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1999 Polaris Snowmobile Service repair manual

This manual includes all the service and repair information about 1999 Polaris Snowmobile . Model Indy 340 ,Indy 500 Black,Indy 440 XCR,Indy 500 XC ,Indy 500 XC SP,Indy 600 XC,Indy 700 XC ,Indy 700 XCR,Indy 800 XCR,Indy 500 RMK,Indy 600 RMK,Indy 700 RMK,Indy 700 SKS ,Indy Tran Sport,Indy WideTrak LX.etc,Everything from wiring to rebuilding the machine – as well as electrical diagrams, service procedures, fluid capacities, etc.

This is Manual Covers:
Chapter 1 – General Information
Chapter 2 – Maintenance / Tune Up
Chapter 3 – Engines
Chapter 4 – Fuel System / Carburetion
Chapter 5 – Clutches
Chapter 6 – Body and Steering
Chapter 7 – Suspension
Chapter 8 – Brakes / Final Drive
Chapter 9 – Electrical

1999 wiring diagram-indy 700 XCR,800 XCR ELECTRICAL
1999 wiring diagram-400 XCR,500 XC/XC SP,600 XC/XC SP,700 XC/XC SP,700 SKS,600 RMK,700 RMK
1999 wiring diagram-XLT Special electrical
1999 wiring diagram-indy widetrak LX electrical
1999 wiring diagram-indy 340,340 toruing,340 deluxe
and more

