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post #1 of 18 (permalink) Old 10-12-2007, 01:41 PM Thread Starter
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Restoring '86 Indy 400

Greetings - here is what I have...

86 Indy 400 - last year of the high compression 400's I believe, and the year before the Indy 500 came-to-be.

It's been in storage (ok, under a tarp) since '94, and I'd like to get it running again. So far, I've found I need to replace all hoses (gas, oil injection, coolant puke-tank overflow, crank-case pulse line, but seemingly not the heat exchanger lines.)

The track and driveline seem to be in good shape, the engine exibits good compression and both carbs are clean. Clutches both likely need rebuilding.
I had it started last winter by squirting gas/oil mix into the carb intakes - so ignition is working.

I need a new fuel cap as well as a tank cover and seat (sems there are salvage yards local with these items).

The barbed fitting at the bottom of the injection oil reservoir broke off - does anyone know the size of the threads so I can substitute a brass one?

Better still - is there a service manual available on-line anywhere for this little fella?
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post #2 of 18 (permalink) Old 01-06-2008, 10:27 PM Thread Starter
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I don't know how many of you folks read this, but I thought I'd add a bit more.

I found the time to do all the hose replacements, (even the fuel pick-up tube was lieing in the bottom of the tank). Brake fluid reservoir was full of thick goo that might ahve been DOT 3 fluid at one time... I got that cleaned out and working again.

since all the coolant lines going to the puke tank were rotten, it had no coolant in it. I changed the lines, added coolant and it held!

It started up, runs fine, I haven't confirmed that the oil injection pump is still working, so first tank of gas was pre-mixed at 40:1 (so lots of smoke.)

The fuel hose routing seemed to be goofy right from the factory, it comes out of the tank, rises up to the fuel shut-off, then goes back down to the filter, then to the fuel pump. there is a large air lock that appears in the fuel shut-off portion, but it still draws fuel through and up this portion - without displaceing the air "bubble" and allows it to run, Any idea if this is normal?

I still need a seat, tank cover, fuel cap/gauge, low windshield, and some wax for the cowl - and maybe a new decal kit.

Does anybody know what stops the thumb throttle assy from spinning on the handlebars?

Oh, anyone have a seat cover/foam and seat base board? colour not critical.
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post #3 of 18 (permalink) Old 01-07-2008, 08:19 AM
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Originally Posted by Bent
Does anybody know what stops the thumb throttle assy from spinning on the handlebars?
There is a set screw on the underside of it.

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post #4 of 18 (permalink) Old 01-07-2008, 08:58 PM Thread Starter
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I'll look closer - thanks
(must be these 40 year old eyeballs I have.)
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post #5 of 18 (permalink) Old 01-19-2008, 04:57 PM Thread Starter
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would it be that hex-head screw I think I saw?
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post #6 of 18 (permalink) Old 01-19-2008, 05:05 PM
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what do you mean by the last high compression 400's? what was different about the motor never heard of it thanks!

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-1994 indy trail 500- all stock, great on gas
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post #7 of 18 (permalink) Old 01-19-2008, 08:02 PM Thread Starter
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IIRC in 87, Polaris introduced the Indy 500, the performance of the 400 was just a little too close to the new '500 - and Polaris wanted some model distinction, so they apparently detuned the 400 somewhat to provide a more defined cut-line between the two.

compression ratios were marginally lowered in '87 compared to '86.
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post #8 of 18 (permalink) Old 01-19-2008, 08:45 PM
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ahh right on so the 86 400's would be slighty faster than a 1991 400?

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-1995 zr580- aaen pipe, epi clutch kit, camoplast ripsaw/120studs, 3inch riser, flybars, upgraded foxshocks, weisco pistons, lightly ported, 19tooth top 32thooth bottom soon to come bored carbs, plastic skis, new helix and ramps BRAAAP

-1994 indy trail 500- all stock, great on gas
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post #9 of 18 (permalink) Old 01-19-2008, 10:38 PM Thread Starter
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I can't say if it would be faster - there certainly should have been some technological advancements across the whole line-up in 5 years. It merely was known as a high performance machine in it's day as there were only two water pumpers made at the time.
The 400 twin and the 600 triple.
If memory serves, the original 340 XC indy (TXl indy?) was rated at 56 HP as was the two following 400's and the "lower compression" 400 that followed them was also rated at 56 HP.
later on came the evolution of the suspension, reed valved motors, incorporation of exhaust port valves that did the equivalent of varying the exhaust ports, etc.
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post #10 of 18 (permalink) Old 01-20-2008, 08:59 AM
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I bought a cd for polaris 84-89 from this guy for 5.00 , sent him a paypal payment and got the cd in a couple of days , heres a link to the craigslist ad, he has a couple other for arctic cat, yamaha and ski doo also
SNOWMOBILE REPAIR MANUALS ON CD
Artic Cat 2 manuals
1990 to 1998 all models
2004 all models

Polaris 3 manuals
1984 to 1989 all models
1990 to 1995 all models
1996 to 1998 all models

Yamaha one CD
1997 to 2002 all models

Ski doo two manuals
1996 and 1997

he lives in south Carolina If you would like to buy one of these manuals please contact him

1996 Ski Doo Formula 500 SL
1995 Polaris Indy 500 EFI 136
94 Ski doo Formula Z 583
1980 Artic cat Trail cat 340, what a fun old sled
1986 Polaris Indy 400

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post #11 of 18 (permalink) Old 01-20-2008, 09:01 AM
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I have an 86 indy 400 and love it, really a reliable sled

1996 Ski Doo Formula 500 SL
1995 Polaris Indy 500 EFI 136
94 Ski doo Formula Z 583
1980 Artic cat Trail cat 340, what a fun old sled
1986 Polaris Indy 400

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post #12 of 18 (permalink) Old 01-20-2008, 10:53 AM
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sorry on the hijack, i saw the cd,s thought it was a scam,nice to know it isnt.thanks

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post #13 of 18 (permalink) Old 01-20-2008, 11:30 AM
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Nope not a scam, I offered him 2.00 to just email, but it was to big of a file, so he just burned me a copy for 5, mailed it, and it works great, alot of gteat information on those cd's

1996 Ski Doo Formula 500 SL
1995 Polaris Indy 500 EFI 136
94 Ski doo Formula Z 583
1980 Artic cat Trail cat 340, what a fun old sled
1986 Polaris Indy 400

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post #14 of 18 (permalink) Old 02-06-2008, 08:02 PM
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Hi, I'm also interested. Did this CD have good info on engine overhaul? Like cylider head tightening and torque specs? Thanks!
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post #15 of 18 (permalink) Old 02-07-2008, 03:30 AM
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The fuel line on my Brothers and my GFs sled is routed the same way... One has a 86 Indy Trail 400/440? and the other is a 87 Indy Trail 488.
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post #16 of 18 (permalink) Old 01-19-2009, 08:32 AM
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Originally Posted by JheLrey View Post
The fuel line on my Brothers and my GFs sled is routed the same way... One has a 86 Indy Trail 400/440? and the other is a 87 Indy Trail 488.
Anyone have a gray/maroon piping gas tank cover for an 87 indy trail 500?
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post #17 of 18 (permalink) Old 12-07-2009, 06:17 AM
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I need a service manual for a 1985 indy 400. Does anyone know where i can download one ? My son going to be sad when he wakes up cause its snowing and i havent fixed the sled. any help would be great. I need to replace both gears and chain.
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post #18 of 18 (permalink) Old 12-07-2009, 08:49 AM
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Clymers Manual on E-Bay would do the job
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