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Polaris 450 MXR Offroad Vehicle User Manual

1. 24 3 7 11 15 19 22 26 30 34 32 4 8 12 16 20 24 28 32 36 40 1 5 9 13 17 21 25 29 33 37 48 1 5 9 13 18 22 26 30 34 38 56 2 6 10 14 18 22 26 31 35 39 64 2 6 10 15 19 23 27 31 35 40 72 2 7 _ 11 15 19 23 28 32 36 40 80 3 7 11 15 20 24 28 33 37 41 88 3 7_ 12 16 20 24 29 33 37 42 96 3 8 12 16 21 25 29 34 38 42 Frostbite in gt gt 30 min 10 min WINDCHILL CHART C Wind Actual Thermometer Reading C Speed 5 2 4 l 7 10 13 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature C Cam 5 2 1 4 7 10 13 16 19 22 8 3 o 4 7 11 14 18 22 25 29 16 2 2 1 6 10 13 17 21 24 28 32 1 0 20 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protec tion Read and follow the instructions of the decals and other warnings on the snowmobile carefully If any of the decals depicted in this manual differ from the decals on your snowmobile always read and follow the instructions of the decals on the snowmobile If any decal becomes illegible
2. 6 20 P Park Brake Lever Lock 43 Polaris Products 98 Preload IFS Shock Spring 29 Pre Ride Checklist 40 Pre Ride Suspension Inspection 94 R Rail Slide Wear 94 Rear Rear Scissor Stop 35 Rear Suspension Adjustments 30 36 Rear To Front Coupling 35 Recoil Rope 45 Recommended Maintenance 7 Registration Warranty 106 REVETSO icc 2 fk Puede are cherie 58 59 Reverse Warning 23 Rider Capacity 11 Riding Apparel 9 Riding Position 8 RRS Siei een aw pte tag eae ce ds 35 S Safety Decals 21 24 Safety Symbols 6 Sap swiss du tai dese dees EE BESS 32 Sediment Trap 75 Signal Words 6 Ski Alignment 92 Ski Pressure 00 33 Ski Skags 0 000 93 Slide Rail and Track Cooling 49 Snow Conditions 18 Spark Plug 0 71 Spark Plug Condition 71 Spark Plugs 70 71 Speed aves sed aiiet teed atawdks 11 Spring Preload 32 Spring Preload IFS Shock 29 Spring Preload Rear IQ 32 Starting the Engine 47 Steering Inspection Adjustment 91 Steering System 44 91 94 Stopping Emergency 48 Stor
3. 34 Front Suspension Adjustments 28 29 Front To Rear Coupling 34 FRS S oinas pee oes 34 BUC seanse tono sate ayers 51 52 Fuel Filter 22 500 4500 ce eee 13 Fuel Lites jcc oc ee eae atte eak 73 FueliPump i 2 42 had Sans Sk BAe 72 Fuel System Deicers 52 Fuel Valve 27 52 H Handlebar Adjustments 38 Headlight Adjustment 27 Headlight Bulb Installation 80 Headlight Bulb Removal 80 Hood Latches 45 l Ice and Snow Build up 14 TES 2g fat te crs AO 28 IFS Adjustment Options 28 IFS Components 28 Inadequate Snow Conditions 18 Intake Filters 72 Intake Silencer 17 J Jetting Guidelines 55 L ighis respe o tegnies 80 81 Limiter Strap Position 33 Low Oil Indicator Light 53 Lubrication 66 69 M Maintenance 17 Maintenance Interval Table 63 65 Maintenance Log 113 115 Maintenance Program 62 Maneuverability 17 N No Passenger Warning 22 Nois eed uangkaa ave sae Pa da be 5 0 Oil Manin e a e ls 53 Oil Filtera ete gee eek anda 72 Oil Injection System 49 Ol Level aes ais Beet ete yas 53 Oil DineSivee aca aes Boe Sass 72 Oil Recommendations 49 Operation Warning 23 24 Operator Safety
4. e Inspect and adjust Sticky clutch e SEE YOUR DEALER Engine doesn t turn Seized engine e SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock e Fuel may have entered the crankcase while the vehicle was standing or being transported SEE YOUR DEALER to correct the cause Drain plug s are located on the lower crankcase for emergency draining Engine doesn t start electric start mod els Wire connections e SEE YOUR DEALER Engine requires more than normal pulls to start Poor fuel e Replace with fresh winter fuel Not enough fuel get ting to engine e SEE YOUR DEALER 100 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition TROUBLESHOOTING e Install new spark plug s If engine still fails to start check for spark If there s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on Use the choke Make sure fuel tank contains fuel Ice may be in fuel line filter or pump Add isopropyl alcohol to fuel system On the standard Polaris car buretor the choke will not function with the throttle depressed See sec ond item under Probable Cause of Engine Continually Backfires Flooded engine too much choke used Hold throttle open crank engine several times may be necessary to
5. 55010 Shit pm Pantone 426C For your nearest Polaris dealer GD POLARIS ca 1800 POLARIS ane Way Oui or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922316 Rev 01 Printed in USA A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris enthusiasts Be sure to visit us online at www polarisindustries com for the latest news new product introduc tions upcoming events career opportunities and more Here at Polaris we proudly produce an exciting line of utility and recre ational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of y
