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1999 Polaris Service Manual

1. DRIVE DRIVEN 36 22 41 68 P 36 22 41 68 P 36 22 41 68 P 36 22 41 68 P Chaincase Gearing 3 4 HYVO 3 4 HYVO 3 4 HYVO 3 4 HYVO Outside Circumference 47 250 d ix Wen Spin Soana Center Distance 12 305mm 0 900 AL j Shift Weights 10 AL Bushed 03000 Busnea Pete Siver Secondary Spring Silver lt dio is memos we Driven Helix 36 2 eo00 9000 BOMB Reamwnite Siver ARES SOME reat a ENGINE Type lt 0 4224 peek sea ae ele Fan Cooled Piston Port Displacement 488 cc BOIG cid tae ia ads oe 2 8346 72mm SttoKe coc cese EEG 2 3622 60mm Piston Cylinder Clearance 0 0039 0 0063 0 10 0 16mm Service Limit 0 0078 0 20mm Piston Marking M 1 Piston Ring Marking R Piston ring end gap 008 019 20 49mm Head cc s Uninstalled 26 7cc Head cc s Installed 24 1cc Operating RPM 200 7000 RPM Idle RPME200 1600 RPM Engagement RPM 300 3600 RPM Cylinder Head Torque 18 19 ft Ibs 2 5 2 8 kgm Cylinder Base Nut Torque 30 34 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft Ibs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5 kgm Flywheel Torque 60 65 ft Ibs 8 3 9 kgm 10 98 Polaris Industries Inc GENERAL 1999 Model Specificat
2. Liquid Cooled Hydraulic Disc IFS Spring Rate 120 in Front Spring Preload 1 063 Thread Adjust Front Vertical Travel 9 30 in 23 62cm Rear Suspension XTRA 10 Rear Travel 10 2 in 25 91cm Front Track Shock Fox IFP Spring Rate 200 in variable Rear Track Shock Fox IFP Rear Springs 359 sq 77 Track Type 15 x121 x 91 38 1x307 34x2 31cm Track Tension 3 8 1 2 9 65 12 7mm slack with 10st 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR SUSPENSION SPRINGS MEDIUMSTO FAM 347 sq diameter 77 359 sq diameter 77 375 sq diameter 77 L H 7041627 067 L H 7041629 067 L H 7041631 067 R H 7041628 067 R H 7041630 067 R H 7041632 067 Polaris Industries Inc 1 63 10 98 GENERAL 1999 Model Specifications MODEL INDY 800 XCR MODEL NUMBER 099AB8AS ENGINE MODEL EC79PL011 CARBURETION JETTING CHART Type O EAE TM38 Mikuni AMBIENTIEMPEHATURE BIS rs teh ht n nn zo Altitude Below zo ao 1o o 10 or Above 40 F HOT Jel curra as elow o to Above 5 C Jet Needle 9DH6 54 3 Won 450 Needle Jet P 4 Fixed Cutaway 2 0 poes 420 Idle Mixture Screw 1 25 Turn Valve Seat 1 5 Fuel Octane R M 2 Adjustable with RUE 350 key switch Starter Jet 145 yox Pilot Air Jet 1 0 ax refers to the clip position from top of je
3. XXX 8X refers to the clip position from top of jet needle C Production Setting CLUTCH CHART DRIVEN Altitude Shit Clutch Chaincase Outside Circumference 47 250 Weight Spring Gearing Center Distance 12 305mm Meters ET 16 j 3e 20 40 66 P Shift Weights 10 Bushed Feet 3000 Bushea Redhtte 2 3 4 HYVO Secondary Spring Siver lt EFE A 7 Driven Helix 36 2 60009000 O MB RedMnite is ao 00012000 gushed Red White za vemo ENGINE A O deus tens Fan Cooled Piston Port Displacement 488 cc Bore paa sae eae tiene ts 2 8346 72mm SOKE ocios ee Sees 2 3622 60mm Piston Cylinder Clearance 0 0039 0 0063 0 10 0 16mm Service Limit 0 0078 0 20mm Piston Marking M 1 Piston Ring Marking R Piston Ring End Gap 008 019 20 49mm Head cc s Uninstalled 26 7cc Head cc s Installed 24 1cc Operating RPM 200 7000 RPM Idle RPME200 1600 RPM Engagement RPM 300 3600 RPM Cylinder Head Torque 18 19 ft lbs 2 5 2 8 kgm Cylinder Base Nut Torque 30 34 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5 kgm Flywheel Torque 60 65 ft lbs 8 3 9 kgm 10 98 Polaris Industries Inc
4. R 8 4 2 18002700 gu 203968P 6000 9000 3 4 HYVO 2700 3700 Wwe Almond Silver R32 20 3968 P 9000 12000 Bushed Gold Blue 3 3 4 HYVO ENGINE Type ci Liquid Cooled Case Reed Displacement 438 cc A eure eee ee RES 2 598 66mm ONOKE aon otis ccc eee 2 520 64mm Piston Cylinder Clearance 0 0023 0 0037 0 06 0 095mm Service LiMit 0 0059 0 15mm Piston Marking EK2185B Piston Ring Marking o faces upward Piston Ring End Gap 008 020 20 51mm Head cc s Uninstalled 19 6 cc Head cc s Installed 18 5 cc Operating RPM 200 8250 RPM Idle RPME200 1600 RPM Engagement RPM 300 5000 RPM Cylinder Head Torque 20 24 ft lbs 2 8 3 3 kgm Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 30 34 ft lbs 4 15 4 7 kgm 20 24 ft lbs 2 8 3 3 kgm N A 90 ft lbs 12 4 kgm 10 98 1 26 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL 440 XCR MODEL NUMBER 099SX4CS ENGINE MODEL S44 44 98A1 ELECTRICAL CAPACITIES Flywheel I D 4060141 Fuel Tank 10 5 gallons 39 7 liters CDI Marking 4060190 Oil Tank 3 quarts 2 8 liters Alternator Output 280 Watts Coolant 3 Quarts 2 8 liters Ignition Timing 2
5. 34 93mm DRIVEN Side Angle Overall 28 Altitude Shift Clutch Clutch Chaincase Outside Circumference 47 250 Weight Spring Gearing Center Distance 12 305mm Goan lt dae 10M Gold 34t 1f 2241 68 P Shift Weights 10M Bushed S pE esni SEINS Primary Spring Gold ooo Blue Gold Gold Sar 22 41 08 P Secondary Spring Gold pushed ZPS Driven Helix 34 2 1800 2700 Mote WU a se 22 4168 P 10M s ES ENGINE A irre Sits doar NE Liquid Cooled Piston Port Displacement 488 cc BONE 3674 3430065030 RE eum 2 8346 72mm A esu bane YALE 2 3622 60mm Piston Cylinder Clearance Service Limit 0 0035 0 0049 0 09 0 125mm 0 0078 0 20mm Piston Marking 5B Piston Ring Marking 5B Piston Ring End Gap 008 016 20 40mm Head cc s Uninstalled 28cc Head cc s Installed 23 6cc Operating RPM 200 7800 RPM Idle RPME200 1600 RPM Engagement RPM 300 4000 RPM Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 8mm 17 20 ft lbs 10mm 24 26 ft lbs 24 28 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft lbs 3 2 3 5 kgm 60 65 ft lbs 8 3 9 kgm 1 38 Polaris Industries Inc MODEL 500 CLASSIC MODEL NUMBER 099ED4BS ENGINE MODEL
6. EC50PL172 ELECTRICAL Flywheel L D FP5445 CDI Marking CU6417 Alternator Output 200 Watts Ignition Timing 28 BTDC 3000RPM 1 5 0 173 BTDC 0 0175 4 40mm BTDC 0 48mm Operating Timing 16 7500 RPM Spark Plug Gap Champion RN 3C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 202 watts Brake 1017 watts Voltage Regulator LR9 LR2 Electric Start Standard LR9 Half wave voltage regulator LR2 Rectifier only for battery charging SUSPENSION CHASSIS Body Style Evolved Front Suspension XTRA 12 Maximum Width 42 50 107 95cm Camber 0 5 16 0 8mm Toe Out 1 8 1 4 3 6 35mm Front Shocks Nitrex IFS Spring Rate 65 in Front Spring Preload Front Vertical Travel 0 5 Thread Adjust 10 in 25 4cm GENERAL 1999 Model Specifications CAPACITIES Fuel Tank 11 8 gallons 44 7 liters Oil Tank 2 quarts 1 9 liters Coolant 3 quarts 2 8 liters Chaincase Oil 9 fl oz 265cc CHAINCASE Sprockets Chain 22 41 68 P 3 4 HYVO Reverse Standard Brake Pads Type 69 Chaincase Center Dist 6 5 8 16 83cm Driveshaft Sprockets 2 Drivers Brake Type Hydraulic Disc Rear Suspension XTRA 12 Rear Travel 12 0 in 30 48cm Front Track Shock Indy Select Spring Rate 75 1 25 in Rear Track
7. Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 0 0023 0 0037 0 06 0 095mm 0 0059 0 15mm 70 38 ELCO 2205 o faces upward 012 018 30 46mm 28 6cc 25 4cc 8000 RPM 1500 RPM 4200 RPM 20 24 ft lbs 2 8 3 3 kgm 30 34 ft Ibs 4 15 4 7 kgm 20 24 ft lbs 2 8 3 3 kgm N A 90 ft lbs 12 4 kgm DRIVEN Chaincase Gearing 22 41 70 P 3 4 HYVO 22 41 70 P 3 4 HYVO 22 41 70 P 3 4 HYVO 22 41 70 P 3 4 HYVO 10 98 1 50 Polaris Industries Inc MODEL MODEL NUMBER ENGINE MODEL ELECTRICAL Flywheel I D CDI Marking Alternator Output ignition Timing Operating Timing Spark Plug Gap Lights Head Tall usse Brake Voltage Regulator Electric Start INDY 500 XC 500 XC SP 099SB5AS 099SP5AS 50 44 99A2 4060141 4060198 280 Watts 12 BTDC 3000RPM 1 5 0 034 BTDC 0 008 0 872mm BTDC 0 208mm 15 7500 RPM Champion RN 2C 0 028 0 7mm Halogen 75 60 watts 2 8 watts XC 2 2 watts SP 208 watts XC 10 17 wattsSP LR7 N A LR7 Full wave voltage regulator SUSPENSION CHASSIS Body Style Gen Il Front Suspension XC 10
8. sq diameter 77 375 sq diameter 77 L H 7041627 067 L H 7041629 067 L H 7041631 067 R H 7041628 067 R H 7041630 067 R H 7041632 067 Polaris Industries Inc 1 53 10 98 GENERAL 1999 Model Specifications MODEL INDY 700 XC 700 XC SP MODEL NUMBER 099SB7AS 099SP7AS ENGINE MODEL SN70 70 99A2 CARBURETION IVDO is ERR 2 Keihin PWK 39 Main Jet PTO 185 MAG 190 Pilot Jet 38 Jet Needle R1368G 3 Needle Jet 2 9mm fixed Cutaway 5 5 Air Screw 1 0 Turn Valve Seat 1 8 Fuel Octane R M 2 87 Non Oxygenated or 89 Oxygenated Throttle Gap Under Cutaway 059 1 5mm Idle Sync Gap Under Cutaway 063 1 6mm CLUTCH Type oo eee ee eee P 85 Belt hd anda Panes 3211065 Belt Width Projected 1 438 36 53mm Side Angle Overall 28 Outside Circumference 48 375 Center Distance 12 5 317 5mm Shift Weights 10 60 Bushed Primary Spring Dark Blue Secondary Spring Silver JETTING CHART AMBIENT TEMPERATURE 1800 2700 6000 9000 2700 3700 9000 12000 XXX X C Production Setting refers to the CLUTCH CHART Altitude Meters Feet 0 900 0 3000 Altitude Below 20 F 20 t0 10 F 10 to 40 F Above 40 F Below 29 C 29 to 12 C 12 to 5 C Above
9. 2700 3700 9000 12000 ENGINE Type scr be DP Liquid Cooled Case Reed Twin Displacement 700cc A Lm Rees 3 1889 81mm Stroke eeror sin ninani 2 6772 68mm Piston Cylinder Clearance 0043 0053 11 135mm Service Limit 0078 20mm Piston Marking EK2108 Piston Ring Marking o faces upward Piston Ring End Gap 014 020 36 51mm Head cc s Uninstalled 40 2cc Head cc s Installed 32 5cc Operating RPM 200 8000 RPM Idle RPM 200 1500 RPM Engagement RPM 300 4200 RPM Cylinder Head Torque 20ft Ibs 2 8kgm Cylinder Base Nut Torque 35 40 ft lbs 4 8 5 5 kgm Crankcase Torque 8mm N A Crankcase Torque 10mm 35 40 ft lbs 4 8 5 5 kgm Flywheel Torque 55 ft lbs 7 4 kgm 10 98 1 58 DRIVE Shift Weight 10 60 Bushed 10 58 Bushed 10 58 Bushed Air Screw 1 2 tum Clutch Spring Dark Blue Dark Blue Clutch Spring Silver Blue 10 to 40 F 12 to 5 C Air Scre 1 2 turn ore Above 40 F Above 5 C Air Screw 1 2 turn Chaincase Gearing 21 4170P 3 4 HYVO Dark Blue 10 56 Bushed Dark Blue Silver R 11 21 41 70 P Blue 2 3 4 HYVO Silver R 11 21 4170P Blue 2 3 4 HYVO Silver R 11 21 4170P Blue 3 4 HYVO Polaris Industrie
10. 9 67 12 7mm slack with 10 4 54kg weight16 40 64cm ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS 393 diameter 77 406 diameter 82 406 diameter 77 L H 7041555 067 L H 7041521 067 L H 7041463 067 R H 7041556 067 R H 7041522 067 Polaris Industries Inc 1 19 R H 7041464 067 10 98 GENERAL 1999 Model Specifications MODEL INDY SPORT TOURING MODEL NUMBER 099ST4DS ENGINE MODEL EC44 3PM025 CARBURETION JETTING CHART Type VA the AL n acne ied VM34SS Mikuni MBIENT TEMP RATURE Main Jet 185 ee ee Pilot Jet 35 Below 29 C 29 to 12 C 12 to 5 C Above 5 C Jet Needle 6FJ6 3 Meters 0 90 175 165 Needle Jet P 8 166 od Hai 3 2 Cutaway 2 0 CH 900 1800 160 150 Air Screw 1 0 Turns GAS e qe Valve Seat 1 5 iod 259 gt s 5 7 Fuel Octane R M 2 87 Non Oxygenated or a Ta ias eee 5 89 Oxygenated 2000 12000 2 2 2 2 Throttle Gap Under Cutaway 180 4 57mm Er j Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 200 5 1mm an A CLUTCH Type occ P 90 Belt asis win 3211059 CLUTCH CHART Belt Width Projected 1 250 31 75mm Side Angle Overall 28 Altitud
11. GENERAL 1999 Model Specifications MODEL TRAIL TOURING MODEL NUMBER 099ET4ES A ENGINE MODEL EC50PM044 ELECTRICAL CAPACITIES Flywheel I D FP5441 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU6413 Oil Tank 2 quarts 1 9 liters Alternator Output 200 Watts Coolant N A Ignition Timing 26 BTDC 3000RPM H1 5 Chaincase Oil 9 fl oz 265cc 0 150 BTDC 0 017 3 81mm BTDC 0 43mm Operating Timing 16 6500 RPM Spark Plug Gap NGK BR8ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR9 LR2 Electric Start Standard LR9 Half wave voltage regulator LR2 Rectifier only for battery charging SUSPENSION CHASSIS CHAINCASE Body Style Evolved Sprockets Chain 20 40 66 P 3 4 HYVO Front Suspension XTRA 10 Reverse Standard Maximum Width 42 50 107 95cm Brake Pads Type 69 Camber 0 5 16 0 8 mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 1 8 1 4 3 6 35mm Driveshaft Sprockets 2 Drivers Front Shocks Nitrex Brake Type Hydraulic Disc IFS Spring Rate 80s in Front Spring Preload 0 13 Thread Adjust Front Vertical Travel 10 0 in 25 4cm Rear Suspension XTRA 10 Rear Travel 11 5 in 29 21cm Front Track Shock Nit
12. Outside Circumference 45 125 idi weight Spring Spring cane Center Distance 12 305mm Meters 0 900 17 41 66 P Shift Weights 10 Fes axo 19 Brown B2 3 4HYVO Primary Spring Brown ome AGM Reg 365 de r ing Red a la a de 5 B 2 1800 2700 10M Gold 36 5 17 4166P NR og E mS 5 6000 9000 Bushed 3 4 HYVO AE CNN ENGINE TYDE 20545 va A aiii Fan Cooled Piston Port Displacement 432 cc BOIS s 2 2a 58 50045 ad os d de 2 6661 67 72mm Stroke 0 eee eee eee 2 3622 60mm Piston Cylinder Clearance 0 0035 0 0055 0 09 0 14mm Service Limit 0 0078 0 20mm Piston Marking M 6 Piston Ring Marking R Piston Ring End Gap 008 019 20 49mm Head cc s Uninstalled 28 6cc Head cc s Installed 23cc Operating RPM 200 7000 RPM Idle RPME200 1600 RPM Engagement RPM 300 3500 RPM Cylinder Head Torque 18 19 ft lbs 2 5 2 8 kgm Cylinder Base Nut Torque 24 28 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5kgm Flywheel Torque 60 65 ft Ibs 8 3 9 kgm 10 98 1 20 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL INDY SPORT TOURING MODEL NUMBER 099ST4DS ENGINE MODEL EC44 3PM025 ELECTRICAL CAPACITIES Flywheel I D FP
13. sq diameter 77 375 sq diameter 77 L H 7041627 067 L H 7041629 067 L H 7041631 067 R H 7041628 067 R H 7041630 067 R H 7041632 067 Polaris Industries Inc 1 27 10 98 GENERAL 1999 Model Specifications MODEL TRAIL MODEL NUMBER 099EB4ES A ENGINE MODEL EC50PM044 CARBURETION TYPE eer eae VM34SS Mikuni Main Jet 230 Pilot Jet 40 Jet Needle 6DH7 3 Needle Jet P 8 166 Cutaway 3 0 CH Air Screw 1 0 Tums Valve Seat 15 Fuel Octane R M 2 87 Non Oxygenated or 89 Oxygenated Throttle Gap Under Cutaway 219 5 55mm Idle Sync Gap Under Cutaway 240 6 1mm CLUTCH Type citan P 85 Belinda 3211070 Belt Width Projected 1 375 34 93mm Side Angle Overall 28 JETTING CHART AMBIENT TEMPERATURE Altitude Below 20 F 20 to 10 F 10 to 40 F Above Below 29 C 29 to 12 C 12 to 5 C Abovi 090 240 0 3000 Meters Feet 900 1800 210 40 F e 5 C 1800 2700 3000 6000 3 6000 9000 3 2 200 195 185 180 3 3 2 2 2700 3700 9000 12000 190 180 180 180 3 2 2 2 XXX X E Production Setting refers to the clip position from top of jet needle CLUTCH CHART
