Std N/A Standard N/A Standard Option Standard Option Standard
- 50. c Indy Lite 0953433 EngineType Fan Twin Engine Model Number EC34-2PM02 Displacement (cc) 339 Bore x Stroke (mm) 62.3 x 55.6 CarburetionfThrottle Body 2 Mikuni VM30SS Slide Oil Injected Standard Ignition COl Alternator Output 12V 150W Length (in./cm.) 105/266.7 Width (in./cm.) 42.5/1 08 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 Storage Rear of Seat Top of Hood Speedometer Standard c Tachometer N/A Electric Fuel Gauge N/A Accessory Lights N/A Electric Start Option HandwarmerslThumbwarmer Option/Option Two-Up Seat N/A Backrest N/A Storage Rack Option Tow Hitch Option 1.49 MODELS AND SPECIFICATIONS 1995 Model Identification StarLite 0953427 Fan Single EC25PS07 244 72 x 60 1 Mikuni VM30SS Slide Standard COl 12V 150W 105/266.7 42.5/108 44/111.8 37/94 15/38.1 121/307.3 8/6.7/30.3 87 Octane Min. Parallel Link Trailing Arm IFS Mechanical Disc Rear of Seat Top of Hood Option N/A N/A N/A N/A Option/Option N/A N/A Option Option 8/94
- 51.
- 52. CHAPTER 2 BODY ANDSTEERING 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 Metton™ 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
- 53.
- 54. Cleaning And PreservationOf Hood, Chassis And Trim BODY AND STEERING Summer Storage 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). Ifthe machine is equipped with electric start, disconnectthe battery cables and clean the cables and battery posts. Fill battery to proper level and charge to full capacity. Remove and store the battery in a cool dry place. The machine should be stored in a dry garage or shed out of the sunlight and covered with a fabric snowmobile cover. Do not use plastiC to cover the machine; moisture will be trapped inside causing rust and corrosion problems. Controls And Linkage All bushings, spindle shafts and tie rod ends should be coated with a light coat of oil or grease. Throttle controls and cables should be lubricated with Polaris clutch and cable lubricant (PN 2870510). Force a small amount of lubricant down cables. Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with petroleum jelly or dielectric grease and reconnect. Replace worn or frayed electrical wire and connectors. Clutch And Drive System Remove drive belt and store in a cool dry location. Lubricate surface faces, shaft and ramps of drive and driven clutches with light oil. This oil must be cleaned off before installing belt for service. A generous amount of lubrication, such as Polaris clutch and cable lubricant should be applied onto the rollers and weight pins. Replace chaincase lubricant with new oil. Apply lubricant to steel drive shafts, etc., to reduce rusting. Track And Suspension To prevent corrosion which will destroy the bearings, always grease jackshaft and drive shaft clutch side bearings with a high quality bearing grease. (This includes fittings added to late 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. Use Polaris Fogging Oil (PN 2870791) on shock absorber shafts to help prevent corrosion. Under normal conditions moderate track tension should be maintained during summer storage. Rubber track tension should be maintained at the prescribed normal operating tension specified in this manual. The rear of the machine should be supported off the ground to allow free hanging of track. 2.1 Ski Spindle ~ndW/ Ings ~ III. 1 III. 2 Jackshaft Bearing Driveshaft Bearing Grease Grease W( 0 _Mo Located on left side of machine (clutch side) 8/94
- 55. BODY AND STEERING SummerStorage 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 fill 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 fuel. 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 CD
- 56. BODY AND STEERING GasTank and Seat Removal -Cutlass SS Be sure the fuel tank is emptied before beginning the removal procedure. A WARNING Gasoline is extremely flammable and explosive under certain conditions. ...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. 2. Disconnect the seat wire harness at the tank and remove the seat. 3. Remove the six 10-24 x 5/8 bolts (A) securing the console to the chassis. See photo at right. 4. Remove the fuel line from the fuel pump. 5. Locate tank vent line on upper left front side of tank. Cut line from its fitting. CAUTION: Do not attempt to pull the line off as damage to the vent fitting may result. 6. Roll the front and rear tank hold-down springs off the tank. 7. Disconnect the fuel gauge sight line, both top and bottom, from the right front side of the tank. 8. Remove the fuel cap. 9. Lift the console Slightly and remove the tank. 10. Reverse procedure for reinstallation. 2.3 8/94
