Sunday, December 29, 2013

DOWNLOAD Polaris SnowMobile Owners Service Manuals PDF

This INSTANT REPAIR MANUAL DOWNLOAD for the Polaris snowmobiles were designed primarily for factory service Polaris snow mobile technicians in a properly equipped shop. However, enough information in these Polaris snow mobile repair manuals is given for do-it-yourself or apprentice mechanics to correctly and safely perform repair work to their Polaris snow mobile and components. Individuals using this Polaris snow mobile repair manual should possess basic knowledge of tools and mechanical theory. The Polaris snow mobile mechanic should carefully read the text and become familiar with the Polaris snow mobile service manual procedures before beginning the work. Some repair procedures in this Polaris snow mobile downloadable manual may require the use of special tools. Its recommended to only use the exact tools, as specified in the factory Polaris snow mobile manual. Most tools can be rented at local parts stores. There's nothing these Polaris snow mobile repair manuals doesn't cover. From Polaris snow mobile maintenance procedures to complete Polaris snow mobile overhaul, these Polaris snow mobile manual covers it all.



TROUBLESHOOTING

The following check list of possible operating troubles and their probable causes will be helpful in keeping a motorcycle in good operating condition. More than one of these conditions may be causing the trouble and all should be carefully checked.

ENGINE

Starter Motor Does Not Operate or Does Not Turn Engine Over

  1. Ignition switch not in ON position.
    2. Engine run switch in OFF position.
  2. 5. Electric starter shaft pinion gear not engaging or overrunning clutch slipping.
    6. TSM/TSSM Bank Angle Sensor tripped and ignition switch not cycled OFF then ON.
    3. Discharged battery, loose or corroded connections (solenoid chatters).
    4. Starter control circuit, relay, or solenoid faulty.
Engine Turns Over But Does Not Start

  1. Fuel tank empty or fuel supply valve turned off.
    2. Fouled spark plugs.
  2. 5. Discharged battery, loose or broken battery terminal connections.
    6. Engine lubricant too heavy (winter operation).
    7. Spark plug cables in bad condition and shorting, cable connections loose or cables connected to incorrect cylinders.
    3. Engine flooded with gasoline as a result of over use of enrichener.
    4. Vacuum hose to automatic fuel supply valve disconnected, leaking, or pinched.
    8. Loose wire connection at coil, battery, ECM connector or ignition control module connector.
    9. Ignition timing incorrect due to faulty coil, ECM, ignition control module or sensors (MAP, CKP).

Starts Hard

  1. Spark plugs in bad condition or have improper gap or are partially fouled.
    2. Spark plug cables in bad condition.
    3. Battery nearly discharged.
  2. 7. Intake air leak.
    8. Fuel tank vent hose and vapor valve plugged, or carburetor fuel line closed off, restricting fuel flow.
    9. Enrichener valve inoperative.
    4. Loose wire connection at one of the battery terminals,
    coil, ECM connector or ignition control module connector.
    5. Carburetor controls not adjusted correctly.
    6. Water or dirt in fuel system and carburetor.
    10. Engine lubricant too heavy (winter operation).
    11. Ignition not functioning properly (possible sensor failure).
    12. Faulty ignition coil.
    13. Valves sticking.

Starts But Runs Irregularly or Misses

  1. Spark plugs in bad condition or partially fouled.
    2. Spark plug cables in bad condition and leaking.
    3. Spark plug gap too close or too wide.
    4. Faulty ignition coil, module, or sensor.
    5. Battery nearly discharged.
    11. Air leak at intake manifold or air cleaner.
    12. Damaged carburetor.
    13. Loose or dirty ECM connector or ignition control module connector.
    14. Faulty Sensor(s): Manifold Absolute Pressure (MAP) and/or Crank Position (CKP).
    15. Incorrect valve timing.
  2. 6. Damaged wire or loose connection at battery terminals, coil, ECM connector or ignition control module connector.
    7. Intermittent short circuit due to damaged wire insulation.
    8. Water or dirt in fuel system, carburetor or filter.
    9. Fuel tank vent system plugged or carburetor vent line closed off.
    10. Carburetor controls misadjusted.
    16. Weak or broken valve springs.
    17. Damaged intake or exhaust valve.

A Spark Plug Fouls Repeatedly

  1. Fuel mixture too rich or enrichener left on too long.
  2. 3. Piston rings badly worn or broken.
    4. Valve guides or seals badly worn.
    2. Incorrect spark plug for the kind of service.

Pre-Ignition or Detonation (Knocks or Pings)

  1. Fuel octane rating too low.
    2. Faulty spark plugs.
    3. Incorrect spark plug for the kind of service.
    4. Excessive carbon deposit on piston head or in combustion chamber.
    5. Ignition timing advanced due to faulty sensor inputs (MAP and/or CKP).