14. 0 8mm Toe Out 1 8 1 4 3 6 35mm Front Shocks Indy Select IFS Spring Rate 75 in Front Spring Preload Front Vertical Travel 0 25 Thread Adjust 10 0 in 25 4cm GENERAL 1999 Model Specifications CAPACITIES Fuel Tank 11 8 gallons 44 7 liters Oil Tank 2 quarts 1 9 liters Coolant 3 quarts 2 8 liters Chaincase Oil 9 fl oz 265cc CHAINCASE Sprockets Chain 22 41 68 P 3 4 HYVO Reverse Standard Brake Pads Type 69 Chaincase Center Dist 6 5 8 16 83cm Driveshaft Sprockets 2 Drivers Wide Brake Type Hydraulic Disc Rear Suspension XTRA 12 Rear Travel 12 0 in 30 48cm Front Track Shock Ryde AFX Spring Rate 75 125 in Rear Track Shock Ryde AFX with 85 Spring Rear Springs 406 55 Track Type 15 x121 x 82 38 1x307 34x2 08cm Track Tension OPTIONAL REAR SUSPENSION SPRINGS some nw Polaris Industries Inc 1 47 3 8 1 2 9 65 12 7mm slack with 10st 4 54kg weight 16 40 64cm ahead of rear idler shaft 10 98 GENERAL 1999 Model Specifications MODEL XLT TOURING MODEL NUMBER 099ET6AS A ENGINE MODEL EC58PL131 CARBURETION JETTING CHART TVDe z doe ES VM34SS Mikuni AMBIENT TEMPERATURE Main Jet 250 Altitude Below 20 F 20 to 1010 eee Pilot J
15. Displacement 598cc A RE ERR 2 5600 65 025mm Stroke cose RE da 2 3622 60mm Piston Cylinder Clearance 0 0035 0 0049 0 09 0 125mm Service Limit 0 0078 0 20mm Piston Marking 58F Piston Ring Marking 3N Piston ring end gap 012 020 30 50mm Head cc s Uninstalled 20 5cc Head cc s Installed 17 1cc Operating RPM 200 8300 RPM Idle RPM 200 1900 RPM Engagement RPM 300 4200 RPM Cylinder Head Torque 8mm 17 20 ft lbs 10mm 24 26 ft lbs Cylinder Base Nut Torque 24 28 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5 kgm Flywheel Torque 60 65 ft lbs 8 3 9 kgm 10 98 1 44 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL XLT SPECIAL MODEL NUMBER 099AB6AS ENGINE MODEL EC58PL160 ELECTRICAL CAPACITIES Flywheel I D FP9102 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU2552 Oil Tank 2 quarts 1 9 liters Alternator Output 280 Watts Coolant 3 quarts 2 8 liters Ignition Timing 28 BTDC 3000RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 173 BTDC 0 0175 4 40mm BTDC 0 48mm Operating Timing 20 7500 RPM Spark Plug Gap Champion RN 2C 0 028 0 7mm Lig
16. SOG acicate dime 2 3622 60mm Piston Cylinder Clearance Service Limit Piston Marking Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 0 0035 0 0049 0 09 0 125mm 0 0078 0 20mm 58F 3N 012 020 30 50mm 19 9cc 19 5cc 8000 RPM 1900 RPM 3800 RPM 8mm 17 20 ft lbs 10mm 24 26 ft lbs 24 28 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft lbs 3 2 3 5 kgm 60 65 ft lbs 8 3 9 kgm 1 48 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL XLT TOURING MODEL NUMBER 099ET6AS A ENGINE MODEL EC58PL131 ELECTRICAL CAPACITIES Flywheel L D FP9102 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU2552 Oil Tank 2 quarts 1 9 liters Alternator Output 280 Watts Coolant 3 quarts 2 8 liters Ignition Timing 28 BTDC 3000RPM 1 5 Chaincase Oil 9 fl oz 265cc 0 173 BTDC 0 0175 4 40mm BTDC 0 48mm Operating Timing 20 7500 RPM Spark Plug Gap Champion RN 3C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail
17. Unit of Measure CINE I Zz 3 in mm Em Ounces ox RRB Grams 9 A 3 x o l Q 3 Cubic inches cu in x 16 387 Cubic centimeters cc Cubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l x 1 76 Imperial pints Imp pt Kilograms force per square cm x 98 1 C to F 9 C 40 5 40 F F to C 5 F 40 9 40 C Polaris Industries Inc 1 9 10 98 GENERAL Victor Specialty Tools POLARIS INDUSTRIES IMC VST Service Tools FOREWORD This catalog has been produced to assist Polaris dealers and distributors in ordering Polaris Service tools from Victor Specialty Tool Company VST To keep the information contained in this catalog current and accurate Tool Catalog Update pages will be mailed annually Information on new service tools will be included in the General section of the monthly Service Team Tips dealer news letter Tools listed in this catalog as commercially available cannot be ordered through VST The sug gested tool or an equivalent can be purchased through most automotive tool suppliers or tool manufacturers Note to new Dealers or Distributors Suggested new Dealer Distributor tool kit contents for each product line or combination thereof are listed separately in the Index Addendum section of this catalog Contact VST for a current tool price list Inquiries regarding tool availa
18. ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS Polaris Industries Inc 1 21 359 sq diameter 77 10 98 GENERAL 1999 Model Specifications MODEL INDY TRANSPORT MODEL NUMBER 0995U4DS ENGINE MODEL EC44 3PM025 Type Li sia tue VM34SS Mikuni AMBIENT TEMPERATURE Main Jet 185 Altitude Below 20 F 20 to 10 F 10 to 40 F Above 40 F Pilot Jet 35 Below 29 C 29 to 12 C 12 to 5 C Above 5 C Jet Needle 6FJ6 3 fea Needle Jet P 8 166 Cutaway 2 0 CH 900 1800 Air Screw 1 0 Turns Deer dio Valve Seat 15 A V as UND Fuel Octane R M 2 87 Non Oxygenated or 00755 Tas ma 158 89 Oxygenated 9000 12000 2 2 2 2 Throttle Gap ENS Under Cutaway 180 4 57mm Idle Sync Gap refers to the clip position from top of jet needie Under Cutaway 200 5 1mm E CLUTCH Type cor P 90 Belt iioc Ee 3211059 CLUTCH CHART Belt Width Projected 1 250 31 75mm Side Angle Overall 28 DRIVE DRIVEN i Altitude Shift c Clutch Chai Outside Circumference 45 125 Won sete M Sen bra Center Distance 12 305mm Meters 0 900 T 365 16 3964P Shift Weights 10 Fee 0 300 19 Pow l B2 3 4 HYVO Primary Spring Brown 900 1800 10
19. to 40 ove 40 j ACCS E l EAC a e ise bese Main Jet 185 MGE iBE 180 Pilot Jet 50 Feet 2 Jet Needle R1367G 2 Air Screw 2 tums Needle Jet 2 9x4 6x1 5mm fixed bs Cutaway 6 0 Notched Ai SEew lS Uns Air Screw 1 0 Tum 1800 2700 195 Valve Seat 1 8 2 2 Fuel Octane R M 2 87 Non Oxygenated or Ar Screw LP 89 Oxygenated 2700 4700 Throttle Gap Air Screw 1 2 turn Air Screw 1 2 tum Air Scre 1 2 turn Air Screw 1 2 tum Under Cutaway 0 102 2 6mm ai Idle Sync Gap Under Cutaway Ad 0 11 8 x 3 0mm refers to the clip position from top of jet needle CLUTCH C Production Setting Type 2 cece eee eee P 85 A 23 9208 eneth 3211065 Belt Width Projected 1 438 36 53mm Side Angle Overall 28 Outside Circumference 48 375 CLUTCH CHART DRIVE Altitude Shift Weight Dark Blue Dark Blue Dark Blue Dark Blue DRIVEN Clutch Spring Chaincase Gearing Silver R 8 19 40 68 P Blue 2 3 4 HYVO Silver R 8 19 40 68 P Blue 2 3 4 HYVO Silver R 8 19 40 68 P Blue 2 3 4 HYVO Silver R 8 19 40 68 P Blue 2 3 4 HYVO Center Distance 12 5 317 5mm Shift Weights 10 54 Bushed Primary Spring Dark Blue yes 1068 Secondary Spring Silver Blue IPTE EP Driven Helix R 8 2
20. 10 98 GENERAL 1999 Model Specifications MODEL 440 XCR MODEL NUMBER 099SX4CS ENGINE MODEL S44 44 98A1 CARBURETION JETTING CHART Type tn VM34SS Mikuni AMBIENT TEMPERATURE Main Jet o2 icf 360 Altitude E 20 F 20 to 10 F 10 to 40 F Above 40 F Pilot Jet 45 Below 29 C 29 to 12 C 12 t045 C Above S C Jet Needle 6DH7 3 Meters 090 380 320 Feet 0 3000 ps d Needle Jet P 4 286 Cutaway 2 0 CH 300 280 Air Screw 1 25 Turns P Od Valve Seat 1 5 Viton 6000509 SX B 270 20 Fuel Octane R M 2 H ar or sE 5597 ot 849 e 3 3 3 3 Throttle Gap X Under Cutaway 189 4 80mm 3 16 Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 208 5 3mm 13 64 C pta CLUTCH TYDE ie as P 85 Belt hoses 3211074 CLUTCH CHART Bett Width Projected 1 438 34 93mm i DRIVEN O Side Angle Overall 28 Altitude Shift T Clutch Sal Chaincase Outside Circumference 47 625 Weight Spring Gearing Center Distance 12 305mm Meters Ses Among 20 39 68 P Shift Weights S 53 Red Feet Red Gold 3 4 HYVO Primary Spring Almond Gold 900 1800 S 53 Almond 20 39 68 P Secondary Spring Silver Blue 09992209 E Le oH SNe Driven Helix
21. 203 watts Brake 18 watts Voltage Regulator LR7 LR2 Electric Start Standard LR7 Full wave voltage regulator LR2 Rectifier only for battery charging SUSPENSION CHASSIS CHAINCASE Body Style Evolved Sprockets Chain 20 40 66 P 3 4 HYVO Front Suspension XTRA 12 Reverse Standard Maximum Width 42 50 107 95cm Brake Pads Type 69 Camber 0 5 16 0 8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 1 8 1 4 3 6 35mm Driveshaft Sprockets 4 Drivers Front Shocks Indy Select Brake Type Hydraulic Disc IFS Spring Rate 120 in Front Spring Preload 0 13 Thread Adjust Front Vertical Travel 10 0 in 25 4cm Rear Suspension XTRA 12 Rear Travel 12 0in 30 48cm Front Track Shock Ryde AFX Spring Rate 90 150 t in Rear Track Shock Indy Select with 275 Spring Rear Springs 437 77 Track Type 15 x133 5 x 82 38 1x339 09x2 08cm Track Tension 1 1 1 8 2 54 2 86cm free hand 16 40 64cm ahead of rear idler shaft with no weight OPTIONAL REAR SUSPENSION SPRINGS sor wemw SI Polaris Industries Inc 1 49 10 98 GENERAL 1999 Model Specifications MODEL INDY 500 XC 500 XC SP MODEL NUMBER 099SB5AS 099SP5AS ENGINE MODEL S50 44 99A2 CARBURETION JETTING CHART Types
22. 22mm BTDC 0 105mm Operating Timing 13 7500 RPM Spark Plug Gap Champion RN 2C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR7 Electric Start Optional LR7 Full wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 19 40 68 P 3 4 HYVO Front Suspension RMK CRC Reverse Option Maximum Width 38 00 96 52cm Brake Pads Type 69 Camber 11 32 5 16 9 8mm Chaincase Center Dist 7 05 17 91cm Toe Out 3 8 1 2 9 65 12 7 mm Driveshaft Sprockets 2 Drivers Wide Front Shocks Nitrex Brake Type Polaris HPB Liquid Cooled IFS Spring Rate 100 in Front Spring Preload 0 13 Thread Adjust Front Vertical Travel 8 05in 20 54cm Rear Suspension XTRA 10 Rear Travel 11 5 in 29 21cm Front Track Shock Nitrex Spring Rate 200 in variable Rear Track Shock Indy Select Rear Springs 359 sq 77 Track Type 15 x136 x1 75 2 0 38 1x345 44x4 44 5 08cm Track Tension 3 8 1 2 9 65 12 7mm slack with 10st 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR SUSPENSION SPRINGS MEDIUMSTO FRM 347 sq diameter 77 359 sq diameter 77 375 sq diameter 77 L H 7041627 067 L H 7041629 067 L H 7041631 067 R H 704162
23. 3 Brake Fluid 1e rese ee Gain 2870990 Fogging O 225554223 ed C4205222 434 4262 dG bw es 2870791 Corrosion Resistant Dielectric Grease 2871027 Fox Shock Oll Lue bin s dr aa ds 2870995 Premium All Season Grease 14 1 2 OZ 2871423 Premium All Season Grease 3 oz 2871322 Premium 60 40 Anti Freeze Coolant 2871323 Premium Carbon Clean Fuel System Additive 2871326 Polaris Battery Tender v c 5020 4 692688248 2871076 Carbon Clean Fuel System Additive 2871326 T 9 Metal Protectant c 2871064 Crankcase Sealant 3 Bond 1215 2871557 10 98 1 6 Polaris Industries Inc 1 64 Sx pa bern 0156 1792 citet SEDES 0312 3 64 ets e E ERES 0469 Wir 0625 A O 0781 MI 0938 TIOA ARA 1094 1 8 its 1250 MUA a ens 1406 5 832 ira 1563 UA ais 1719 9 16 oes 1875 VOCE ci ee ert nes 2031 TIS Qe 222166 36 svn erii 2188 NA 2 5 290 264 NR nes 2344 When 25 17 64 ss ERRORS 2656 9 82 As 2813 19 64 sette 2969 A ee 3125 21 64 Li or MA es 3281 1192 4 528 wate e 3438 23 64 loi ARR e SRS 3594 BIB os 375 25 64 745 364 468 ER PER erede 3906 13 82 onse rte rhe 4063 QUO EIAS Es 4219 TING 284904333 dica 4375 29 64 e rs EET 4531 15 82 oS 4688 31 64 eek nem t eate 4844 WMA rige 33 64 oor eer 5156 17 82 eese mes 5313 35 64 c e vH REUS AES 5469 Miras 5625 931 64 ir rte Raves 5781 19 92 r
24. 38 1x345 44x3 175cm Track Tension 3 8 1 2 9 65 12 7mm slack with 108 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS 375 sq diameter 77 L H 7041631 067 R H 7041632 067 OFT 347 sq diameter 77 L H 7041627 067 R H 7041628 067 Polaris Industries Inc 1 33 10 98 GENERAL 1999 Model Specifications MODEL SUPER SPORT MODEL NUMBER 099SB5BS ENGINE MODEL EC55PMO011 CARBURETION JETTING CHART Type Lab Ses Hie eet VM34SS Mikuni Main Jet 310 Altitude Below 20 F 201 TN ADove TATE Pilot Jet 35 tee vate fretta E Jet Needle 6DH7 3 Tm um Needle Jet Q 2 480 Feet gt 900 Cutaway 3 0 Air Screw 1 5 Turns 3000 6000 pe Valve Seat 1 5 T8002708 305 N96 Fuel Octane R M 2 87 Non Oxygenated or 6000 9000 2 2 89 Oxygenated 2700 3700 Throttle Gap iba Under Cutaway 218 5 54mm XXX Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 242 6 15mm ES Production Setting CLUTCH TVDe ese eret P 85 Beltiiiss esse 3211070 Belt Width Projected 1 375 34 93mm CLUTCH CHART Side Angle Overall 28 bmw DRIVEN Outside Circumference 47 250 Altitude Shift Clutch Clutch Driven Chaincase Center Distance 12 305mm Weight Spri
25. 5 Chaincase Oil 7 fl oz 210cc 145 BTDC 129 161 3 67mm BTDC 3 28 4 08mm Operating Timing 15 5 E 7000 RPM Spark Plug Gap NGK BR8ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts 9 watts Touring Brake 18 watts 18 watts Touring Voltage Regulator LR9 All LR9 and LR2 for Deluxe Electric Start Option Std on Deluxe LR9 Half wave voltage regulator LR2 Rectifier only for battery charging SUSPENSION CHASSIS CHAINCASE Body Style Indy 340 Sprockets Chain 17 41 66 P 3 4 HYVO Front Suspension 37 FS Reverse Option Maximum Width 37 25 94 62cm Brake Pads Std Mechanical Camber 0 x5 16 Bmm Chaincase Center Dist 6 5 8 16 83cm Toe Out 1 8 1 4 3 6 35mm Driveshaft Sprockets 2 drivers Front Shocks Nitrex Brake Type Mechanical Disc IFS Spring Rate 105 in Front Spring Preload 3 shims Front Vertical Travel 7 in 17 78cm Rear Suspension XTRA Lite 121 133 5 Rear Travel 10 0 in 25 4cm 10 875 in 27 62cm Touring Front Track Shock Nitrex Spring Rate 80 in Rear Track Shock Nitrex Rear Springs 393 80 340 340 Dhx Rear Springs 359 sq 84 Touring Track Type 15 x121 x 66 15 x133 5 x 82 Touring 38 1x307 34x1 68cm 38 1x339 09x2 18cmTour Track Tension 3 8 1 2 9 65
