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1999 Polaris Service Manual

1. 2 Rivet holes across from one another in unison 10 98 6 42 Polaris Industries Inc BODY AND STEERING Nosepan Replacement Procedure Nosepan Replacement Procedure Gen II XTRA 10 Front Suspension IMPORTANT When installing a replacement nosepan the open circles represent rivets installed from inside the nosepan through the bottom The filled in circles represent rivets installed from the under side of nosepan through to the top NOTE The rivet for polyethylene nosepans is PN 7621467 NOTE Rivet holes may require drilling into the bulkhead Non tipped in trailing arm style NOTE 1 When transfer drilling holes do not force pan into a position which is not uniform with the other side Use the same method to drill both sides 2 Rivet holes across from one another in unison Liquid cooled models will have recesses on both sides like reference A Fan cooled models will not have recesses and will look like reference B on both sides Polaris Industries Inc 6 43 10 98 BODY AND STEERING Nosepan Replacement Procedure Nosepan Replacement Procedure Gen Il XC 10 Front Suspension IMPORTANT When installing a replacement nosepan the open circles represent rivets installed from inside the nosepan through the bottom The filled in circles represent rivets installed from the under side of nosepan through to the top NOTE The rivet for polyethylene nosepans is PN 7621467 NOTE Rivet holes may require drilling into the
2. side bumpers and side panels There should be 3 16 5cm 1 8 3cm 0 clearance between hood to side panels and side bumpers If adjustment is required open hood and loosen nuts D Adjust and re tighten one nut per hinge Close hood and recheck alignment 5 After correct alignment is achieved tighten all nuts Hood and Hinge need not be flush Polaris Industries Inc 6 45 10 98 BODY AND STEERING Hood Adjustment Nosepan Front Bumper and Side Bumper Adjustment Evolved Style 1 Open hood and remove side panels 2 Remove foil tape covering right side nose pan bracket i FORWARD Line Of Fill Hole w Movement Rivet amp Washer 3 Drill out rivets 3 and slide bracket outward 1 4 6 35 mm as shown in the illustration below Be sure to mount the bracket at the same angle as before so the side panel fits squarely against the mounting bracket Lh Side Panel Bracket Move Out 1 2 RH Side Panel Bracket Move Out 1 4 4 Transfer drill holes in bracket to 3 16 1875 or 4 75 mm and rivet in new location using rivet PN 7621485 5 Apply anew section of foil tape PN 5810908 over the bracket 6 Repeat this procedure for the left side with the following exceptions move the bracket outward 1 2 12 7 mm Fill the open hole at the tip of the bracket with a rivet and washer 10 98 6 46 Polaris Industries Inc BODY AND STEERING Decal Removal and Installati
3. 1 kg m O E 28 30 ft Ibs T 3 9 4 1 kg m 28 30 ft Ibs E 3 9 4 1 kg m Replace locking fasteners if removed 28 30 ft Ibs 3 9 4 1 kg m 10 98 6 6 Polaris Industries Inc BODY AND STEERING Steering Assembly Exploded View 1999 XLT Classic XLT Touring 28 30 ft Ibs er 3 9 4 1 kg m A oh 28 30 tt Ibs 3 9 4 1 kg m 28 30 ft Ibs 3 9 4 1 kg m Va WY A N Bi 28 30 ft Ibs Ka z f eee TA 3 9 4 1 kg m UO J L 28 30 ft lbs 3 9 4 1 kg m Replace locking fasteners if removed 6 7 Polaris Industries Inc 10 98 BODY AND STEERING Steering Assembly Exploded View 1999 440 XCR 500 XC SP 28 30 ft Ibs 3 9 4 1 kg m 35 40 ft Ibs 28 30 ft Ibs 4 8 5 5 kg m 3 9 4 1 kg m 17 19 ft Ibs 22 NO 2 4 2 6 kg m lt 17 19 ft Ibs 35 40 ft Ibs D 2 4 2 6 kg m 4 8 5 5 kg m ee 9 22 SS 28 30 ft Ibs N 3 9 4 1 kg m 40 45 ft Ibs ANE LZ 5 5 6 2 kg m lG l VA pS Ee z Z 7 28 30 ft Ibs 3 9 4 1 kg m Replace locking fasteners if removed 10 98 6 8 Polaris Industries Inc BODY AND STEERING XC 10 CRC Steering Assembly Exploded View 1999 600 XC SP 700 XC SP lilustration depicts proper orientation of rod ends and bolts on steering components for most models 35 40 ft Ibs 4 8 5 5 kg m A A N X ss NA NOTE Typical XC 10 shown Y B S Orientation of drag link and ax Po
4. 4 1 kg m 35 40 ft Ibs 4 8 5 5 kg m 28 30 ft Ibs 3 9 4 1 kg m 45 50 ft Ibs 6 2 6 9 kg m 28 30 ft Ibs 3 9 4 1 kg m Replace locking fasteners if removed Polaris Industries Inc 6 3 10 98 BODY AND STEERING Steering Assembly Exploded View 1999 WideTrak LX illustration depicts proper orientation of rod ends and bolts on steering components 45 50 ft Ibs 6 2 6 9 kg m 28 30 ft Ibs 28 30 ft Ibs 3 9 4 1 kg m 3 9 4 1 kg m 28 30 ft Ibs f 3 9 4 1 kg m ZZ 28 30 ft Ibs 3 9 4 1 kg m Replace locking fasteners if removed 10 98 6 4 Polaris Industries Inc BODY AND STEERING Steering Assembly Exploded View 1999 Trail RMK 500 RMK Illustration depicts proper orientation of rod ends and bolts on steering components 55 60 ft Ibs 7 6 8 3 kg m 28 30 ft Ibs 28 30 ft Ibs 3 9 4 1 kg m 3 9 4 1 kg m T 35 40 ft Ibs XU US 28 30 ft Ibs 4 8 5 5 kg m Sa Nt 3 9 4 1 kg m 45 50 ft Ibs 6 2 6 9 kg m 28 30 ft Ibs 3 9 4 1 kg m 28 30 ft Ibs 3 9 4 1 kg m Replace locking fasteners if removed Polaris Industries Inc 6 5 10 98 BODY AND STEERING Steering Assembly Exploded View 1999 Supersport Trail Trail Touring 500 500 Classic Classic Touring illustration depicts proper orientation of rod ends and bolts on steering components 28 30 ft Ibs 3 9 4 1 kg m 0 0 j Oj O 28 30 ft Ibs S 3 9 4
5. 6 39 10 98 BODY AND STEERING Taillight Assembly Replacement Taillight Assembly Replacement Standard Indy 1 After removal of seat cover drill out three rivets from top of taillight 2 Remove taillight assembly and wire harness 3 Install new taillight assembly and rivet into place 4 Connect taillight wire harness NOTE Taillight harness wires must be routed away from any possible contact with seat cover staples to prevent electrical shorts 5 Pull seat cover tightly and evenly into position and re staple to seat pan 6 Inspect cover for a wrinkle free finish before reinstalling on the snowmobile 10 98 6 40 Polaris industries Inc Seat Length Matrix BODY AND STEERING Seat Interchangeability The following chart lists seat interchangeability for 1999 models Arrows indicate interchangeability For produc tion seats only Standard Length Indy 340 340 Deluxe Super Sport white XLT Special w bw flags 500 XC w bw flags 600 XC w bw flags 700 XC w bw flags 700 XCR w bw flags 800 XCR w bw flags Mid Long 2 Up Length Length Lite Trail RMK pb 600 RMK pb 700 RMK pb xc Performance XCF w o pads w bw flags 500 XC SP w bw flags 600 XC SP w bw flags 700 XC SP w bw flags 4400 XCR w bw flags Deluxe 2 Standard 2Up Up Touring 2 Up WideTrak Touring Trail Trg Sport Trg WideTrak LX Classic Trg TranSport XLT Trg 700 SKS pb