Glossary of Terms:
ACS: Alternator control switch.
ACV: Alternating current voltage.
Air Gap Spark Test: A good check for ignition voltage and general ignition system condition. Spark should arc 3/8″ (1 em)
minimum from end of high tension lead to ground. Several testers are available commercially.
Alternator: Electrical generator producing alternating current voltage.
Bore: Diameter of cylinder.
BTDC: Before Top Dead Center.
Bump Steer: When skis toe in and toe out through suspension travel.
CDI: Capacitor Discharge Ignition. Ignition system which stores voltage generated by the stator plate exciter coil in a
capacitor or condenser (in CDI box). At the proper moment a voltage generated by the stator plate pulser coil closes an
electronic switch (thyristor) in the CDI box and allows the voltage in the capacitor to discharge into the primary windings of
the ignition coil.
Center Cylinder: On three cylinder engines, the cylinder between Mag and PTO ends.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 em). Polaris measures chain length in number of pitches.
Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face
as the engine torques back.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive
clutch to close.
Coil: A winding of wire around an iron core which has the ability to generate an electrical current when a magnetic field
passes through it.
Combustion Chamber: Space between cylinder head and piston dome at TDC.
Compression: Reduction in volume or squeezing of a gas.
Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and CDI systems.
Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between
centers on V blocks or resting in lower half of crankcase. Measure at various points especially at PTO. Maximum allowable
run-out is .006″ (.02 em).
DCV: Direct current voltage.
Detonation: The spontaneous ignition of the unburned fuel/air mixture after normal spark ignition. Piston looks
“hammered” through, rough appearance around hole. Possible causes: 1) lean fuel/air mixture; 2) low octane fuel; 3)
over-advanced ignition timing; 4 )compression ratio too high for the fuel octane.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in
the cylinder bore.
Effective Compression Ratio: Compression ratio measured from after the piston closes the exhaust port.
Electrical Open: Open circuit. An electrical circuit which isn’t complete. (i.e. poor connections or broken wire at hi-lo beam
switch resulting in loss of headlights.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended component.
(i.e. a bare wire touching the snowmobile chassis under the seat resulting in loss of taillights and brake lights).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
Flat Head Bolt: To be used where finished surfaces require a flush fastening unit. Countersunk.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
Head Volume: Cylinder head capacity in cc, head removed from engine with spark plug installed.
Heat Exchanger: A device used to transfer heat. Mounted under running boards, they dissipate engine heat to the
t Hex Head Bolt: Standard type of wrench-applied hexagon head, characterized by clean, sharp corners trimmed to
close tolerances. Recommended for general commercial applications.
Hi-Fax: Trademark of Himont Advanced Materials. The special slide material which fits onto the bottom of the suspension
High Side: Sled pushes or tips up.
High Tension Wire: The heavy insulated wire which carries the high secondary voltage from the coil to the spark plug.
Hole Shot: A term used when machine starts a race from a dead stop.
Holed Piston: Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2} pre-ignition.
Ignition Coil: A type of transformer which increases voltage in the primary windings (approx. 200V) to a higher voltage in the
secondary windings (approx. 14KV- 32KV) through inductions. Secondary voltage is high enough to arc the air gap at the
spark plug.
Ignition Generating Coil: Exciter coil or primary charge coil. Stator plate coil which generates primary ignition voltage. CDI
system uses one ignition generating coil.
Inch Pound: ln. lb. 12 in. lbs. = 1 ft. lb.
Kg/cm2: Kilograms per square centimeter. Metric equivalent of PSI.
Keystone Ring: A piston ring with bevel on upper surface.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. Metric
equivalent of ft. lbs.
L Ring: A wide face piston ring with an “L” shaped cross section. Leg of “L” goes up when installing on piston.
Labyrinth Seal: A pressure type center seal identified by series of grooves and lands. Polaris engines us this type of seal to
separate the cylinders in the crankcase halves.
Left Side: Always referred to based on normal operating position of the driver.
Lighting Coil: Generates voltage for lights, battery charging, etc by electromagnetic induction.
Loose: When the rear of the vehicle slides outward in a turn. The track does not grab sufficiently.
mm: Millimeter. Unit of length in the metric system. 1 mm = .040″.
Mag End: Flywheel side of engine.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
This is how mechanical energy in our engines is converted to electrical energy in the lighting coil, ignition generating coils
and trigger coil.
Ohm: The unit of electrical resistance opposing current flow.
~Oval Head Screw: Fully specified as “oval countersunk”, this head is identical to the standard flat head, but
possesses a rounded upper surface for attractiveness of design.
PTO End: Power Take Off drive (clutch side} .
• Pan Head Screw: Provides a low, large diameter head, but with characteristically high outer edges along the outer
edge of the head where driving action is most effective. Slightly different head contour when supplied with Phillips Recess.
See dotted line.
Piston Clearance: Total distance between piston and cylinder wall.
Piston Erosion: Piston dome melts. Usually occurs at the exhaust port area. Possible causes: 1) lean fuel/air mixture; 2)
improper spark plug heat range.
Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston looks
melted at area of damage. Possible causes: 1 )incorrect spark plug heat range; 2} spark plug not properly torqued; 3}
“glowing” piece of head gasket, metal burr or carbon in the combustion chamber; 4} lean fuel/air mixture; 5) Incorrect ignition
Primary Circuit: This circuit is responsible for the voltage build up in the primary windings of the coil. Parts of this circuit
include the exciter coil, points and condenser, wires from the stator plate to the small primary winding in the ignition coil. In
the CDI system the parts include the exciter coil, the trigger coil, the wires from stator plate to CDI box and to the low
resistance primary windings in the ignition coil.
Primary Clutch: Drive clutch on engine.
Primary Compression: Pressure built up in the crankcase of a two stroke engine.
psi.: Pounds per square inch.
Pushing: When the front of the vehicle does not steer as much as the driver desires. The skis do not grab sufficiently.
R & R: Remove and replace.
RFI: Radio Frequency Interference. Caused by high voltage from the ignition system. There are special plug caps and
spark plugs to help eliminate this problem. Required in Canada.
RPM: Revolutions Per Minute.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to
Right Side: Always referred to based on normal operating position of the driver .
• Round Head Screw:The familiar head most universally used for general application.
underhead bearing surface and finished appearance are characteristic of this head.
Good slot depth, ample
Running Time: Ignition timing when fully advanced or at specified RPM.
Secondary Circuit: This circuit consists of the large secondary coil windings, high tension wire and ground through the
spark plug air gap.
Secondary Clutch: Driven clutch on chaincase or jackshaft.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Self Steer: Pulling the machine to the inside of the track.
Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4″ (2 em) reach plugs.
Static Timing: Ignition timing when engine is at zero RPM.
Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coils.
Stroke: The maximum movement of the piston from bottom dead center to top dead center. It is characterized by 180° of
crankshaft rotation.
Surge Tank: The fill tank in the liquid cooling system.
TDC: Top Dead Center. Piston’s most outward travel from crankshaft.
Transfer: The movement of fuel/air from the crankcase to the combustion chamber in a two stroke engine.
Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in CDI systems.
Small coil mounted at the top of the stator plate next to the ignition generating coil.
V Regulator: Voltage regulator. Maintains maximum lighting coil output at approx. 14.5 ACV as engine RPM increases.
Venturi: An area of air constriction. A venturi is used in carburetors to speed up air flow which lowers pressure in venturi to
below atmospheric pressure, causing fuel to be pushed through jets, etc., and into the venturi to be mixed with air and form a
combustible air/fuel mixture.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.

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