26. 5 C Meters PA MAG195 MAG 190 MAG 182 MAG 178 Feet 03999 PTO 190 Pro 185 PTO 178 PTO 172 3 3 3 3 900 1800 MAG 182 MAG 180 MAG 172 MAG 168 3000 6000 PTO 178 PTO175 PTO 168 PTO 162 MAG 175 PTO 170 MAG 162 PTO 158 3 3 MAG 170 PTO 165 3 MAG 160 MAG 155 MAG 150 PTO 155 PTO 150 PTO 145 2 2 2 3 MAG 162 PTO 158 2 3 MAG 160 PTO 155 2 3 3 clip position from top of jet needle DRIVE Shitt Clutch Weight Spring oen Clutch Chaincase Spring Gearing Driven 36 Silver Mod 24 40 70 P 3 4 HYVO 10 60 Bushed Dark Blue Driven Helix 36 Mod 2 2 900 1800 10 58 Silver R 11 24 40 70 P 3000 6000 Bushed Blue 3 4 HYVO 1800 2700 10 56 Silver R 11 23 41 70 P 6000 9000 Bushed Blue 3 4 HYVO 2700 3700 10 54 Almond Silver R 11 23 40 70 P 9000 12000 Bushed Gold Blue 2 3 4 HYVO TYPO coins Liquid Cooled Case Reed Twin Stroke 2 eee eee 981 Piston Cylinder Clearance Service Limit Piston Marking Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase
27. 5446 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU6416 Oil Tank 2 quarts 1 9 liters Alternator Output 200 Watts Coolant N A Ignition Timing 26 BTDC 3000RPM 1 5 Chaincase Oil 7 fl oz 210cc 150 BTDC 133 167 3 81mm BTDC 3 39 4 25mm Operating Timing 16 6500 RPM Spark Plug Gap NGK BR8ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 2 3 watts Brake 18 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 17 41 66 P 3 4 HYVO Front Suspension 41 IFS Reverse Option Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 9 16 x5 16 14x8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 0 1 8 0 3mm Driveshaft Sprockets 2 drivers Front Shocks Nitrex Brake Type Polaris HPB IFS Spring Rate 105 in Front Spring Preload 0 13 Thread Adjust Front Vertical Travel 7 56 in 19 20cm Rear Suspension XTRA Lite Rear Travel 10 875 in 25 40cm Front Track Shock Nitrex Spring Rate 80 in Rear Track Shock Nitrex Rear Springs 359 sq 84 Track Type 15 x133 5 x 82 38 1x339 09x2 08cm Track Tension 3 8 1 2 9 65 12 7mm slack with 10 4 54kg weight 16 40 64cm
28. Nitrex Spring Rate 200 in variable Rear Track Shock Indy Select Rear Springs 359 sq 77 Track Type 15 x136 x1 75 2 0 38 1x345 44x4 44 5 08cm Track Tension OPTIONAL REAR SUSPENSION SPRINGS R H 7041630 067 R H 7041628 067 3 8 1 2 9 65 12 7mm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft Polaris Industries Inc 1 59 10 98 GENERAL 1999 Model Specifications MODEL INDY 700 SKS MODEL NUMBER 099SS7AS ENGINE MODEL SN70 70 99A1 CARBURETION Type Loco 2 Keihin PWK 39 Main Jet PTO 185 MAG 190 Pilot Jet 38 Jet Needle R1368G 3 Needle Jet 2 9mm fixed Cutaway 5 5 Air Screw 1 0 Turn Valve Seat 1 8 Fuel Octane R M 2 87 Non Oxygenated or 89 Oxygenated Throttle Gap Under Cutaway 051 1 3mm Idle Sync Gap Under Cutaway 063 1 6mm CLUTCH TYPO Rente P 85 Belinda Cocos de 3211065 Belt Width Projected 1 438 36 53mm Side Angle Overall 28 JETTING CHART AMBIENT TEMPERATURE 20 to 10 F 29 to 12 C 0 300 MAG195 MAG 190 0 3000 PTO 190 PTO 185 3 3 3 3 900 1800 MAG 182 MAG 180 MAG 172 MAG 168 8000 6000 PTO 178 PTO 175 PTO 168 PTO 162 3 3 3 3 1800 2700 MAG 175 MAG 170 MAG 162 MAG 160 6000 9000 PTO 170 PT
29. Shock Nitrex with 85 Spring Rear Springs 406 55 Track Type 15 x121 x 82 38 1x307 34x2 08cm Track Tension OPTIONAL REAR TORSION SPRINGS 421 diameter 55 Polaris Industries Inc 1 39 1 2 12 7mm free hang 2 5 08cm behind rail bumper with no weight attached 10 98 GENERAL 1999 Model Specifications MODEL INDY 500 RMK MODEL NUMBER 099ER4BS ENGINE MODEL EC50PL162 CARBURETION JETTING CHART TIE ERR V F Mikuni ACCS AMBIENT TEMPERATURE Pilot Jet 55 ARS EE mE Jet Needle 6FJ43 3 ics otc Mesa Needle Jet P 0 480 Fee H p Fon PA Cutaway aft Siew i eased 2 5 CH 5001800 240 Air Screw 1 25 Turns 3000 6000 3 Valve Seat 1 5 1800 2700 290 270 260 240 Fuel Octane R M 2 87 Non Oxygenated or MM 3 3 89 Oxygenated 2700 3700 270 260 240 Throttle Gap ee 3 3 Under Cutaway 0 203 5 16mm EX CES 0 228 5 8 x refers to the clip position from top of jet needle nder Cutaway 5 8mm C Production Setting CLUTCH Type soii cbe P 85 Belts cosas died 3211070 Belt Width Projected 1 375 34 93mm CLUTCH CHART Side Angle Overall 28 DRIVE pRvN Outside Circumference 47 250 Altitude Shift Clutch Clutch Chaincase Center Distance 12 305mm Ne SENS Sp SATUS TS ES
30. Stator Plate The plate mounted under the flywheel supporting the primary ignition components and lighting coils Stroke The maximum movement of the piston from bottom dead center to top dead center It is characterized by 180 of crankshaft rotation Surge Tank The fill tank in the liquid cooling system TDC Top Dead Center Piston s most outward travel from crankshaft Transfer The movement of fuel air from the crankcase to the combustion chamber in a two stroke engine Trigger Coil Pulser coil Generates the voltage for triggering closing the thyristor and timing the spark in CDI systems Small coil mounted at the top of the stator plate next to the ignition generating coil V Regulator Voltage regulator Maintains maximum lighting coil output at approx 14 5 ACV as engine RPM increases Venturi An area of air constriction A venturi is used in carburetors to speed up air flow which lowers pressure in venturi to below atmospheric pressure causing fuel to be pushed through jets etc and into the venturi to be mixed with air and form a combustible air fuel mixture Volt The unit of measure for electrical pressure of electromotive force Measured by a voltmeter in parallel with the circuit Watt Unit of electrical power Watts amperes x volts Polaris Industries Inc 1 13 10 98 GENERAL Service Tips in order to perform service work efficiently and to prevent costly errors the technician should read the text in this
31. cylinder between Mag and PTO ends Center Distance Distance between center of crankshaft and center of driven clutch shaft Chain Pitch Distance between chain link pins No 35 3 8 or 1 cm Polaris measures chain length in number of pitches Clutch Buttons Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven clutch Clutch Offset Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face as the engine torques back Clutch Weights Three levers in the drive clutch which relative to their weight profile and engine RPM cause the drive clutch to close Coil A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic field passes through it Combustion Chamber Space between cylinder head and piston dome at TDC Compression Reduction in volume or squeezing of a gas Condenser Capacitor A storage reservoir for electricity used in both E T and CDI systems Crankshaft Run Out Run out or bend of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in lower half of crankcase Measure at various points especially at PTO Maximum allowable run out is 006 02 cm DCV Direct current voltage Detonation The spontaneous ignition of the unburned fuel air mixture after normal spark ignition Piston looks hammered
32. in the metric system Head Volume Cylinder head capacity in cc head removed from engine with spark plug installed Heat Exchanger A device used to transfer heat Mounted under running boards they dissipate engine heat to the atmosphere E Hex Head Bolt Standard type of wrench applied hexagon head characterized by clean sharp corners trimmed to close tolerances Recommended for general commercial applications Hi Fax Trademark of Himont Advanced Materials The special slide material which fits onto the bottom of the suspension rails High Side Sled pushes or tips up High Tension Wire The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug Hole Shot A term used when machine starts a race from a dead stop Holed Piston Piston in which a hole has formed on the dome Possible causes 1 detonation 2 pre ignition Ignition Coil A type of transformer which increases voltage in the primary windings approx 200V to a higher voltage in the secondary windings approx 14KV 32KV through inductions Secondary voltage is high enough to arc the air gap at the spark plug Ignition Generating Coil Exciter coil or primary charge coil Stator plate coil which generates primary ignition voltage CDI system uses one ignition generating coil Inch Pound in Ib 12 in lbs 1 ft Ib Kg cm2 Kilograms per square centimeter Metric equivalent of PSI Keystone Ring A piston ring with bevel on upp
33. lbs Cylinder Base Nut Torque 24 28 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5 kgm Flywheel Torque 60 65 ft lbs 8 3 9 kgm 10 98 1 62 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL INDY 700 XCR MODEL NUMBER 099AB7BS ENGINE MODEL EC70PLO11 ELECTRICAL CAPACITIES Flywheel I D FP9104 Fuel Tank 11 8 gal 44 7L 10 5 39 7 CDI Marking K7A08 Oil Tank 2 4 quarts 2 3 liters Alternator Output 280 Watts Coolant nicas 3 quarts 2 8 liters ignition Timing 20 BTDC 1750RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 098 BTDC 0 007 2 476mm BTDC 0 018mm Operating Timing 18 8100 RPM Spark Plug Gap Champion RN 2C 028 7mm Lights Head Halogen 130 110 watts Tail 209 watts Brake 2018 watts Voltage Regulator LR7 Electric Start N A LR7 Full wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Aggressive Sprockets Chain 24 40 68 P 3 4 HYVO Front Suspension XTRA 10 CRC Reverse Option Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 3 4 5 16 19 05 8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 3 8 1 2 9 65 12 7mm Driveshaft Sprockets 4 Drivers Front Shocks Fox IFP Brake Type
34. model and serial numbers be called out Laser engraved model and serial numbers are located on the crankcase intake side Polaris Industries Inc 10 98 GENERAL 1999 Model Specifications MODEL INDY 340 INDY 340 DELUXE INDY 340 TOURING MODEL NUMBER 099LB3AS 099LD3AS 099LT3AS ENGINE MODEL EC34 2PM051 CARBURETION JETTING CHART Type A EAA VM30SS Mikuni Fun C AMBIENT TEMPERATURE Main Jet 150 Altitude Below 20 F 20 to 10 F 10 t0 40 F Above 40 F Pilot Jet 35 Below 29 C 29 to 12 C 12 to 5 C Above 5 C Jet Needle 5DP7 2 veer Needle Jet 0 6 169 Cutaway 2 5AL 90071800 Air Screw 1 5 Turns Pe 2 Valve Seat 1 5 000 8000 E 129 ns Fuel Octane R M 2 87 Non Oxygenated or A ie TT o Tos al 89 Oxygenated 9000 12000 yo 1 1 1 Throttle Gap Under Cutaway 219 5 55mm Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 240 6 1mm LT eis CLUTCH TYPE s cue sas cheese P 90 Belts uate sont 3211058 CLUTCH CHART Belt Width Projected 1 250 31 75mm DRIVEN Side Angle Overall 28 Altitude Chaincase Outside Circumference 43 313 Gearing Center Distance 11 280mm Meters 36 50 17 4166P Shift Weights 10 Eee SE sage Primary Spring Silver Gold 30006000 10MB
35. x121 x 82 38 1x307 34x2 08cm Track Tension 3 8 1 2 9 65 12 7mm slack with 104 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS sore wom Pw 406 diameter 77 421 diameter 77 437 diameter 77 L H 7041463 067 L H 7041461 067 L H 7041465 067 R H 7041464 067 R H 7041462 067 R H 7041466 067 Polaris Industries Inc 1 29 10 98 GENERAL 1999 Model Specifications MODEL TRAIL TOURING MODEL NUMBER 099ET4ES A ENGINE MODEL EC50PM044 CARBURETION TUDO ds VM34SS Mikuni Main Jet 230 Pilot Jet 40 Jet Needle 6DH7 3 Needle Jet P 8 166 Cutaway 3 0 CH Air Screw 1 0 Turns Valve Seat 1 5 Fuel Octane R M 2 87 Non Oxygenated or 89 Oxygenated Throttle Gap Under Cutaway 219 5 55mm Idle Sync Gap Under Cutaway 240 6 1mm CLUTCH Type ree P 85 Belts te Moot t 3211070 Belt Width Projected 1 375 34 93mm Side Angle Overall 28 JETTING CHART AMBIENT TEMPERATURE Altitude Below 20 F 20 to 10 F Below 29 C 29 to 12 C 10 to 40 F 12 to 5 C Above 40 F Above 5 C 210 3 Meters 0 900 Feet 0 3000 900 1800 3000 6000 1800 2700 185 180 6000 9000 3 3 2 2 2700 3700 190 180 180 180 2000 12000 3 2 2 2
36. 0 173 BTDC 0 0175 4 40mm BTDC 0 48mm Ignition Timing Operating Timing 16 7500 RPM Spark Plug Gap Champion RN 3C 0 028 0 7mm Lights Head Halogen 75 60 watts Malditas 202 watts Brake 1017 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS Body Style Evolved Front Suspension XTRA 10 Maximum Width 42 50 107 95cm Camber 0 x5 16 0 8mm Toe Out 1 8 1 4 3 6 35mm Front Shocks Nitrex IFS Spring Rate 80 in Front Spring Preload Front Vertical Travel 0 5 Thread Adjust 10 0 in 25 4cm GENERAL 1999 Model Specifications CAPACITIES Fuel Tank 11 8 gallons 44 7 liters Oil Tank 2 quarts 1 9 liters Coolant 3 quarts 2 8 liters Chaincase Oil 7 fl oz 210cc CHAINCASE Sprockets Chain 22 41 68 P 3 4 HYVO Reverse Option Brake Pads Type 69 Chaincase Center Dist 6 5 8 16 83cm Driveshaft Sprockets 2 Drivers Brake Type Hydraulic Disc Rear Suspension XTRA 10 Rear Travel 10 0 in 25 4cm Front Track Shock Nitrex Spring Rate 200 in variable Rear Track Shock Indy Select Rear Springs 406 77 Track Type 15 x121 x 82 38 1x307 34x2 08cm Track Tension OPTIONAL REAR TORSION SPRINGS SOFTISTO MEDIUM 406 diame
37. 099SR5BS ENGINE MODEL EC55PM021 ELECTRICAL CAPACITIES Flywheel I D F004T32971 Fuel Tank 11 8 gallons 44 7 liters CDI Marking F6291A Oil Tank 3 quarts 2 8 liters Alternator Output 240 Watts 4000 RPM Coolant N A Ignition Timing 27 BTDC 3000RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 175 BTDC 0 157 0 195 4 45mm BTDC 3 97 4 93mm Operating Timing 17 6500 RPM Spark Plug Gap NGK BR8ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 18 41 68 P 3 4 HYVO Front Suspension 38 RMK Reverse Option Maximum Width 38 00 96 52cm Brake Pads Type 69 Camber 0 45 16 0 8mm Chaincase Center Dist 7 05 17 91cm Toe Out 1 8 1 4 3 6 35mm Driveshaft Sprockets 2 Drivers Front Shocks Nitrex Brake Type Polaris HPB IFS Spring Rate 80 in Front Spring Preload 0 3 Thread Adjust Front Vertical Travel 8 18 in 20 78cm Rear Suspension XTRA Lite 136 Rear Travel 12 0 in 30 48cm Front Track Shock Hydraulic Spring Rate 181 in Rear Track Shock Indy Select Rear Springs 359 sq 77 Track Type 15 x136 x1 25