6. Lift the machine several times working the suspension and front skis until an average is obtained NOTE To prevent carbide skags from grabbing make sure the surface under the skis will allow full side to side movement Avoid rough concrete asphalt or carpet which may cause carbide skags to grab or catch and restrict movement Toe Adjustment Normal Ride Height NOTE Measurements A amp B should be taken 10 254 mm from center of ski spindle SERVICE HINT Before final measurement is taken skis should be pushed together lightly at the tips to remove A 1 8 1 4 greater than play in the steering components This will help achieve B at normal ride height accurate measurement If a strap is used be sure it is not too tight or it will alter measurement this is most impor tant on models with composite skis Centerline Straight Edge Polaris Industries Inc 6 19 10 98 BODY AND STEERING High Performance XTRA 10 CRC and XC 10 CRC Inspection and Alignment Pages 6 20 6 25 pertain to precise CRC front set up information for high performance or racing applications The following procedures can be performed only on XTRA 10 CRC or XC 10 front suspensions if desired These instructions should not be used for 38 RMK CRC or non CRC front suspensions 10 98 6 20 Polaris Industries Inc BODY AND STEERING High Performance Controlled Roll Center CRC Steering Alignment XTRA 10 CRC and XC 10 CRC Stee
7. Trail 1 w 500 2 pb Classic pb XLT Class ph 500 RMK pb Sport pb Trail 2 w 500 1 pb NOTE All domestic and new 440 550 fans use 90 degree outlet on tank making them unique w white Polaris pb process blue fade Polaris bw flags black and white flags e Any evolved seat will interchange with another evolved seat However some have a white Polaris decal and others have a process blue fade Polaris decal e Any Gen Il one up standard style seat with a white Polaris decal will interchange with a Gen II one up standard style seat with a process blue Polaris decal For example a Super Sport with a white Polaris decal will interchange with a 700 SKS process blue Polaris decal seat if a customer desires a different length seat Polaris Industries Inc 6 41 10 98 BODY AND STEERING Nosepan Replacement Procedure Nosepan Replacement Procedure Evolved Style IMPORTANT When installing a replacement nosepan this rivet sequence must be followed correctly in order to ensure proper nosepan and body panel fit NOTE The rivet for polyethylene nosepans is PN 7621467 oe 7T amp Front of Nosepan Ss A Wy IRA e Rivet from outside Rivet from inside aA id Kl le 33 AS 34 NOTE 1 When transfer drilling holes do not force pan into a position which is not uniform with the other side Use the same method to drill both sides
8. XCR 500 XC 500 XC SP 600 XC 600 XC SP 700 XC 700 XC SP XTRA 12 500 Classic Classic Touring XLT Classic XLT Touring 36 15 16 93 80 cm 3 4 ALL MODELS 40 5 16 102 40 cm 9 16 4 8 1 4 Toe Out a At Normal Ride Height 11 16 37 9 16 95 40 cm 40 7 16 102 70 cm 39 1 4 99 70 cm 39 99 00 cm 40 7 16 102 70 cm WIDTH NOTE Width is measured in inches from the center of the spindles near the grease fitting for the ski mount bolt located at the base of the spindle The tolerance on this measurement is 1 4 TOE ADJUSTMENT NOTE Toe is measured in inches with the machine on the ground and resting at normal ride height not full rebound Measure at a point 10 254mm forward of the ski mount bolt and 10 behind the ski mount bolt preferably on the centerline of carbide skags Note Measurements to points on the skis may be inaccurate NOTE Cambermeasurement is taken in inches from top of alignment bar to the top of ski mount hole in the spindle bushing removed All camber specifications are 5 16 or 1 2 the diameter of the alignment bar 8mm An alternate method of alignment using the Camber and Toe Alignment Travel Bars Kit PN 2871537 can be performed on snowmobiles equipped with XTRA 10 CRC or XC 10 CRC front suspension The travel bars are not intended for use on 38 RMK CRC or non CRC models 10 98 6 14 Polaris Industries Inc BODY AND STEERING St
9. bar 6 Repeat procedure for second torsion bar Torsion Bar Installation 1 Rivet support in place using Polaris PN 7621449 rivets NOTE These high strength Q rivets are the only replacement rivets recommended for this application PN 7621449 2 Reinstall torsion bar 3 Reinstall trailing arm assembly 4 Check camber and toe adjustments Refer to Chapter 2 Polaris Industries Inc 6 33 10 98 BODY AND STEERING Handlebar Torque Handlebar Torque and Sequence Indy Style 1 Remove handiebar cover and foam 2 Using a 7 16 11 mm wrench loosen four nuts on bottom of adjuster block NOTE Turn handlebar to left or right for access to back nuts 3 Adjust handlebar to the desired height Be sure that handlebars brake lever and throttle lever operate smoothly and do not hit the fuel tank windshield or any other part of the machine when turned fully to the left or right IMPORTANT When adjusting the handlebar be sure the serrations in handlebar and adjuster block match be fore torquing 4 Torque the handlebar adjuster block bolts to specification following sequence shown The gap should be equal at front and rear Socket Screws Handlebar Adjuster Block Bolt Torque 11 13 ft Ibs 1 5 1 8 kgm 5 Replace handlebar cover and foam Handlebar Torque and Sequence Evolved and Aggressive Style 1 Remove two plastic fasteners holding console cover located below handlebar cover o
