Polaris snowmobile 1972-1987 Repair Service Manual 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986

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Type: Snowmobile

Vendor:

Sku: 87576

Tags: 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 ATV Polaris Powersports Snowmobile

Product variants

Description

This comprehensive repair service manual covers a wide range of Polaris snowmobile models manufactured between 1972 and 1987. Polaris, a brand with a significant legacy in snowmobile innovation, produced many iconic machines during this era, including the revolutionary Indy series. This manual provides detailed information for numerous models such as Colt SS, Charger SS, Mustang, ATX, TX, Custom II, Electra, TC, Starfire, Cobra, Gemini, Apollo 340, Centurion, Galaxy, Indy Trail, and many others, reflecting the diverse engineering and design trends of the period. It is an essential resource for understanding and maintaining these vintage snowmobiles. This manual is designed to assist DIY enthusiasts, professional technicians, and mechanics in performing all aspects of snowmobile maintenance and repair. It offers detailed, step-by-step instructions, factory specifications, torque values, and clear illustrations, including part diagrams and exploded views. Coverage encompasses all major systems, including engine overhaul, drivetrain, electrical components, chassis, brakes, fuel, cooling, exhaust, and steering. Procedures for routine maintenance, performance tuning, and troubleshooting are thoroughly explained, empowering users to diagnose and resolve issues efficiently and save on repair costs.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Snowmobile (Various Models)

Product Type:

Repair Service Manual

Codes

Product Identifier:

Polaris Snowmobile 1972-1987 Repair Service Manual PDF Download

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts, professional technicians, mechanics, workshops

Competitive Analysis

Value Proposition:

Saves money by enabling self-repair, provides professional-level repair information

Key Features

Manual Advantage:

Official factory quality, step-by-step instructions, comprehensive coverage for a wide range of models and years

Diy Focus:

Explicitly geared towards empowering the DIY owner to perform repairs and maintenance, saving costs associated with professional service.

📋 Manual Details

Coverage Areas

Applicable Years:

1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987

Specific Models Mentioned:

Colt SS, Charger SS, Mustang, ATX, TX, Custom II, Electra, TC, Starfire, Star Fire, Cobra, Gemini, Apollo 340, Centurion, TXC, Galaxy, TX-C, TX-L, Indy Cutlass SS, Star Sport, Indy Trail, Indy Cross Country, Long Track, Indy 600, Indy 400, Sprint, Star Trak, Star Track

Model Variations:

Covers a broad spectrum of Polaris snowmobile models from the era, reflecting the diverse configurations and engine options available.

Page Count

Estimated Pages:

Manual Type

Type:

Repair Service Manual / Workshop Manual / Factory Manual

Origin:

Likely a compilation of factory service manuals, technical bulletins, and workshop guides for the specified years.

Language

Language:

English

Format

Format:

PDF Download (potentially ZIP/RAR/EXE)

File Format

Download Access:

Instant download link provided via email after payment, with a limited window for download (e.g., three days).

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, piston, crankshaft, connecting rod, bore, stroke, compression ratio, mixture screw, carburettor (carburetor), slow jet, main jet, pilot jet, fuel pump, ignition, stator, magneto, coil, EFI (if applicable), fuel injection (if applicable), PGM-FI (if applicable), spark, no spark troubleshooting, cylinder, valves, valve clearance, camshaft, flywheel, exhaust, muffler, intake

Drivetrain And Transmission:

Clutch (primary, secondary), primary reduction gear, transmission, drive train, drive shaft, axle, suspension, swingarm, bogey, struts, ski, skis, track, propulsion system, reverse, turbo (if applicable)

Electrical And Controls:

Electronic systems, rectifier, regulator, switches, switchs, battery, charging, starter, kickstart, kicker, fuse, wiring diagrams, lights, handle, throttle cable, gearshift

Body And Chassis:

Frame, body, fenders, panels, plate, hull, plastic, plastics, seat, tank, bars, trees, front, rear, cooler, radiator, air, fluid, coolant, ski, steering

Brakes And Wheels:

Brake, brakes, brake pads, wheel, tire, tires

Fuel System Details:

Fuel tank, fuel lines, fuel pump (if applicable), carburetor, intake manifold, airbox, choke system.

Cooling System Details:

Radiator, fan, coolant hoses, thermostat, water pump (for liquid-cooled models). Air-cooled engine maintenance procedures.

Steering System:

Handlebars, steering post, tie rods, spindles, ski and ski-is (wear bars/carbides).

Exhaust System Details:

Exhaust pipes, mufflers, silencers, and any associated heat shields or mounting hardware.

