1986 POLARIS 400 Snowmobile Service Repair Manual

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Typ: Snowmobile

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Art.-Nr: 92766

Stichworte: 1986 400 ATV Misc Polaris Powersports Snowmobile

Produktvarianten

Beschreibung

The 1986 Polaris 400 is a performance-oriented utility snowmobile, representing a mid-1980s evolution of Polaris's robust chassis and engine technology. Known for its reliable Polaris engine and Independent Front Suspension (IFS) that enhances handling, this model was designed to offer a balance of power and maneuverability. It stands as a testament to Polaris Industries' heritage as a prominent American manufacturer in the powersports sector, appealing to owners, technicians, and vintage snowmobile enthusiasts seeking to maintain its performance and longevity. This Service Repair Manual provides comprehensive maintenance and repair information for the 1986 Polaris 400 snowmobile. It covers essential areas including engine mechanicals, fuel and ignition systems, drivetrain, suspension, brakes, and electrical systems. The manual details scheduled maintenance, troubleshooting procedures for common issues, and in-depth repair guidance from basic adjustments to full component overhauls. With critical torque values, clearances, and exploded diagrams, this manual serves as an authoritative resource for owners and technicians to ensure the continued optimal performance and reliability of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Year:

Vehicle Type:

Snowmobile

Codes

Product Code:

POL-86-400-SRM

👋 Introduction

Market Position

Segment:

Performance-oriented utility snowmobile

Competitive Analysis

Competitors:

Arctic Cat Panther series, Ski-Doo Citation series of the era

Key Features

Features:

Reliable Polaris engine, IFS for improved handling, robust construction for its time

Target Audience

User:

Polaris owners, technicians, and vintage snowmobile enthusiasts

Value Proposition

Manual Value:

Authoritative guide for maintaining and repairing the 1986 Polaris 400, preserving its performance and longevity

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive maintenance and repair

Page Count

Estimated Pages:

250-350

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Printed

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, component inspection, tuning

Fuel System:

Carburetor (Mikuni VM30 recommended), fuel pump, fuel lines, tank service

Ignition System:

CDI, spark plugs, stator, flywheel, timing

Cooling System:

Air cooling system, airflow management

Exhaust System:

Exhaust pipe, muffler, gasket replacement

Drivetrain:

Drive clutch (P-85 Primary), driven clutch (AD/AC Secondary), chaincase, drive axle, track system

Suspension Front:

IFS (Independent Front Suspension) components, shock absorbers, skis, steering system

Suspension Rear:

Rear suspension (articulated), bogie wheels, shock absorbers, track tension adjustment

Brakes:

Hydraulic disc brake system, caliper, master cylinder, brake fluid specifications

Electrical System:

Wiring diagrams, lighting, battery, starter (if applicable), kill switch

Bodywork Chassis:

Body panel removal/installation, seat, handlebars, controls, frame inspection

Procedures Included

Scheduled Maintenance:

Regular service checks, lubrication points, cleaning procedures

Troubleshooting:

Diagnostic charts for common starting, running, and performance issues

Engine Repair:

Piston replacement, ring service, cylinder head repair, crankshaft service

Clutch Service:

Clutch inspection, cleaning, weight/spring replacement, calibration

Suspension Adjustment:

Track tension and alignment, shock absorber settings

Brake Maintenance:

Brake bleeding, pad replacement, rotor inspection

Carburetor Adjustment:

Jetting, float level, idle speed adjustments

Electrical Diagnostics:

Troubleshooting ignition and lighting circuits

Technical Depth

Depth:

In-depth, from basic adjustments to full engine rebuilds and component overhauls

Diagnostics:

Detailed diagnostic procedures and troubleshooting guides

Specifications:

Includes critical torque values, clearances, and tolerances

Diagrams:

Features exploded views and detailed diagrams of all major components and systems

📊 Manual Specifications

File Format

File Type:

Physical print

Print Quality

Print Quality:

