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1990-1995 SKS RXL XLT GT 400 500 650 Clymer Polaris Snowmobile Service Manual

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Description

This Clymer Polaris Snowmobile 1990 1991 1992 1993 1994 1995 Shop Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1990-1991 Polaris 400, 1992-1995 Polaris 440, 1993-1995 Polaris 400SKS, 1990-1995 Polaris 500, 1990-1995 Polaris 500SKS, 1990-1992 Polaris 500SP, 1990-1992 Polaris 650, 1990 Polaris 650SKS, 1990-1993 Polaris Classic, 1991-1995 Polaris RXL, 1992-1993 Polaris RXL SKS, 1990-1995 Polaris Sport, 1990-1992 Polaris Sport GT, 1995 Polaris Touring, 1994-1995 Polaris Super Sport, 1990-1995 Polaris Trail, 1993-1995 Polaris XLT, 1993-1995 Polaris XLT SKS, and 1993-1995 Polaris XLT SP snowmobiles.

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION

Manual organization, Notes, cautions and warnings, Safety first, Service hints, Engine and chassis serial numbers, Engine operation, Torque specification, Fasteners, Lubricants, RTV gasket sealant, Threadlock, Gasket remover,  , Basic hand tools, Precision measuring tools, Special tools, Mechanic’s tips, Ball bearing replacement, Oil seals, Snowmobile operation, Snowmobile safety, Snowmobile code of ethics

CHAPTER TWO, TROUBLESHOOTING

Operating requirements, Testing electrical components, Engine electrical system troubleshooting, Lighting coil output test, Charging coil output test, Voltage regulator, Charging system (carbureted with electric starting) , Charging system (fuel injected models) , Ignition switch, Electric starting system, Fuel system (fuel-injected models) ,  Fuel system (carbureted models) , Engine, Two-stroke pressure testing, Power train, Skis and steering, Track assembly

CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP

Pre-ride checks, Fluid checks, Break-in procedure, Maintenance schedules, Lubrication, Cooling system, Scheduled maintenance, Non-scheduled maintenance, Engine tune-up

CHAPTER FOUR, ENGINE–TWO CYLINDERS

Engine lubrication, Service precautions, Serial numbers, Servicing engine in frame, Engine removal (carbureted engines) , Engine removal (fuel-injected engines) , Engine plates, Engine installation (carbureted engines) ,  Engine installation (fuel-injected engines) , Engine top end, Cylinder, Piston, piston pin and piston rings, Crankcase and crankshaft

CHAPTER FIVE, ENGINE–THREE CYLINDERS (650/RXL)

Engine lubrication, Service precautions, Serial numbers, Engine removal (carbureted engines) , Engine removal (fuel-injected engines) , Engine plates, Engine installation (carbureted engines) , Engine installation (fuel-injected engines) , Engine top end, Cylinder, Piston, piston pin and piston rings, Crankcase and crankshaft

CHAPTER SIX, ENGINE–THREE CYLINDERS (XLT)

Engine lubrication, Service precautions, Serial numbers, Servicing engine in frame, Engine removal, Engine plates, Engine installation, Engine top end, Cylinder, Piston, piston pin and piston rings, Crankcase and crankshaft

CHAPTER SEVEN, FUEL SYSTEM–CARBURETED MODELS

Air box, Intake tubes, Carburetor, Carburetor operation, Carburetor identification, Carburetor service, Carburetor vent system, Fuel pump, Fuel tank, Throttle cable replacement

CHAPTER EIGHT, FUEL SYSTEM–FUEL-INJECTED MODELS

Fuel injection system components, Fuel injection system operation, Fuel injection diagnostic tool (select monitor) , Adjustments, Depressurizing the fuel system, Troubleshooting, EFI component service, Throttle cable replacement, Fuel tank

CHAPTER NINE, EXHAUST SYSTEM

Exhaust system, Exhaust system repair

CHAPTER TEN, ELECTRICAL SYSTEM

Battery, Capacitor discharge ignition (CDI) ,  CDI control unit (twin cylinder) , CDI box (650 and RXL) , CDI box (XLT) , Ignition coils (3-cylinder) , Voltage regulator, Electric starting system, Lighting system, Meter assembly, Throttle safety switch, Switches (except safety switch) , Oil level sensor, Fuel gauge sensor, Circuit breaker, Handwarmer, Wiring diagrams

CHAPTER ELEVEN, OIL INJECTION SYSTEM

System components, Oil pump service, Component replacement

CHAPTER TWELVE, LIQUID COOLING SYSTEM

Water pump (400, 440 and 500) ,  Water pump (XLT) ,  Water pump (650) ,  Filter, Check valve, Heat exchanger, Hoses

CHAPTER THIRTEEN, RECOIL STARTER

Recoil starter, Starter drive cup

CHAPTER FOURTEEN, DRIVE SYSTEM

Drive unit, Primary sheave assembly, Secondary sheave, Drive belt, Primary sheave service, Secondary sheave service (except later 1990-1995 sport) , Secondary sheave service (1990 [late]-1995 sport)

CHAPTER FIFTEEN, DISC BRAKE

Brake pad replacement, Brake caliper, Master cylinder, Front brake hose replacement, Brake disc, Bleeding the system

CHAPTER SIXTEEN, CHAINCASE, JACKSHAFT AND DRIVESHAFT

Drive chain and sprockets, Chaincase and jackshaft, Driveshaft

CHAPTER SEVENTEEN, FRONT SUSPENSION AND STEERING

Skis, Front suspension, Shock absorber, Handlebar and grips, Steering assembly, Steering adjustment

CHAPTER EIGHTEEN, TRACK AND REAR SUSPENSION

Lubrication and maintenance, Rear suspension adjustment, Rear suspension service, Rail tips, Hi-fax, Rear suspension assembly, Torsion springs, Suspension and guide wheels, Rear idlers installation, Pivot shaft, Track

CHAPTER NINETEEN, OFF-SEASON STORAGE

INDEX

WIRING DIAGRAMS

Additional information

Weight 3.1 lbs
Dimensions 10.75 x 8.25 x 0.7 in
ISBN

9780892876495