- 57. BODY AND STEERING GasTank and Seat Removal- Indy Models 1. Remove tank cover by disconnecting snaps. 2. Remove vent line at front LH side of tank. 3. Remove gas cap and rubber grommet. 4. Remove air silencer box. 5. Disconnect fuel line from fuel pump and plug line to prevent fuel spillage from tank. See photo at right. WARNING: Gasoline is extremely flammable and explosive under certain conditions. 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 cloth- ing, immediately wash if off with soap and water and change clothing. Prolonged exposure to pe- troleum based products may cause paint failures. Always protect finished surfaces and wipe up any spills immediately. 6. Roll front tank hold-down spring forward off tank saddle. 7. If machine is equipped with a fuel gauge connector, this should be unplugged. 8. Remove two bolts holding rear of seat to tunnel. 9. Slide seat rearward enough to gain access to taillight connector at RH side of fuel tank. Unplug connector. Slide seat off machine and set aside. 10. Fuel tank can now be removed from chassis by disconnecting two springs at center of fuel tank. One Piece Fuel Tank/Seat Removal Proce- dure (1994 440/SKS, 500 EFIISKS, ClassicI Touring) 1. Remove front tank retaining spring located behind driven clutch area. 2. Remove fuel cap and grommet. 3. Remove fuel lines. 4. If machine is equipped with gauges, unplug gauge wires. 5. Remove two bolts in tool box. 6. DisconnecUaillight wiring. 7. Remove two console bolts attaching console to tunnel. 8. Remove two console bolts located under hood. 9. Remove fuel cap and lift console up. Replace fuel cap. 10. Lift up at rear of seat and slide out. 8/94 2.4 , La
- 58. 1. Remove seatcushion 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. 4. Place the seat foam on the seat base assembly as shown in III. 1. 5. Drape the seat cover over the seat foam. 6. Insert and pull the two seat bucket hold down straps, attached to the seat cover, through the two holes in the seat foam and the routed-out holes located in the storage box area on the plastic seat base. HINT: A stiff wire attached to the 3 bar slide on the hold down strap will aid in this process. NOTE: Use the rear two holes for a longer length seat and the forward two holes for the standard length seat. 2.5 BODY AND STEERING Seat Cover Replacement (Plastic Base) ILL. 1 ~t? o~~ SEAT BUCKET HOLD DOWN STRAP FOR USE WITH LONG SEAT STORAGE BOX AREA PLASTIC SEAT BASE 8/94
- 59. BODY AND STEERING SeatCover 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. 8. 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. 9. 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 LOCATION --==-__---:':~~ INDICATORS 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. 8/94 2.6 SEWN SEAMS TACK COVER HERE SECOND STAPLING CHANNEL STAPLE HERE FIRST ' STAPLE HERE SECOND STAPLE HERE THIRD STAPLE SEQUENCE ILL. 2
- 60. BODY AND STEERING SeatCover 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 • OneiTwo Piece Seat and Tank PN 9912521 • 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. 2. Remove the taillight assembly and wire harness. 3. Install new taillight assembly and rivet into place. 4. Connect taillight wire harness. NOTE: Taillight harness wires must be routed away from any possible contact with seat cover staples to prevent electrical shorts. 5. Pull the seat cover tightly and evenly into position and re-staple to the seat pan. 6. Inspect cover for a wrinkle-free finish before reinstalling on the snowmobile. 2.7 8/94
- 61. BODY AND STEERING DecalRemoval 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 Brite™ 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 the 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. 5. If decal has a pre-mask, carefully remove.. NOTE: If the decal being applied needs to be stretched around a radius, follow these recommendations: 6. Fasten a straight edge to tail end of decal. 7. Pull or stretch remaining portion of decal around radius and into position. NOTE: A small amount of heat applied to the decal will aid in forming it to the radius. The mass of the decal which was secured in previous steps will hold it in position while pulling. 8. Again, apply soapy water solution to top of decal and remove trapped air using a clean, soft rubber squeegee. Use care to prevent scratching the decal surface. 9. Apply a small amount of heat to the decal to fasten it securely. 10. Carefully remove excess decal material. 8/94 2.8 (
- 62. c BODY AND STEERING ABSNosepan - 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 house- hold or commercial type wax sparingly in a thin, even film with a soft clean cloth. • Polish waxed surfaces lightly with a clean cotton flannel or jersey cloth. After polishing, wipe gently with a damp cloth to ground any electrostatic charges which may attract dust particles. Do Not: • Use cloths containing grit or abrasive particles or kitchen scouring compounds to clean or dust. Light scratches may be rubbed out with wax. • Use boiling water or strong solvents to clean, as they will soften the plastic. • Use strong soaps or abrasives. Special Cleaning Problems 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. 2. Cut a piece of fiberglass cloth approximately 3 (76 mm) wide and long enough to extend 1to 2 (25 to 50 mm) past the ends of the fracture. 3. Separate edges of crack slightly and fill void with cement. Press edges together, clamp in place, and wipe excess cement from outside of pan. 4. Liberally coat inside surface of pan with cement, covering approximately 1 1/2 (38 mm) on either side of the fracture. 5. Lay fiberglass cloth over fracture. 6. Wearing rubber gloves, work cloth into pan using a squeegee or your fingers. NOTE: ASS cement is a solvent cement which dissolves the outer surface of the nosepan. The cement and cloth will change color as this happens. 2.9 8/94
