Polaris Indy Trail 400 600 SE Star SS LongTrack Snowmobile Complete Workshop Service Repair Manual 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995

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Type: Snowmobile

Vendor:

Sku: 87755

Tags: 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 400 600 Indy Trail LongTrack Polaris Powersports SE Snowmobile Snowmobiles SS SS Models Star

Product variants

Description

The Polaris Indy Trail snowmobile, produced between 1985 and 1995, represents a robust and reliable platform designed for a variety of snow conditions and riding styles. Available in multiple sub-models including the 400, 600, SE, Star, SS, and LongTrack, these snowmobiles offered a balance of performance and utility, making them a popular choice for recreational riders. Their engineering focused on durability and consistent performance, characteristic of Polaris's long-standing reputation in the powersports industry. The Indy Trail line evolved over its production run, incorporating advancements in chassis and drivetrain technology to maintain its appeal and effectiveness in diverse winter environments. This comprehensive workshop service repair manual provides in-depth guidance for the Polaris Indy Trail snowmobiles from 1985 to 1995, covering all engine, trim, and transmission types. It is meticulously designed to assist DIY enthusiasts, owners, and professional mechanics in maintaining and repairing these vehicles. The manual details essential procedures for engine overhaul, transmission service, chassis maintenance, electrical system diagnostics, fuel system adjustments, and brake system upkeep. With step-by-step instructions, troubleshooting guides, and technical specifications, this resource ensures that owners can effectively manage all aspects of their snowmobile's care, from routine maintenance to complex repairs, thereby maximizing performance and longevity.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Indy Trail

Sub Model:

400, 600, SE, Star, SS, LongTrack

Vehicle Type:

Snowmobile

Codes

Product Code:

INDYTRAIL400600SESSTARSSLONGTRACK1985-1995

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts, snowmobile owners, mechanics seeking comprehensive repair information for Polaris Indy Trail models from 1985-1995.

Competitive Analysis

Value Proposition:

Offers significant cost savings on repairs compared to dealership or professional shop services. Provides in-depth technical guidance comparable to OEM manuals.

Key Features

Ease Of Use:

Easy-to-follow, step-by-step instructions with accompanying pictures for all repair and service jobs.

Accessibility:

Downloadable to multiple devices for convenient access in the workshop or on the go.

📋 Manual Details

Coverage Areas

Covered Years:

1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995

Covered Models:

Indy Trail 400, Indy Trail 600, Indy Trail SE, Indy Trail Star, Indy Trail SS, Indy Trail LongTrack

Covered Variants:

All engine, trim, and transmission types

Page Count

Estimated Page Count:

Comprehensive (Exact count not specified, but described as 'Complete' and 'A-Z')

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, tuning, lubrication, cooling, fuel, exhaust, starting, ignition systems

Transmission:

Clutch operation, drive clutch, driven clutch, belt replacement, gearcase lubrication, drive chain adjustment

Chassis:

Frame inspection and repair, suspension systems (front and rear), steering system, skis, track assembly

Electrical:

Ignition system, lighting, wiring diagrams, battery maintenance, starter system

Fuel System:

Carburetor adjustment and cleaning, fuel lines, fuel pump, fuel tank service

Brakes:

Brake system maintenance, hydraulic fluid, caliper service, brake pad replacement

Bodywork:

Body panel removal and installation, seat service, hood maintenance, graphics and decals

Procedures Included

Maintenance:

Scheduled maintenance, lubrication points, fluid level checks, filter replacements

Troubleshooting:

Diagnostic procedures, common problems and solutions, symptom-based troubleshooting guides

Repair:

Step-by-step repair instructions for all major systems

Disassembly Assembly:

Detailed procedures for component disassembly and reassembly

Specifications:

Torque specifications, clearances, settings for all adjustable components

Technical Depth

Depth:

Comprehensive: Covers everything from basic adjustments and fluid changes to complete engine and transmission rebuilds.

📊 Manual Specifications

File Format

Compatibility:

All PC & MAC Computers, tablets, smartphones (Requires Adobe Reader)

Print Quality

Printability:

Printable (individual pages, chapters, or entire manual)

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Rotary Valve 2-Stroke (Specific engine codes vary by year and model, typically Fuji-built engines)

Typical Displacement 400:

Approx. 398cc to 400cc

Typical Displacement 600:

Approx. 580cc to 600cc

Performance

Horsepower Range:

Varies significantly by specific engine and year, typically ranging from 40-70 HP for 400cc and 60-90 HP for 600cc models.