38. 1 Polaris Industries Inc 1 1 10 98 GENERAL Paint Codes 1999 Polaris Snowmobile Paint Codes Description P No Description P No Candy Red moy WideTrak DO Indy WideTrak LX P210 P227 Order Polaris P Number from Midwest Industrial Coatings 612 934 8252 Mix as directed 10 98 1 2 Polaris Industries Inc GENERAL Bulletin Index 1998 By Model 1998 Model 700 XC S 98 03 Service Exhaust Heat Shield Kit Float Level Information 700 XCR S 97 05R Safety Alert Pitman Arm Weld Failure And Pitman Arm to Steering Rack Bolt Replacement PY S 97 05 Safety Alert Refer To S 97 05R 700 RMK S 97 05R Safety Alert Pitman Arm Weld Failure And Pitman Arm to Steering Rack Bolt Replacement S 97 08 Service Nosepan Heat Damage S 98 04 Exhaust Heat Shield Kit Bulletin Type Service Ultra eo c lt O Service Passenger Hand Grip Heaters Ultra Touring S 98 05 Exhaust Heat Shield Kit Running Quality Up 600 XC S 98 01 grades 600 XCR S 97 05R Safety Alert Pitman Arm Weld Failure And Pitman Arm to Steering Rack Bolt Replacement HA S 97 05 Safety Alert Refer To S 97 05R 600 RMK S 97 05R Safety Alert Pitman Arm Weld Failure And Pitman Arm to Steering Rack Bolt Replacement Service A S 97 05 Safety Alert Refer To S 97 05R S 97 08 Service Nosepan Heat Damage REDE S 98 02 Exhaust Heat Shield Kit Jet Needle E clip Posi tion S 97 05R Saf
39. 1 2 9 65 12 7mm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS SOFr STD mom 406 diameter 77 421 diameter 77 L H 7041463 067 L H 7041461 067 R H 7041462 067 437 diameter 77 L H 7041465 067 R H 7041466 067 R H 7041464 067 Polaris Industries Inc 1 35 10 98 GENERAL 1999 Model Specifications MODEL INDY 500 MODEL NUMBER 099EB4BS A ENGINE MODEL EC50PL172 CARBURETION JETTING CHART VPO 6654 Sets VM38SS Mikuni AMBIENT TEMPERATURE Main Jet 350 Below 20 F 20 to 10 to Above 40 F Pilot Jet 45 res xen 850 m dide Jet Needle 6F9 3 Malar Needle Jet P 6 247 Fest Cutaway IA 2 5 CH 900 3800 290 270 Air Screw 3 4 Turn 3000 6000 a 2 Valve Seat 1 5 Viton 800 2700 270 250 230 Fuel Octane R M 2 87 Non Oxygenated or 89 Oxygenated Or TAO Throttle Gap Under Cutaway 219 5 55mm Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 240 6 1mm E a CLUTCH A Se chs P 85 Belt codes 3211070 CLUTCH CHART Belt Width Projected 1 375 34 93mm DRIVEN Side Angle Overall 28 Altitude Shit Clutch Clutch Chaincase Outside Circumference 4
40. 12 7mm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft The stock springs are the softest available for the Indy 340 and Indy 340 Deluxe OPTIONAL REAR TORSION SPRINGS INDY 340 AND INDY 340 DELUXE INDY 340 TOURING 393 diameter 77 406 diameter 82 347 diameter 77 359 diameter 77 L H 7041555 067 L H 7041521 067 L H 7041627 067 7041629 067 R H 7041556 067 R H 7041522 067 R H 7041628 067 7041630 067 Polaris Industries Inc 1 17 10 98 GENERAL 1999 Model Specifications MODEL INDY SPORT MODEL NUMBER 099SB4DS ENGINE MODEL EC44 3PM025 CARBURETION JETTING CHART Type E VM34SS Mikuni AMBIENT TEMPERATURE Main Jet 185 Altitude Below 20 F 20 to 10 F 10 to 40 F Above 40 F Pilot Jet 35 Below 29 C 29 to 12 C 12 to 5 C Above 5 C Jet Needle 6FJ6 3 Ver Needle Jet P 8 166 Cutaway 2 0 800 1800 Air Screw 1 0 Turns n Valve Seat 1 5 70000 0000 Fuel Octane R M 2 87 Non Oxygenated or eae 89 Oxygenated 8000 12000 Throttle Gap xx Under Cutaway 180 4 57mm Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 200 5 1mm LI CLUTCH Type coro P 90 Belt bmx 3211059 CLUTCH CHA
41. 42 1 43 Model Specifications XLT Special 1 44 1 45 Model Specifications XLT Classic 1 46 1 47 Model Specifications XLT Touring 1 48 1 49 Model Specifications 500 XC 500 XC SP 1 50 1 51 Model Specifications 600 XC 600 XC SP 1 52 1 53 Model Specifications 700 XC 700 XC SP 1 54 1 55 Model Specifications 600 RMK 1 56 1 57 Model Specifications 700 RMK 1 58 1 59 Model Specifications 700 SKS 1 60 1 61 Model Specifications 700 XCR 1 62 1 63 Model Specifications 800 XCR 1 64 1 65 Model Specifications Wide Trak LX 1 66 1 67 GENERAL Publication Numbers 1999 Publication Numbers Supplement Manual Microfiche ndy XLT Classic 9914813 ndy XLT Special 9914812 ndy 340 Touring 9914671 ndy Sport Touring 9915045 ndy Trail Touring Blue 9914806 ndy Trai Touring Green 9914806 ndy Classic Touring 9974804 ndy XLT Touring Blue Indy 500 XC SP 099SP5AS 9914861 9914845 9914818 Indy 600 XC 0995B6DS 9914861 9914846 9914819 Indy 600 XC SP O99SP6DS 9914861 9914847 9914820 9914849 ndy 800 XCR indy Trail RMK ndy 500 RMK indy 600 RMK 175776 Indy 600 AMK z Tack indy 700 AMK Tack indy 700 AMK Z Track ndy 700 SKS ndy Tran Sport indy Wide Trak DX 1999 Snowmobile Owner s Manual All PN 9914668 Snowmobile Assembly Manual PN 991391
42. 5 BTDC 3500RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 146 BTDC 0 017 3 72mm BTDC 0 435mm Operating Timing 16 9 8250 RPM Spark Plug Gap Champion RN 2C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 202 watts Brake 1017 watts Voltage Regulator LR7 Electric Start N A LR7 Full wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 20 39 68 P 3 4 HYVO Front Suspension XC 10 CRC Reverse Option Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 1 05 5 16 26 67 8mm Chaincase Center Dist 7 05 17 90cm Toe Out 0 1 8 0 3mm Driveshaft Sprockets 2 Drivers wide Front Shocks Fox FP Brake Type Polaris HPB Liquid Cooled IFS Spring Rate 74 120 in Front Spring Preload 0 75 Thread Adjust Front Vertical Travel 9 0 in 22 86cm Rear Suspension XTRA 10 Rear Travel 8 0 in 20 32cm Front Track Shock Fox IFP Spring Rate 190 in Rear Track Shock Fox IFP with Remote Reservoir Rear Springs 359 sq 77 Track Type 15 x121 x 82 38 1x307 34x2 08cm Track Tension 3 8 1 2 9 65 12 7mm slack with 104 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS wenuwsm FRM 347 sq diameter 77 359
43. 7 250 Weight Spring Spring Gearing Center Distance 12 305mm 0 900 10M sd me 36 22 4168P Shift Weights 10M Bushed 199999 Bushed Ez CS HO Boca Sand 5 Gok A E Driven Helix 36 2 8902700 M mes a 22 41 68 E 2700 3700 10M 36 22 41 68 P 900012000 pushed Dark Blue Gold 2 3 4 HYVO ENGINE TVDO secet Rees Liquid Cooled Piston Port Displacement 488 cc BOTE eo eite in e iia 2 8346 72mm StIOKO nic enden 2 3622 60mm Piston Cylinder Clearance 0 0035 0 0049 0 09 0 125mm Service Limit 0 0078 0 20mm Piston Marking 5B Piston Ring Marking 5B Piston Ring End Gap 008 016 20 40mm Head cc s Uninstalled 28cc Head cc s Installed 23 6cc Operating RPM 200 7800 RPM Idle RPME200 1600 RPM Engagement RPM 300 4000 RPM Cylinder Head Torque 8mm 17 20 ft lbs 10mm 24 26 ft lbs Cylinder Base Nut Torque 24 28 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5 kgm Flywheel Torque 60 65 ft lbs 8 3 9 kgm 10 98 1 36 Polaris Industries Inc MODEL INDY 500 MODEL NUMBER 099EB4BS A ENGINE MODEL EC50PL172 ELECTRICAL Flywheel l D FP5445 CDI Marking CU6417 Alternator Output 200 Watts 28 BTDC 3000RPM 1 5
44. 8 067 R H 7041630 067 R H 7041632 067 Polaris Industries Inc 1 57 10 98 GENERAL 1999 Model Specifications MODEL INDY 700 RMK MODEL NUMBER 099SR7AS A ENGINE MODEL S70 70 99A3 AMBIENT TEMPERATURE 20 to 10 F 29 to 12 C 195 Air Screw 2 tums CARBURETION JETTING CHART Type ces 2 Keihin PWK 39 ACCS Altitude Below 20 F Main Jet 190 sss lees Pilot Jet 48 Fee 00000 Jet Needle R1368G 2 Air Screw 2 tums Needle Jet 2 9x4 6x1 5mm fixed Cutaway 6 0 Notched ke nel Air Screw 1 0 Turn mee 200 Valve Seat 1 8 6000 9000 42 Fuel Octane R M 2 87 Non Oxygenated or Air Screw 1 tum 89 Oxygenated 2700 3700 200 Throttle Gap 2 Under Cutaway 0 102 2 6mm ae Idle Sync Gap Under Cutaway ersero 0 1 1 8 gt 3 0mm x refers to the clip position from top of jet needle CLUTCH C Production Setting Type P 85 Belt ess oce 3211065 Belt Width Projected 1 438 36 53mm Side Angle Overall 28 CLUTCH CHART Outside Circumference 48 375 Center Distance 12 5 317 5mm Altitude Shift Weights 10 58 Bushed Primary Spring Dark Blue Meters aT Secondary Spring Silver Blue Feet 0 3000 Driven Helix R 11 2 900 1800 3000 6000 1800 2700 6000 9000
45. 9 fl oz 265cc 0 173 BTDC 0 0175 4 40mm BTDC 0 48mm Operating Timing 16 7500 RPM Spark Plug Gap Champion RN 3C 0 028 0 7mm Lights Head Halogen 75 60 watts EPA 209 watts Brake 2018 watts Voltage Regulator LR9 LR2 Electric Start Standard LR9 Half wave voltage regulator LR2 Rectifier only for battery charging SUSPENSION CHASSIS CHAINCASE Body Style Evolved Sprockets Chain 19 40 66 P 3 4 HYVO Front Suspension XTRA 12 Reverse Standard Maximum Width 42 50 107 95cm Brake Pads Type 69 Camber 0 5 16 0 8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 1 8 1 4 3 6 35mm Driveshaft Sprockets 2 Drivers Front Shocks Indy Select Brake Type Hydraulic Disc IFS Spring Rate 100 in Front Spring Preload 0 43 Thread Adjust Front Vertical Travel 10 0 in 25 4cm Rear Suspension XTRA 12 Rear Travel 12 0 in 30 48cm Front Track Shock Indy Select Spring Rate 90 150 in Rear Track Shock Indy Select with 275 Spring Rear Springs 437 77 Track Type 15 x133 5 x 82 38 1x339 09x2 08cm Track Tension 1 1 1 8 2 54 2 86cm free hand 16 40 64cm ahead of rear idler shaft with no weight OPTIONAL REAR SUSPENSION SPRINGS sor wem FmWSm Polaris Industries Inc 1 43 10 98 GENERAL 1999 Model Specif
46. AL 1999 Model Specifications MODEL XLT CLASSIC MODEL NUMBER 099ED6AS ENGINE MODEL EC58PL131 CARBURETION JETTING CHART TP VM34SS Mikuni AMBIENTTEMBERATURE Main Jel ee 14 KP 250 Altitude galow sao E ps ee oot Pilot Jet 40 29 t0 12 C 12 to 45 C Jet Needle 6DP17 2 Meters Needle Jet Q 4 480 tend Cutaway 2 5 CH 900 1800 Air Screw 1 Turn 0099 8029 Valve Seat 1 5 Viton ES Fuel Octane R M 2 87 Non Oxygenated or AC 89 Oxygenated 6000 12000 Throttle Gap Under Cutaway 210 5 53mm Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 234 5 94mm C ais CLUTCH TYP si oe eine P 85 A Le 1A 3211070 GEUTEH CHART Belt Width Projected 1 375 34 93mm DRIVE DRIVEN Side Angle Overall 28 Altitude Shift Clutch Clutch Chaincase Outside Circumference 47 250 bt EUM Esa Gearing A 5 eters o P Shift Weights 10M Bushed He EL as seno Ele Aid A eee He nie e Silver Gold ae zai e8 Driven Helix 34 2 1800 2700 are aii 340 21 41 68 P Bushed 2 3 4 HYVO aes Ped caro E ENGINE MYPO td tddi Liquid Cooled Piston Port Triple Displacement 598cc A pn ES 2 5600 65 025mm STOKE cid eed 2 3622 60mm Piston Cylinder Cl
47. Bushed 1800 2700 10 54 6000 9000 Bushed 2700 3700 10 9000 12000 Bushed ENGINE TVD6 das Liquid Cooled Case Reed Twin Displacement 593 cc BOIS 22i cul E E ERES 2 9930 74 5mm Stroke nereseno iari one brs 2 6772 68mm Piston Cylinder Clearance 0043 0059 11 15mm Service Limit 0078 2mm Piston Marking EK2202 Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque o faces upward 012 018 30 46mm 34 0cc 26 0cc 8000 RPM 1500 RPM 4200 RPM 20ft lbs 2 8kgm 35 40 ft lbs 4 8 5 5 kgm N A 35 40 ft lbs 4 8 5 5 kgm 55 ft lbs 7 4 kgm 10 98 1 56 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL INDY 600 RMK MODEL NUMBER 099SR6DS A ENGINE MODEL SN60 70 99A1 ELECTRICAL CAPACITIES Flywheel I D 4010139 Fuel Tank 11 8 gal 44 7L CDI Marking 4060209 Oil Tank 3 quarts 2 8 liters Alternator Output 280 Waits Coolant 3 quarts 2 8 liters Ignition Timing 6 BTDC 1750RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 0086 BTDC 0 0045 0
48. C55PM011 ELECTRICAL CAPACITIES Flywheel I D F004T32971 Fuel Tank 11 8 gallons 44 7 liters CDI Marking F6291A Oll TAM ius 3 quarts 2 8 liters Alternator Output 240 Watts 4000 RPM Coolant N A Ignition Timing 27 BTDC 3000RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 175 BTDC 0 157 0 195 4 45mm BTDC 3 97 4 93mm Operating Timing 17 6500 RPM Spark Plug Gap NGK BR8ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 19 39 66 P 3 4 HYVO Front Suspension XTRA 10 Reverse Option Maximum Width 42 50 107 95cm Brake Pads Type 69 Camber 0 x5 16 0x8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 1 8 1 4 3 6 35mm Driveshaft Sprockets 2 Drivers Front Shocks Nitrex Brake Type Polaris HPB IFS Spring Rate 80 in Front Spring Preload 0 5 Thread Adjust Front Vertical Travel 10 0 in 25 4cm Rear Suspension XTRA 10 Rear Travel 10 0 in 25 4cm Front Track Shock Nitrex Spring Rate 200 in variable Rear Track Shock Indy Select Rear Springs 406 77 Track Type 15 x121 x 82 38 1x307 34x2 08cm Track Tension 3 8
49. CHAPTER 1 GENERAL INFORMATION Publication Numbers 1 1 A A nnd 0280064 taro dens 1 2 1998 Bulletin Index 1 3 1999 Bulletin Index 1 4 Standard Torque Specifications 1 5 Recommended Shop Supplies Accessories 1 6 Decimal Equivalents 17 Tap Drill Sizes IR 1 8 Measurement Conversion Table 1 9 Victor Tool Ordering Information 1 10 Glossary of Terms ia out ia 1 11 1 13 General Service TipS 1 14 1999 Model Number Identification 1 15 Model Specifications 340 340 Dix 340 Tour 1 16 1 17 Model Specifications Sport 1 18 1 19 Model Specifications Sport Touring 1 20 1 21 Model Specifications TranSport 1 22 1 23 Model Specifications XCF 1 24 1 25 Model Specifications 440 XCR 1 26 1 27 Model Specifications Trail 1 28 1 29 Model Specifications Trail Touring 1 30 1 31 Model Specifications Trail RMK 1 32 1 33 Model Specifications Super Sport 1 34 1 35 Model Specifications 500 1 36 1 37 Model Specifications 500 Classic 1 38 1 39 Model Specifications 500 RMK 1 40 1 41 Model Specifications Classic Touring 1
50. CRC Maximum Width 41 00 104 14cm Camber 1 05 5 16 26 67 8mm Toe Out 0 1 8 0 3mm Front Shocks Indy Select XC Fox IFP SP IFS Spring Rate Front Spring Preload Front Vertical Travel Rear Suspension Rear Travel Front Track Shock Spring Rate Rear Track Shock Rear Springs Track Type Track Tension 100 in XC 74 120 in SP GENERAL 1999 Model Specifications CAPACITIES Fuel Tank 11 8 gal 44 7L 10 5 39 7 Oil Tank 3 quarts 2 8 liters Coolant 3 quarts 2 8 liters Chaincase Oil 7 fl oz 210cc CHAINCASE Sprockets Chain 22 41 70 P 3 4 HYVO Reverse Option Brake Pads Type 69 Chaincase Center Dist 7 05 17 91cm Driveshaft Sprockets 2 Drivers Wide Brake Type Polaris HPB 0 20 Thread Adjust XC 1 13 Thread Adjust SP 9 0 in 22 86cm XTRA 10 8 25 in 21cm Ryde FX XC Fox IFP SP 200tt in variable XC 190 in SP Polaris Position Sensitive Shock 359 sq 77 15 x121 x 82 38 1x307 34x2 08cm 3 8 1 2 9 65 12 7mm slack with 10st 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR SUSPENSION SPRINGS SOFT Polaris Industries Inc 1 51 wemuwsm FRM 10 98 GENERAL 1999 Model Specifications MODEL INDY 600 XC 600 XC SP MOD
