Polaris Indy 500 Problems

The Polaris Indy 500, a snowmobile that once dominated trails and mountain slopes, holds a special place in the hearts of many riders. However, like any machine, the Indy 500 wasn't without its quirks and challenges. From engine woes to suspension snags, understanding these common problems can help current owners keep their sleds running smoothly and potential buyers make informed decisions.

So, What Were the Biggest Headaches with the Indy 500?

The Polaris Indy 500, despite its popularity and generally robust design, faced a few recurring issues that plagued owners over the years. These problems often stemmed from a combination of factors, including the age of many existing machines, the harsh environments they operate in, and the specific design choices made by Polaris.

Engine Issues (The Heart of the Matter)

Perhaps the most common area of concern revolved around the engine. The Fuji-built 488cc fan-cooled engine, while generally reliable, wasn't immune to problems.

Piston Failure: This was a fairly common occurrence, especially in older models. Overheating, often due to lean fuel mixtures or inadequate cooling fan operation, could lead to piston scoring and eventual failure. Symptoms included reduced power, unusual engine noises, and difficulty starting. Regular maintenance, including checking the carburetor settings and ensuring the cooling system is functioning properly, was crucial for preventing this. Using high-quality two-stroke oil and keeping the engine properly jetted are critical for longevity.
Carburetor Problems: Carburetor issues were another frequent source of frustration. Dirty or improperly adjusted carburetors could cause a range of problems, from poor fuel economy and rough idling to hesitation and stalling. Regular cleaning and tuning of the carburetors are essential, especially after periods of storage. Rebuilding the carburetors with fresh kits is also a good preventative measure.
CDI Box Failure: The Capacitor Discharge Ignition (CDI) box is responsible for controlling the spark timing. When it fails, the engine may not start or may run erratically. CDI box failures can be difficult to diagnose without proper testing equipment. Replacing the CDI box with a known good unit is often the most straightforward solution.
Crankshaft Issues: While less frequent than piston failures, crankshaft issues could also arise, particularly in high-mileage machines or those that had been subjected to excessive abuse. Worn crankshaft bearings could lead to excessive vibration and engine damage. Regular inspection of the crankshaft for play or unusual noises is recommended. Rebuilding the crankshaft is a complex task best left to experienced mechanics.

Suspension Woes (Keeping You Comfortable)

The Indy 500's suspension, while adequate for its intended purpose, wasn't without its shortcomings.

Shock Absorber Degradation: Over time, the shock absorbers would lose their damping ability, resulting in a bouncy and uncomfortable ride. This was particularly noticeable on rough trails or in deep snow. Replacing the shocks with new or rebuilt units is a common upgrade. Consider upgrading to gas-charged shocks for improved performance and durability.
Leaf Spring Sagging (Early Models): Older Indy 500 models used leaf spring suspensions in the rear. These springs could sag over time, reducing the sled's ride height and compromising its handling. Replacing the leaf springs with new ones or adding helper springs can restore the sled's ride height and improve its performance.
Wear and Tear on Bushings and Pivot Points: The various bushings and pivot points in the suspension system were prone to wear and tear, leading to sloppy handling and increased play. Regular inspection and replacement of worn bushings and pivot points are essential for maintaining proper suspension performance. Greasing the suspension components regularly can also help to prolong their lifespan.

Electrical Gremlins (Lights Out!)

Electrical problems, while not as prevalent as engine or suspension issues, could still be a source of annoyance.

Wiring Harness Issues: The wiring harness could become brittle and cracked over time, leading to shorts and other electrical problems. Careful inspection of the wiring harness for damage is recommended. Repairing or replacing damaged sections of the harness is often necessary.
Headlight Problems: Headlight bulbs could burn out frequently, and the headlight switch could become corroded, leading to intermittent headlight operation. Replacing the headlight bulb with a higher-quality unit and cleaning the headlight switch contacts can often resolve these issues.
Ignition Switch Problems: The ignition switch could become worn or corroded, leading to difficulty starting the sled. Replacing the ignition switch is often the most reliable solution.

Other Common Issues

Beyond the engine, suspension, and electrical systems, a few other problems were known to crop up.

Track Wear and Tear: The snowmobile track, being a wear item, would eventually need to be replaced. The lifespan of the track depended on factors such as riding conditions, maintenance, and riding style. Regular inspection of the track for damage and proper tension is important.
Drive Belt Slippage: The drive belt, which connects the engine to the drive system, could slip or break if it was worn, improperly adjusted, or subjected to excessive heat. Replacing the drive belt regularly and ensuring proper clutch alignment are essential for preventing slippage.
Fuel System Issues: Fuel lines could become brittle and cracked over time, leading to fuel leaks. The fuel pump could also fail, causing the engine to starve for fuel. Regular inspection of the fuel system for leaks and proper operation is important. Replacing the fuel lines and fuel pump as needed can prevent these problems.
Brake Problems: The brake system could develop leaks, causing a loss of braking power. The brake pads could also wear down, reducing the effectiveness of the brakes. Regular inspection of the brake system for leaks and proper operation is essential. Replacing the brake pads and bleeding the brakes as needed can ensure safe braking performance.

How to Keep Your Indy 500 Running Strong (Preventative Measures)

Prevention is always better than cure, especially when it comes to snowmobiles. Here's how to keep your Indy 500 in tip-top shape:

Regular Maintenance: Adhere to the recommended maintenance schedule outlined in the owner's manual. This includes changing the oil, greasing the suspension, inspecting the brakes, and cleaning the carburetors.
Proper Storage: When storing your snowmobile for the off-season, take the necessary steps to protect it from the elements. This includes stabilizing the fuel, fogging the engine, and covering the snowmobile to prevent rust and corrosion.
Use Quality Parts: When replacing parts, opt for high-quality aftermarket or OEM parts. This will ensure that your snowmobile performs reliably and lasts longer.
Listen to Your Sled: Pay attention to any unusual noises or vibrations that your snowmobile may be making. These could be early warning signs of a problem.
Don't Neglect the Cooling Fan: Make sure the cooling fan is operational and that all fins are intact. A broken or non-functioning fan can lead to severe overheating.

Frequently Asked Questions (Indy 500 Edition)

Why does my Indy 500 keep fouling spark plugs?
- This is often due to a rich fuel mixture. Check your carburetor settings and ensure the choke isn't sticking.
My Indy 500 is hard to start when it's cold. What's the problem?
- This could be due to a weak battery, a dirty carburetor, or low compression. Have these components checked by a qualified mechanic.
What's the best two-stroke oil to use in my Indy 500?
- A high-quality synthetic or semi-synthetic two-stroke oil designed for air-cooled engines is recommended. Refer to your owner's manual for specific recommendations.
How often should I grease the suspension on my Indy 500?
- Grease the suspension after every few rides or at least once a season. This will help to prevent wear and tear.
My Indy 500 is overheating. What should I do?
- Stop riding immediately and check the coolant level. Also, inspect the cooling fan for damage and ensure that it's operating properly.

The Last Run: Keeping the Legend Alive

The Polaris Indy 500, while not without its flaws, remains a beloved snowmobile for its simplicity, affordability, and reliability. By understanding the common problems and taking preventative measures, you can keep your Indy 500 running strong for years to come. Remember to perform regular maintenance and address any issues promptly to ensure a safe and enjoyable riding experience.