Fuel System

Carburetion:

Dual Mikuni carburetors common (e.g., VM30/32/34 series), specific sizes vary by engine and year. Manual covers adjustment and rebuilding.

Cooling System

Cooling Type:

Fan-cooled (Forced Air)

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

Lubrication

Oil Delivery:

Autolube (Premix injection system) or separate oil tank. Manual covers inspection and servicing.

🔧 Transmission

Standard

Type:

CVT (Continuously Variable Transmission) with Polaris Variable Ratio Drive (PVT) system.

Optional

Optional Transmissions:

N/A for these models; CVT was standard.

Features

Clutch Service:

Detailed procedures for drive clutch (e.g., P85/P90 series) and driven clutch (e.g., P-82/P-85 series) inspection, service, weight/spring changes, and belt replacement.

Gearcase

Gearcase Oil:

Manual provides specifications for gearcase oil type and capacity, along with lubrication intervals and drain/fill procedures.

📐 Dimensions

Exterior

Chassis Type:

Phazer chassis (early models) evolving to Polaris-specific chassis designs through the years.

Track Length Longtrack:

LongTrack models typically feature extended track lengths (e.g., 133.5 inches or longer) for improved flotation and traction.

Weights

Dry Weight:

Varies by model and year, generally in the range of 450-550 lbs (approx. 204-250 kg).

🛡️ Safety Features

Ratings

Safety Standards:

Adherence to relevant snowmobile safety standards of the era. Manual provides guidance on safe operating practices.

Active Features

Braking System:

Hydraulic disc brake system. Manual details maintenance and inspection of brake components.

Passive Features

Throttle Safety:

Throttle cable adjustment and safety interlocks. Manual covers proper function verification.

💡 Technology Features

Infotainment

Instrument Panel:

Basic analog gauges for speedometer, tachometer, engine temperature/warning lights, and fuel level. Manual explains gauge functions and troubleshooting.

Driver Assistance

None:

These models predate modern electronic driver assistance systems.

Connectivity

None:

No electronic connectivity features.

🔧 Maintenance

Service Intervals

Spark Plugs:

Recommended replacement/cleaning based on mileage or operating hours (details in manual).

Clutch Maintenance:

Regular inspection of drive belts, clutches, and rollers is critical. Manual provides guidance on frequency.

Lubrication:

Regular lubrication of suspension, steering components, and drive chain (if applicable). Intervals detailed in the manual.

Fluid Specifications

Gearcase Oil Type:

Typically SAE 80W-90 gear oil. Specifics and capacity in the manual.

Coolant Type:

N/A (Fan-cooled engines do not use coolant)

2-Stroke Oil Type:

High-quality synthetic or semi-synthetic 2-stroke snowmobile oil. Manual will specify recommended types for optimal performance and engine longevity.

Known Issues

Drive Belt Wear:

Common issue across CVT systems. Manual provides inspection and replacement procedures. Proper clutch alignment is crucial.

Carburetor Fouling:

Can occur with fuel quality or storage. Manual details cleaning and adjustment procedures.

Suspension Wear:

Bushings and bearings in suspension and steering can wear over time. Manual guides on inspection and replacement.

Track Tension:

Incorrect track tension can lead to premature wear. Manual provides adjustment specifications.

📚 Vehicle History

Brand Heritage

Polaris Heritage:

Polaris has a long-standing reputation in the powersports industry, known for its innovation in snowmobiles since the 1950s.

Model Evolution

Indy Trail Evolution:

The Indy Trail line represented Polaris's popular mid-range to touring snowmobiles, offering a balance of performance, comfort, and utility. The extended production run indicates a successful and well-received platform that saw incremental updates over the years.

Production

Manufacturing Era:

Mid-1980s to Mid-1990s, a period of significant technological advancement in snowmobile design.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for individual model years aren't listed, the Polaris Indy Trail series was consistently a strong performer and popular choice in consumer reviews and comparative tests throughout its production.