51. Distance 12 305mm 5506 10 58 o 19 4066 P Shift Weights 10 58 3000 Bushea Dark Blue 2 3 4 HYvO ht Fe eee E e SA SRM oss own ow NERA Driven Helix 36 4 2 Ro 056 Dark Bius Missi o xen ete pou mers E MAT ENGINE Types 060034 eti naei Fan Cooled Cylinder Reed Displacement 431 cc A PUE 2 559 65mm STOKE ow necs des Bene ETE 2 559 65mm Piston Cylinder Clearance 0 0039 0 0053 0 10 0 135mm Service Limit 0 0078 0 20mm Piston Marking 4MB Pistn Ring Marking N Piston Ring End Gap 009 017 24 45mm Head cc s Uninstalled 26 2 cc Head cc s Installed 23 2 CC Operating RPM 200 6500 RPM Idle RPM 200 1600 RPM Engagement RPM 300 4000 RPM Cylinder Head Torque 18 19 ft Ibs 2 5 2 8 kgm Cylinder Base Nut Torque 24 28 ft Ibs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5kgm Flywheel Torque 60 65 ft Ibs 8 3 9 kgm 10 98 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL XCF MODEL NUMBER 099SP4AS ENGINE MODEL EC45PM011 ELECTRICAL CAPACITIES Flywheel I D F004T32971 Fuel Tank 10 5 gallons 39 7 liters CDI Marking F6291A Oil Tank 3 quarts 2 8 liters Alternator Output 240
52. E EEE Secondary Spring Red SOMB Gold Red qr ee Driven Helix 34 2 S Axa 068p 6000 0000 Bushed Dark Blue Ree 2 anwo gers 040 oem me 30 manos ENGINE TPC amic em dus Liquid Cooled Piston Port Displacement 488 cc O E E 2 ncaa 2 8346 72mm Stroke c s ndt i eee eee eee 2 3622 60mm Piston Cylinder Clearance 0 0024 0 0037 0 06 0 095mm Service Limit 0 0078 0 20mm Piston Marking 5W Piston Ring Marking 51A Piston Ring End Gap 008 016 20 40mm Head cc s Uninstalled 28cc Head cc s Installed 22cc Operating RPM 200 7800 RPM Idle RPME200 1600 RPM Engagement RPM 300 3800 RPM Cylinder Head Torque 8mm 17 20 ft lbs 10mm 24 26 ft lbs Cylinder Base Nut Torque 24 28 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5 kgm Flywheel Torque 60 65 ft lbs 8 3 9 kgm 10 98 1 40 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL INDY 500 RMK MODEL NUMBER 099ER4BS ENGINE MODEL EC50PL162 ELECTRICAL CAPACITIES Flywheel I D FP5445 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU6417 Oil Tank 2 quarts 1 9 liters Alternator Output 200 Watts Coolant riara eeke 3 quarts 2 8 liters Ign
53. EL INDY 800 XCR MODEL NUMBER 099AB8AS ENGINE MODEL EC79PLO11 ELECTRICAL CAPACITIES Flywheel LD FP9103 Fuel Tank 11 8 gal 44 7L 10 5 39 7 CDI Marking CU7311 Oil Tank 2 4 quarts 2 3 liters Alternator Output 280 Watts Coolant 3 quarts 2 8 liters Ignition Timing 26 BTDC 3250RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 163 BTDC 0 008 4 138mm BTDC 0 021mm Operating Timing 15 8300 RPM Spark Plug Gap Champion RN 2C 028 7mm Lights Head Halogen 130 110 watts Tail 209 watts Brake 2018 watts Voltage Regulator LR7 Electric Start N A LR7 Full wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Aggressive Sprockets Chain 24 39 68 P 3 4 HYVO Front Suspension XTRA 10 CRC Reverse Option Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 3 4 5 16 19 05 8mmy Chaincase Center Dist 6 5 8 16 83cm Toe Out 3 8 1 2 9 65 12 7mm Driveshaft Sprockets 4 Drivers Front Shocks Fox IFP Brake Type Liquid Cooled Hydraulic Disc IFS Spring Rate 120 in Front Spring Preload 1 063 Thread Adjust Front Vertical Travel 9 30 in 23 62cm Rear Suspension XTRA 10 Rear Travel 10 2 in 25 91cm Front Track Shock Fox IFP Spring Rate 200 in variable Rear Track Sho
54. EL NUMBER 099SB6DS 099SP6DS ENGINE MODEL SN60 70 99A2 Type a eof UNI o neus 2 Keihin PWK 39 Daa C AMBIENTTEWPERATURE V A oR oe Altitude Below 20 F 20 t0 10 F 10 10 40 F Above 40 F Hot Jet elow 29 C 29 to 12 12 to 5 Above 5 C Jet Needle R1368G 3 Meters 0 178 172 Needle Jet 2 9mm fixed VULTIS 3 3 Cutaway 5 5 900 1800 Air Screw 1 0 Turn p Valve Seat 1 8 2206 0000 Fuel Octane R M 2 87 Non Oxygenated or SOINS 89 Oxygenated 9000 12000 Throttle Gap Under Cutaway 028 7mm Idle Sync Gap i refers to the clip position from top of jet needle Under Cutaway 059 1 5mm ES asa CLUTCH TP iii P 85 Belt c sore 3211065 CLUTCH CHART Belt Width Projected 1 438 36 53mm DRIVEN Side Angle Overall 28 Altitude personen Outside Circumference 48 375 weg Spring p Center Distance 12 5 31 7 5mm Meters 10 58 R 32 22 4070P Shift Weights 10 58 Bushed Fee 03000 Busheg DarkBlue Siver 42 34HYvo Primary Spring Dark Blue 900 1800 10 56 Almond ER R 3 22 40 70 P Secondary Spring Silver 3000 6000 Bushed Gold 2 3 4 HYVO Driven Helix R 32 4 2 cemzme 1054 Amona EUN catas on e RETE ENGINE TPE
55. Gold H Secondary Spring Silver pares mier EOP rE Driven Helix 36 5 A 1 6000 9000 t 3 4 HYVO AEG om Be Go T ENGINE A rhet e sra Fan Cooled Piston Port Displacement 339 cc 276 lt svo tee eO ErRPRARS T 2 4528 62 3mm STOKE Lo oe etes 2 1889 55 6mm Piston Cylinder Clearance Service Limit Piston Marking Piston Ring Marking Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 Piston ring end gap NoD 0 0031 0 0055 0 08 0 14mm 0 0078 0 20mm 34A RN 008 014 20mm 36mm 21 1cc 17 3cc 7000 RPM 1600 RPM 4100 RPM 18 19 ft lbs 2 5 2 8 kgm 24 28 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft lbs 3 2 3 5kgm 60 65 ft lbs 8 3 9 kgm Polaris Industries Inc GENERAL 1999 Model Specifications MODEL INDY 340 INDY 340 DELUXE INDY 340 TOURING MODEL NUMBER 099LB3AS 099LD3AS 099LT3AS ENGINE MODEL EC34 2PM051 ELECTRICAL CAPACITIES Flywheel I D FP 5439 Fuel Tank 8 8 gallons 33 3 liters CDI Marking CU6409 Oil Tank 2 quarts 1 9 liters Alternator Output 180 Watts Coolant N A Ignition Timing 26 5 BTDC 3000RPM 1
56. L 1999 Model Specifications ELECTRICAL CAPACITIES Flywheel I D FP 5446 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU6416 Oil Tank 2 quarts 1 9 liters Alternator Output 200 Watts Coolant N A Ignition Timing 26 BTDC 3000RPM 1 5 Chaincase Oil 7 fl oz 210cc 150 BTDC 133 167 3 81mm BTDC 3 39 4 25mm Operating Timing 16 6500 RPM Spark Plug Gap NGK BR8ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 19 39 66 P 3 4 HYVO Front Suspension 41 IFS Reverse Option Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 9 16 45 16 14 8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 0 1 8 0 3mm Driveshaft Sprockets 2 drivers Front Shocks Nitrex Brake Type Polaris HPB IFS Spring Rate 105 in Front Spring Preload 1 shims Front Vertical Travel 7 56 in 19 20cm Rear Suspension XTRA Lite Rear Travel 10 00 in 25 40cm Front Track Shock Nitrex Spring Rate 80 in Rear Track Shock Nitrex Rear Springs 406 82 Track Type 15 x121 x 71 38 1x307 34x1 80cm Track Tension 3 8 1 2
57. M 36 5 16 39 64 P Sec e ins Su g Red 3000 6000 Bushed P Red 3 4 HYVO H o 1800 2700 10M 36 5 16 39 64 P Driven Helix 36 5 B 2 ECJEXNENC Red Ea li aie 2700 3700 10MB 36 5 16 39 64 P Busned 2 Red 3 4 HYVO ENGINE TYDE wee V d E E Fan Cooled Piston Port Displacement 432 cc BOlG pa RA ada 2 6661 67 72mm Stroke iaa 2 3622 60mm Piston Cylinder Clearance Service Limit Piston Marking Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 0 0035 0 0055 0 09 0 14mm 0 0078 0 20mm M 6 R 008 019 20 49mm 28 6cc 23cc 7000 RPM 1600 RPM 3500 RPM 18 19 ft lbs 2 5 2 8 kgm 24 28 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft lbs 3 2 3 5kgm 60 65 ft Ibs 8 3 9 kgm 1 22 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL INDY TRANSPORT MODEL NUMBER 099SU4DS ENGINE MODEL EC44 3PM025 ELECTRICAL CAPACITIES Flywheel LD FP 5446 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU6416 Oil Tank 2 quarts 1 9 liters Altern
58. O 165 PTO 158 PTO 155 3 3 2 2 MAG 162 MAG 160 MAG 155 MAG 150 PTO 158 PTO 155 PTO 150 PTO 145 3 2 2 2 Below 20 F Below 29 C 410 to 40 F Above 40 F 12 to 5 C Above 5 C Meters MAG 182 MAG 178 Feet PTO 178 PTO 172 2700 3700 9000 12000 XXX 8X C Production Setting refers to the clip position from top of jet needle CLUTCH CHART Outside Circumference 48 375 Altitude DEE DRIVEN Center Distance 12 5 317 5mm AE Es peres Shift Weights 10 60 Bushed z j F Primary Sarna to Dark Blue re ms ee omnes Sher o Secondary Spring Silver Blue 900 1800 1058 DarkBlue Sive R 11 23 40 70 P Driven Helix R 11 4 2 3000 6000 Bushed Blue 2 3 4 HYVO 1800 2700 10 56 Dark Blue Silver R 11 21 41 70 P 6000 9000 Bushed Blue 2 3 4 HYVO 2700 3700 10 54 Dark Blue Silver R 11 21 4170P 9000 12000 Bushed Blue 2 3 4 HYVO ENGINE TYPO Ili reme e Liquid Cooled Case Reed Twin Displacement 700 cc BONE V 462 rex LAV 3 1889 81mm Stroke 2 0 eee eee eee 2 6772 68mm Piston Cylinder Clearance 0043 0053 11 135mm Service Limit 0078 2mm Piston Marking EK2108 Piston Ring Marking o f
59. RT Belt Width Projected 1 250 31 75mm Side Angle Overall peas Altitude Shift ea Clutch a Chaincase Outside Circumference 45 125 Weight Spring Helix Gearing Center Distance 12 305mm Meters P 36 50 19 39 66 P Shift Weights 10 AL Feet 03000 TAL RedWhite jj Red B2 34HYvo SEU TA EEES EEES Diver He 955 B sam ox om ar mare 2700 3700 10MB Red White ES 365 19 3966P 9000 12000 Bushed Gold B 2 3 4 HYVO ENGINE TyyDe veo eek ene Dh es Fan Cooled Piston Port Displacement 432 cc O ea dade 2 6661 67 72mm Stroke nuca oet eet 2 3622 60mm Piston Cylinder Clearance 0 0035 0 0055 0 09 0 14mm Service Limit 0 0078 0 20mm Piston Identification Marking Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 M 6 R 008 019 20 49mm 28 6cc 23cc 7000 RPM 1600 RPM 4000 RPM 18 19 ft lbs 2 5 2 8 kgm 24 28 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft lbs 3 2 3 5kgm 60 65 ft lbs 8 3 9 kgm 1 18 Polaris Industries Inc MODEL INDY SPORT MODEL NUMBER 099SB4DS ENGINE MODEL EC44 3PM025 GENERA
60. STATE REQUIREMENTS AND CANADA MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE MFD DATE MADE IN U S A 1999 ENGINE DESIGNATION NUMBERS 3A 340 F C Piston Port 4A 440 F C Cylinder Reed 4B 488 L C Piston Port 4C 440 L C Case Reed domestic 4D 440 F C Piston Port 4E 488 F C Piston Port 5A 497 L C Case Reed 2 Cylinder domestic 5B 544 F C Cylinder Reed 6A 597 UC 3 Cylinder 6D 593 L C Case Reed 2 Cylinder domestic 7A 700 L C Case Reed 2 Cylinder domestic 7B 700 VES L C Case Reed 3 Cylinder 8A 800 VES L C Case Reed 3 Oylinder PSLARIS PATENT NOTICE Mfd by Polaris Industries Inc in Roseau MN under one or more of the following patents U S Patents 3 605 511 3 580 647 3 483 766 3 533 662 3 545 821 3 605 510 3 525 412 Patented Canada 3 613 810 882 491 71 3 867 991 4 793 950 5 038 881 5 172 675 5 090 386 5 050 564 5 050 559 5 048 503 5 056 482 5 099 813 5 074 271 5 191 531 3 613 811 883 694 71 864 394 71 Canadian Rd 34 573 71 34 572 71 1 227 823 87 7072133 These numbers should be referred to in any correspondence regarding warranty service or replacement parts The machine model and serial number identification decal is located on the right front side of the tunnel The serial number is permanently stamped into the tunnel The model number is embossed on the decal Whenever corresponding about an engine it is important that the engine
61. Specifications MODEL WIDETRAK LX MODEL NUMBER 099SU4BS ENGINE MODEL EC50PL202 ELECTRICAL CAPACITIES Flywheel I D FP5445 Fuel Tank 11 8 gal 44 7Ly10 5 39 7 CDI Marking CU6417 Oil Tank 2 4 quarts 2 3 liters Alternator Output 200 Watts Coolant 3 quarts 2 8 liters Ignition Timing 28 BTDC 3000RPM 1 5 Chaincase Oil 20 fl oz 590cc 0 173 BTDC 0 0175 4 40mm BTDC 0 48mm Operating Timing 16 7500 RPM Spark Plug Gap Champion RN 3C 028 7mm Lights Head Halogen 75 60 watts TAI 25 4 42404 8 watts Brake 29 watts Voltage Regulator LR9 LR2 Electric Start Standard LR9 Half wave voltage regulator LR2 Rectifier only for battery charging SUSPENSION CHASSIS CHAINCASE Body Style Gen H Sprockets Chain 19 41 66 P 3 4 HYVO Front Suspension 38 IFS Reverse Standard Hi Low Maximum Width 38 00 96 52cm Brake Pads Type 69 Widetrak Camber 25 32 5 16 20 8mm Chaincase Center Dist N A Toe Out 0 1 8 0 3mm Driveshaft Sprockets 4 Drivers Widetrak Front Shocks Nitrex Brake Type Mechanical Disc IFS Spring Rate 105 in Front Spring Preload 3 Shims Front Vertical Travel 7 25 in 18 42cm Rear Suspension Slide Rail Rear Travel 9 in 22 86cm Front Track Shock Nitrex Spring Rate 181 in Re
62. Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 700 cc 3 1889 81mm 2 6772 68mm 0043 0053 11 135mm 0078 2mm EK2108 o faces upward 014 020 36 51mm 40 2cc 32 5cc 8000 RPM 1500 RPM 4200 RPM 20ft Ibs 2 8kgm 35 40 ft lbs 4 8 5 5 kgm N A 35 40 ft Ibs 4 8 5 5 kgm 55 ft lbs 7 4 kgm Polaris Industries Inc 1 54 GENERAL 1999 Model Specifications MODEL INDY 700 XC 700 XC SP MODEL NUMBER 099SB7AS 099SP7AS ENGINE MODEL SN70 70 99A2 ELECTRICAL CAPACITIES Flywheel I D 4010139 Fuel Tank 11 8 gal 44 7L 10 5 39 7 CDI Marking 4060212 Oil Tank 3 quarts 2 8 liters Alternator Output 280 Watts Coolant 3 quarts 2 8 liters Ignition Timing 6 BTDC 1750RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 009 BTDC 0 005 0 22mm BTDC 0 105mm Operating Timing 17 7500 RPM Spark Plug Gap Champion RN 2C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail ces 208 watts XC 2992 watts SP Brake 208 watts XC 1017 watts SP Voltage Regulator LR7 Electric Start Optional LR7 Full wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 24 40 70 P 3 4 HYVO Front Suspension XC 10 CRC Reverse Option Maximum Width 41 00 104 14cm Brake Pads Ty
63. Watts 4000 RPM Coolant N A Ignition Timing 27 BTDC 3000RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 175 BTDC 0 157 0 195 4 45mm BTDC 3 97 4 93mm Operating Timing 17 6500 RPM Spark Plug Gap NGK BR9ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 19 40 66 P 3 4HYVO Front Suspension XTRA 10 CRC Reverse Option Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 3 4 5 16 19 05 8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 3 8 1 2 9 65 12 7mm Driveshaft Sprockets 2 Drivers Front Shocks Indy Select Brake Type Polaris HPB IFS Spring Rate 80 in Front Spring Preload 06 Thread Adjust Front Vertical Travel 9 30 in 23 62cm Rear Suspension XTRA 10 Rear Travel 10 0 in 25 4cm Front Track Shock Ryde FX Spring Rate 200 in variable Rear Track Shock Ryde AFX Rear Springs 406 77 Track Type 15 x121 x 82 38 1x307 34x2 08cm Track Tension 3 8 1 2 9 65 12 7mm slack with 104 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS Polaris Industries Inc 1 25 somemy NED