10. by adjusting radius rod length and must not exceed the Maximum Setup Spindle To Chassis Width listed in the appropriate table at the front of Centering this section after all steering adjustments are Left Right 1 8 complete See illustration below for procedure Measure Set Up Width Here Do not exceed maximum Polaris Industries Inc 6 15 10 98 BODY AND STEERING Steering Inspection All IFS CAMBER INSPECTION All Models Elevate Front End Shocks Installed Typical CRC Shown Style varies by model Suspension Free Hanging With IFS Shocks Installed Upper radius rod Radius Rod End Jam Nuts Attaching Bolts Refer to specifications for elFS type Specified amount of camber O To adjust lengthen or shorten appropriate lower radius rod until top of bar is within specified camber distance Measurement should be taken from top of alignment bar to top of ski pivot bushing hole in spindle bushing removed Radius rod must be re attached to trailing arm before measuring CAMBER ACCEPTABLE RANGE EXAMPLE Specified Camber 3 4 19mm Specified Tolerance 5 16 8mm Acceptable Range 7 16 1 1 16 11 27mm Refer to specifications on page 6 14 10 98 6 16 Polaris Industries Inc BODY AND STEERING Steering Adjustment All IFS Camber Adjustment 1 Determine which spindle requires the greatest amount of correction by installing the alignment bar through one side to the
11. ee placement of pitman and idler 45 50 ft Ibs BS F arms reversed on some models 17 19 ft Ibs 2 4 2 6 kg m 6 2 6 9 kg m b Sv 35 40 ft Ibs 4 8 5 5 kg m 4 28 30 ft Ibs LF 3 9 4 1 kg m S Steering Arm 28 30 ft Ibs 3 9 4 1 kg m Jam Nuts 8 14 ft Ibs 1 1 1 9 kg m Idler Arm Pitman Arm Tie Rod Ends Steering Rack Tie Rod 8 14 ft Ibs 1 1 1 9 kg m Polaris Industries Inc 6 9 10 98 BODY AND STEERING XC 10 CRC Steering Assembly Exploded View 1999 600 RMK 700 RMK Illustration depicts proper orientation of rod ends and bolts on steering components for most models 35 40 ft Ibs 4 8 5 5 kg m 28 30 ft Ibs 3 9 4 1 kg m 40 45 ft Ibs 5 5 6 2 kg m 28 30 ft Ibs nae i an 3 9 4 1 kg m 35 40 ft Ibs 4 8 5 5 kg m 17 19 ft Ibs R 2 4 2 6 kg m pe 45 50 ft Ibs 6 2 6 9 kg m 28 30 ft Ibs 3 9 4 1 kg m 28 30 ft Ibs 3 9 4 1 kg m Replace locking fasteners if removed 10 98 6 10 Polaris Industries Inc BODY AND STEERING Steering Assembly Exploded View Models 1999 XLT Special 700 SKS 700 XCR 800 XCR Illustration depicts proper orientation of rod ends and bolts on steering components Idler Arm and Pitman Arm Pivot Steering Arm Steering Post 4 8 5 5 kg m 28 30 ft Ibs LJ mg 9 4 1 kg Idler Arm to Rack Ge g m lt 17 19 ft Ibs A J 2 4 2 6 kg m a E PO
12. operation after completing adjustments or repairs 1 The steering arms on each spindle should be parallel to slightly inward in relation to each ski When correctly installed Ill 1 the centerline of the ski and centerline of the ski bolt hole in the spindle Forward will form approximately a 90 angle or slightly greater Correct As Close To 90 As Possible Threads engage tie rod at least 3 4 19mm Steering Arm Bolt Torque 30 ft Ibs 4 15 kg m 2 If the steering arm is installed incorrectly the threads of the steering tie rod end will not engage the tie rod sufficiently and the angle formed between ski and ski bolt centerlines is considerably Forward less than 90 as shown at right Incorrect Threads do not engage tie rod at least 3 4 19mm 3 Reinstall torsion bar linkage where applicable Torque attaching bolts to specification Polaris Industries Inc 6 29 10 98 BODY AND STEERING Ski Skag Removal IFS When performing normal maintenance or tune up check the ski skags for wear To prevent damage to the skis and for greater steering control replace all skags which are half worn or greater Ski Skag Removal 1 Remove retaining nuts as shown 2 Push bolt down through ski 3 Pull rear of skag from ski as shown This frees the skag for removal from the ski Ski Skag Installation 1 Push skag forward then up into position 2 Reinstall nuts and torque to
13. opposite spindle Remove the bar and install it through the other side to the opposite spindle 2 Using a 3 8 1 cm drive 11 16 1 7 cm crow foot wrench and 20 51 cm long 3 8 1 cm drive extension loosen the radius rod end jam nut Remove the lower radius rod bolt from the spindle requiring the most camber correction Adjust the opposite side next 3 To adjust camber change lower radius rod length until alignment bar measurement is within specified range for each spindle Refer to charts on page 6 14 for camber specifications On models with neutral camber 0 the bar should slide freely through both spindles 5 16 Radius rod ends must remain parallel to the bulkhead Bulkhead after rod end jam nuts are tightened to specified A Jam Nut torque See illustration at right 4 Tighten all jam nuts Torque radius rod attaching bolts to specification Rod end parallel to mounting surface Rod End when jam nut is tight A WARNING After camber adjustment is complete be sure to measure set up width outlined on page 6 15 and compare to specifications listed on page 6 14 Do not attempt to set suspension wider than the specified maximum set up width If set up width exceeds maximum adjust upper and lower radius rods equally to maintain camber adjustment Polaris Industries Inc 6 17 10 98 BODY AND STEERING Steering Adjustment All IFS Handlebar Centering 5 With alignment bar installed through s
14. specification Ski Skag Retaining Nut Torque Steel Ski Steel w skins 15 ft Ibs 2 1 kg m Plastic Ski 20 25 ft Ibs 2 76 3 45 kg m Ski Skag Removal EZ Steer 1 Remove the three nuts from the skag 2 Pull down and rearward to remove the skag Ski Skag Installation EZ Steer 1 Install flat bar as shown 2 Install IFS carbide skag 3 Reinstall nuts and torque to specification Ski Skag Retaining Nut Torque 15 ft Ibs 2 1 kgm 10 98 6 30 Polaris Industries Inc BODY AND STEERING Ski Skin Installation Ski Skin Installation 1 Lift and support front end of machine for easier access to skis A WARNING Be sure the machine is stable and solidly supported before proceeding Serious injury may result if ma chine tips or falls 2 Remove cotter pin from ski bolt 3 Remove ski bolt and take off ski Note direction of rubber ski stop 4 Remove the bolts from the skag Pry the back of the skag downward from the ski and remove from the front slot 5 Place heel of ski on a solid surface and slide plastic ski skin onto toe of ski as shown 6 Tap ski skin toe with plastic mallet to be sure it has snapped completely onto the toe Check to see that the skag holes line up Working from the toe of the ski continue snapping ski skin onto ski NOTE Clamps may be used if the skin is difficult to install 8 Replace skag removed in step 4 9 Replace s
