2000 Polaris Indy 500 & 600 Triumph Liquid-Cooled Snowmobile Shop Manual (P/N 9915981)

This Polaris shop manual, P/N 9915981 (September 1999), covers the 2000 Indy 500 liquid-cooled models and 600 Triumph triple, including the Classic, Touring, WideTrak LX, XC, SKS and RMK configurations listed above. The 600 twin-cylinder performance models use a separate service manual.

Searchable Text and Chapter Bookmarks

Search and wiring detail: The service text is searchable, and nine embedded PDF bookmarks lead to the chapter openings. Labels within the five final wiring diagrams are not searchable; small wiring labels require enlargement.

The download contains one printable, 413-page PDF in English, including nine chapter contents pages.

Engine, Clutch and Chassis Service

These selected topics cover major workshop jobs; the manual also includes off-season storage guidance and recoil-starter spring replacement.

• Engine repair: Step-by-step disassembly and assembly for Fuji liquid-cooled twins, the three-cylinder monoblock and domestic case-reed twins, plus V.E.S. service.

• Carburetion: Mikuni VM and TM-38 inspection, overhaul and throttle synchronization, with model-specific jetting charts for temperature and elevation.

• Clutches: P-85 drive and driven clutch service, spider indexing, bushing replacement, belt alignment and symptom-based troubleshooting.

• Brakes and final drive: Hydraulic brake bleeding, caliper service, chaincase repair, and WideTrak LX transmission, suspension and track removal.

• Steering and suspension: Controlled Roll Center (CRC) alignment, XTRA-10 suspension adjustment, Fox shock rebuilding and Polaris Position Sensitive Shock service.

• Electrical diagnosis: CDI ignition, starter and lighting tests, throttle-position-sensor testing, timing advance curves and model-specific wiring diagrams.

Suited to technicians familiar with mechanical theory, precision measurement and shop procedures, with the equipment needed for internal engine and chassis work.

Engine Inspection, V.E.S. and Cooling

Factory specifications and illustrated procedures support in-house engine and drivetrain service. The engine sections cover crankshaft truing and indexing, piston and cylinder measurements, and oil-pump inspection and bleeding.

Torque sequences for cylinder heads and crankcases accompany component-specific fastener specifications, including flywheel torque. Incorrect torque or fuel calibration can damage the engine; critical drivetrain work requires the qualifications and precautions specified in the manual.

The 500 XC SP 45th Anniversary V.E.S. section covers exhaust-valve removal, carbon cleaning, bellows inspection and reassembly. Its troubleshooting chart connects poor acceleration or failure to reach operating speed with valve, spring and pressure-feed problems.

Cooling-system diagrams show the different hose and cooler arrangements. Separate bleeding procedures address Fuji engines and domestic twins.

Fuel Calibration and Electrical Troubleshooting

For elevation tuning, detailed jetting charts map main-jet sizes and needle-clip positions across ambient temperatures and altitudes. The carburetor troubleshooting tables separate faults by throttle opening, helping a mechanic relate plug fouling or weak acceleration to the relevant fuel circuit.

Electrical coverage includes dynamic and static starter testing, ignition fault isolation and TPS adjustment using test kit P/N 2201519. The Typical Timing Advance Curves explain the relationship between test speed and timing readings, alongside the model-specific wiring diagrams.

P-85 Clutches, Brakes and WideTrak Drive

Drive and driven clutch exploded views and Drive Clutch Spring Rates charts support component inspection and setup. The indexing cautions explain how lost reference marks combined with changed or misplaced spider shims can leave the clutch out of balance and require replacement.

The warning for the Almond drive-clutch spring, P/N 7041566, identifies reversed installation as a cause of premature clutch or spring wear. Drive-clutch maintenance and repair are restricted in the manual to authorized Polaris dealers with the specified current-model service training and factory-authorized tools.

Hydraulic-brake coverage includes Hayes master-cylinder cartridge replacement and liquid-cooled caliper rebuilding. Separate WideTrak LX procedures cover the mechanical brake and internal Hi/Low transmission service.

CRC Alignment and Fox Shock Rebuilding

Steering Assembly Exploded Views show rod-end and fastener orientation for the covered chassis. CRC alignment procedures distinguish spindle centering, setup width, camber and toe adjustments.

The Typical Shock Valving Arrangement drawing accompanies shock-specific valving tables. Fox rebuilding procedures include seal replacement, internal floating piston (IFP) depth checks, oil bleeding and nitrogen recharging.

A Look at Engine Torque and Fluid Capacities

For EC50 engines, the cylinder-head torque table specifies 18–19.5 ft-lb (25–27 Nm), with separate tightening-pattern drawings for the Fuji liquid-cooled twin.

The WideTrak LX specification sheet lists 3 quarts (2.8 liters) of coolant. Lubricant capacities are model-specific: the Indy 500 chaincase holds 7 fl oz (210 cc), while the WideTrak LX transmission is listed at 20 fl oz (590 cc).