High-quality, durable paper, clear and legible text and diagrams

Binding Type

Binding:

Staple-bound or perfect-bound (typical for OEM manuals)

Paper Type

Paper Type:

Heavy-duty, shop-resistant paper

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, fan-cooled, twin-cylinder

Displacement:

Approx. 398cc (specific variant may exist)

Bore X Stroke:

Refer to manual for exact specifications

Compression Ratio:

Refer to manual for exact specifications

Performance

Horsepower:

Estimated 35-45 HP (varies by tuning and exact model)

Torque:

Refer to manual for specific torque figures

Fuel System

Carburetor Model:

Likely Mikuni VM30 or similar

Fuel Type:

Unleaded gasoline with 2-stroke oil mixture

Oil Recommendation:

API-TC rated 2-stroke engine oil

🔧 Transmission

Standard

Type:

CVT (Continuously Variable Transmission) with Polaris P-85 Primary Clutch and AD/AC Secondary Clutch

Optional

Optional Transmission:

N/A (CVT was standard)

Features

Clutch Calibration:

Weights, springs, and helix can be adjusted for different riding conditions

Chaincase Oil:

Specific chaincase oil type and capacity detailed in manual

📐 Dimensions

Exterior

Length:

Refer to manual for specific dimensions

Width:

Refer to manual for specific dimensions

Height:

Refer to manual for specific dimensions

Weights

Dry Weight:

Estimated 450-500 lbs (varies by features)

Ski Stance:

Refer to manual for specific dimensions

Cargo

Rack Capacity:

Typically equipped with front and rear racks, capacity details in manual

🛡️ Safety Features

Ratings

Safety Standards:

Adherence to industry safety standards for snowmobiles of its era

Active Features

Braking System:

Hydraulic disc brake for reliable stopping power

Throttle Safety:

Self-returning throttle with safety stop

Passive Features

Kill Switch:

Handlebar-mounted emergency kill switch

Lighting:

Headlight and taillight for visibility

💡 Technology Features

Infotainment

Gauge Cluster:

Basic instrumentation including speedometer, tachometer (if equipped), engine temp light, oil light.

Driver Assistance

Assistance Features:

N/A (Focus on mechanical systems)

Connectivity

Connectivity Features:

N/A (No electronic connectivity features)

🔧 Maintenance

Service Intervals

Initial Breakin:

Specific break-in procedure and mileage/time recommendations in manual

Clutch Inspection:

Every 50-100 hours of operation or annually

Spark Plug Replacement:

As recommended by spark plug manufacturer, typically based on hours or performance degradation

Chaincase Oil Change:

Every 100-200 hours of operation or annually

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for exact specification)

Chaincase Fluid:

Refer to manual for specific viscosity and type (e.g., SAE 30 or 80W-90 gear oil, depending on model year specifics)

2 Stroke Oil:

API-TC rated 2-stroke engine oil suitable for air-cooled engines

Known Issues

Clutch Wear:

Common wear on clutch rollers, buttons, and belt due to age and use

Carburetor Gumming:

Fuel residue buildup in carburetor jets and passages, requiring cleaning

Engine Seals:

Leaking crankshaft seals can cause air leaks and performance issues

Suspension Bushings:

Wear in suspension bushings leading to loose handling and noise

📚 Vehicle History

Brand Heritage

Polarishistory:

Polaris Industries is a long-standing American manufacturer known for its snowmobiles, ATVs, and powersports vehicles. Founded in 1945.

Model Evolution

Polaris400Lineage:

The 400cc class was a popular segment for Polaris, offering a balance of power and maneuverability. The 1986 model represents an evolution of their chassis and engine technology from the early to mid-80s.

Production

Production Era:

Mid-1980s

Manufacturing Location:

Roseau, Minnesota, USA (Polaris's historical manufacturing base)

🏆 Awards & Recognition

Recognitions

Historical Awards:

While specific awards for the 1986 model are not readily documented, Polaris snowmobiles of this era were generally well-regarded for their reliability and performance within their class.