15. tank cover by disconnecting snaps Remove vent line at front LH side of tank Remove gas cap and rubber grommet Remove air silencer box Disconnect fuel line from fuel pump and plug line to prevent fuel spillage from tank See photo one at right 6 Roll front tank hold down spring forward off tank saddle 7 If machine is equipped with a fuel gauge connector this should be unplugged 8 Remove two bolts holding rear of seat to tunnel OY Pe 2 4 9 Slide seat rearward enough to gain access to taillight connector at RH side of fuel tank Unplug connector Slide seat off machine and set aside 10 Fuel tank can now be removed from chassis by disconnecting two springs at center of fuel tank Polaris Industries Inc 6 35 10 98 BODY AND STEERING Fuel Tank and Seat Removal One Piece Fuel Tank Seat Removal t Remove front tank retaining spring located behind driven clutch area 2 Remove fuel cap and grommet Remove fuel lines 4 If machine is equipped with gauges unplug gauge wires 5 Remove two bolts in tool box 6 Disconnect taillight wiring 7 Remove two console bolts attaching console to tunnel 8 Remove two console bolts located under hood 9 Remove fuel cap and lift console up Replace fuel cap 10 Lift up at rear of seat and slide out w 10 98 6 36 Polaris Industries Inc BODY AND STEERING Seat Cover Replacement Plastic Base Seat Co
16. 70 Travel Location Bars Disconnect Loosen Remove to adjust radius rods Alignment Bar 10 98 6 22 Polaris Industries Inc BODY AND STEERING High Performance CRC Steering Adjustment Camber Adjustment XTRA 10 CRC and XC 10 CRC Cont 8 Using a 3 8 drive 11 16 1 7 cm crow foot wrench and 20 51 cm long 3 8 1 cm drive extension loosen the radius rod end jam nut and remove the lower radius rod bolt from the spindle requiring the most camber correction Adjust the opposite side next Change radius rod length until alignment bar slides freely through both spindles 9 When adjustment is correct tighten jam nuts to 24 25 ft Ibs 3 31 3 45 kg m Torque radius rod attaching bolts to 28 30 ft Ibs 3 86 4 14 kg m Radius rod ends must remain parallel to the mounting Bulkhead brackets after the rod end jam nuts are tightened to i Jam Nut the specified torque See illustration at right 10 Tighten all jam nuts Torque radius rod attaching bolts to specification 11 Re check set up width and compare to BE Ey pang specifications g when jam nut is tight Handlebar Centering CRC 12 With alignment bar in spindles and tie rod ends disconnected center the steering rack by pointing the pitman arm and idler arm straight forward Handlebar Centering CRC 13 Center the handlebars by adjusting drag link length Tighten jam nuts to 24 25 ft Ibs 3 31 3 45 kg m 14 The steering arms shou
17. CHAPTER 6 BODY AND STEERING Torque Spec s Steering Asm Exploded Views 6 1 6 11 Steering Inspection oo nel ean ey bv emia ee 6 12 Steering Adjustment Guidelines AILIFS 6 13 Steering Adjustment AIl IFS 6 14 6 15 Steering Inspection AIKIFS 6 16 6 19 High Performance Steering Inspection Alignment 6 20 6 25 Ski Spindle Bushing Replacement 6 27 6 28 Steering Arm Installation 005 6 29 Ski Skag Removal 0 2 cee eee eee 6 30 Ski Skin Installation 2 0 2 0 0 2c4000des awe aces 6 31 Ski Installation Steel Skis Composite 6 32 Torsion Bar Replacement 0e ee eee 6 33 Handlebar Torque cece eee c eee eens 6 34 Fuel Tank and Seat Removal 6 35 6 36 Seat Cover Replacement 06 6 37 6 39 Hood Repair ss evatiac twa deste sero ies 6 39 Taillight Assembly Replacement 6 40 Seat Length Matnixicss ccciwseteseesd ong ere dense 6 41 Nosepan Replacement Evolved Style 6 42 Nosepan Replacement Gen II XTRA 10 Style 6 43 Nosepan Replacement Gen II XC 10 Style 6 44 Hood Adjustment Evolved 05 6 45 6 46 Decal Removal and Installation 6 47 Troubleshooting iss sci oarw Rome aw aca eiwe ae ares 6 48 BODY AND STEERING Torque Specifications Steering Assembly Exploded View Torque Application List D
18. ODY AND STEERING Seat Cover Replacement 7 Turn the assembly over and begin upholstering by lining up the seat cover vinyl side flaps with the indented square location indicators located on the plastic seat base as shown in Ill 1A Apply staples in the stapling channel only See Ill 1 If you apply staples outside the channel you will damage the fuel tank reservoir in the seat base If this happens you must replace the entire seat base assembly 8 Using a staple gun tack each side of the vinyl cover in place using two staples If cover has a Polaris emblem carefully align emblem with bottom edge of seat This will help ensure that the cover is positioned properly 9 Align the two sewn seams located at the rear of the seat cover with the two back corners of the seat base See Ili 1 Pull the vinyl tight and tack the seat cover to the plastic seat base in each corner Use two or three staples per corner 10 Now that the seat cover is correctly positioned and tacked to the plastic seat base in four places turn the assembly over and inspect it If the seat cover seems to fit correctly and everything looks straight including the tool compartment flap continue with step 11 Bottom View Of Seat Assembly N Sewn Seams Tack Cover Here Stapling Channel Tack Cover Here First Location Indicators 11 Staple the remainder of the unattached seat cover to the plastic seat base as shown in IIl 1 HINT Always Staple Here First stap
19. S Tie Rod Or Radius Rod End Tie Rod Or Radius Rod End Must Engage Rod A Minimum Of 2x Thread Diameter When Adjustment Is Complete EXAMPLE 7 16 Rod End x 2 7 8 Minimum Thread Engagement 7 8 1imm x2 22mm Minimum Thread Engagement 22mm Polaris Industries Inc 6 13 Diameter Of Rod End x 2 Minimum Thread Engagement BODY AND STEERING Steering Adjustment Guidelines All IFS Positive Negative and Neutral 0 Camber Front View Mounting Surface Incorrect Correct Jam Nut Tie Rod Or Radius Rod Thread Engagement 10 98 BODY AND STEERING Steering Adjustment All IFS 1999 IFS Steering Alignment Specifications The following information is to be used for 1999 Polaris Snowmobile front suspension setup The data in the following table is based on the 1999 Polaris factory settings Maximum Width and Camber measurements are to be taken with the front end elevated and shocks at full extension Toe alignment is measured at ride height ee Suspension Type Maximum Setup Width 1 4 6mm 5 16 Toe eee ree Ride AA MS Tey LITE 340 Indy 340 Deluxe 340 Touring 36 5 16 92 25 cm 38 RMK 36 3 4 93 35 cm Trail RMK 500 RMK 38 RMK CRC 600 RMK 700 RMK 38x7 WIDETRAK 41x7 Spor Sport Touring Transport XTRA 10 Trail Trail Touring Supersport 500 Indy XTRA 10 CRC 600 SKS Euro 700 SKS 700 SKS Euro XLT SP XCF 700 XCR 800 XCR XC 10 CRC 440
