Polaris Indy Trail, 400, 500, 600, 650, Classic, Storm, XLT, RXL, Wide Trak, Lite, Star Lite, XCR and Sport Touring Snowmobile Service Manual (1985-1995)
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Sample pages from the Polaris Indy Trail, 400, 500, 600, 650, Classic, Storm, XLT, RXL, Wide Trak, Lite, Star Lite, XCR and Sport Touring Snowmobile Service Manual (1985-1995) manual
Purchase Information
Technical Specifications
- Document Number / Seller:
- 32032 / Melissa Phillips
- File Size:
- 83.68 MB
- File Type:
- Language:
- English (some of our manuals are multilingual)
- Pages:
- 657
- Printable:
- Yes
- Estimated Download Time:
- 1.71 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Snowmobile
- Brand:
- Polaris
- Reviewed and Approved:
- Jan 2, 2026
Polaris Models and Parts Covered in this Snowmobile Manual
- Polaris Indy Trail (1985-1995)
- Polaris Indy 400 (1985-1991)
- Polaris Indy 600 (1985-1987)
- Polaris Indy 600 SE (1985)
- Polaris Star (1985-1990)
- Polaris SS (1985-1986)
- Polaris Long Track (1985-1986)
- Polaris Indy 600 LE (1986)
- Polaris Sprint (1986-1988)
- Polaris Sprint ES (1986-1990)
- Polaris Indy Sport (1987-1995)
- Polaris Indy 133 SKS (1987-1988)
- Polaris Indy 400 SKS (1987-1988)
- Polaris Indy Trail ES (1987-1988)
- Polaris Indy Trail SKS (1987-1995)
- Polaris Long Track LTR (1987-1989)
- Polaris Star Trak (1987-1990)
- Polaris Indy 650 (1988-1992)
- Polaris Indy 650 SKS (1988-1991)
- Polaris Indy 400 Classic (1988)
- Polaris Indy Trail SP (1988-1989)
- Polaris Indy Trail Deluxe (1988-1995)
- Polaris Indy 500 (1989-1995)
- Polaris Indy 500 SKS (1989-1991)
- Polaris Indy 500 Classic (1989-1990)
- Polaris Indy 500 SP (1989-1991)
- Polaris Indy Trail Super Trak (1989-1990)
- Polaris Indy Sport GT (1989-1992)
- Polaris Wide Trak (1990-1993)
- Polaris Wide Trak LX (1994-1995)
- Polaris Wide Trak GT (1994-1995)
- Polaris Indy Trail SuperTrak (1991-1992)
- Polaris Indy Lite (1991-1995)
- Polaris Star Lite (1991-1994)
- Polaris RXL (1991-1995)
- Polaris RXL SKS (1991-1993)
- Polaris 500 Classic (1991-1995)
- Polaris RXL Touring (1994-1995)
- Polaris 500 SP EFI (1992)
- Polaris 500 SKS EFI (1992-1994)
- Polaris 440 XCR (1992-1995)
- Polaris 440 Indy (1992-1995)
- Polaris Indy Lite GT (1992-1995)
- Polaris Indy Lite Deluxe (1992-1995)
- Polaris Star Lite GT (1993-1994)
- Polaris Storm (1993-1995)
- Polaris Storm SKS (1993-1995)
- Polaris XLT (1993-1995)
- Polaris XLT SP (1993-1995)
- Polaris XLT SKS (1993-1995)
- Polaris Classic Touring (1993-1995)
- Polaris 440 SKS (1993-1995)
- Polaris 500 EFI (1993-1995)
- Polaris 500 EFI SKS (1993-1995)
- Polaris Super Sport (1994-1995)
- Polaris 440 XCR SP (1994)
- Polaris 600 XCR (1994-1995)
- Polaris XLT Special XTRA (1994)
- Polaris XLT Touring (1995)
- Polaris Storm SKS/PT (1995)
- Polaris XLT SKS/PT (1995)
- Polaris 500 EFI SKS/PT (1995)
- Polaris Sport Touring (1995)
Complete Manual Information
Polaris Indy Snowmobile Service Manual - 1985-1995
This professional service manual provides high-level technical guidance for the maintenance and repair of Polaris snowmobiles manufactured between 1985 and 1995. It integrates factory-validated procedures with detailed specification tables to ensure maximum machine reliability and performance. Utilizing the correct electrical anti-corrosive lubricant on all connections is critical for preventing high resistance and corrosion in EFI systems, directly impacting long-term electronics uptime.
