Professional Polaris Indy 500 Snowmobile Service Manual (2000) 412 Page Volume | Shop Standards

POLARIS INDY 500 SERIES (2000) Service Manual

This master-level technical guide provides the essential data required for precision maintenance of the 2000 liquid-cooled 488cc and 500cc twin-cylinder platforms. Snowmobile engine longevity and track-drive efficiency depend on meeting strict factory benchmarks for timing, torque, and clearance. Professionals utilizing these protocols eliminate the risks associated with diagnostic guesswork and ensure secondary systems like the XTRA suspension and hydraulic HPB brakes operate at peak safety.

Active Model Coverage & Configuration Data

Actionable repair data in this volume covers the following primary Gen II and specialized chassis variants for the 2000 model year:

• Indy 500 / Indy 500 Classic: S00SB4BS / S00SD4BS
• Indy Classic Touring / WideTrak LX: S00ST4BS / S00SU4BS
• Indy 500 XC / 500 XC SP: S00SB5AS / S00SP5CS
• Indy 500 SKS (European) / 500 RMK: E00SS5AU / S00SR5AS
• Series Inclusions: Coverage extends to 45th Anniversary editions and high-utility liquid-cooled configurations utilizing Fuji and Domestic case-reed powerplants.

Technical Document Logistics

• File Format: High-Resolution PDF
• Total Page Count: Approximately 412 Pages
• Publication Code: PN 9915981 (Mid-Range Liquid Cooled 500/600)
• Official Revision Date: September 1999

Operational Investment & Equipment ROI

• Avoid "Component Swapping": Use exact electrical resistance values for stators and CDI units to prevent unnecessary part costs.
• Maintain Critical Clearances: Precision Piston-to-Cylinder gaps (0.0035" - 0.0063") prevent premature seizure and power loss.
• Protect Drive Components: Strict clutch offset and alignment specifications ensure maximum drive belt life and torque transfer.
• Safety Protocol Enforcement: Follow torque-to-yield sequences on steering and suspension fasteners to prevent mechanical failure during high-speed operation.

Integrated Technical Data Matrix

High-Resolution Schematic Depth

Visual protocols include ultra-high-resolution wiring diagrams for specialized 45th Anniversary CDI systems and standard pulse-timing setups. Detailed thread-paths for mechanical brake linkages and hydraulic hose routing for LC (Liquid Cooled) calipers ensure error-free reassembly. Exploded views cover P-85 drive and driven clutch internals, documenting every shim, roller, and spring position for precise CVT tuning.

Electrical & System Logic Diagnostics

• Ignition Troubleshooting: Systematic testing for the CDI control box, exciter coils, and pulser (trigger) coils using dedicated Ohms (Ω) resistance values.
• Speed Control Assurance: Functional logic tests for the two-series throttle safety switches to prevent "runaway" engine conditions.
• TPS Calibration: Full procedures for the Throttle Position Sensor (Domestic Engines) with a target range of 3.70 to 4.50 Volts at Wide Open Throttle (WOT).
• Cooling Integrity: Pressure testing guidelines for the surge tank and radiator cap (LR9/LR2 regulators) to verify system circulation and boil-over protection.

Primary Service Chapters

• Chapter 1: General Information & Detailed Model Specifications
• Chapter 2: Maintenance, Tune-Up, and Off-Season Storage Protocols
• Chapter 3: Engine Overhaul (Fuji 488cc / Domestic 500cc Case-Reed)
• Chapter 4: Fuel Systems (Mikuni VM34SS, VM38SS, and TM38 Service)
• Chapter 5: Clutches & Drive Belts (P-85 System Calibration)
• Chapter 6: Body, Steering, and IFS Front Suspension Alignment
• Chapter 7: Rear Suspension (XTRA-10, XTRA-12, and XTRA-Lite tuning)
• Chapter 8: Brakes & Final Drive (Chaincase, Gears, and Hydraulic Service)

FAQ

What specific ignition timing values are required to ensure peak engine performance?

Precise ignition synchronization is vital for the longevity of the Fuji and Domestic 500cc powerplants. For the 2000 Indy 500 (Fuji 488cc), the stator must be indexed to 28° BTDC at 3000 RPM. In contrast, the high-performance 500 XC SP (Domestic) requires a dynamic curve starting at 12° BTDC and reaching 26° BTDC at 3500 RPM. Setting these benchmarks accurately prevents destructive detonation and ensures the power valves operate within their designed thermal envelope.

How do I troubleshoot intermittent spark or total ignition failure on the Gen II chassis?

Systematic electrical logic is required to isolate failures in the CDI and stator systems. The shop protocol involves measuring the resistance of the exciter and pulser coils under the flywheel; for instance, checking if the black/white wire circuit maintains continuity or if the throttle safety switches (TSS) are causing a ground-out. By verifying that the CDI module matches the specific CU code (found on the box) and testing for a consistent 0.028" (0.7mm) spark gap, technicians can avoid the high cost of unnecessary component replacement.

Which model variants and serial configurations are supported by these technical protocols?

This forensic data covers the entire 2000 liquid-cooled 500cc lineup, including the Gen II Indy 500, Classic, and WideTrak LX, as well as the specialized XC and RMK series. It provides explicit data for the 45th Anniversary XC SP and the European SKS variants. Using the specific model number identification (e.g., S00SB5AS for the 500 XC), a foreman can match the chassis to the correct cooling system pressure, which must maintain a 12-14 PSI regulator cap limit to prevent field overheating.

What are the critical drive system tolerances for maintaining maximum belt life?

Maintaining field uptime depends on the precise alignment of the P-85 drive clutch and the driven unit. The manual specifies a strictly enforced offset and a center-to-center distance (typically 12.0 inches) to ensure the drive belt does not experience side-loading or excessive heat. Furthermore, the drive clutch spider must be torqued to 200 ft-lbs during a rebuild, a benchmark that ensures the CVT system handles the engine’s torque without mechanical harmonics or failure during high-speed operation.

Why are high-resolution wiring schematics essential for the 45th Anniversary XC SP?

The 500 XC SP 45th Anniversary model utilizes a unique electrical harness compared to the standard Indy 500. Having access to high-res schematics allows a technician to trace the specific ignition kill circuits and lighting coil outputs without the risk of wire-piercing damage. This precision is critical when diagnosing the 3-phase charging systems or the integrated sensors on Domestic case-reed engines, ensuring that electrical repairs meet factory air-seal and resistance standards for long-term reliability.