20. SS aS A A i ae Drag Link I uf Pitman Arm x STEEN Steering j Rod End W Stud Rack oS fy 17 19 ft Ibs LC 2 4 2 6 kg m yy PA T A Torsion Bar Upper Radius Rod A Trailing Arm Bx Q 7 A 28 30 ft Ibs Lower Radius Rod a 3 9 4 1 kg m Steering Arm oS Weld Positioned Up NES Wig y Indicates direction of bolt 28 30 ft Ibs Spindle 3 9 4 1 kg m Polaris Industries Inc 6 11 10 98 BODY AND STEERING Steering Inspection Inspection Prior to performing steering alignment inspect all steering and suspension components for wear or damage and replace parts as necessary Refer to steering assembly exploded views in this chapter for identification of components and torque values of fasteners While disassembling make notes of what direction a bolt goes through a part what type of nut is used in an application in which direction do the steering arms go on weld up or weld down etc Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store Always use genuine Polaris parts and hardware when replacing front end components Review steering adjustment guidelines on page 6 13 before making adjustments The following components must be inspected at this time NOTE Always follow rod end engagement guidelines found on page 6 13 Maximum setup width must be checked whenever front suspension components are adjusted or replaced Tie rods and tie rod ends Radius rods and radius rod ends
21. Torsion bar and bushings linkage where applicable Handlebars and steering post assembly Spindles and bushings Trailing arms and bushings Skis and skags Bell crank Pitman arm idler arm Steering arms Shock absorbers shock mounts springs All related fasteners check torque Refer to steering exploded views at the beginning of this section Grease all fittings OOOO0OOO00O0O000 Alignment Bar Specifications arn 45 114 3 cm 4 4 a E EJ 623 625 5 8 Alignment Bar PN 8700231 15 83 15 88 mm 10 98 6 12 Polaris Industries Inc Camber Definition All IFS The following definitions of camber use automotive terminology to describe positive and negative posi tions Refer to the illustration at right e 0 Neutral Camber Spindle is 90 perpendicu lar to ground e Positive Camber Spindle bottom is canted inward toward chassis Negative Camber Spindle bottom is canted outward from chassis Radius Rod and Tie Rod End Torque Procedure Radius rod and tie rod ends must be parallel to their respective mounting surface after tightening jam nut as shown at right Hold tie rod or radius rod and tigh ten jam nut If possible support the edge of the rod end as shown to keep it from rotating out of position until jam nut is tight When tie rod ends are properly tightened the tie rod should rotate freely approxi mately 1 8 turn Rod End Engagement Guidelines All IF
22. ag centerline to equal and taken 10 254 mm fore and straightedge to determine the amount of adjustment aft of spindle center as shown with toe required per ski Measuring from points on skis may angimentravelbars stalled vary and should not be used sraigtedse Against Trac Li 10 98 6 24 Polaris Industries Inc BODY AND STEERING High Performance CRC Steering Adjustment Toe Adjustment XTRA 10 CRC and XC 10 CRC cont 22 To adjust toe hold tie rod flats or support edge of tie rod end with a wrench or flat stock to keep it from rotating Loosen jam nuts on each end of both tie rods Turn tie rod as required to adjust toe 23 Hold tie rod and tighten jam nuts Be sure to position inner and outer tie rod ends parallel to their respective mounting surface as shown When tie rod ends are properly tightened the tie rod should rotate freely approximately 1 8 turn Mounting Surface Incorrect Correct Tie Rod Jam Nut Torque 8 14 ft Ibs 1 1 1 9 kg m Polaris Industries Inc 6 25 10 98 BODY AND STEERING All Models Body and Steering Continued 10 98 6 26 Polaris Industries Inc BODY AND STEERING Ski Spindle Bushing Replacement Ski Spindle Bushing Removal 1 Using aa scribe center punch or paint mark the spindle and steering arm for reference during reassembly Note direction of steering arm bolt and remove Also note orientation of grease
23. bulkhead Tipped In trailing arm style Qe O O O O O o e e e o o e C A e s O o os e s NOTE 1 When transfer drilling holes do not force pan into a position which is not uniform with the other side Use the same method to drill both sides 2 Rivet holes across from one another in unison 10 98 6 44 Polaris Industries Inc BODY AND STEERING Hood Adjustment Hood to Belly Pan Alignment Evoived Style The gap between the hood and belly pan should always be 3 16 1 8 4 8 mm 3 mm Refer to Ill 2 for adjust ment procedures NOTE Hood may have to be removed to make this adjustment The gap between the hood and the belly pan should be 3 16 1 8 If gap is too little at this point move hole in hinge brace toward top of slot in hood brace If gap is too large at this point move hole in hinge brace toward bottom of slot in hood brace Ze O eee ae see Hood Adjustment Evolved Style 1 Check to see that hood and upper hood hinge are properly aligned To adjust loosen nuts A and align properly Tighten nuts See Ill 1 2 With hood open loosen nut B See Ill 1 3 Close hood and remove both rubber plugs Then using a 7 16 4 cm socket with an 8 20 cm extension loosen nut C Adjust hood to pan gap Tighten nuts 4 Check outer perimeter alignment and front and rear alignment of hood
24. ct Adjust Toe Up Width Camber Travel Location Bar Suspension Fully Install 13 70 Bars Install 11 65 Bars Length Extended Shocks XTRA 10 ONLY Installed Set Toe w Shocks Installed on XC 10 models A WARNING Maximum set up width is the maximum allowable distance between ski spindle centers with front end of vehicle off the ground and suspension fully extended The Maximum Set Up Width specifications listed on page 6 14 are maximum width measurements and are critical to ensure adequate torsion bar engagement with the trailing arm If the suspension is set too wide the torsion bar can come loose and interfere with steering Do not attempt to set the suspension wider than the specified Maximum Set Up Width Polaris Industries Inc 6 21 10 98 BODY AND STEERING High Performance CRC Steering Adjustment CRC Steering Adjustment To ensure accurate adjustment of the CRC steering mechanism all steps listed below must be performed in se quential order e Spindle to Chassis Centering must also be checked after adjustment Set Up Width adjustment must also be checked after adjustment e Camber Adjustment e Handlebar Centering e Toe Adjustment e Verify Spindle to Chassis Centering and Set up width are within limits 1 Securely support the front of the machine high enough to remove the skis Make sure machine is level 2 Remove skis Spindle to Chassis Centering 3 Follow procedure on page 6 15 Set Up Width Measurement 4 Foll
