INSTANT DOWNLOAD Polaris snowmobile repair manuals directly to your computer in seconds. A polaris snowmobile repair manual, also known as workshop manual or service manual, is a comprehensive instructional booklet designed to assist a repair technician or backyard mechanic in the process of maintenance, overhaul and repair of the vehicle’s components. This instant digitally delivered pdf manual covers the following topics:
IMPORTANT: Depending on model and year, some repair procedures will differ fore each snowmobile. The following repair procedures are the typical service procedures that would be found in a snowmobile manual. Due to space limitations of this webpage, all procedures aren't listed. However, each manual covers everything from basic maintenance to complete engine overhaul.
Chapter 1 - Model and specifications
- Model identification
- Engine specifications
- Fuel specs
- Suspension specs
- Body spec
- Track specs
- Serial numbers
- Model designation numbers
Chapter 2 - Body and steering
- Summer storage
- Gas tank and removal
- Seat cover replacement
- Decal removal and installation
- Nose pan replacement procedure
- Mim metton part repair
- Fiberglass repair
- Hood and nose pan adjustment
- Steering - conventional front suspension
- Steering - IFS independent front suspension
- Adjustable torsion bar
- Shock and spring chart
- Torsion bar removal and install
- Toe and camber adjustment
- SKI alignment
- Ski spindle bushing replacement - handlebar torque specs and sequence
- Ski Skag removal
- Model seat lengths
- Paint codes
Chapter 3 - Electrical
- Electrical test equipment, digital multi-tester
- Bulb replacement and headlight adjustment
- Headlight bulb test
- Seat harness troubleshooting
- Lighting system test, regulated and unregulated
- Low/Hi switch testing
- Ignition switch testing (non battery models, electric start and fuel injected)
- Coolant temperature hot light
- Speed control assurance testing
- Wiring diagrams and schematics
- Handlebar thumb warmers
- Alternator diagrams
- Timing ignition system
- Current timing advance curves
- Conversion chart - degrees to piston position B. TDC
- Fan CDI ignition
- CDI ignition exploded view
- CDI Ignition pulse, trigger, pulseless exploded view
- Operating PRM timing check
- Ignition system troubleshooting
- Ignition system testing
- Ignition charging system testing
- Alternator troubleshooting
- Alternator output test - open circuit
- Pulser or lighting coil replacement
- Battery service
- Electric starter system
- Electronic fuel injection
- EFI data
- EFI introduction and operation
- Power-up testing
- Alternator controlled switches
- Fuel handling system
- Tank, hose and filters
- Fuel pump
- Fuel rail
- Return hose
- Injector (mechanical)
- Pressure regulator
- Throttle body
- EFI fuel system maintenance and testing
- Electronic control system
- RPM sensor/select monitor
- Intake air temperature sensor
- Throttle position sensor
- Barometric pressure sensor
- Crankcase temperature sensor
- Fuel injectors
- MR adjustments
- ECU diagnostics
- Mode description chart
- Memory fail code description
- Wiring diagrams
- Dropping resistor
Chapter 4 - Engine
- Engine specifications
- Piston identification
- Two cycle operation
- 4 cycle operation
- Metric conversion factors
- Spark plug information
- Fuel mixtures
- Lubricants
- Torque specs
- Removal, disassembly, assembly, installation procedures on entire engine
- Reed valve
- Crankshaft tuning and crankcase bearing fit
- Piston/cylinder clearance
- Oversize piston and rings
- Cylinder hone and selection and honing
- Recoil starter rope/spring replacement
- Cooling system
- Oil pump bleeding and adjustment
- Oil pump operation and troubleshooting
Chapter 5 - Carburetor & EFI Models
- Fuel system warnings
- Jet part numbers
- Mikuni carburetor exploded view
- Fuel delivery system
- Carburetor components
- Carburetor adjustment and tune-up
- Fine tuning
- Throttle synchronization procedure
- Throttle synchronization
- Choke adjustments
- Fuel pumps
- Troubleshooting
- Individual EFI (electronic fuel injection) components
- Trouble codes
- Throttle position censor
- Throttle body flange and assembly
- Wiring diagrams
- Troubleshooting fuel system (EFI)
Chapter 6 - Clutching
- Drive clutch servicing parts
- Drive clutch actual size and weight identification
- Drive clutch spring data
- Drive clutch spring rates
- Drive belt adjustment
- Clutch alignment
- Drive clutch
