Clymer Polaris Snowmobile 1984-1989 Shop Manual

Description

This Clymer Polaris Snowmobile 1984 1985 1986 1987 1988 1989 Shop Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1984-1989 Polaris Indy Trail, 1984-1989 Polaris Indy 400, 1984-1987 Polaris Indy 600, 1987-1989 Polaris Indy Sport, 1988-1989 Polaris Indy 650, and 1989 Polaris Indy 500 snowmobiles.

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION

Manual organization, Notes, cautions and warnings, Safety first, Service hints, Engine and chassis serial numbers, Engine operation, Torque specifications, Fasteners, Lubricants, RTV gasket sealant, Threadlock, Gasket remover, Basic hand tools, Precision measuring tools, Special tools, Mechanic’s tips, Ball bearing replacement, Oil seals, Snowmobile operation, Snowmobile safety, Snowmobile code of ethics

CHAPTER TWO, TROUBLESHOOTING

Operating requirements, Troubleshooting instruments, Testing electrical components, Engine electrical system troubleshooting, Alternator output test, Voltage regulator, Charging system (with electric starting), Electric starting system, Fuel system, Engine, Two-stroke pressure testing, Power train, Skis and steering, Track assembly

CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP

Pre-ride checks, Fluid checks, Break-in procedure, Maintenance schedules, Lubrication, Cooling system, Scheduled maintenance, Non-scheduled maintenance, Engine tune-up

CHAPTER FOUR, HIGH-ALTITUDE AND REAR SUSPENSION ADJUSTMENT

High-altitude carburetor tuning, High-altitude clutch tuning, Gearing, Suspension adjustment

CHAPTER FIVE, ENGINE–TWO CYLINDER

Engine lubrication, Service precautions, Serial numbers, Servicing engine in frame, Engine removal, Engine plate, Engine installation, Engine top end, Cylinder, Piston, wrist pin and piston rings, Crankcase and crankshaft

CHAPTER SIX, ENGINE–THREE CYLINDER

Engine lubrication, Service precautions, Serial numbers, Servicing engine in frame, Engine removal, Engine plates, Engine installation, Engine top end, Cylinder, Piston, wrist pin and piston rings, Crankcase and crankshaft

CHAPTER SEVEN, FUEL AND EXHAUST SYSTEMS

Air box, Carburetor, Carburetor operation, Fuel pump, Fuel tank, Throttle cable replacement, Exhaust system, Exhaust system repair

CHAPTER EIGHT, ELECTRICAL SYSTEM

Battery, Capacitor discharge ignition (CDI),  CDI control unit (twin cylinder), CDI box (600,650), Ignition coils (600,650),  Voltage regulator, Electric starting system, Lighting system, Meter assembly, Throttle safety switch, Switches (except safety switch), Oil level sensor, Circuit breaker, Wiring diagrams

CHAPTER NINE, OIL INJECTION SYSTEM

System components, Oil pump service, Component replacement

CHAPTER TEN, LIQUID COOLING SYSTEM

Water pump (400 and 500), Water pump (600 and 650), Heat exchanger, Hoses

CHAPTER ELEVEN, RECOIL STARTER

Recoil starter assembly (1984 600), Recoil starter housing (trail, sport, 400, 500 and 1985-on 600,650)

CHAPTER TWELVE, DRIVE SYSTEM

Drive unit, Primary sheave assembly, Secondary sheave, Drive belt, Primary sheave service, Secondary sheave service

CHAPTER THIRTEEN, DISC BRAKE

Brake pad replacement, Brake caliper, Master cylinder, Front brake hose replacement, Brake disc, Bleeding the system

CHAPTER FOURTEEN, CHAINCASE, JACKSHAFT AND DRIVESHAFT

Drive chain and sprockets, Chaincase and jackshaft, Driveshaft

CHAPTER FIFTEEN, FRONT SUSPENSION AND STEERING

Skis, Front suspension, Shock absorber, Steering assembly, Steering adjustment

CHAPTER SIXTEEN, TRACK AND REAR SUSPENSION

Rear suspension, Rail tips (1986-on), Hi-Fax, Rear suspension assembly, Suspension and guide wheels, Track

CHAPTER SEVENTEEN, OFF-SEASON STORAGE

INDEX

WIRING DIAGRAMS