Overheating

  1. Insufficient oil supply or oil not circulating.
    Pressure (MAP) and/or Crank Position (CKP).
    5. Leaking valve.
  2. 2. Insufficient air flow over engine.
    3. Heavy carbon deposit.
    4. Ignition timing retarded due to faulty sensor(s): Manifold Absolute

Valve Train Noise

  1. Low oil pressure caused by oil feed pump not functioning properly or oil passages obstructed.
  2. 5. Rocker arm binding on shaft.
    6. Valve sticking in guide.
    7. Chain tensioning spring or shoe worn.
    2. Faulty hydraulic lifters.
    3. Bent push rod.
    4. Incorrect push rod length.

Excessive Vibration

  1. Wheels and/or tires worn or damaged.
  2. 4. Engine to transmission mounting bolts loose.
    5. Upper engine mounting bracket loose.
    6. Ignition timing advanced due to faulty sensor inputs (MAP and/or CKP)/poorly tuned engine.
    2. Engine/transmission/rear wheel not aligned properly.
    3. Primary chain badly worn or links tight as a result of insufficient lubrication or misalignment.
    7. Internal engine problem.
    8. Broken frame.

Check Engine Light Illuminates During Operation

  1. Fault detected. Check trouble codes for more information in service manual.

Oil Does Not Return To Oil Pan

  1. Oil pan empty.
    2. Oil pump not functioning.
    3. Restricted oil lines or fittings.
    4. Restricted oil filter.
    5. Oil pump misaligned or in poor condition.
    6. O-ring damaged or missing from oil pump/crankcase junction (also results in poor engine performance).

Engine Uses Too Much Oil Or Smokes Excessively

  1. Oil pan overfilled.
  2. 4. Restricted oil filter.
    5. Oil pump misaligned or in poor condition.
    6. Piston rings badly worn or broken.
    7. Valve guides or seals worn.
    2. Restricted oil return line to pan.
    3. Restricted breather operation.
    8. O-ring damaged or missing from oil pump/crankcase junction (also results in poor engine performance).
    9. Plugged crankcase scavenge port.

Engine Leaks Oil From Cases, Push Rods, Hoses, Etc.

  1. Loose parts.
    2. Imperfect seal at gaskets, push rod cover, washers, etc.
    3. Restricted breather hose to air cleaner.
    4. Restricted oil filter.
    5. Oil pan overfilled.
    6. Lower rocker housing gasket installed incorrectly (upside down).
    7. Restricted oil return line to tank.

Low Oil Pressure

  1. Oil pan underfilled.
    2. Faulty low oil pressure switch.
    5. Ball or clean-out plug missing or leaking in cam support plate.
    6. O-ring missing from cam support plate.
  2. 3. Oil pump O-ring damaged or missing.
    4. Bypass valve stuck in open position.

High Oil Pressure

  1. Oil pan overfilled.
    2. Bypass valve stuck in closed position.

ELECTRICAL SYSTEM - Alternator Does Not Charge

  1. Voltage regulator/rectifier module not grounded.
  2. 4. Loose or broken wires in charging circuit.
    5. Faulty stator and/or rotor.
    2. Engine ground wire loose or broken.
    3. Faulty regulator-rectifier module.

Alternator Charge Rate Is Below Normal

  1. Weak or damaged battery.
  2. 3. Faulty regulator-rectifier module.
    4. Faulty stator and/or rotor.
    2. Loose connections.

Speedometer Operates Erratically

  1. Contaminated speedometer sensor (remove sensor and clean off metal particles).
    2. Loose connections.

CARBURETOR Floods

  1. Dirt or other foreign matter between valve and its seat.
    2. Inlet valve sticking.
    6. Excessive “pumping” of hand throttle grip.
  2. 3. Inlet valve and/or valve seat worn or damaged.
    4. Float misadjusted.
    5. Leaky or damaged float.

Shifts Hard

  1. Primary chaincase overfilled with lubricant.
  2. 4. Shifter return spring (inside transmission) bent or broken.
    5. Bent shifter rod.
    2. Clutch dragging slightly.
    3. Transmission lubrication too heavy (winter operation).
    6. Shifter forks (inside transmission) sprung.
    7. Corners worn off shifter clutch dogs (inside transmission).

Jumps Out Of Gear

  1. Shifter rod improperly adjusted.
  2. 4. Shifter forks bent.
    5. Damaged gears.
    2. Shifter drum (inside transmission) damaged.
    3. Shifter engaging parts (inside transmission) badly worn and rounded.

