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1996 - 1997 - 1998 Polaris Snowmobile Factory Service Manual
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Basic Information Identification Make: Polaris Product Type: Factory Service Manual Product Format: PDF Download Product Name: 1996 - 1997 - 1998 Polaris Snowmobile Factory Service Manual PDF Download Generation Model...
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Type: Snowmobile
Vendor:
Sku: 21789
Tags:
1996
1997
1998
ATV
Polaris
Powersports
Snowmobile
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| Basic Information | |
| Identification | |
| Make: | Polaris |
| Product Type: | Factory Service Manual |
| Product Format: | PDF Download |
| Product Name: | 1996 - 1997 - 1998 Polaris Snowmobile Factory Service Manual PDF Download |
| Generation | |
| Model Years Covered: | 1996, 1997, 1998 |
| Codes | |
| Internal Code: | POL9698FSM |
| Introduction | |
| Market Position | |
| Positioning: | Essential resource for Polaris snowmobile owners and independent service technicians seeking accurate OEM repair and maintenance information. |
| Competitive Analysis | |
| Comparison: | Offers superior detail and accuracy compared to generic repair manuals, providing the same information used by authorized Polaris dealerships. |
| Key Features | |
| Features: | Instant PDF download, portability across devices, searchable text, print-on-demand capability for specific tasks, lifetime access to download links. |
| Manual Details | |
| Coverage Areas | |
| Vehicles Covered: | Comprehensive list of 1996, 1997, and 1998 Polaris Snowmobile models |
| Specific Models 1996: | Indy XLT, XLT SP, XLT SKS, XLT RMK, XLT Touring, 600 XCR, 600 XCR SP, RXL, Ultra SP, Ultra SKS, Ultra RMK, Storm, Storm SKS, Storm RMK. |
| Specific Models 1997: | Indy Lite, Lite Deluxe, Lite GT, Sport, TranSport, Super Sport, Sport Touring, 440 LC, XCF, XC, Trail, Trail Touring, Trail RMK, Classic, Classic Touring, 500, 500 SKS, 500 RMK, 500 EFI, Wide Trak LX, Wide Trak GT, XLT, XLT SP, XLT SKS, XLT RMK, XLT Touring, XLT LTD, XLT LTD SP, 600 XC, 600 XCR, 600 XCR SE, RXL, Ultra, Ultra SP, Ultra SPX, Ultra SPX SE, Ultra Touring, 700 XC, 700 SKS, 700 RMK, Storm, Storm SE, Storm RMK, 440 XCR. |
| Specific Models 1998: | Indy Lite, Lite Deluxe, Lite Touring, Sport, TranSport, Sport Touring, XCF, 440 LC, Trail, Trail Touring, Trail RMK, Super Sport, 440 XCR, 500 RMK, Classic, Classic Touring, WideTrak LX, XLT Touring, XLT LTD, XLT SP, XLT Classic, 600 XC, 600 RMK, 600 XCR, Ultra, Ultra Touring, 700 XCR, 700 XC, 700 RMK, Storm. |
| Page Count | |
| Total Pages: | 822 |
| Manual Type | |
| Type: | Factory Service Manual (OEM) |
| Language | |
| Language: | English |
| Format | |
| Format: | Digital PDF Download |
| Manual Coverage | |
| Systems Covered | |
| General Information: | Includes general specifications, identification, and safety procedures. |
| Maintenance Tune Up: | Detailed procedures for routine maintenance, tune-ups, and inspections. |
| Engines: | Covers engine disassembly, assembly, component inspection, and rebuilding for various Polaris engine types. |
| Electronic Fuel Injection: | In-depth coverage of EFI system diagnostics, component testing, and calibration. |
| Fuel System Carburetion: | Detailed carburetor adjustment, cleaning, and rebuilding procedures, along with fuel pump and tank servicing. |
| Clutches: | Comprehensive guide to primary and secondary clutch inspection, maintenance, adjustment, and replacement. |
| Body Steering: | Covers body panel removal/installation, steering column, handlebar, and ski alignment procedures. |
| Suspension: | Detailed instructions for front and rear suspension component service, shock absorber maintenance, and track system. |
| Brakes Final Drive: | Covers brake system maintenance, hydraulic service, caliper rebuilding, and final drive chain/gearbox. |
| Electrical: | Extensive coverage of the electrical system, including ignition, lighting, charging system, troubleshooting diagrams, and component testing. |
| Procedures Included | |
| Repair Procedures: | Step-by-step instructions for major and minor repairs across all vehicle systems. |
| Maintenance Schedules: | Scheduled maintenance intervals for lubrication, adjustments, and component replacement. |
| Troubleshooting Guides: | Systematic troubleshooting trees and diagnostic flowcharts for common and complex issues. |
| Diagnostic Procedures: | Guidance on identifying and resolving mechanical and electrical faults. |
| Component Rebuilds: | Detailed instructions for rebuilding key components like engines, transmissions, and clutches. |
| Technical Specifications: | Provides critical torque values, clearances, and settings for accurate repairs. |
| Specifications Torque Values: | Detailed torque specifications for engine fasteners, suspension components, and chassis bolts. |
| Wheel Bolt Pattern: | Wheel bolt patterns are generally not applicable to snowmobiles in the same way as cars; however, track and suspension mounting hardware specifications are provided. |
| Technical Depth | |
| Depth: | Comprehensive, covering everything from basic maintenance to complete engine and component overhauls. |