25. e mask carefully remove NOTE If the decal being applied needs to be stretched around a radius follow these recommendations 6 Fasten a straight edge to tail end of decal 7 Pull or stretch remaining portion of decal around radius and into position NOTE A small amount of heat applied to the decal will aid in forming it to the radius The mass of the decal which was secured in previous steps will hold it in position while pulling 8 Again apply soapy water solution to top of decal and remove trapped air using a clean soft rubber squeegee Use care to prevent scratching the decal surface 9 Apply a small amount of heat to the decal to fasten it securely 10 Carefully remove excess decal material Polaris Industries Inc 6 47 10 98 BODY AND STEERING Troubleshooting Machine darts from side to side Incorrect ski toe alignment Adjust to correct toe alignment Incorrect camber Adjust to correct camber Loose or worn steering compo Tighten or replace nents or fasteners Cracked or broken skis skags or Replace if necessary carbides Tie rod hits trailing arm Steering arm installed incorrectly Index correctly in relation to spindle Tie rod ends worn Replace if necessary Steering has excessive freeplay Steering bellcrank bushing worn _ Tighten or replace if necessary or loose Drag link worn or loose Tighten or replace if necessary Steering post loose Tighten as needed Steering post bushi
26. eering Adjustment All IFS Prior to performing steering alignment the suspension should be inspected for damage or wear and replacement parts installed as required See inspection on page 6 12 A WARNING A maximum set up width is listed in the chart on page 6 14 Maximum set up width is the maximum allowable distance between ski spindle centers with front end of vehicle off the ground and suspension fully extended The Maximum Set Up Width specifications are maximum width measurements and are critical to ensure adequate torsion bar engagement with the trailing arm If the suspension is set too wide the torsion bar can come loose and interfere with steering Do not attempt to set the suspension wider than the specified Maximum Set Up Width Spindle Centering Set Up Width 1 Make sure the track is properly aligned Refer to Maintenance Chapter for procedure This will be used as a reference point for final toe out measurement Support the front of the machine 1 2 2 5 5 1 cm off the floor Remove skis and ski pivot bushings Disconnect adjustable torsion bar linkage where applicable Measure spindle to chassis centering as shown and record measurement Both spindles should be an equal distance 1 8 3 mm from the center of the chassis after adjusting camber width and toe alignment This measurement is controlled by adjusting radius rod length ak oN 6 Measure set up width and record This measurement is controlled
27. fitting for ski pivot bushing The fitting faces forward on models with leading spindle and rearward on trailing spindles 2 Remove steering arm 3 Slide spindle and ski assembly out bottom of trailing arm Inspect spindle for wear or damage 4 Remove old bushings and washer from bottom of spindle tube with a drift punch Inspect condition of washer and replace if worn Install new bushings tapered end first Washer Polaris Industries Inc 6 27 10 98 BODY AND STEERING Ski Spindie Bushing Replacement Ski Spindle Bushing Installation 5 Grease spindle shaft and new bushings with Polaris All Season Grease All Season 6 Install spindle into trailing arm with grease fitting facing forward standard and leading spindles or rearward trailing spindles Standard 7 With ski facing straight forward attach steering arm Align with marks made in step 1 8 Install steering arm bolt and torque to specification 10 98 6 28 Leading Type Trailing 97 Polaris Industries Inc BODY AND STEERING Steering Arm Installation Steering Arm Orientation A WARNING Steering arm orientation is important to ensure proper steering tie rod end thread engagement and steering perfor mance Always mark steering arms and spindles before removal for reference upon reassembly When installing new parts or after steering arm installation refer to the illustrations and text below Always verify proper steering
28. ki removed in steps 2 and 3 10 Repeat procedure for second ski Polaris Industries Inc 6 31 10 98 BODY AND STEERING Ski Skag Removal Ski Installation SKI INSTALLATION STEEL SKIS 1 Install ski over spindle slight Ski Spindle Ski Saddle e ly in front of ski saddle with ski pointing outside L Slide ski forward until spindle is just behind ski saddle and turn to the forward position _ Slide ski forward so spindle is behind ski saddle J Apply soapy water solution to the rear portion of the rubber ski stop Install ski stop on top of ski saddle with large portion forward _ Push ski back to slide spindle into place From outside of ski install bolt and castle nut Torque to 36 ft Ibs Install cotter pin and bend both legs SKI INSTALLATION COMPOSITE _ Install ski stop with large portion toward front of ski Instali cotter pin ds and bend both legs _ Install ski to spindle From outside of ski install bolt washers and castle nut Carefully lower machine Torque to 36 ft lbs 4 97 kg m 10 98 6 32 Polaris Industries Inc BODY AND STEERING IFS Torsion Bar Torsion Bar Removal 1 Remove trailing arm assembly 2 Using a small pin punch tap out the rivet mandrels in the center of the torsion bar support rivets 3 Using a 1 4 bit drill out the center portion of the rivets 4 Punch out the rivet body 5 Remove support and torsion