Clutch Slips

  1. Clutch controls improperly adjusted.
    2. Insufficient clutch spring tension.
    3. Worn friction discs.

Clutch Drags Or Does Not Release

  1. Lubricant level too high in primary chaincase.
    2. Clutch controls improperly adjusted.
    3. Primary chain badly misaligned.
    4. Clutch spring tension.
    5. Clutch discs warped.

Clutch Chatters

  1. Friction discs or steel discs worn or warped.

HANDLING - Irregularities

  1. Improperly loaded motorcycle. Non-standard equipment on the front end such as heavy radio receivers, extra lighting equipment or luggage tends to cause unstable handling.
    2. Damaged tire(s) or improper front-rear tire combination.
    3. Irregular or peaked front tire tread wear.
    4. Incorrect tire pressure.
    8. Rear wheel out of alignment with frame and front wheel.
    9. Steering head bearings improperly adjusted. Correct adjustment and replace pitted or worn bearings and races.
    10. Loose spokes (laced wheel vehicles only).
    11. Tire and wheel unbalanced.
    12. Rims and tires out-of-round or eccentric with hub.
    13. Rims and tires out-of-true sideways.
    14. Rear fork pivot.
  2. 5. Shock absorber not functioning normally.
    6. Loose wheel axle nuts. Tighten to recommended torque specification.
    7. Excessive wheel hub bearing play.


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DOWNLOAD Polaris Snowmobile Repair Manuals 1985-2011

This INSTANT REPAIR MANUAL DOWNLOAD for the Polaris snowmobiles were designed primarily for factory service Polaris snowmobile technicians in a properly equipped shop. However, enough information in these Polaris snowmobile repair manuals is given for do-it-yourself or apprentice mechanics to correctly and safely perform repair work to their Polaris snowmobile and components. Individuals using this Polaris snowmobile repair manual should possess basic knowledge of tools and mechanical theory. The Polaris snowmobile mechanic should carefully read the text and become familiar with the Polaris snowmobile service manual procedures before beginning the work. Some repair procedures in this Polaris snowmobile downloadable manual may require the use of special tools. Its recommended to only use the exact tools, as specified in the factory Polaris snowmobile manual. Most tools can be rented at local parts stores. There's nothing these Polaris snowmobile repair manuals doesn't cover. From Polaris snowmobile maintenance procedures to complete Polaris snowmobile overhaul, these Polaris snowmobile manual covers it all.