64. aces upward Piston Ring End Gap 014 020 36 51mm Head cc s Uninstalled 40 2cc Head cc s Installed 32 5cc Operating RPM 200 8000 RPM Idle RPM 200 1500 RPM Engagement RPM 300 4200 RPM Cylinder Head Torque 20ft Ibs 2 8kgm Cylinder Base Nut Torque 35 40 ft lbs 4 8 5 5 kgm Crankcase Torque 8mm N A Crankcase Torque 10mm 35 40 ft lbs 4 8 5 5 kgm Flywheel Torque 55 ft lbs 7 4 kgm 10 98 Polaris Industries Inc MODEL INDY 700 SKS MODEL NUMBER 099SS7AS ENGINE MODEL SN70 70 99A1 ELECTRICAL Flywheel I D 4010139 CDI Marking 4060212 Alternator Output 280 Watts Ignition Timing 6 BTDC 1750RPM 1 5 0 009 BTDC 0 005 0 22mm BTDC 0 105mm Operating Timing 17 7500 RPM Spark Plug Gap Champion RN 2C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR7 Electric Start Optional LR7 Full wave voltage regulator SUSPENSION CHASSIS Body Style Gen Il Front Suspension XTRA 10 CRC Maximum Width 41 00 104 14cm Camber 3 4 5 16 19 05 8mm Toe Out 3 8 1 2 9 65 12 7mm Front Shocks Nitrex IFS Spring Rate 100 in Front Spring Preload Front Vertical Travel 0 38 Thread Adjust 9 30 in 23 62cm GENERAL 1999 Model Specif
65. ar Track Shock Nitrex Rear Springs 468 sq 74 Track Type 20 x156 x1 0 50 8x396 24x2 54cm Track Tension 3 4 1 1 90 2 54cm slack with 10s 4 54kg weight 16 40 64cm ahead of rear idler shaft Polaris Industries Inc 1 67 10 98
66. as 5938 39 64 i rivo eI RU dw 6094 lines e 625 41 64 iaa 6406 21 32 vr enda 6563 43 64 A Ren pius 6719 11 6 2212395003 264 6875 45 64 ar 7031 29 82 iii Pe 7188 47 64 is ae sinters 7344 3 4 75 49 64 ii rennes 7656 EA eie Er 7813 51 64 eL e E 7969 TITE io 5448 8125 53 60 O 8281 27132 i e ers 8438 55 64 Lenis ots rere 8594 MIB i renes 875 57 64 232 2524 R E D res 8906 29 32 iia is 9063 59 64 A 9219 15 16 eu 9375 61 64 cis tie nea ey ete 9531 91 32 it 9688 63 64 diia 9844 o5 esee 1 0 Polaris Industries Inc 1 7 10 mm 0394 0787 1181 1575 1969 2362 2756 3150 3543 3937 4331 4724 5118 5512 5906 6299 6693 7087 7480 7874 8268 8661 9055 9449 9843 GENERAL Decimal Equivalents 10 98 GENERAL Tap Drill Charts SAE Tap Drill Sizes Thread Size Drill Size Thread Size Drill Size 1 2 13 27 64 1 2 20 29 64 9 16 12 31 64 9 16 18 33 64 5 8 11 17 32 5 8 18 37 64 3 4 10 21 32 3 4 16 11 16 7 8 9 49 64 7 8 14 13 16 1 8 7 8 1 12 59 64 1 1 8 7 63 64 1 1 8 12 1 3 64 1 1 4 7 1 7 64 1 1 4 12 1 11 64 1 1 2 6 1 11 32 1 1 2 12 1 27 64 1 3 4 5 19 16 1 3 4 12 1 43 64 2 4 1 2 1 25 32 2 12 1 59 64 2 1 4 4 1 2 2 1 32 2 1 2 4 2 1 4 2 3 4 4 2 1 2 3 4 2 3 4 10 98 1 8 Polaris Industries Inc GENERAL Conversion Table Multiplied by
67. ator Output 200 Watts Coolant N A Ignition Timing 26 BTDC 3000RPM 1 5 Chaincase Oil 9 fl oz 265cc 150 BTDC 133 167 3 81mm BTDC 3 39 4 25mm Operating Timing 16 6500 RPM Spark Plug Gap NGK BR8ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 8 watts Brake 29 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 16 39 64 P 3 4 HYVO Front Suspension 41 IFS Reverse Standard Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 9 16 5 16 14 8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 0 1 8 0 3mm Driveshaft Sprockets 2 drivers Front Shocks Nitrex Brake Type Polaris HPB IFS Spring Rate 105 in Front Spring Preload 5 shims Front Vertical Travel 7 56 in 19 20cm Rear Suspension 141 GT Rear Travel 7 in 17 78cm Front Track Shock Nitrex Spring Rate 181 in Rear Track Shock Nitrex Rear Springs 406 75 Track Type 15 x141 x1 125 38 1x358 14x2 86cm Track Tension 3 4 1 19 05 25 4mm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS MEDIUNSTO FRM 375 diameter 75 406 diameter 75 468 d
68. bility sugges tions or usage should be directed to VST at the phone number listed below Information photographs and illustrations contained in this manual are general representations and actual tools may differ All information subject to change without notice TO PLACE AN ORDER Canadian Dealers order directly from Polaris Winnipeg TOLL FREE ORDER FAX ORDERS ONLY 1 800 716 3938 PHONE ORDERS OR INFORMATION 1 716 742 1790 Service Tool Catalog Part Number 9914681 10 98 1 10 Polaris Industries Inc GENERAL Glossary of Terms ACS Alternator control switch ACV Alternating current voltage Air Gap Spark Test A good check for ignition voltage and general ignition system condition Spark should arc 3 8 1 cm minimum from end of high tension lead to ground Several testers are available commercially Alternator Electrical generator producing alternating current voltage Bore Diameter of cylinder BTDC Before Top Dead Center Bump Steer When skis toe in and toe out through suspension travel CDI Capacitor Discharge Ignition Ignition system which stores voltage generated by the stator plate exciter coil in a capacitor or condenser in CDI box At the proper moment a voltage generated by the stator plate pulser coil closes an electronic switch thyristor in the CDI box and allows the voltage in the capacitor to discharge into the primary windings of the ignition coil Center Cylinder On three cylinder engines the
69. ck Fox IFP Rear Springs 359 sq 77 Track Type 15 x121 x 91 38 1x307 34x2 31cm Track Tension 3 8 1 2 9 65 12 7mm slack with 104 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR SUSPENSION SPRINGS sor wemmem FIRM Polaris Industries Inc 1 65 10 98 GENERAL 1999 Model Specifications MODEL WIDETRAK LX MODEL NUMBER 099SU4BS ENGINE MODEL EC50PL202 CARBURETION ecos Si VM34SS JETTING CHART Main Jet let ers 195 AMBIENT TEMPERATURE Pilot Jet 35 Altitude Below 20 F 20 to 10 F 10 to 40 F Above 40 F Jet Needle 6EJ26 2 Below PPO nee PS qc ASA e Needle Jet P 6 166 feet 03000 PA 12 Cutaway 3 0 CH Air Screw 0 5 Turn 19066 5066 be Valve Seat 1 5 SOUS 5 Fuel Octane R M 2 87 Non Oxygenated or 0009000 We 163 159 129 89 Oxygenated 2700 3700 Throttle Gap 2000 12000 1 1 1 Under Cutaway 219 5 55mm XXX Idle Sync Gap me Under Cutaway mA i 240 6 1 mm refers to the clip position from top of jet needle E Production Setting CLUTCH Type Loco eee P 85 Bellini eure cue teens 3211070 Belt Width Projected 1 375 34 93mm Side Angle Overall 28 Outside Circumference 47 250 CLUTCH CHART Cen
70. dle Jet P 4 825 Cutaway 2 0 Idle Mixture Screw 1 5 Turn Valve Seat 1 5 60009000 Fuel Octane R M 2 Adjustable with TRU key switch 9000 12000 Starter Jet 145 A R XXX NOAA pra un refers to the clip position from top of jet needle C Production Setting CLUTCH TYPOS rd as R abs P 85 Belt traes ner 3211075 CLUTCH CHART Belt Width Projected 1 438 36 52mm DRIVE bDRVN Side Angle Overall 26 Altitude Shift Clutch Driven Chaincase Outside Circumference 47 625 Weight Spring Helix Center Distance 12 305mm Meter ved Shift Weights ed JNE EA Primary Spring Almond 001800 10 56 Siver R 12 24 40 68 P S RUR Spina Silver Blue Sushed E E Driven Helix R 12 2 ret dE pus salee e ENGINE Type circa Liquid Cooled Case Reed Triple with VES Displacement 700 cc TN 2 6614 67 6mm SIOKE gt servicio aa nem hee 2 5591 65mm Piston Cylinder Clearance 0027 0041 070 105mm Service LiMit 0059 15mm Piston Marking 70A Piston Ring Marking 70A Piston Ring End Gap 012 018 30 45mm Head cc s Uninstalled 25 3cc Head cc s Installed 21 2cc Operating RPM 200 8500 RPM Idle RPM 200 1500 RPM Engagement RPM 300 4000 RPM Cylinder Head Torque 8mm 17 20 ft lbs 10mm 24 26 ft
71. e black cable first and reconnect it last Battery electrolyte contains sulphuric acid and is poisonous Serious burns can result from contact with the skin eyes or clothing ANTIDOTE External Flush with water Internal Drink large quantities or water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention 10 98 1 14 Polaris Industries Inc GENERAL 1999 Model Identification MODEL NUMBER IDENTIFICATION 1999 MODEL DESIGNATION YEAR DESIGNATION E European Model MODEL CHASSIS DESIGNATION ENGINE DESIGNATION Color Option o 9 9 a A S North American Model U European Model MODEL LINE 4TH DIGIT MODEL TYPE 5TH DIGIT A Aggressive B Basic S Standard Indy U Utility E Evolved D Deluxe L Lite P Performance R RMK X Racer T Touring S SKS 1999 MODEL DESIGNATION NUMBERS Chassis LB Indy 340 LD Indy 340 Deluxe LT Indy 340 Touring SU Transport WideTrak LX ST Sport Touring SB Sport Supersport 500 XC 600 XC 700 XC SP XCF ER 500 RMK EB Indy 500 Trail XLT LTD ED Indy 500 Classic XLT Classic ET Classic Touring Trail Touring XLT Touring SR Trail RMK 600 RMK 700 RMK AB XLT Special 700 XCR 800 XCR SX 440 XCR SP 500 XC SP 600 XC SP 700 XC SP SS 700 SKS MODEL NO V ILN NO THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL AND
72. earance 0 0035 0 0049 0 09 0 125mm Service Limit 0 0078 0 20mm Piston Marking 58F Piston Ring Marking 3N Piston Ring End Gap 012 020 30 50mm Head cc s Uninstalled 19 9cc Head cc s Installed 19 5cc Operating RPM 200 8000 RPM Idle RPME200 1900 RPM Engagement RPM 300 4000 RPM Cylinder Head Torque 8mm 17 20 ft lbs 10mm 24 26 ft lbs Cylinder Base Nut Torque 24 28 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5 kgm Flywheel Torque 60 65 ft lbs 8 3 9 kgm 10 98 1 46 Polaris Industries Inc MODEL XLT CLASSIC MODEL NUMBER 099ED6AS ENGINE MODEL EC58PL131 ELECTRICAL Flywheel I D FP9102 CDI Marking CU2552 Alternator Output 280 Watts 28 BTDC Q9 3000RPM 1 5 0 173 BTDC 0 0175 4 40mm BTDC 0 48mm Ignition Timing Operating Timing 20 7500 RPM Spark Plug Gap Champion RN 3C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail ss 202 watts Brake 1017 watts Voltage Regulator LR7 LR2 Electric Start Standard LR7 Full wave voltage regulator LR2 Rectifier only for battery charging SUSPENSION CHASSIS Body Style Evolved Front Suspension XTRA 12 Maximum Width 42 50 107 95cm Camber 0 5 16
73. em RIS TM38 Mikuni AMBIENT TEMPERATURE Main Jet 370 Altitude Below 20 F 20 to 10 F 10 to 40 F Above 40 F Pilot Jet AAA 45 Below 29 C 29 to 12 C 12 to 5 C Above 5 C Jet Needle 9FH4 57 3 MES a 334 Needle Jet P 6 Cutaway 1 5 22600 6006 A pos ag Air Screw 2 Turns E Du eS Valve Seat 1 5 Viton 6000 9000 pos zs p P Fuel Octane R M 2 87 Non Oxygenated or 2700 3700 89 Oxygenated Starter Jet 155 Pilot Air Jet vore 1 0 2 refers to the clip position from top of jet needle C Production Setting EZ Line zone should remove washer from underneath needle and place on top CLUTCHES OS P 85 Belt naci ee es 3211074 Belt Width Projected 1 438 36 52mm Side Angle Overall 28 CLUTCH CHART Outside Circumference 47 625 SM Altitude Shift Clutch Clutch Center Distance 12 305mm Weight Spring Spring Shift Weights eh n t nt 1 0 56 Meters 0 900 Primary Spring Dark Blue Fee 9300 1058 Dark Blue Driven Hoc 1 R22 ETE 1800 2700 10AL or Almond 6000 9000 10 Goid 2700 3700 Almond 900 1200 1 Gold ENGINE Type i act eae one ees Liquid Cooled Case Reed Displacement 500 cc BONS eu er f REY 2 776 70 5mm Stroke racial cite 2 520 64mm Piston Cylinder Clearance Service LiMit Piston Marking Piston Ring Marking
74. er 77 L H 7041627 067 L H 7041629 067 L H 7041631 067 R H 7041628 067 R H 7041630 067 R H 7041632 067 Polaris Industries Inc 1 41 10 98 GENERAL 1999 Model Specifications MODEL CLASSIC TOURING MODEL NUMBER 099ET4BS ENGINE MODEL EC50PL192 CARBURETION JETTING CHART ppa E a O Mikuni AMBIENT TEMPERATURE ain Jet f A leo ara Pg de UD 40 EE cm enm Jet Needle 6EJ26 3 __ qul Meters 0 900 260 Needle Jet P 2 480 Feet A oe F Cutaway 3 0 CH Air Screw 3 4 Turn 13066 6000 IES pel 219 Valve Seat 1 5 18000900 ETA E 887 Fuel Octane R M 2 87 Non Oxygenated or 6000 9000 3 3 42 2 89 Oxygenated 2700 3700 200 190 180 175 Throttle Gap ME eS 2 42 2 Under Cutaway 218 5 54mm XXX ne xA ae 240 6 4 refers to the clip position from top of jet needle nder Cutaway 6 1mm C Production Setting CLUTCH TYPE atea P 85 Baldini td 3211070 Belt Width Projected 1 375 34 93mm CLUTCH CHART Side Angle Overall 28 Outside Circumference 47 250 Altitude Shift Clutch Clutch Driven Chaincase Center Distance 12 305mm Weight Spring Spring Gearing i i Meters T piney Sigs ceed em um am a Secondary Spring Silver ono sock R
75. er surface Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction Metric equivalent of ft Ibs L Ring A wide face piston ring with an L shaped cross section Leg of L goes up when installing on piston Labyrinth Seal A pressure type center seal identified by series of grooves and lands Polaris engines us this type of seal to separate the cylinders in the crankcase halves Left Side Always referred to based on normal operating position of the driver Lighting Coil Generates voltage for lights battery charging etc by electromagnetic induction Loose When the rear of the vehicle slides outward in a turn The track does not grab sufficiently mm Millimeter Unit of length in the metric system 1mm 040 Mag End Flywheel side of engine Magnetic Induction As a conductor coil is moved through a magnetic field a voltage will be generated in the windings This is how mechanical energy in our engines is converted to electrical energy in the lighting coil ignition generating coils and trigger coil Ohm The unit of electrical resistance opposing current flow Oval Head Screw Fully specified as oval countersunk this head is identical to the standard flat head but possesses a rounded upper surface for attractiveness of design PTO End Power Take Off drive clutch side Pan Head Screw Provides a low large diameter head but with characteristically hi
76. et 40 A oodd qeu dd Jet Needle 6DP17 2 Meter 0 900 Needle Jet Q 4 480 os 300 H Cutaway 2 5 CH 900 1800 Air Screw 1 Turn 3009 8000 Valve Seat 1 5 Viton pericia Fuel Octane R M 2 87 Non Oxygenated or 89 Oxygenated 200012000 Throttle Gap E Under Cutaway 210 5 53mm Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 234 5 94mm LESS eon Soin CLUTCH Type P 85 Belt 3211070 CLUTCH CHART Belt Width Projected 1 375 34 93mm DRIVEN Side Angle Overall 28 Altitude Shift Clutch Clutch Driven Chaincase Outside Circumference 47 250 Went Spring SS Hel Gearing Meters 0 900 10MB z 34 20 40 66 P Center Distance 12 305mm Feet 03000 praca SiverGold aol SAIO Shift Weights 10M Bushed EY 1 i n 900 1800 34 20 40 66 P Primary Spring Silver Gold 2000 6000 Blue Siver Gold o Secondary Spring Silver usne Driven Helix 34 2 1800 2700 10M 340 20 4066P 6000 9000 White Dark Blue 2 S AHYVO 10M 2700 3700 s 34 20 40 66 P 9000 12000 e T Dark Blue Silver F2 3 4 HYVO L_e ENGINE Type iria os Liquid Cooled Piston Port Triple Displacement 598cc Data Paes 2 5600 65 025mm
