1986 Polaris Indy 400 Manual PDF

The 1986 Polaris Indy 400 is a classic snowmobile featuring a 398cc air-cooled twin-cylinder engine, CDI ignition, slide rail suspension, and Polaris Variable Ratio (PVR) drive system. This manual covers operation, maintenance, troubleshooting, and specifications for the iconic winter sports vehicle. Below are key sections for safety, features, operation, maintenance, and technical specifications.

Features at a Glance

Key components: 398cc twin-cylinder engine, CDI ignition system, slide rail suspension, PVR drive clutch, mechanical disc brake, and Polaris trailing arm front suspension.

Safety Information

Always wear proper safety gear and follow operating guidelines.

1. Always wear helmet, eye protection, and appropriate winter clothing.
2. Never operate under the influence of alcohol or drugs.
3. Check local laws and regulations before operating.
4. Inspect snowmobile before each use.

WARNING! Snowmobile operation requires skill and attention. Always operate at safe speeds for conditions.

Operation Instructions

Proper starting and operating procedures for optimal performance.

1. Pre-ride inspection: Check fuel, oil, track, and controls.
2. Starting procedure: Set choke, pull recoil starter smoothly.
3. Warm-up: Allow engine to warm up for 2-3 minutes.
4. Operation: Use throttle and brake controls smoothly.
5. Shut-down: Allow engine to idle briefly before turning off.

CAUTION! Always operate in well-ventilated areas to prevent carbon monoxide exposure.

Specifications

• Engine Type: 398cc air-cooled twin-cylinder
• Bore x Stroke: 72mm x 61mm
• Carburetion: Two VM34 Mikuni carburetors
• Ignition: CDI electronic
• Drive System: PVR drive clutch with chain case
• Suspension Front: Polaris trailing arm
• Suspension Rear: Slide rail
• Track: 15" x 121" rubber
• Fuel Capacity: 10.5 US gallons
• Oil Capacity: 3.0 US quarts

Controls and Instrumentation

Main controls: Throttle lever, brake lever, choke knob, ignition switch.

Instrumentation: Speedometer, tachometer, fuel gauge, temperature warning light, oil warning light.

Throttle: Right-hand lever control. Brake: Left-hand lever. Choke: Pull knob for cold starts. Ignition: Key-operated switch. Emergency switch: Kill switch for immediate engine shutdown.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

1. Daily: Check fuel, oil, track tension, ski alignment.
2. Every 500 miles: Change engine oil, check spark plugs.
3. Every 1000 miles: Inspect drive belt, check chain case oil.
4. Seasonal: Grease fittings, check suspension components.
5. Storage: Proper winterization procedures.

Tip: Always use genuine Polaris parts for maintenance and repairs.

Engine Service

Engine maintenance and troubleshooting procedures.

1. Spark plugs: NGK B9ES, gap 0.020-0.024 inches.
2. Compression: 120-140 psi per cylinder.
3. Carburetor adjustment: Main jet 240, pilot jet 40.
4. Oil mixture: 40:1 ratio with Polaris injection oil.
5. Cooling: Ensure cooling fins are clean and unobstructed.

WARNING! Engine components become hot during operation. Allow to cool before servicing.

Drive System

PVR drive clutch and chain case maintenance.

1. Drive belt: Inspect for wear and proper tension.
2. Clutch maintenance: Clean sheaves, check weights and springs.
3. Chain case: Check oil level and condition.
4. Track adjustment: Proper tension and alignment.
5. Lubrication: Grease drive shaft and jack shaft bearings.

CAUTION! Always disconnect spark plug wires when working on drive system.

Electrical System

CDI ignition and lighting system maintenance.

Battery: 12V maintenance-free. Lighting: Headlight, taillight, brake light. Ignition: CDI unit, stator, trigger coil. Troubleshooting: Check connections, test components with multimeter.

Troubleshooting

Service: Contact authorized Polaris dealer for major repairs.

Parts: Use genuine Polaris replacement parts.