- Drive clutch identification and removal
- Drive clutch disassembly and inspection
- Spider assembly
- Spider indexing
- Aluminum driven clutch
- Troubleshooting
Chapter 7 - Brakes and final drive
- Hydraulic brake system operation
- Master cylinder overhaul
- Brake caliper removal and inspection
- Brake caliper repair and assembly
- Brake system service
- Bleeding procedures
- Exploded view
- Jackshaft speed VS MPH chart
- Drive system overhaul
- Drive shaft sprocket installation tips
- Transmission overhaul
Chapter 8 - Suspension
- Suspension operation
- Track tension specs
- Track tension and alignment
- Tunnel adjustment
- Track clip replace
- Direct drive track and front drive shaft remove and install
- Track removal -two sprocket and four sprocket design
- Track, transmission and suspension removal, reassembly and installation
- Suspension adjustments
- Suspension shock removal and install
- Shock spring chart
- Rear suspension center shock
- Troubleshooting
- Shock rebuild
- Valving charts
Chapter 9 - Maintenance & Troubleshooting
- Engine hard to start
- Poor idling
- Poor performance
- Slow response to throttle
- Poor acceleration
- Loss of power
- Excessive fuel consumption
- Clogged or loose main jet
- Pilot screw adjustment
- Throttle stop screw
- Starter motor does not operate
- Batter is not charged
- No spark or weak spark
- Headlight, meeter light or tail light doesn't come on
- Brake light won't work
- Grip warmer does not operate
- Periodic maintenance table
- Engine maintenance
- Power-train maintenance
- Chassis maintenance
- Carburetor tuning
- High altitude tuning
Chapter 10 - Wiring diagrams
- Complete illustrations of all wiring diagrams of all electrical components
POLARIS REPAIR MANUALS
1985 MODEL
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1986 MODELS
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1987 MODELS
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1988 MODELS
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1989 MODELS
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| Long Track Indy Trail SS Star 600 SE 600 400 | Indy Trail SS Sprint Sprint ES Star 600 LE 600 400 Long Track | Indy 600Long Track Long Track LTR Indy 400Indy Sport Sprint Sprint ES Star Star Track Indy 400 SKS Indy Trail Trail ES Trail SKS | Indy 650 SKS Indy 400 Indy 650 400 SKS Indy 400Indy Sport Sprint Star Long Track Reverse Star Track Classic 400 Indy Trail Indy SP Deluxe ES SKS | Indy 650500 SKS Indy 500 Classic Indy 500 SP Indy 650 SKS Indy 500 Indy 400 Indy TrailSprint ES Star Long Track Reverse Star Track SP Deluxe ES SKS Indy Sport Indy Sport GT |
1990 MODELS
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1991 MODELS
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1992 MODELS
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1993 MODELS
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1994-1995 MODELS
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| 650500 Classic 500 SP Indy 400 Indy Trail 650 SKS 500 500 SKS Indy Trail DeluxeSprint ES Star Star Trak WideTrak Indy Trail SuperTrak Indy Sport Indy Sport GT | 650 RXL RXL SKS 500Trail Deluxe Indy Sport Indy Sport GT 500 SKS 500 Classic 500 SP 400 Indy Trail SuperTrak WideTrak Indy Lite Star Lite | RXL RXL SKS 650 ClassicSuper Trak Trail Deluxe Trail Sport GT 500 SP EFI 500 SKS EFI 500 Wide Trak 440 XCR 440 Sport 440 Indy Lite GT Indy LIte Lite Deluxe Star Lite | Storm Storm SKS RXL RXL SKS XLTTouring WideTrak 440 XCR 440 SKS XLT SP XLT SKS 500 EFI 500 SKS EFI Classic Classic Trail Trail Deluxe Sport 440 Indy Lite GT Lite Deluxe Indy Lite Indy StarLite GT Indy Star Lite | Storm Storm SKSXLT PT XLT SKS XLT Special XLT Touring Storm SKS/PT RXL RXL Touring XLT XLT SP 500 500 EFI 500 EFI SKS 500 EFI SKS/PT Classic Classic Touring WideTrak LX WideTrak GT 600 XCR 440 XCR 440 XCR SP 440 Indy 440 Indy SKSIndy Lite GT StarLite GT StarLite Indy Lite 600 XCR Trail Deluxe Trail Super Sport Super Sport Touring Sport Sport SKS Indy LIte Deluxe |
1996 MODELS
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1997 MODELS
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1998 MODELS
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1999 MODELS
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2000 MODELS