| Accuracy: | OEM factory specifications, ensuring maximum accuracy and reliability for repairs. |
| Diagrams Illustrations: | Includes detailed diagrams, exploded views, and photographic illustrations to aid understanding. |
| Manual Specifications | |
| File Format | |
| Format: | |
| Searchability: | Fully indexed and searchable for quick information retrieval. |
| Print Quality | |
| Quality: | High-resolution, suitable for printing specific sections or the entire manual. |
| Binding Type | |
| Type: | N/A (Digital Download) |
| Paper Type | |
| Type: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Types Covered: | Various Polaris 2-stroke engines used across the covered model years and lines (e.g., 500cc, 600cc, 700cc displacement ranges). |
| Performance | |
| Horsepower Torque: | Specific horsepower and torque figures are detailed within the manual for individual engine models and tuning recommendations. |
| Fuel System | |
| Fuel Delivery: | Covers both Carbureted and Electronic Fuel Injection (EFI) systems, including detailed specifications and procedures for each. |
| Cooling System | |
| Cooling Method: | Details for both liquid-cooled and fan-cooled engine configurations. |
| Ignition System | |
| Ignition Type: | CDI (Capacitor Discharge Ignition) and related components like stator, ignition coil, and spark plugs. |
| Transmission | |
| Standard | |
| Transmission Type: | CVT (Continuously Variable Transmission) utilizing Polaris' clutch systems. |
| Optional | |
| Gearing: | Information on drive and driven clutch settings, belt maintenance, and related components. |
| Features | |
| Clutch Adjustment: | Detailed procedures for clutch calibration, spring tensions, and weight adjustments for optimal performance. |
| Dimensions | |
| Exterior | |
| Dimensions General: | Specific dimensions (length, width, height) vary significantly by model and are detailed within the manual's model-specific sections. |
| Weights | |
| Dry Weight: | Dry weight specifications are provided for each model covered, crucial for transportation and handling. |
| Gross Vehicle Weight Rating: | GVWR information for safe operation and payload capacity is included. |
| Safety Features | |
| Ratings | |
| Safety Standards: | Adherence to applicable snowmobile safety standards of the era. |
| Active Features | |
| Braking System: | Hydraulic disc brake system details for effective stopping power. |
| Passive Features | |
| Emergency Stop: | Information on kill switches and safety tether systems where applicable. |
| Technology Features | |
| Infotainment | |
| Features: | Basic instrumentation including speedometer, tachometer, odometer, and indicator lights. No advanced infotainment systems. |
| Driver Assistance | |
| Features: | No electronic driver assistance features typical of modern vehicles; focus is on mechanical and basic electrical systems. |
| Connectivity | |
| Features: | N/A |
| Maintenance | |
| Service Intervals | |
| Tune Up Intervals: | Recommended intervals for spark plug replacement, belt inspection, chaincase lubrication, and general inspection. |
| Fluid Specifications | |
| Engine Oil: | Specific 2-stroke oil recommendations (e.g., API TC, JASO FD certified oils) and required quantities. |
| Coolant: | Type and mixture of antifreeze for liquid-cooled models (e.g., ethylene glycol-based, 50/50 mix). |
| Chaincase Oil: | Specifications for chaincase lubricant (e.g., Polaris premium gearcase lubricant or equivalent). |
| Brake Fluid: | DOT 3 or DOT 4 hydraulic brake fluid recommendations. |
| Known Issues | |
| Common Problems: | The manual addresses potential wear items and common issues such as clutch wear, primary drive belt failure, and carburetor/EFI system adjustments. |
| Filter Part Numbers | |
| Air Filter: | Part numbers and replacement procedures for air filters are included for various models. |
| Oil Filter: | N/A for 2-stroke engines which typically do not have oil filters in the traditional sense; focus is on oil premix or injection systems. |
| Vehicle History | |
| Brand Heritage | |
| Heritage: | Polaris, a long-standing American manufacturer of powersports vehicles, known for innovation and performance in snowmobiling. |
| Model Evolution | |
| Evolution: | The 1996-1998 period saw Polaris refining its popular Indy chassis and introducing advanced technologies like EFI and improved suspension systems. |
| Production | |
| Manufacturing Location: | Polaris snowmobiles were primarily manufactured in the USA, particularly at their facilities in Minnesota and Iowa. |
| Awards & Recognition | |
| Recognitions | |
| Brand Awards: | Polaris has consistently been a leader in snowmobile innovation and sales, though specific awards for these model years are not typically detailed in service manuals. |
| Ratings | |
| Consumer Reviews: | Consumer reviews from the period often praised the performance and reliability of the Indy line, especially models equipped with the Liberty engines and advanced chassis. |
| Certifications | |
| Emissions Standards: | Adherence to prevailing emissions standards for snowmobiles of the late 1990s. |