6. Item See Frequency Page 750 mi 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CLUTCH Clutch Alignment Offset 82 l l l without belt Drive Belt Condition 83 l l l l Clutches disassemble 82 03 Cc c Belt Tension l l l l Clutch Sheaves 82 l l l l ENGINE Engine Mounts l l l l Engine Mounting Plate l l l Engine Torque Stop 85 l l l l Cylinder Head Bolts l l l Cylinder Base Nuts l l l l Ignition Timing BTDC l l l Recoil Rope l l l l Spark Plug Condition 71 l l l R l Exhaust Pipe 73 l l Exhaust Retaining 73 l l l l Inspect clean adjust tighten C Clean R Replace L Lubricate lubricate replace if necessary 63 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 750 mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season BRAKES Hose Routing l l l l Hose Condition l l l l Fluid Leaks l l l l Brake Pads 77 l l l l Brake Disc l l l l Parking Brake 43 l l l l Brake System 42 77 l Brake Fluid 78 R FUEL MANAGEMENT Pilot Air Screws l l l Carburetor 74 l l l synchronize Idle RPM l l Throttle Lever 57 l l l l l Oil Pump Lever l l l synchronize Throttle Cable 67 L L L Choke Cable 67 L L L Choke 67 l l l Vent Lines l l l l Fuel Lines 73 l l l
7. 9 5 I Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 95 1 2872951 Synthetic Chaincase Lubricant 12 0z 355 ml Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 0z 89 ml 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean Plus 12 0z 355 ml 2870652 Fuel Stabilizer 16 0z 473 ml 2872189 DOT 4 Brake Fluid 12 0z 355 ml 2872893 Engine Degreaser 12 0z 355 ml 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner 98 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Probable Cause Solution Erratic engine oper ating RPM during acceleration or load variations Drive clutch binding e Disassemble drive clutch to inspect shift weights for wear and free oper ation SEE YOUR DEALER Clean and polish stationary shaft hub Driven clutch mal function Replace ramp buttons and rollers SEE YOUR DEALER Inspect movable sheaves for exces sive bushing clearance and replace if necessary SEE YOUR DEALER Clutch alignment out of spec Harsh drive clutch Drive belt worn or e Replace the drive belt engagement too narrow Excessive belt e SEE YOUR DEALER
8. The low oil indicator light will alert the operator if the oil level is low Visually check for oil in the bottle Add oil before further operation of the snowmobile See page 49 for oil recommendations Low Oil Level Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous ter rain NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling Add oil as needed Always maintain a visible level of oil in the tank If oil is not visible continued operation may cause serious engine damage See page 49 for oil recommendations The Polaris oil cap on the oil bottle is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts 53 OPERATION Carburetion Proper carburetor adjustment is critical A lean mixture too much air too little fuel may result in piston burning bearing failure or complete engine failure A rich mixture too much fuel too little air may foul plugs and cause generally poor engine performance A lean mixture may be caused by things like fuel line restrictions for eign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filter in the air intake system Either condition may be caused by
9. change plug s Poor engine com pression Mixture is too lean A main jet that is too small will cause seizure result ing in loss of power This indicates a major engine problem that must be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective Replace the plug s spark plug s Fuel filter loss of e Check fuel filter flow Disconnect high RPM power hose and drain 1 2 cup Fuel flow should be steady and encompass the entire diameter of fuel line If not replace filter backfires Incorrect clutching e SEE YOUR DEALER Carburetor and fuel SEE YOUR DEALER pump Engine continually Faulty plug s e Change plug s Carburetor Fuel System Dirt or ice may be in the fuel system add deicer to non ethanol fuel at all times to prevent icing Incorrect throttle freeplay or faulty switch e SEE YOUR DEALER 101 TROUBLESHOOTING IQ Suspension Troubleshooting Problem Solution Rear suspension bot Adjust torsion spring preload to achieve proper static sag toms too easily see page 32 e Change torsion spring to stiffer optional spring see your dealer e Revalve rear track shock see your dealer Rides too stiff in rear Check for binding suspension shafts and grease all pivot points Adjust torsion spring preload to achieve proper static sag see page 32 Change torsion spring to softer optional spring see your d