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| Indy LiteIndy Sport Indy TranSport Indy Sport Indy Lite Deluxe Indy Lite GT Touring Indy Super Sport Indy 440 LC Indy 440 XCRIndy Trail Indy Trail Touring Indy 500 Indy 440 XCR SP Indy WideTrak GT Indy WideTrak LX Indy 500 SKS Indy 500 RMK Indy ClassicIndy XLT SKS Indy XLT RMK Indy XLT SP Indy Classic Trg. Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy XLT Indy XLT Touring Indy 600 XCRIndy Storm Indy Storm SKS Indy Storm RMK Indy 600 XCR SP Indy RXL Indy Ultra SP Indy Ultra SKS Indy Ultra RMK | Indy Lite Indy TranSport Indy Sport Touring Indy Super SportIndy Lite Deluxe Indy Lite GT Indy Sport Indy KCF Indy 440 LC Indy 440 XC Indy 440 XCRIndy 500 SKS Indy 500 RMK Indy Classic Indy WideTrak GT Indy WideTrak LX Indy Trail Indy Trail Touring Indy 500 Indy Classic Trg. Indy 500 EFI Indy 500 EFI SKS Indy 500 EFI RMK Indy XLT Indy XLT SKS Indy XLT RMK Indy XLT SPIndy 700 SKS Indy 700 RMK Indy 700 XC Indy XLT SP LTD Indy XLT Touring Indy 600 XC Indy 600 XCR SE Indy RXL Indy Ultra Indy Ultra SP Indy Ultra SPX Indy Storm SE Indy Storm RMK | Indy Lite Indy Lite Deluxe Indy Lite Trg. Indy Sport Indy TranSport Indy Sport Trg.Indy Trail Trg. Indy Trail RMK Indy 500 Indy 500 Indy Super Sport Indy XCF Indy 440 Indy 440 XCR Indy Trail Classic Indy 500 RMK Indy Classic Trg. Indy WideTrak LX Indy XLT LTDIndy 600 RMK Indy 700 RMK Indy 600 XC Indy 700 XC Indy XLT Clasic Indy XLT SP Indy XLT Trg. Indy 600 XCR Indy 700 XCR Indy Storm Indy Ultra Indy Ultra Trg. | 340 340 DLXTrail Trail Touring Trail RMK 340 Touring Sport Sport Touring TranSport XCF 440 Super Sport 500 500 Classic 500 RMK Classic Touring XLT XLT Classic XLT Touring700 SKS 700 SKS 700 XCR 800 XCR 500 XC 500 XC SP 600 XC 600 XC SP 700 XC 700 XC SP 600 RMK 700 RMK Wide Trak LX | 120 XC 120 XP SP 120 PRO X Youth 120 |
2001 MODELS
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2002 MODELS
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2003 MODELS
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2004 MODELS
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2005 MODELS
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| 120 XC 120 XP SP440 Edge Pro X 600 Edge Pro X 500 XC Edge 120 PRO X Youth 120 440 XCF SP 500 XC SP 500 XC DP Edge 600 RMK 600 XC SP700 XC SP Edge 800 XC SP Edge 800 RMK 800 S.C. Special 600 Edge X 600 Edge Pro X 700 XC SP 800 XC SP 800 XCR 600 RMK 700 RMK | 120 XC 120 XP SP 120 PRO X Youth 120 | 120 XC 120 XP SPPro X 600 Pro X 700 Pro X 800 120 PRO X Youth 120 Pro X 440 | 120 XC 120 XP SP 120 PRO X Youth 120700 Pro X2 800 Pro X 800 Pro X2 800 Pro XR 440 Pro XR 550 Pro X 600 Pro X 600 Pro X2 700 Pro X | 120 XC 120 XP SP 120 PRO X900 RMK 600 Switchback 800 Switchback Youth 120 Trail RMK 600 RMK 700 RMK 800 RMK |
2006 MODELS
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2007 MODELS
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2008 MODELS
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2009 MODELS
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2010 MODELS
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| 120 Youth FS Classic FST Classic FS Touring FST Touring FST Switchback - FST IQ FST IQ LXIQ Turbo LX Turbo Switchback FS IQ Touring FST IQ Touring IQ Cruiser FS IQ Touring FST IQ Touring FST IQ Cruiser FST IQ Switchback & Turbo Dragon | 120 Youth FS Classic FST Classic FS TouringFST IQ Touring FST IQ Cruiser FST IQ FST Touring FST Switchback - FST IQ FST IQ LX FS IQ Touring Switchback & Turbo DragonHO IQ CFI HO IQ LX CFI 600 RMK 144 155 Shift 600 Dragon RMK 155 700 155 163 IQ Turbo LX Turbo Switchback FS IQ Touring FST IQ Touring IQ Cruiser 600 HO IQ 600 HO Switchback HO RMK | 120 Youth FS Classic FST ClassicFS IQ Touring FST IQ Touring FST IQ Cruiser FST IQ FS Touring FST Touring FST Switchback - FST IQ FST IQ LX Switchback & Turbo Dragon IQ Turbo LX Turbo Switchback FS IQ Touring FST IQ Touring IQ Cruiser 600 HO IQTrail Touring Deluxe Trail RMK Widetrak LX 600 HO Switchback HO RMK HO IQ CFI HO IQ LX CFI 600 RMK 144 155 Shift 600 Dragon RMK 155 700 155 163 340 340 Transport Supersport 550 LX | 550 IQ Shift 600 IQ Shift IQ / 600 Dragon SP800 RMK 155 800 Dragon RMK 155 800 Dragon RMK 163 600 IQ Shift 136 Switchback Dragon Switchback 600 IQ Touring 600 RMK Shift 144/155 700 RMK 155 800 IQ 800 Dragon SP 800 Dra./Switch 800 RMK Shift 800 RMK Assault 146 | 600 Rush Pro Ride600 LX 600 Switch/Dra. 600 IQ Touring 550 IQ Shift 600 IQ Shift 600 IQ 600 WideTrak IQ 800 IQ 800 IQ Dragon 800 Switch/Dra. 600 RMK 144800 RMK 155 800 RMK Assault 146 800 Dra. RMK 155 / 163 600 RMK 155 700 RMK 155 800 RMK 144 |
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