77. ety Alert Pitman Arm Weld Failure And Pitman Arm to Steering Rack Bolt Replacement rou S 97 05 Safety Alert Refer To S 97 05R Service Passenger Hand Grip Heaters Service Passenger Hand Grip Heaters 0 Widetrak LX Trail Touring Trail RMK Sport Super Sport Sport Touring Lite Lite DIx Lite Trg Polaris Industries Inc 1 3 10 98 GENERAL Bulletin Index 1999 By Model Classic Bus Type Jotas pce e IP Service Updates for 1999 Gen H Pilot Builds Service Updates for 1999 Gen H Pilot Builds Service Updates for 1999 Gen II Pilot Builds Service Updates for 1999 Gen II Pilot Builds Service Updates for 1999 Gen I Pilot Builds CS ser Sport S 98 06 Super Sport S 98 06 Service Updates for 1999 Gen II Pilot Builds Service Updates for 1999 Gen II Pilot Builds Service Updates for 1999 Gen II Pilot Builds XCF 10 98 1 4 Polaris Industries Inc GENERAL Standard Torque Specifications The following torque specifications are to be used as a general guideline when torque value is not specified There are exceptions in the steering suspension and engine areas di consult the torque chart and the specific manual section for torque values of fasteners Q Q Q Bolt Size Threads In Grade 2 Grade 5 Grade 8 MM Thread Torque in lbs kg m 10 X ETEN TASI PR ODE O i at donet 60 69 10 E aeta 7 31 80 cs ae egret 49 56 ex sn das 68 78 Torque f
78. gh outer edges along the outer edge of the head where driving action is most effective Slightly different head contour when supplied with Phillips Recess See dotted line Piston Clearance Total distance between piston and cylinder wall Piston Erosion Piston dome melts Usually occurs at the exhaust port area Possible causes 1 lean fuel air mixture 2 improper spark plug heat range 10 98 1 12 Polaris Industries Inc GENERAL Glossary of Terms Pre Ignition A problem in combustion where the fuel air mixture is ignited before normal spark ignition Piston looks melted at area of damage Possible causes 1 incorrect spark plug heat range 2 spark plug not properly torqued 3 glowing piece of head gasket metal burr or carbon in the combustion chamber 4 lean fuel air mixture 5 Incorrect ignition timing Primary Circuit This circuit is responsible for the voltage build up in the primary windings of the coil Parts of this circuit include the exciter coil points and condenser wires from the stator plate to the small primary winding in the ignition coil In the CDI system the parts include the exciter coil the trigger coil the wires from stator plate to CDI box and to the low resistance primary windings in the ignition coil Primary Clutch Drive clutch on engine Primary Compression Pressure built up in the crankcase of a two stroke engine psi Pounds per square inch Pushing When the front of the vehicle does no
79. hts Head Halogen 130 110 watts Tail 209 watts Brake 2018 watts Voltage Regulator LR7 Electric Start Option LR7 Full wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Aggressive Sprockets Chain 22 41 68 P 3 4 HYVO Front Suspension XTRA 10 CRC Reverse Option Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 3 4 45 16 19 05 8mm Chaincase Center Dist 6 5 8 16 83cm Toe Out 3 8 1 2 9 65 12 7mm Driveshaft Sprockets 2 Drivers wide Front Shocks Indy Select Brake Type Hydraulic Disc IFS Spring Rate 100 in Front Spring Preload 0 13 Thread Adjust Front Vertical Travel 9 30 in 23 62cm Rear Suspension XTRA 10 Rear Travel 8 25 in 25 4cm Front Track Shock Ryde FX Spring Rate 200 in variable Rear Track Shock Polaris Position Sensitive Shock Rear Springs 359 sq 77 Track Type 15 x121 x 82 38 1x307 34x2 08cm Track Tension 3 8 1 2 9 65 12 7mm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR SUSPENSION SPRINGS SOFT MEDIUM STD FIRM 347 sq diameter 77 359 sq diameter 77 375 sq diameter 77 L H 7041627 067 L H 7041629 067 L H 7041631 067 R H 7041628 067 R H 7041630 067 R H 7041632 067 Polaris Industries Inc 1 45 10 98 GENER
80. iameter 74 L H 7041318 067 L H 7041320 067 L H 7041239 067 R H 7041319 067 R H 7041321 067 R H 7041240 067 Polaris Industries Inc 1 23 10 98 GENERAL 1999 Model Specifications MODEL XCF MODEL NUMBER 099SP4AS ENGINE MODEL EC45PMO11 CARBURETION Type sive es VM34SS Mikuni Main Jet 270 Pilot Jet 40 Jet Needle 6DP1 3 Needle Jet P 8 480 Cutaway 3 0 Air Screw 1 0 Turns Valve Seat 1 5 Fuel Octane R M 2 87 Non Oxygenated or 89 Oxygenated Throttle Gap Under Cutaway 218 5 54mm Idle Sync Gap Under Cutaway 240 6 1mm CLUTCH TYPO s eeepc oak P 85 Belts cowed bes 3211070 Belt Width Projected 1 375 34 93mm JETTING CHART AMBIENT TEMPERATURE Altitude Below 20 F 20 t0 10 F 10 t0 40 F Above 40 F Below 29 C 29 to 12 C 12 to 5 C Above 5 C Meters 230 Feet 3 3 900 1800 220 195 3000 6000 43 3 2 1800 2700 220 200 180 165 6000 9000 3 3 2 2 uL 180 170 150 135 3 2 2 52 j XXX X refers to the clip position from top of jet needle C Production Setting CLUTCH CHART Side Angle Overall 28 i DM SEC me E 47 25 uisi S Bos aa breed cc Center
81. ications CAPACITIES Fuel Tank 11 8 gal 44 7L 10 5 39 7 Oil Tank 3 quarts 2 8 liters Coolant 3 quarts 2 8 liters Chaincase Oil 7 fl oz 210cc CHAINCASE Sprockets Chain 23 40 70 P 3 4 HYVO Reverse Option Brake Pads Type 69 Chaincase Center Dist 7 05 17 91cm Driveshaft Sprockets 2 Drivers Wide Brake Type Polaris HPB Liquid Cooled Rear Suspension XTRA 10 Rear Travel 9 5 in 24 13cm Front Track Shock Nitrex Spring Rate 200 in variable Rear Track Shock Indy Select Rear Springs 359 sq 77 Track Type 15 x136 x1 25 38 1x345 44x3 175cm Track Tension OPTIONAL REAR SUSPENSION SPRINGS 347 sq diameter 77 359 sq diameter 77 375 sq diameter 77 3 8 1 2 9 65 12 7mm slack with 10st 4 54kg weight 16 40 64cm ahead of rear idler shaft L H 7041627 067 L H 7041629 067 L H 7041631 067 R H 7041628 067 R H 7041630 067 R H 7041632 067 Polaris Industries Inc 1 61 10 98 GENERAL 1999 Model Specifications MODEL INDY 700 XCR MODEL NUMBER 099AB7BS ENGINE MODEL EC70PL011 CARBURETION JETTING CHART TYP iio TM38 Mikuni AMBIENT TEMPERATURE SENS A A Fa Ead DUE pd 2 pruna yea een Above 40 F HOLMER gop ieee 24404 elow 29 to 12 12 to 45 Above 5 C Jet Needle 9CG1 54 3 Meier Nee
82. ications MODEL XLT SPECIAL MODEL NUMBER 099AB6AS ENGINE MODEL EC58PL160 CARBURETION JETTING CHART Type e 3 TM38 Mikuni Main Jet 360 AMBIENT TEMPERATURE Pilot Jet 35 ll come N tie Jet Needle 9DH3 54 4 MT asters 22101826 o N Meter 0 900 G ANI feat omm a E Idle Mixture Screw 1 5 Turns 900 1800 320 300 Valve Seat 1 5 Viton 4 3 Fuel Octane R M 2 87 Non Oxygenated or 6000 8000 cox p F Z 89 Oxygenated z Starter Jet 155 dc 000012000 ahs a Pilot Air Jet 1 0 X C Production Setting refers to the clip position from top of jet needle CLUTCH TVDe css tative aati P 85 Bellido redi 3211070 Belt Width Projected 1 375 34 93mm CLUTCH CHART Side Angle Overall 28 Outside Circumference 47 250 roan E DAVEE 3 Es Center Distance 12 305mm EN ES Ces Shift Weights 10M Bushed mane ears a Saree Primary Spring Dark Blue Feet 0300 Busheg Dark Blue 3 4 HYVO Secondary Spring Silver 900 1800 10MB 340 22 4168 P Driven Helix R 32 2 3000 6000 Bushea DAK BUe Siver x 34Hvvo AE m seems see T Senes eme mm osse sue Re oos ENGINE TYPE tii cat 7 KEA RAT Liquid Cooled Piston Port Triple
83. ighty Spring Shift Weights 10 56 Bushed yon 10 60 Dark Blue Primary Spring Dark Blue Me Secondary Spring Silver Blue 60006000 pores DarkBlue Driven Helix R 32 2 60008000 uand Park Blue 00012000 pushed Park Blue ENGINE TYPO iras Fan Cooled Reed Assist Displacement 544 cc BONS sl is eee 2 874 73mm Stroke ise RR RR 2 559 65mm Piston Cylinder Clearance Service Limit Piston Marking Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 0 0041 0 0055 0 104 0 139mm 0 0078 0 20mm 5MB N 015 022 40 55mm 33 8 cc 27 7 cc 6800 RPM 1600 RPM 3600 RPM 18 19 ft Ibs 2 5 2 8 kgm 30 34 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft lbs 3 2 3 5 kgm 60 65 ft lbs 8 3 9 kgm 1 32 DRIVEN Driven Clutch Spring Silver Blue Silver Blue Silver Blue Silver Blue 2 R 32 2 2 Chaincase Gearing 18 41 68 P 3 4 HYVO 18 41 68 P 3 4 HYVO 18 41 68 P 3 4 HYVO 18 41 68 P 3 4 HYVO Polaris Industries Inc GENERAL 1999 Model Specifications MODEL TRAIL RMK MODEL NUMBER
84. ions MODEL TRAIL MODEL NUMBER 099EB4ES A ENGINE MODEL EC50PM044 ELECTRICAL CAPACITIES Flywheel LD FP5441 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU6413 Oil Tank 2 quarts 1 9 liters Alternator Output 200 Watts Coolant N A Ignition Timing 26 BTDC 3000RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 150 BTDC 0 017 3 81mm BTDC 0 43mm Operating Timing 16 6500 RPM Spark Plug Gap NGK BR8ES 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Evolved Sprockets Chain 22 41 68 P 3 4 HYVO Front Suspension XTRA 10 Reverse Option Maximum Width 42 50 107 95cm Brake Pads Type 69 Camber 0 x5 16 03 8mm Chaincase Center Dist 6 5 8 16 83cm Toe Ou criada 1 8 1 4 3 6 35mm Driveshaft Sprockets 2 drivers Front Shocks Nitrex Brake Type Hydraulic Disc IFS Spring Rate 80 in Front Spring Preload 0 5 Thread Adjust Front Vertical Travel 10 0 in 25 4cm Rear Suspension XTRA 10 Rear Travel 10 0 in 25 4cm Front Track Shock Nitrex Spring Rate 200 in variable Rear Track Shock Indy Select Rear Springs 406 77 Track Type 15
85. ition Timing 28 BTDC 3000RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 173 BTDC 0 0175 4 40mm BTDC 0 48mm Operating Timing 16 9 7500 RPM Spark Plug Gap Champion RN 3C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR9 Electric Start Option LR9 Half wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Evolved Sprockets Chain 17 41 66 P 3 4 HYVO Front Suspension 38 RMK Reverse Option Maximum Width 38 00 96 52cm Brake Pads Type 69 Camber 0 5 16 0 8mm Chaincase Center Dist 6 5 8 16 83cm Toe OU iios 3 8 1 2 9 65 12 7mm Driveshaft Sprockets 2 Drivers Front Shocks Nitrex Brake Type Hydraulic Disc IFS Spring Rate 80s in Front Spring Preload 0 6 Thread Adjust Front Vertical Travel 8 18 in 20 78cm Rear Suspension XTRA 10 Rear Travel 11 5 in 29 21cm Front Track Shock Nitrex Spring Rate 200 in variable Rear Track Shock Indy Select Rear Springs 359 sq 77 Track Type 15 x133 5 x1 25 38 1x339 09x3 175cm Track Tension 3 8 1 2 9 65 12 7mm slack with 10st 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR SUSPENSION SPRINGS SOFT MEDIUM STD 347 sq diameter 77 359 sq diameter 77 375 sq diamet
86. manual thoroughly familiarizing him herself with procedures before beginning Pictures and illustrations have been included with the text as an aid Notes cautions and warnings have also been included for clarification of text and safety concerns However a knowledge of mechanical theory tool use and shop procedures is necessary to perform the service work safely and satisfactorily Use only genuine Polaris service parts A Cleanliness of parts and tools as well as the work area is of primary importance Dirt and foreign matter will act as an abrasive and cause damage to precision parts Clean the snowmobile before beginning service Clean new parts before installing A Watch for sharp edges which can cause personal injury particularly in the area of the tunnel Protect hands with gloves when working with sharp components A If difficulty is encountered in removing or installing a component look to see if a cause for the difficulty can be found If it is necessary to tap the part into place use a soft face hammer and tap lightly A Some of the fasteners in the snowmobile were installed with locking agents Use of impact drivers or wrenches will help avoid damage to fasteners A Always follow torque specifications as outlined throughout this manual Incorrect torquing may lead to serious machine damage or as in the case of steering components can result in injury or death for the rider s A If a torquing sequence is indicated for nuts bolt
87. ng Spring Helix Gearing Shift Weights 10 60 Bushed Meters 0 900 10 60 Siver 36 19 3966P Primary Spring Dark Blue Feet 0 3000 Busnea Park Blue Blue 2 3 4HYVO ne eats 900 1800 10 58 Silver 36 19 3966P Secondary Spring Silver Blue Bushed DarkBlue Siue 45 Driven Helix 36 2 18002700 1056 pax pue Ser se 19 3966P 6000 9000 Bushed Blue 42 3 4 HYVO 2700 3700 10 54 Silver 36 19 39 66 P 9000 12000 Bushea 99 Blue 2 ENGINE TYPO Lorenz umi Rhet ee ree Fan Cooled Reed Assist Displacement Bore Stroke Piston Cylinder Clearance 544 cc 2 874 73mm 2 559 65mm 0 0041 0 0055 0 104 0 139mm Service Limit 0 0078 0 20mm Piston Marking 5MB Piston Ring Marking N Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 015 022 40 55mm 33 8 cc 27 7 CC 6500 RPM 1600 RPM 3600 RPM 18 19 ft Ibs 2 5 2 8 kgm 30 34 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft Ibs 3 2 3 5 kgm 60 65 ft lbs 8 3 9 kgm 10 98 1 34 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL SUPER SPORT MODEL NUMBER 099SB5BS ENGINE MODEL E
88. oss E She eee A ue Driven Helix 34 2 T T ouw au m se 1940 E gt quel ees ENGINE TVDe oe tm RR ee Liquid Cooled Piston Port Displacement 488 cc A pedis ree nan ep 2 8346 72mm Stroke 2 0 cece eee eee 2 3622 60mm Piston Cylinder Clearance 0 0024 0 0037 0 06 0 095mm Service Limit 0 0078 0 20mm Piston Marking 5W Piston Ring Marking 51A Piston Ring End Gap 008 016 20 40mm Head cc s Uninstalled 28cc Head cc s Installed 23 6cc Operating RPM 200 7800 RPM Idle RPME200 1600 RPM Engagement RPM 300 4000 RPM Cylinder Head Torque 8mm 17 20 ft lbs 10mm 24 26 ft Ibs Cylinder Base Nut Torque 24 28 ft lbs 3 3 3 9 kgm Crankcase Torque 8mm 17 18 ft lbs 2 2 2 3 kgm Crankcase Torque 10mm 23 25 ft lbs 3 2 3 5 kgm Flywheel Torque 60 65 ft lbs 8 3 9 kgm 10 98 1 42 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL CLASSIC TOURING MODEL NUMBER 099ET4BS ENGINE MODEL EC50PL192 ELECTRICAL CAPACITIES Flywheel I D FP5445 Fuel Tank 11 8 gallons 44 7 liters CDI Marking CU6417 Oil Tank 2 quarts 1 9 liters Alternator Output 200 Watts Coolant 3 quarts 2 8 liters Ignition Timing 28 BTDC 3000RPM 1 5 Chaincase Oil
