Target Audience:
Owners, mechanics, and enthusiasts of vintage Polaris snowmobiles from 1972-1987 seeking comprehensive repair and maintenance information.
Value Proposition:
Provides factory-level repair data for a wide range of Polaris models over a significant production span, offering a cost-effective alternative to multiple individual manuals or expensive dealer service.
Content Depth:
Covers complete tear down and rebuild, detailed pictures, part diagrams, torque specifications, maintenance schedules, and extensive troubleshooting guides.
Support:
Offers free replacement of lost manuals.
Model Years Covered:
1972-1987
Model List:
Colt, Colt SS, Charger, Charger SS, Mustang, ATX (TX), TX, Custom II, Electra, TC, Starfire, TX-L, S/S 340, Cobra, Gemini, Apollo 340, Centurion, TXC, Apollo, Galaxy, Cutlass, Cutlass SS, TX-L Indy, Centurion Indy, Star, Sport, Indy Trail, Indy Cross Country, Indy 600, Long Track, Indy 400, Indy 600 LE, Sprint, Star Trak, Sprint (ES), Indy Sport, Indy Trail (ES) (133 SKS), Indy 400 (133 SKS), Indy 600 (Reverse/Low Range)
Type:
Factory Repair Manual
Engine:
Complete engine teardown, rebuild, maintenance, troubleshooting, performance tuning, component identification, lubrication, cooling systems, fuel systems (carburetion, EFI where applicable).
Drivetrain:
Clutch systems (primary, secondary), drive chain/belt maintenance, gearcase overhaul, drive shaft, propulsion system components, reverse mechanism (if applicable).
Chassis And Suspension:
Front suspension (forks, skis, steering), rear suspension (bogies, track system, struts, swingarm), chassis components, frame, body panels, fenders, seats.
Electrical System:
Ignition system (magneto, coils, spark plugs), starting system (kickstart, electric start components), lighting, switches, wiring diagrams, battery, charging system (rectifier, regulator).
Braking System:
Brake system diagnosis, maintenance, component replacement (pads, rotors, cables, hydraulic systems where applicable).
Fuel System:
Carburetor identification, adjustment (mixture screw, idle), cleaning, rebuilding, fuel pump, fuel lines, fuel tank maintenance.
Repair Procedures:
Complete teardown and rebuild instructions for all major snowmobile systems, component-specific repair guides, step-by-step instructions.
Maintenance Schedule:
Recommended service intervals for lubrication, filter changes, adjustments, and inspections.
Troubleshooting:
Systematic diagnostic procedures for common problems such as no spark, starting issues, poor performance, and unusual noises.
Technical Specifications:
Torque specifications for critical fasteners, engine specifications (bore, stroke, compression ratio), fluid capacities, electrical specifications.
Part Identification:
Detailed part diagrams and illustrations for component identification and assembly.
Depth:
Comprehensive, covering routine maintenance, diagnostics, component replacement, and full overhauls. Suitable for DIY enthusiasts and professional mechanics.
Engine Types Covered:
A variety of 2-stroke gasoline engines, with displacements varying by model. Specific engine variants (e.g., fan-cooled, liquid-cooled) are detailed within the manual.
Performance Details:
Manual provides specifications for horsepower, torque, compression ratios, and tuning parameters relevant to each model's engine.
Carburetor Information:
Detailed information on various Mikuni, Keihin, and other carburetor models used, including jetting, adjustments, and rebuilding procedures. Some later models may include EFI details.
Oil Type:
Manual specifies appropriate 2-stroke oil mixtures or injection system requirements. Typical recommendations include specific viscosity grades (e.g., SAE 5W-30, SAE 10W-40) and API service classifications for transmissions and crankcases.
Transmission Type:
CVT (Continuously Variable Transmission) with clutch systems (primary and secondary). Some models may have geared transmissions or specific drive train configurations.
Gear Reduction:
Information on primary and secondary gear reductions, clutch engagement/disengagement speeds, and belt maintenance.
Clutch Adjustment:
Detailed procedures for clutch weight adjustment, spring changes, and helix profiles to optimize performance for different riding conditions.
Safety Features:
Manual details safety systems such as kill switches, brake lever interlocks, and proper operation of lighting systems. Crash ratings are not applicable to this product category.
Operation Guidelines:
Emphasis on safe operating practices, pre-ride inspections, and emergency procedures.
Component Integrity:
Information on maintaining the structural integrity of the chassis, suspension, and steering for safe operation.
Regular Maintenance:
The manual outlines specific service intervals for: checking/adjusting drive belt tension, greasing suspension and steering components, inspecting/cleaning air filter, checking/changing chaincase oil, inspecting track and sliders, spark plug maintenance, and carburetor cleaning.
Coolant Type:
For liquid-cooled models, the manual specifies the required coolant type (typically a 50/50 mixture of antifreeze and distilled water) and capacity. For fan-cooled models, coolant is not applicable.
Gearcase Oil:
Recommended gearcase oil viscosity (e.g., SAE 80W-90 GL-4 or GL-5) and capacity for the chaincase/gearbox.
Common Problems:
The manual addresses common issues such as stator failure, clutch wear, carburetor performance problems, track slippage, and suspension component wear, providing diagnostic steps and repair solutions.
Spark Plug Replacement:
Recommended spark plug types (e.g., NGK BR9ES, Champion N4C) and correct gap specifications. Procedures for cleaning or replacing spark plugs.
Idle Speed Adjustment:
Detailed instructions on adjusting idle speed and mixture screws for optimal engine performance and fuel economy across different altitudes and temperatures.
Polarishistory:
Polaris has a long-standing history in snowmobile manufacturing, known for innovation and performance across various model lines, from utility to racing.
Development:
The period 1972-1987 saw significant advancements in Polaris snowmobiles, including the introduction of the popular Indy series, liquid-cooled engines, advanced suspension designs, and improved reliability.
Manufacturing:
Polaris snowmobiles are primarily manufactured in the United States.