Technical Applicability & Model Configurations
Monoblock & Multi-Cylinder Liquid Cooled (LC) Generations
- Triple LC Series (600cc - 800cc): Indy 600, 600 SE/LE, 650, RXL, RXL SKS, Storm, Storm SKS, XLT, XLT SP.
- Twin LC Series (400cc - 500cc): Indy 400, 400 SKS, 440, 440 XCR, 500, 500 SKS, 500 EFI, Classic, Wide Trak.
High-Efficiency Fan Cooled (FC) Chassis Groups
- Twin FC Series (340cc - 488cc): Indy Trail, Trail Deluxe, Trail ES/SKS, SS, Sport, Sport GT, Super Sport, Sprint, Long Track.
- Single FC Series (244cc): Star, Star Trak, StarLite, StarLite GT, Indy Lite, Lite Deluxe.
Specialized Chassis & Utility Variants
- Extended Track & Utility Models: Wide Trak GT/LX, SuperTrak, Long Track LTR/RLR, SKS (Specialized Kneeling Suspension) configurations.
Performance Reliability & Maintenance ROI
- Factory-grade calibration data for Mikuni VM Series carburetors and Electronic Fuel Injection (EFI) throttle bodies ensures optimal fuel-to-air ratios across all elevations.
- Detailed torque sequences for cylinder heads and crankcases prevent fastener fatigue and structural assembly failures during high-stress operation.
- Comprehensive diagnostic procedures for CDI ignition systems and high-output alternators facilitate rapid troubleshooting of electrical faults.
Documentation Metadata
- Document Type: Factory Service Manual
- Technical Publication: 8/94 Edition (Covers 1985-1995)
- Coverage: System-wide (Engine, Drive, Chassis, Electrical)
Technical Depth & Factory Benchmarks
Polaris engineering standards define the baseline for all service procedures contained within this documentation. Technical personnel must adhere to specific piston-to-cylinder clearances, such as the .0055" benchmark for EC60PL-02 engines, to maintain thermal efficiency. The manual provides precise ignition timing dial indicator ranges (0-1") to calibrate piston BTDC positions across the entire engine lineup.
Drive System & Steering Architecture
- Torque-O-Matic Drive Data: Specific shift weight and spring rate identification for P-85 drive clutches categorized by production year and elevation requirements.
- IFS Component Calibration: Detailed alignment bar specifications (0.623"-0.625" diameter) for spindle alignment on Independent Front Suspension models.
- Brake System Hydraulics: Service protocols for Type H2 and Type 3 master cylinders, including specific torque values (30 ft. lbs.) for caliper carrier bolts.
Table of Contents
- Chapter 1: Models and Specifications
- Chapter 2: Maintenance and Tune-Up
- Chapter 3: Engine Service and Troubleshooting
- Chapter 4: Fuel Systems and Carburetion
- Chapter 5: Electrical Systems and Wiring
- Chapter 6: Drive Clutch and Transmission
- Chapter 7: Suspension and Chassis Steering
- Chapter 8: Brake Systems and Final Drive
Operational Limits & Specifications
- Torque Specifications: Cylinder head (17-18 ft. lbs. for EC25PS), Flywheel (60-65 ft. lbs.), and Cylinder Base Studs (24-28 ft. lbs.).
- Fluid Parameters: Requirements for low-temp grease, DOT 3 brake fluid, and specialized Fox shock oil for IFP configurations.
- Tolerances: Piston ring end gap standards of .20 mm to .45 mm (.008" - .018") across all liquid and fan-cooled powerplants.
Download Instructions for Polaris Snowmobile Manual
Frequently Asked Questions - Polaris Snowmobile Manual
Is this manual suitable for beginners?
Yes, this Polaris manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Snowmobile maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (83.68 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Polaris Snowmobile manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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