- 63. BODY AND STEERING ABSNosepan - Care, Cleaning, and Repair 7. When fiberglass cloth is well worked in, wipe off excess cement and let dry. Drying time will depend on the brand of cement used. Refer to manufacturer's instructions. 8. Lightlysand the outside of the pan and paint. The results will be more professional looking if the repaired area on the inside of the pan is also painted. Replacement Nosepan Installation When installing a replacement 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. 2. The following aluminum rivets must be used to attach nosepan: • PN 7621448, 3/16 x .652, Quantity required - 7 • PN 7621403, 3/16 x .527, Quantity required - 39 All holes are to be drilled into the nosepan using a 7/32 drill bit (.218). NOTE: This will be larger than the diameter of the 3/16 rivet. 3. Position new nosepan in place and attach to bulkhead at the top using (7) 3/16 x .652 rivets (PN 7621448). See illustration below. All remaining holes require 3/16 x .527 rivets (PN 7621403). 4. Make sure there is 1/4 (.6 cm) clearance around the exhaust outlet. 5. Install foil (PN 5810108) in the same location as the original part. Rivet PN 7621448 6 4 2 1 3 5 7 o o @ 8 9 Rivet PN 7621403 8/94 2.10
- 64. BODY AND STEERING NosepanReplacement 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. o ·24 0 + 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) 2. Rivet holes across from one another in unison. 2.11 8/94
- 65. BODY AND STEERING RIMMetton 1M Part Repair Polaris has approved the use of Evercoat Plastik Works' as a repair for the RIM Metton TM Type Materials. This two part repair system is number coded for different types of plastic material. See example below. The patch kit can be obtained from your local automotive parts house. It is suitable for repair 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, which can be repaired either with a two part repair kit or by hot air type plastic welding. 8/94 2.12
- 66. o Fiberglass Repair Damaged fiberglasscan 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. 4. Mix enough polyester resin and catalyst to complete the repair, following instructions for resin being used. 5. Apply resin to inside of patch area using a disposable paint brush. 6. Lay in small pieces of shredded fiberglass matt. Use the paint brush to force 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. 7. Keep adding matt and resin until patch area is filled up to the original thickness. 8. Let resin cure thoroughly. 9. Remove masking tape from outside of repair. 10. Remove any high spots from outside with a disc grinder. 11. Fill and smooth any defects with polyester auto body filler. 12. Sand smooth and feather with 360 to 400 grit sandpaper. 13. Paint outside of repair following instructions on paint container. Hood Adjustment Sequence (New Style 1994 to Current) BODY AND STEERING Fiberglass Repair and Hood Adjustment ;1 ----- --- -..., / I I / I HOOd~ 1/ I I / I I , ------...,1 I Upper 0 '-' I I I I Hinge II ~ I L _________ ..l I A I I Hood and Hinge I ~ I need not be flush I - -- I I I I I I I I I 8 III. 1 III. 2 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. 2. With hood open, loosen nut (8). See III. 1. 3. Close hood and remove both rubber plugs. Then, using a 7/16 (.4 cm) socket with an 8 (20 cm) extension, loosen nut (C). Adjust hood to pan gap. Tighten nuts. 4. Check outer perimeter alignment and front and rear alignment of hood, side bumpers and side panels. There should be 3/16(.5cm) + 1/8(.3cm) -0 clearance between hood to side panels and side bumpers. If adjustment is required, open hood and loosen nuts (D). Adjust and re-tighten one nut per hinge. Close hood and recheck alignment. . 5. After correct alignment is achieved, tighten all nuts. Nosepan, Front Bumper and Side Bumper Adjustment (New Style 1994 to Current) If the nosepan, front bumper or side bumper are removed and reinstalled, it is imperative that these components be properly adjusted before hood installation. See 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 will result in improper adjustment. See III. 2. 2.13 8/94
- 67. 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. CAUTION: The steering assembly should be checked whenever a machine comes in for tune-up or repair. Steering Removal NOTE: To retain proper ski alignment, the spindle and steering arm should be marked. 1. Remove steering arm bolt (A). 2. Adjust tie rod end (8) by turning clockwise or counterclockwise until skis are parallel with each other and with vehicle track and frame when handlebars are in straight ahead position. CAUTION: If there is evidence of wear or stress on the tie rods or tie rod end bearings, they should be re- placed as a complete unit. 3. Remove spindle from body. CAUTION: If spindles are cracked or bent they must be replaced. NOTE: Spindles should be lubricated annually to in- sure proper steering. 8/94 2.14 A B 1 I =-~....r--'=- lbll 11- -~.P - - /,- 151 0 0 II II II /I 1 'I '-.J
- 68. Thank you verymuch for your reading. Please Click Here Then Get More Information.