Procedures Included

Repair And Rebuild:

Complete tear down and rebuild, overhaul, repair procedures, installation, component replacement

Maintenance And Tuning:

Preventative maintenance, servicing, lubrication, fluid changes (e.g., change coolant, engine oil specifications), adjustments (e.g., idle, mixture screw), clutch tuning, track tensioning, spark plug gap, carburation tuning

Troubleshooting And Diagnostics:

Troubleshooting, problem diagnosis, error codes, no spark issues, electronic diagnostics, fuel system issues, starting problems

Performance Tuning:

Instructions for optimizing engine performance through proper carburetor jetting, clutch calibration, and timing adjustments.

Technical Depth

Depth:

Comprehensive, detailed step-by-step instructions, factory specifications, torque specs, illustrations, part diagrams, exploded views

Diagnostic Tools:

While not requiring advanced electronic scanners, the manual covers diagnostic procedures for ignition, fuel, and mechanical systems using basic tools and techniques.

Specific Procedures Examples:

Carburetor rebuilding and adjustment, clutch alignment and tuning, primary and secondary clutch service, engine decarbonization, track replacement, suspension shock rebuilding, electrical system troubleshooting (e.g., ignition coil testing, stator testing).

📊 Manual Specifications

File Format

Compatibility:

PC & MAC compatible (Windows 97, 2000, Me, XP, Vista, 7, 10, Linux, Mac OS)

Digital Delivery:

Instant download after payment, not a physical copy

File Size Consideration:

Manuals can be large (up to 4000 MB), requires sufficient storage and internet connection

Print Quality

Printable:

Yes, printable on any computer and printer

Illustration Quality:

Zoomable illustrations, clear images, part diagrams, exploded views

Binding Type

Binding:

Not applicable (digital format)

Paper Type

Paper:

Not applicable (digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Likely 2-stroke, single or twin cylinder (specifics vary by model)

Performance

Displacement Range:

Likely ranging from ~250cc to 600cc+ based on mentioned models like Indy 400, Indy 600, Apollo 340

Fuel System

Carburation:

Mikuni, Keihin, or similar carburettors common for the era; features mixture screw, slow jet, main jet adjustments

🔧 Transmission

Standard

Transmission Type:

CVT (Continuously Variable Transmission) with primary and secondary clutches, often with reduction gearing.

Optional

Gear Options:

Some models may have had single-speed or limited gear options in addition to CVT.

Features

Drive System:

Chain drive to the track, belt drive for CVT system.

📐 Dimensions

Exterior

Track Width Variance:

Varies significantly by model (e.g., trail, mountain, cross country) and year.

Weights

Dry Weight Range:

Typically between 300-500 lbs depending on model and engine size.

🛡️ Safety Features

Ratings

Crash Test Data:

Not applicable for vintage snowmobiles in the same way as modern vehicles.

Active Features

Braking System:

Hydraulic disc brakes or drum brakes depending on model year.

Passive Features

Throttle Safety:

Throttle safety lever (thumb throttle) for controlled acceleration.

💡 Technology Features

Infotainment

Features:

Minimal by modern standards. Likely includes basic analog gauges for speed, RPM, fuel level, and warning lights.

Driver Assistance

Features:

None by modern standards. Focus is on mechanical operation and rider control.

Connectivity

Features:

Not applicable.

🔧 Maintenance

Service Intervals

Routine Maintenance:

Regular checks of track tension, lubrication of suspension components, drive clutch inspection, belt wear inspection, spark plug cleaning/replacement, chain case oil changes (if applicable).

Clutch Maintenance:

Regular inspection and cleaning of clutch sheaves, rollers, and springs. Belt replacement based on wear or mileage.

Fluid Specifications

Engine Oil:

Typically requires specific 2-stroke snowmobile oil. Manual will detail recommended oil types and mixtures (pre-mix or oil injection systems).

Coolant:

Antifreeze/coolant for liquid-cooled models. Manual will specify type and capacity.

Chaincase Oil:

Specific gear oil for the chaincase (if applicable). Manual will provide viscosity and capacity.

Known Issues

Common Wear Items:

Drive belts, suspension bushings, idler wheels, track lugs, carbides, clutch components, carburetor jets.

Engine Specific Concerns:

Potential for carbon buildup in exhaust ports of 2-stroke engines, carburetor jetting issues due to altitude/temperature changes, crank seal leaks.

Electrical Failures:

Aging wiring harnesses, failing voltage regulators, and worn ignition components are common in vintage snowmobiles.

📚 Vehicle History

Brand Heritage

Polaris Legacy:

Polaris is a long-standing American manufacturer known for its pioneering work in snowmobile technology and innovation.

Model Evolution

Design Trends:

Covers a period of significant evolution in snowmobile design, from early modular constructions to more integrated chassis and suspension systems. Introduction of models like the Indy series marked significant advancements.

Key Model Advancements:

The 'Indy' series, introduced in this period, revolutionized snowmobiling with its lightweight chassis and independent front suspension.

Production

Manufacturing Era:

1972-1987 represents a key period for Polaris, encompassing many iconic models and technological developments in the snowmobile industry.