Polaris Indy Lite, Sport, TranSport, Super Sport, 440, XCF, Trail, 500, Classic, Wide Trak, XLT, 600, RXL, Ultra, 700 & Storm Snowmobile Service Manual (1996-1998)

Polaris Indy Snowmobile Service Manual - 1996-1998

This official Polaris Service Manual provides specialized diagnostic and repair procedures for the diverse range of Indy chassis configurations produced between 1996 and 1998. It integrates critical calibration data, such as precise air screw adjustments and altitude-specific jetting compensation, to ensure peak engine performance under varying atmospheric conditions. Utilizing the correct 10-micron secondary fuel filter is vital for maintaining the integrity of the Electronic Fuel Injection (EFI) system, as microscopic debris can cause irreversible injector scaling and significant downtime.

Technical Applicability & Production Variants

1996 Technical Series (096 Chassis Prefixes)

• Light/Sport Chassis: Indy Lite, Lite Deluxe, Lite GT, Indy Sport, Sport Touring, TranSport, Super Sport.
• LC Performance Chassis: Indy 440 LC, 440 XCR, 440 XCR SP.
• 500 Series Liquid-Cooled: Indy 500, 500 SKS, 500 RMK, 500 EFI, 500 EFI SKS/RMK.
• Classic/Utility Chassis: Indy Classic, Classic Touring, Wide Trak GT, Wide Trak LX.
• Triple Cylinder High-Output: Indy XLT, XLT SKS/RMK/SP/Touring, 600 XCR, 600 XCR SP, Indy RXL, Ultra SP/SKS/RMK, Storm, Storm SKS/RMK.

1997 Technical Series (097 Chassis Prefixes)

• Fan-Cooled Generation: Indy Lite, Lite Deluxe, Lite GT, Sport, Sport Touring, TranSport, Super Sport.
• CRC Front Suspension Models: Indy XCF, 440 XC, 600 XC, 700 XC, 700 SKS, 700 RMK.
• Advanced Liquid-Cooled: Indy 440, Trail, Trail Touring, Trail RMK, 500, 500 SKS, 500 RMK, 500 EFI.
• Triple/Ultra Series: Indy XLT, XLT SP, XLT SKS/RMK, XLT Touring, XLT LTD, XLT LTD SP, 600 XCR, 600 XCR SE, RXL, Ultra, Ultra SP, Ultra SPX, Ultra SPX SE, Ultra Touring, Storm, Storm SE, Storm RMK.

1998 Technical Series (098 Chassis Prefixes)

• Evolution Series: Indy Lite, Lite Deluxe, Lite Touring, Sport, Sport Touring, TranSport, XCF, Super Sport.
• Standard/High-Output Variants: Indy 440 LC, 440 XCR, Trail, Trail Touring, Trail RMK, 500, 500 RMK, 500 Classic.
• Triple/Heavy Duty Series: Indy XLT Classic/SP/Touring/LTD, 600 XC, 600 RMK, 600 XCR, Ultra, Ultra Touring, 700 XC, 700 RMK, 700 XCR, Storm, Wide Trak LX.

Operational Benefits & Service Accuracy

• Optimization of engine longevity through verbatim factory torque sequences and tolerance benchmarks.
• Increased safety via detailed hydraulic brake system pressure testing and bleeding procedures.
• Reduced diagnostic intervals with dedicated Electronic Fuel Injection (EFI) System II and III troubleshooting flowcharts.
• Accurate component replacement using actual-size drive clutch weight identification charts.

Document Information

• Publication Date: 09/1997 Revision
• Page Count: 540+ (estimated from internal indexing)
• Document Type: Factory Service Manual

Engineering Standards & Factory Calibration

Factory benchmarks are provided for all major mechanical systems, including the Electronic Fuel Injection (EFI) Alternator Controlled Switch (ACS) testing. Technicians must verify that the pressure regulator maintains a constant fuel rail pressure of 35-37 PSI. For carbureted models, the manual details Mikuni VM30SS through VM38SS specifications, including precise slide cutaway values and jet needle "E" clip positions necessary for maintaining stoichiometric ratios across different elevations.

System Architecture & Wiring Data

Electrical diagnostics are supported by year-specific wiring schematics covering 1995 through 1998 model years. Navigation of the chassis and suspension systems is facilitated by exploded views of the XTRA 10, XTRA 12, and XTRA Lite rear suspension configurations. Specific diagnostic scrolling procedures for the Polaris Select Monitor are included to facilitate rapid ECU communication and error code retrieval.

Table of Contents

• General Information: Model Identification, Publication Numbers, Torque Specifications, Special Tools.
• Maintenance/Tune-Up: Inspection Intervals, Lubrication Points, Chaincase Service, Track Alignment.
• Engine: Engine Assembly/Disassembly (Twin, Triple, Monoblock, Case Reed), Crankshaft Truing, Cooling System Diagrams.
• Fuel System/Carburetion: Mikuni/Keihin Service, Jetting Compensation Charts (1996-1998), EFI Operation/Diagnostics.
• Clutches: P-85 and P-90 Drive/Driven Clutch Service, Spring Rate Charts, Bushing Replacement.
• Body & Steering: IFS Adjustment, Handlebar Torque, Ski Alignment, Seat/Fuel Tank Service.
• Suspension: XTRA 10, XTRA 12, and Sport Suspension Service, Shock Valving, Rail Repair.
• Brakes/Final Drive: Hydraulic System Service, Transmission Overhaul (Series 300), Reverse Kit Maintenance.
• Electrical: Ignition Timing (CDI/Digital), Battery Service, Component Testing, Detailed Wiring Diagrams.

Performance Tolerances & Fluid Requirements

• Standard Fastener Torque: 1/4-20 Grade 5 (8 ft. lbs.); 3/8-16 Grade 8 (45 ft. lbs.).
• Engine Clearances: Maximum allowable crankshaft run-out is .006" (.02 cm).
• Lubrication Grades: Polaris 2-Cycle engine oil is required; DOT 3 brake fluid only for hydraulic systems.
• Clutch Offset: Alignment Bar Specifications provided for 5/8" and 21/32" offset configurations.
• Idle Synchronization: Throttle gap measurements are specified by drill size (e.g., .219" for Lite models).