29. ld be parallel to the ski centerline or slightly inward Pitman Arm and Idler Arm Point Straight Forward 15 Re attach steering tie rod ends C to steering arms It may be necessary to loosen the tie rod adjustment jam nuts B and adjust tie rod length A as required until rod end studs can be installed in steering arm Torque tie rod end attaching nuts to 28 30 ft Ibs 3 86 4 14 kg m If tie rod adjustment was necessary do not tighten them until toe adjustment is complete 16 Perform toe adjustment on following page Polaris Industries Inc 6 23 10 98 BODY AND STEERING High Performance CRC Steering Adjustment Toe Adjustment XTRA 10 CRC XC 10 CRC 17 Remove alignment bar from spindles 18 Remove 13 70 travel location bars and install 11 65 toe alignment bar on XTRA 10 CRC only Toe alignment is set with shocks installed on XC 10 CRC 19 Install skis 20 With the front of the machine still securely supported 11 65 Travel Bars off the ground install a block or spacer between the rear of the ski frame and the bottom of the trailing E S Toe Alignment arm The block should be 3 75 4 0 long The Bar Installed blocks will keep ski to ground surface orientation correct for more accurate toe adjustment 21 Adjust toe so skis carbides are parallel zero toe out or toe in with toe alignment travel bar installed NOTE Measurements A amp B should be Measure from equal point on sk
30. le between two existing staples and follow this procedure until the seat cover is completely stapled to the seat base See Ill 2 12 Turn the seat cushion assembly over and inspect for Staple wrinkles or imperfections If imperfections are Here Second visible remove the staples in the affected area and staple correctly Staple Here Third Staple Sequence 10 98 6 38 Polaris Industries Inc BODY AND STEERING Seat Cover Replacement Models With Grommets In Tool Flap 13 Close tool flap cover making sure it is aligned properly and mark grommet holes Tool Flap 14 Align twist lock with mark from step 13 Verify alignment with grommet in tool flap 15 Using twist lock as a template drill two 160 to f Grommets 164 holes through vinyl and seat base j 16 Rivet twist lock to seat base using rivets provided All Models 17 Trim excess vinyl from the bottom around the back of the seat area only after a satisfactory fit is obtained See Ill 1 page 6 38 18 Reinstall seat by reversing disassembly steps as they apply to your particular model Hood Repair Currently there is no procedures or materials recommended by Polaris for repairing hoods Hoods for 1999 model snowmobiles are made of Thermoplastic Olefin TPO and cannot be repaired f a hood is broken it must be replaced For small cracks you may drill a small hole on both ends of the crack to limit spreading Polaris Industries Inc
31. n hood side of steering post 2 Using a 7 16 11 mm wrench loosen four nuts on bottom of adjuster block NOTE Turn handlebar to left or right for access to rear nuts 3 Adjust handlebar to the desired height Be sure that handlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right 4 Torque the handlebar adjuster block bolts evenly to specification The gap should be equal at the front Bottom of Adjuster Block and rear 5 Replace console cover A WARNING improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars which could result in loss of control 10 98 6 34 Polaris Industries Inc BODY AND STEERING Fuel Tank and Seat Removal A WARNING Gasoline is extremely flammable and explosive under certain conditions Do not smoke or allow open flames or sparks in or near the area where work is being performed If you should get gasoline in your eyes or if you should swallow gasoline see your doctor immediately If you should spill gasoline on your skin or clothing immediately wash if off with soap and water and change clothing Prolonged exposure to petroleum based products may cause paint failures Always protect finished surfaces and wipe up any spills immediately Two Piece Fuel Tank Seat Removal Remove
32. ngs worn Replace if necessary Tie rod ends worn Tighten as needed Spindle bushings worn Replace if necessary Front end bounces or sags IFS shock spring preload too soft Adjust spring tension on shocks Improper shock charge or valving Recharge service or replace if so equipped shocks Some machines with a wide front end may experience darting while following narrower machines on a trail This is caused by the skis moving in and out of the narrower track left by the previous machine 10 98 6 48 Polaris Industries Inc
33. on Decal Removal 1 Before removing old decal it is important to note its position by marking it in several locations 2 Remove old decal completely NOTE A small amount of solvent will aid in removing the old decal 3 The decals are UV based If heat will not remove decal gently buff area with a mild abrasive Use 3M Scotch Brite Graphics Removal Discs with a No 1 Roloc and holder or an equivalent low RPM buffing disc CAUTION Maintain 2500 3500 RPM to prevent damage to hood caused by excessive heat 4 Remove any remaining deca adhesive with a citrus based cleaner or equivalent non solvent based cleaner 3M Scotchbrite Graphics Removal Disc 5 Thoroughly clean area where the new decal will be 3M PN 048011 16855 installed using a solution of mild soap such as dishwashing liquid and clean water NOTE Use No 1 Roloc and holder approximately four ounces soap to one gallon 3M PN 048011 15408 water Decal Installation 1 Apply a solution of mild soap mixed with clean water to the area where the new decal is to be applied Do not wipe off 2 Carefully remove decal backing and apply new decal 3 If decal does not have a pre mask apply additional soapy water solution to top of decal after it is in position 4 Holding decal in position remove all trapped air and soapy water solution from under decal using a clean soft rubber squeegee to prevent scratching of decal surface 5 If decal has a pr