89. park Plug Gap Champion RN 2C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 208 watts XC 20 2watts SP Brake 208 watts XC 1017 watts SP Voltage Regulator LR7 Electric Start Optional LR7 Full wave voltage regulator SUSPENSION CHASSIS CHAINCASE Body Style Gen Il Sprockets Chain 22 40 70 P 3 4 HYVO Front Suspension XC 10 CRC Reverse Option Maximum Width 41 00 104 14cm Brake Pads Type 69 Camber 1 05 5 16 26 67 8mm Chaincase Center Dist 7 05 17 91cm Toe Out 0 1 8 0 3mm Driveshaft Sprockets 2 Drivers Wide Front Shocks Indy Select XC Fox IFP SP Brake Type Polaris HPB Liquid Cooled IFS Spring Rate 100 in XC 74 120 in SP Front Spring Preload 0 20 Thread Adjust XC 1 13 Thread Adjust SP Front Vertical Travel 9 0 in 22 86cm Rear Suspension XTRA 10 Rear Travel 8 25 in 21cm Front Track Shock Ryde FX XC Fox IFP SP Spring Rate 200 in variable XC 190 in SP Rear Track Shock Polaris Position Sensitive Shock Rear Springs 359 sq 77 Track Type 15 x121 x 91 38 1x307 34x2 31cm Track Tension 3 8 1 2 9 65 12 7mm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR SUSPENSION SPRINGS MEDIOMSTO FRM 347 sq diameter 77 359
90. pe 69 Camber 1 05 5 16 26 67 8mm Chaincase Center Dist 7 05 17 91cm Toe Out 0 1 8 0 3mm Driveshaft Sprockets 2 Drivers Wide Front Shocks Indy Select XC Fox IFP SP Brake Type Polaris HPB Liquid Cooled IFS Spring Rate 100 in XC 74 120 in SP Front Spring Preload 0 20 Thread Adjust XC 1 13 Thread Adjust SP Front Vertical Travel 9 0 in 22 86cm Rear Suspension XTRA 10 Rear Travel 8 25 in 21cm Front Track Shock Ryde FX XC Fox IFP SP Spring Rate 200 in variable XC 190 in SP Rear Track Shock Polaris Position Sensitive Shock Rear Springs 359 sq 77 Track Type 15 x121 x 91 38 1x307 34x2 31cm Track Tension 3 8 1 2 9 65 12 7mm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR SUSPENSION SPRINGS SOFT MEDIUM STD FIRM 347 sq diameter 77 359 sq diameter 77 375 sq diameter 77 L H 7041627 067 L H 7041629 067 L H 7041631 067 R H 7041628 067 R H 7041630 067 R H 7041632 067 Polaris Industries Inc 1 55 10 98 GENERAL 1999 Model Specifications MODEL INDY 600 RMK MODEL NUMBER 099SR6DS A ENGINE MODEL SN60 70 99A1 CARBURETION JETTING CHART TIDE ove eur bates 2 Keihin PWK 39 P AMBIENT TEMPERATURE itu w 20 20 to 10 10
91. rex Spring Rate 200 in variable Rear Track Shock Indy Select Rear Springs 437 77 Track Type 15 x133 5 x 82 38 1x339 09x2 08cm Track Tension 3 8 1 2 9 65 12 7mm slack with 10s 4 54kg weight 16 40 64cm ahead of rear idler shaft OPTIONAL REAR TORSION SPRINGS sor o II Polaris Industries Inc 1 31 10 98 GENERAL 1999 Model Specifications MODEL TRAIL RMK MODEL NUMBER 099SR5BS ENGINE MODEL EC55PM021 CARBURETION JETTING CHART Pe pn boue es dc bcn Mikuni ACCS AMBIENT TEMPERATURE Pilot Jet 35 iud ES or Hor Jet Needle 6DH7 3 m pat Needle Jet Q 0 480 Feet osoo 34 Pe Cutaway 3 0 3001800 Air Screw 1 5 Turns 3000 6000 Valve Seat 15 1800 2700 Fuel Octane R M 2 87 Non Oxygenated or utes 89 Oxygenated 2700 3700 Throttle Gap laid aont Under Cutaway 218 5 54mm XXX Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 242 6 15mm C Production Setting CLUTCH TYDO cia P 85 Belt z L uereta mala 3211070 Belt Width Projected 1 375 34 93mm CLUTCH CHART Side Angle Overall 28 Outside Circumference 47 250 Altitude Shift Clutch Center Distance 12 305mm We
92. s Inc MODEL INDY 700 RMK MODEL NUMBER 099SR7AS A ENGINE MODEL S70 70 99A3 ELECTRICAL Flywheel I D Ducati 4010139 CDI Marking 4060211 Alternator Output 280 Watts 12 BTDC 3000RPM 1 5 0 037 BTDC 0 004 0 93mm BTDC 0 22mm Ignition Timing Operating Timing 16 8250 RPM Spark Plug Gap Champion RN 2C 0 028 0 7mm Lights Head Halogen 75 60 watts Tail 203 watts Brake 18 watts Voltage Regulator LR7 Electric Start Optional LR7 Full wave voltage regulator SUSPENSION CHASSIS Body Style Gen Il Front Suspension RMKCRC Maximum Width 38 00 96 52cm Camber 11 32 5 16 9 8mm Toe Out 3 8 1 2 9 65mm 12 7mm Front Shocks Nitrex IFS Spring Rate 100 in Front Spring Preload Front Vertical Travel 0 13 Thread Adjust 8 05in 20 45cm GENERAL 1999 Model Specifications CAPACITIES Fuel Tank 11 8 gal 44 7L Oil Tank 3 quarts 2 8 liters Coolant 3 quarts 2 8 liters Chaincase Oil 7 fl oz 210cc CHAINCASE Sprockets Chain 21 41 70 P 3 4 HYVO Reverse Option Brake Pads Type 69 Chaincase Center Dist 7 05 17 91cm Driveshaft Sprockets 2 Drivers Wide Brake Type Polaris HPB Liquid Cooled Rear Suspension XTRA 10 Rear Travel 11 5 in 29 21cm Front Track Shock
93. s or screws start all fasteners in their holes and hand tighten Then following the method and sequence indicated in this manual tighten evenly to the specified torque value When removing nuts bolts or screws from a part with several fasteners loosen them all about 1 4 turn before removing them A If the condition of any gasket or O Ring is in question replace it with a new one Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks A Some procedures will require removal of retaining rings or clips Because removal weakens and deforms these parts they should always be replaced with new parts When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation A Because removal damages seals replace any oil or grease seals removed with new parts A Polaris recommends the use of Polaris lubricants and greases which have been specially formulated for the top performance and best protection of our machines In some applications such as the engine warranty coverage may become void if other brands are substituted A Grease should be cleaned from parts and fresh grease applied before reassembly of components Deteriorating grease loses lubricity and may contain abrasive foreign matter A Whenever removing or reinstalling batteries care should be taken to avoid the possibility of explosion resulting in serious burns Always disconnect the negativ
94. sue eb nae teas Liquid Cooled Case Reed Displacement 593 cc BOTO 1615 242 0904 DE RER LE 2 x 2 9930 74 5mm Stroke EEN 2 6772 68 0mm Piston Cylinder Clearance 0043 0059 11 15mmy Service Limit 0078 2mm Piston Marking Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPME200 Engagement RPM 300 Cylinder Head Torque Oylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 EK2202 o faces upward 012 018 30 46mm 34 0cc 26 0cc 8000 RPM 1500 RPM 4200 RPM 20ft Ibs 2 8kgm 35 40 ft lbs 4 8 5 5 kgm N A 35 40 ft lbs 4 8 5 5 kgm 55 ft lbs 7 4 kgm 1 52 Polaris Industries Inc GENERAL 1999 Model Specifications MODEL INDY 600 XC 600 XC SP MODEL NUMBER 099SB6DS 099SP6DS ENGINE MODEL SN60 70 99A2 ELECTRICAL CAPACITIES Flywheel I D 4010130 Fuel Tank 11 8 gal 44 7L 10 5 39 7 CDI Marking 4060209 Oil Tank 3 quarts 2 8 liters Alternator Output 280 Watts Coolant 3 quarts 2 8 liters Ignition Timing 6 BTDC 1750RPM 1 5 Chaincase Oil 7 fl oz 210cc 0 009 BTDC 0 005 0 22mm BTDC 0 105mm Operating Timing 13 7500 RPM S
95. t Ibs kg m 1 4 A OOS BTW CPC SA ccc es eerste 12 1 6 1 4 2I esac ite glee DU des ae TOCA ec e rose 14 1 9 516 18 erem TI CT o e eux V7 2 9 os 25 3 5 546 pr qu Sey de DB ecu heic 1942 Gy riick on ved 29 4 0 3 8 I8 di POI 20444 25h 1290154 30 4 0 45 6 2 3 8 pr aree MAE OSSD rit A E zuo eres ois 50 6 9 7 16 D OCDE HN SO 4 0 21553 3592656 34 4 50 6 9 70 9 7 7A6 20 35 4 8 55 7 6 80 11 0 1 2 1 lt AN ATA 50 6 9 75 10 4 110 15 2 1 2 Os 55 7 6 90 12 4 120 16 6 To convert ft Ibs to kg m multiply foot pounds by 138 To convert kg m to N m move the decimal to the right one position Polaris Industries Inc 1 5 10 98 GENERAL Recommended Shop Supplies Accessories Description Part Number Synthetic Chaincase Lubricant One Gallon 2871477 Synthetic Chaincase Lubricant 12 02 2871478 Cable Lubricant orsi es cs 20 620 S ee eee eee 2870510 Fuel System Deicer Isopropyl 2870505 Loctite Primer T 6 Oz Aerosol 2870585 Loctite RC 680 10cc Retaining Compound 2870584 Loctite 515 Gasket Eliminator 50cc Tube 2870587 Loctite Chisel Gasket Remover 18 Oz 2870601 Metal Polish 8 OZ 2 0 cee cece eee nes 2870632 DOT
96. t needle C Production Setting CLUTCH Type ie P 85 B lt e neRRezebvsteu 3211075 CLUTCH CHART Belt Width Projected Side Angle Overall 28 1 438 36 52mm DRIVE DRIVEN Altitude Shit Clutch clutch Driven Chaincase Weight Spring Spring Helix Gearing Outside Circumference 47 625 Center Distance 12 305mm Meters 0 900 10 60 Silver 24 39 68 P Shift Weights 10 60 Bushed Fee 03009 Bushed Blue 3 4 HYVO A 24 39 68 P BASE LE reins EJESEZERE AERE Driven Helix R 12 4 2 EGER EE ESPE p s nt s ENGINE Type c sre ete Liquid Cooled Case Reed Triple with VES Displacement 794 cc zl M T 2 8346 72mm Stroke sc css eu cae awe eens 2 5591 65mm Piston Cylinder Clearance Service Limit Piston Marking Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm Flywheel Torque 10 98 0027 0041 07 105mm 0078 20mm 79B 79B 012 018 80 45mm 28 7 23 9 8500 RPM 1500 RPM 4000 RPM 17 20 ft Ibs 24 28 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft lbs 3 2 3 5 kgm 60 65 ft Ibs 8 3 9 kgm 1 64 Polaris Industries Inc GENERAL 1999 Model Specifications MOD
97. t steer as much as the driver desires The skis do not grab sufficiently R amp R Remove and replace RFI Radio Frequency Interference Caused by high voltage from the ignition system There are special plug caps and spark plugs to help eliminate this problem Required in Canada RPM Revolutions Per Minute Resistance In the mechanical sense friction or load In the electrical sense ohms Both result in energy conversion to heat Right Side Always referred to based on normal operating position of the driver fa Round Head Screw The familiar head most universally used for general application Good slot depth ample underhead bearing surface and finished appearance are characteristic of this head Running Time Ignition timing when fully advanced or at specified RPM Secondary Circuit This circuit consists of the large secondary coil windings high tension wire and ground through the spark plug air gap Secondary Clutch Driven clutch on chaincase or jackshaft Seized Piston Galling of the sides of a piston Usually there is a transfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Self Steer Pulling the machine to the inside of the track Spark Plug Reach Length of threaded portion of spark plug Polaris uses 3 4 2 cm reach plugs Static Timing Ignition timing when engine is at zero RPM
98. ter 77 421 diameter 77 L H 7041463 067 L H 7041461 067 3 8 1 2 9 65 12 7mm slack with 10 4 54kg weight 16 40 64cm ahead of rear idler shaft 437 diameter 77 L H 7041465 067 R H 7041466 067 R H 7041464 067 R H 7041 462 067 Polaris Industries Inc 1 37 10 98 GENERAL 1999 Model Specifications MODEL 500 CLASSIC MODEL NUMBER 099ED4BS ENGINE MODEL EC50PL172 CARBURETION TPE csset s VM38SS Mikuni Main Jet 350 Pilot Jet 45 Jet Needle 6F9 3 Needle Jet P 6 247 Cutaway 2 5 CH Air Screw 3 4 Tum Valve Seat 1 5 Viton Fuel Octane R M 2 87 Non Oxygenated or 89 Oxygenated Throttle Gap JETTING CHART AMBIENT TEMPERATURE Below 20 F 20 to 10 to Above 40 F Altitude Below 29 C 10 F 40 F Above 5 C 29 to 12 C 12 to 5 C Meters 370 330 310 Feet 3 3 3 900 1800 290 270 3000 6000 3 2 1800 2700 250 230 6000 9000 3 3 2 2 2700 3700 250 240 220 210 9000 12000 3 2 2 2 Under Cutaway 219 7 32 5 55mm Idle Sync Gap refers to the clip position from top of jet needle Under Cutaway 240 15 64 6 1mm C EE TE CLUTCH TYDE medias P 85 ES 3211070 CLUTCH CHART Belt Width Projected 1 375
99. ter Distance 12 305mm Altitud tude Shift Clutch Clutch Chaincase Shift Weights 10 Bushed Weight Spring Gearing Primary Spring Brown Meters 0 900 10 So P 96 19 41 66 P Secondary Spring Silver Feet 0 3000 Bushed 2 3 4 HYvO Driven Helix 36 2 900 1800 10 36 19 41 66 P 8000 6000 Bushed Red White Silver 2 3 4HYVO 10M 1800 2700 PA i 36 19 41 66 P 6000 9000 end Red White Silver 2 3 4 HYVO 2700 3700 t 36 19 41 66P 9000 12000 hese Red White Silver 2 3 4 HYVO ENGINE TYPO iii aeieea Liquid Cooled Piston Port Twin Displacement 488 cc Doria dit 2 8346 72mm StroKe s ia 2 3622 60mm Piston Cylinder Clearance Service Limit Piston Marking Piston Ring Marking Piston Ring End Gap Head cc s Uninstalled Head cc s Installed Operating RPM 200 Idle RPM 200 Engagement RPM 300 Cylinder Head Torque Cylinder Base Nut Torque Crankcase Torque 8mm Crankcase Torque 10mm 0023 0037 06 095mm 0078 20mm 5W 51A 008 016 20 40mm 28 8cc 23 6cc 7000 RPM 1600 RPM 3800 RPM 8mm 17 20 ft lbs 10mm 24 26 ft lbs 24 28 ft lbs 3 3 3 9 kgm 17 18 ft lbs 2 2 2 3 kgm 23 25 ft lbs 3 2 3 5 kgm 60 65 ft lbs 8 3 9 kgm 1 66 Polaris Industries Inc GENERAL 1999 Model
100. through rough appearance around hole Possible causes 1 lean fuel air mixture 2 low octane fuel 3 over advanced ignition timing 4 compression ratio too high for the fuel octane Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Displacement The volume of the cylinder displaced by the piston as it travels from BDC to TDC The formula is Bore x Stroke x 3 1416 Displacement in 4 CCs Effective Compression Ratio Compression ratio measured from after the piston closes the exhaust port Electrical Open Open circuit An electrical circuit which isn t complete i e poor connections or broken wire at hi lo beam switch resulting in loss of headlights Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended component i e a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake lights End Seals Rubber seals at each end of the crankshaft Engagement RPM Engine RPM at which the drive clutch engages to make contact with the drive belt Polaris Industries Inc 1 11 10 98 GENERAL Glossary of Terms Je Flat Head Bolt To be used where finished surfaces require a flush fastening unit Countersunk Foot Pound Ft Ib A force of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight

1999 Polaris Service Manual

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