1986 400 
1986 600 / 1986 600 LE 
1986 Indy Trail 
1986 Long Track 
1986 Sprint / 1986 Sprint ES 
1986 SS 
1986 Star
1985 400 
1985 600 / 1985 600 SE 
1985 Indy Trail 
1985 Long Track 
1985 SS 
1985 Star 
1988 Indy 400 / 1988 Indy 400 Classic / 1988 Indy 400 SKS 
1988 Indy 650 / 1988 Indy 650 SKS / 1988 Indy Deluxe 
1988 Indy ES / 1988 Indy SKS / 1988 Indy Sport / 1988 Indy SP / 1988 Indy Trail 
1988 Long Track Reverse 
1988 Sprint 
1988 Star / 1988 Star Trak
1987 Indy 400 / 1987 Indy 400 SKS / 1987 Indy 600 / 1987 Indy Sport 
1987 Indy Trail ES / 1987 Indy Trail SKS 
1987 Long Track / 1987 LTR 
1987 Sprint / 1987 Sprint ES 
1987 Star 
1987 Star Trak 
1990 500 / 1990 500 Classic / 1990 500 SKS / 1990 500 SP 
1990 650 / 1990 650 SKS 
1990 Indy 400 / 1990 Indy Sport / 1990 Indy Sport GT / 1990 Indy Trail 
1990 Indy Trail Deluxe / 1990 Indy Trail SuperTrak 
1990 Sprint ES 
1990 Star / 1990 Star Trak 
1990 WideTrack
1989 Indy 400 
1989 Indy 500 / 1989 Indy 500 Classic / 1989 Indy 500 SKS / 1989 Indy 500 SP 
1989 Indy 650 / 1989 Indy 650 SKS / 1989 Indy Deluxe / 1989 Indy ES 
1989 Indy SKS / 1989 Indy Sport 
1989 Indy Sport GT / 1989 Indy SP / 1989 Indy Trail / 1989 Indy Trail SuperTrak 
1989 Long Track Reverse 
1989 Sprint ES 
1989 Star / 1989 Star Trak 
1991 400 
1991 500 / 1991 500 Classic / 1991 500 SKS / 1991 500 SP 
1991 650 / 1991 650 RXL / 1991 650 RXL SKS 
1991 Indy Lite / 1991 Indy Sport / 1991 Indy Sport GT 
1991 Indy Trail / 1991 Indy Trail Deluxe 
1991 Star Lite 
1991 SuperTrak 
1991 WideTrak 
1993 440 / 1993 440 SKS / 1993 440 XCR 
1993 Indy Lite / 1993 Indy Lite GT / 1993 Indy Lite Deluxe 
1993 Indy StarLite / 1993 Indy StarLite GT 
1993 RXL / 1993 RXL SKS 
1993 Sport 440 
1993 Storm / 1993 Storm SKS 
1993 Trail / 1993 Trail Deluxe 
1993 XLT / 1993 XLT SKS / 1993 XLT SP 
1992 440 / 1992 440 XCR 
1992 500 / 1992 500 SKS EFI / 1992 500 SP EFI 
1992 650 
1992 Classic 
1992 Indy Lite / 1992 Indy Lite Deluxe / 1992 Indy Lite GT 
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1992 SuperTrak 
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1992 WideTrak
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1994 600 XCR 
1994 Classic / 1994 Classic Touring 
1994 Indy Lite / 1994 Indy Lite Deluxe / 1994 Indy Lite GT 
1994 RXL / 1994 RXL Touring 
1994 Sport / 1994 Sport SKS 
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1994 Super Sport 
1994 Trail / 1994 Trail Deluxe 
1994 WideTrak GT / 1994 WideTrak LX 
1994 XLT / 1994 XLT SKS / 1994 XLT SP / 1994 XLT Special XTRA 
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1995 Super Sport 
1995 Trail / 1995 Trail Deluxe 
1995 WideTrak GT / 1995 WideTrak LX 
1995 XLT / 1995 XLT PT / 1995 XLT SKS / 1995 XLT SP / 1995 XLT Touring
1995 440 Indy / 1995 440 Indy SKS / 1995 440 XCR 
1995 500 / 1995 500 EFI / 1995 500 EFI PT / 1995 500 EFI SKS 
1995 600 XCR 
1995 Classic 
1995 Indy Lite / 1995 Indy Lite Deluxe / 1995 Indy Lite GT 
1995 RXL / 1995 RXL Touring 
1995 Sport / 1995 Sport Touring 
1995 StarLite 
Indy XLT 
Indy XLT SP 
Indy XLT SKS 
Indy XLT RMK 
Indy XLT Touring
Indy 600 XCR 
Indy 600 XCR SP 
Indy RXL 
Indy Ultra SP 
Indy Ultra SKS 
Indy Ultra RMK 
Indy Storm 
Indy Storm SKS 
Indy Storm RMK Indy Lite 
Indy Lite Deluxe 
Indy Lite GT 
Indy Sport 
Indy TranSport 
Indy Super Sport 
Indy Sport Touring 
Indy 440 LC 
Indy Wide Trak GT 
Indy XLT 
Indy XLT SP 
Indy XLT SKS
Indy XCF 
Indy XC 
Indy Trail 
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Indy Trail RMK 
Indy Classic 
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Indy 500 
Indy 500 SKS 
Indy 500 RMK 
Indy 500 EFI 
Indy Wide Trak LX 
Indy XLT RMK 
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Indy XLT LTD 
Indy XLT LTD SP 
Indy 600 XC 
Indy 600 XCR 
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Indy RXL 
Indy Ultra 
Indy Ultra SP 
Indy Ultra SPX 
Indy Ultra SPX SE 
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Indy 700 XC 
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Indy XLT Touring 
Indy XLT LTD 
Indy XLT SP
Indy Ultra Touring 
Indy 700 XCR 
Indy 700 XC 
Indy 700 RMK 
Indy Storm 
Indy XLT Classic 
Indy 600 XC 
Indy 600 RMK 
Indy 600 XCR 
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The Polaris service manuals also provide a troubleshooting section to help the owner solve problems. Troubleshooting outlines the identification of symptoms and a logical process of identifying the malfunction, and the steps needed to repair the cause. For example:

NOTE: these examples are not actual troubleshooting procedures. Troubleshooting procedures will differ for all models and years.

Engine looses power; no top end

Condition

  1. Exhaust valves sticking in down position.

Remedy 

  1. Remove carbon deposits, burrs, etc. 

Most polaris repair manuals cover troubleshooting topics such as, engine loses power, poor acceleration or hesitation, fuel pump testing, testing crankshaft positioning sensor, snowmobile running to rich or too lean. Track edge frayed, track worn adjacent to outer drive lugs, loss of brakes or brake dragging. Engine does not start or no spark at spark plugs. No fuel reaching cylinders. Engine does not idle and needs throttle position adjustment. Engine loses power or runs on one cylinder. Engine overheating or backfires. Engine starts and stalls or stops suddenly, or engine wont turn off. Pilot screw, float needle or fuel mixture screw too far out or in. Main jet loose or jet needle worn and needs to be replaced or adjusted. 

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