34. ow procedure on page 6 15 This is the maximum allowable distance between ski spindle centers with front end of vehicle off the ground and suspension fully extended The maximum set up width specifications listed on page 6 14 are maximum width measurements and are critical to ensure adequate thread engagement of steering tie rod and radius rod ends If the suspension is set too wide the torsion bar can come loose and interfere with steering Do not attempt to set the suspension wider than the specified Maximum Set Up Width Camber Adjustment XTRA 10 CRC and XC 10 CRC 5 Remove IFS shocks and install 13 70 travel location bars The travel location bars will locate the IFS at a given point of travel where the camber should be neutral 0 6 Disconnect tie rods from steering arms NOTE f toe adjustment is correct the spindles will not be horizontally aligned with the 13 70 travel location bars installed Therefore the alignment bar will not slide through both spindles Disconnecting the tie rods will eliminate bind on the alignment bar and allow for more precise camber adjustment It may also be helpful to secure the tie rods so they don t interfere with inspection or adjustment 7 Determine which spindle requires the greatest amount of correction by installing the alignment bar through one side to the opposite spindle then remove the bar and install it through the other side to the opposite spindle Camber Adjustment Install 13
35. pindles on 0 camber models center handlebars by adjusting drag link length Fig I On models with negative camber the alignment bar cannot be installed through spindles On these models the pitman and idler arm Fig ll or bellcrank on non CRC models should be pointed straight forward 6 Lubricate ski pivot bushings with Polaris Premium All Season Grease and install in spindle Torque ski bolts to specification Install new cotter pin in castle nut 7 Perform Toe Adjustment on page 6 19 Idler Arm 10 98 6 18 Polaris Industries Inc BODY AND STEERING Steering Adjustment All IFS Toe Adjustment All Models Toe adjustment on all models must be performed with the vehicle weight on the suspension no rider at Normal Ride Height Although not required an alternate high performance method of toe alignment using the travel bar kit 2871537 can be used to set toe on models equipped with XTRA 10 CRC front suspension use 11 65 travel bars On XC 10 CRC models only the camber can be set with the travel bars 13 70 travel bars toe on XC 10 CRC must be set with shocks installed and front end elevated Refer to pages 6 20 6 25 1 Make sure the track is properly aligned This will be used as a reference point for toe out measurement Lift 3 5 7 6 12 7 cm and work suspension to find average 2 To obtain normal ride height of the front suspension lift the front end 3 5 7 6 12 7 cm with the front bumper
36. ring Alignment The following steering alignment procedure can be performed on XTRA 10 CRC or XC 10 CRC front suspensions only and should not be used for 38 RMK CRC or non CRC front suspensions General Set Up Tips Before adjustments are performed on CRC steering inspect all front suspension and steering components While disassembling make notes of what direction a bolt goes through a part what type of nut is used in an application in which direction do the steering arms go on weld up or weld down etc Some of the bolts used in the IFS are special and cannot be purchased at a hardware store Always use genuine Polaris parts and hardware when replacing front end components Tools Tools required Camber XTRA 10CRC amp XC 10 CRC e 8 alignment bar PN 5333508 13 70 e 6 tape measure e Travel location bars 13 70 long PN 5211714 e Travel location bars 11 65 long PN 5211822 11 65 e Chassis stand or blocking NOTE The CRC Travel Location Bars are included in kit PN 2871537 along with a 46 alignment bar and as sorted hardware Kit components are also available separately See tool catalog for tool ordering information Refer to the chart below for travel bar application for width camber and toe adjustments on XTRA 10 CRC and XC 10 CRC models See text on following pages for specific procedures XTRA 10 CRC and XC 10 CRC Models When Measuring Set To Inspect Adjust To Inspe
37. ue to the special grade bolts and nuts required for specific applications observe the following torque values in the areas specified Refer to exploded views for torque values and orientation of components and fasteners 1999 XCF Illustration depicts proper orientation of rod ends and bolts on steering components 28 30 ft Ibs 3 9 4 1 kg m 28 30 ft Ibs 35 40 ft Ibs 3 9 4 1 kg m 4 8 5 5 kg m g m oe A ss 17 19 ft Ibs r LO 2 4 2 6 kg m 4 P Ms WN a 6 17 19ft Ibs 2 4 2 6 kg m 35 40 ft Ibs 4 8 5 5 kg m 28 30 ft Ibs 3 9 4 1 kg m 28 30 ft Ibs 3 9 4 1 kg m Replace locking fasteners if removed Polaris Industries Inc 6 1 10 98 BODY AND STEERING Steering Assembly Exploded View 1999 340 340 Deluxe 340 Touring Illustration depicts proper orientation of rod ends and bolts on steering components 40 45 ft Ibs 28 30 ft Ibs 5 5 6 2 kg m 3 9 4 1 kg m 28 30 ft Ibs 3 9 4 1 kg m 28 30 ft Ibs 28 30 ft Ibs 3 9 4 1 kg m 3 9 4 1 kg m 28 30 ft Ibs 3 9 4 1 kg m 28 30 ft Ibs Ls 3 9 4 1 kg m D Replace locking fasteners if removed 10 98 6 2 Polaris Industries Inc BODY AND STEERING Steering Assembly Exploded View 1999 Sport Sport Touring TranSport Illustration depicts proper orientation of rod ends and bolts on steering components 40 45 ft Ibs 55 60 ft Ibs 5 5 6 2 kg m 7 6 8 3 kg m 28 30 ft Ibs D 3 9
38. ver Replacement 1 Remove seat assembly as outlined on page 6 36 2 Remove seat and seat covering to be replaced Carefully remove staples by loosening with a small flat blade screwdriver Pull each staple straight out with a pliers 3 On some models it will be necessary to drill out the rivets holding the strap buckles Reach inside the tool box and rotate the D ring buckle which secures the center hold down strap Push the D ring through the slot in the tool box and carefully pull it through the foam cushion Reassembly Note For ease of assembly hook a wire to the center strap This will allow you to pull the center strap back through the foam and into the storage box 4 Place the seat foam on the seat base assembly as shown in Ill 1 5 Drape the seat cover over the seat foam 6 Insert and pull the two seat bucket hold down Seat Gover straps attached to the seat cover through the two holes in the seat foam and the routed out holes located in the storage box area on the plastic seat base HINT A stiff wire attached to the 3 bar slide on the hold down strap will aid in this process Seat Bucket NOTE Use the rear two holes for a longer length seat Ait pow and the forward two holes for the standard length seat P 3 bar Slide Seat Foam For Use With For Use With Long Seat Standard kergti I Storage S aS Box Area T lt Plastic Seat Base Polaris Industries Inc 6 37 10 98 B

1999 Polaris Service Manual

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