10. or visit either the American Avalanche Association online at www americanavalancheas sociation org or the U S Forest Service National Avalanche Center at www avalanche org 13 SAFETY Operator Safety Ice and Snow Build up WARNING Ice and snow build up may interfere with the steering of your machine resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving on Slippery Surfaces WARNING Never attempt an abrupt change of direction when operating on slippery surfaces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces 14 SAFETY Operator Safety Driving Downhill When riding downhill shift your weight to the rear of the machine and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the machine and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brak
11. removal procedures 2 Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the L wrench and store it in the tool kit 4 Reinstall the side panel 5 Close and secure the hood Drive Belt Belt width and length must match the center distance of the clutches and sheave width of the drive clutch Polaris recommends the use of O E M belts Other belts may match the dimensions but can drastically change the shift pattern resulting in poor performance Tip A worn belt will continue to function but will not deliver maximum perfor mance Always carry a spare belt in case of an emergency 84 MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge 1 on the belt and apply downward pressure while measuring at point 2 This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment 1 Install the L wrench into the open threaded hole in the outer sheave of the clutch see page 83 Turn the wrench clockwise slightly to remove pressure from the sheaves 2 Loosen the 7 16 jam nut 3 Usinga 1 8 Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves or outward counterclock wise to decrease the distance 4 Tighten the jam nut Store the L wrench in the tool kit Torque Stop Per
12. sheave clearance Drive belt turns over Wrong belt for appli e Replace the drive belt cation Adjust alignment offset SEE YOUR DEALER Engine mount bro ken or loose Inspect and adjust or replace SEE YOUR DEALER Machine fails to move Clutch jammed e Check for twisted belt broken spring sticking weights lubrica tion SEE YOUR DEALER Track jammed e Foreign object may be caught or the rail slide melted to the track clips due to lack of lubrication Track may be iced up or frozen to the ground Chaincase sprocket or chain jammed or broken Chain is loose or broken or chain tightener is loose SEE YOUR DEALER Engine stutters in reverse Misfire mode has activated to prevent engine overheat Shift to forward or restart the engine to clear the misfire mode 99 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys tem Broken drive clutch components e SEE YOUR DEALER Bearing failure chaincase jackshaft or front drive shaft e SEE YOUR DEALER Drive belt surface flat spots e Inspect and replace as needed Drive chain loose e Inspect and adjust or replace Drive chain worn e SEE YOUR DEALER sprocket teeth bro ken Poor low RPM per Worn drive belt Inspect and replace as needed formance Excessive belt sheave clearance e SEE YOUR DEALER Loose torque stop
13. 112 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km 113 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 114 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 115 INDEX A Accessories 000008 37 Adjustable Headlights 27 Air Pollution 5 Altitude Setting 59 Avalanches 000 13 B BearingS eee eee 96 Before Starting the Engine 41 Bleeding the Brake System 79 Brake Components 11 Brake Fluid 78 Brake Inspection 77 Brake Lever Travel 42 77 Brake System Bleeding 79 Brakelight Replacement 81 Brakes 35 6 40 ck obiics oes 42 77 79 c Carbide Skags 37 Carburetion 54 55 Carburetor ovals se sek da 74 Carburetor Adjustments 74 Carburetor Protection 9
14. 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 78 8 Reinstall the gasket and cover 79 MAINTENANCE Lights Do not touch a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot that will shorten the life of the lamp If fin gers do touch the bulb clean it with an alcohol moistened towel Headlight Bulb Removal 1 Remove the plenum covering from the headlight assembly 2 Lift the rubber boot to expose the bulb 2 3 Push down on the spring 1 to j release it from the housing 4 With the wire harness 2 attached to the bulb 3 with 1 draw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Headlight Bulb Installation 1 Hold the bulb by its metal base and install it into the wire harness NOTE Recommended replacement bulbs include H4 HB2 and 9003 bulbs 2 Insert the bulb into the housing 3 Connect the spring to the housing S 4 Carefully flip the spring back into the housing placing it around the wire harness 5 Reinstall the plenum covering on the headlight assembly 6 Verify hea
15. Disengaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Push the yellow reverse button for one second and release The engine will slow and and begin to rotate forward The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the machine is in forward Altitude Setting At higher altitudes above 6000 feet the engine will require a different ignition setting to improve the success of the reverse system To set for a higher altitude start the engine and hold the button down until the light on the instrument panel flashes rapidly then release the button To set the reverse for lower elevations continue holding the button down until the reverse indicator light blinks slowly Once set it s stored in memory until changed whether the machine is running or not 59 OPERATION Towing Do not use the front bumper to pull or drag the snowmobile The front bumper is not designed for this type of use and may detach from the vehicle if force is applied For your safety do not attempt to use a tow hitch until you ve read the following warnings and understand the proper hitch functions WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hi
16. In No single action on your part is as important to long trouble free machine life as proper break in of a new or rebuilt engine Premix the first tank of fuel with one pint of Polaris injection oil for each five gal lons of fuel This in addition to the lubrication supplied by the injection system will assure proper engine break in NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and machine speeds to reduce friction on all close fitting machined parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the machine 48 OPERATION Engine Break In Oil Injection System Always check and fill the oil tank when refueling See page 53 NOTICE Serious engine damage can occur without the proper lubrication Check the oil tank level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately Oil Recommendations Engine lubrication comes from oil added to the fuel and oil injection systems Polaris recommends the use o
17. Printed in U S A 2010 IQ Shift Owner s Manual P N 9922316 2 TABLE OF CONTENTS Introduction 3 hee 9 ose eh ea een et 4 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner s manual DIOL ee alk Bane tek dite ak it Maat tt oi A 6 This section describes safe vehicle operation and identifies warning decals and their locations Features 4 2233 Ske ee Se 25 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 200e20ees 28 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 5 40 This section explains procedures that must be performed before riding Operation os c2ni ieee es gee eee yen es 47 This section explains proper engine break in operation of features and general operating procedures Maintenance 265 56 i ie ee eee ie Ss 61 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris Products oi icine oe os Ve viene Paes 98 Troubleshooting 0000eeeeeee 99 Warranty 23 bib pet iinwe etch ee ian ties 104 Maintenance Log 2 000000e 113 Index nit ttar ase a ae eA Rar EAA 116 INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in
18. Reduce RPM Avoid riding in and slow speed 8000 high ambient temperatures Check for snow ingestion RPM 10 MPH Ice and snow build up between track and tunnel e Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance Loading machines onto trailers e Check for carburetor and choke synchronization fouled plugs debris in the carburetor s and water ice or dirt in the fuel tank or fuel line e Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch engage ment e Use fast aggressive throttle to engage clutch 103 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information con tained in this manual Contact your Polaris dealer for replacement parts ser vice or warranty Your dealer receives frequent updates on changes modifications and tips on snowmobile maintenance which may supersede information contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts s
19. accidents e Remove the key from the ignition when you leave the snowmobile unattended 19 SAFETY Operator Safety Windchill Temperature Charts The following information is provided to help you determine when tem peratures become dangerous for riding WINDCHILL CHART F Wind Actual Thermometer Reading F Spoed 40 35 30 25 20 15 10 5 0 5 10 15 201 25 30 35 40 45 MPH Equivalent Temperature F Calm 40 35 30 25 20 15 10 5 O 5 10 15 20 25 30 35 40 45 5 36 31 25 19 13 7 1 5 11 16 22 28 34 40 46 52 57 63 10 34 27 21 15 9 3 4 10 16 22 28 35 41 47 53 59 66 72 15 32 25 19 13 6 O 7 13 19 26 32 39 45 51 58 64 20 30 24 17 11 4 2 9 15 22 29 35 42 48 55 61 3 1 0 25 29 23 16 30 28 22 15 35 28 21 14 40 27 20 13 45 26 19 12 7 14 21 27 34 41 48 1 8 15 22 29 36 43 50 16 23 30 37 44 50 26 19 12 3 10 17 24 31 38 45 55 25 18 11 3 11 18 25 32 39 46 60 25 17 10 3 4 11 19 26 33 40 Frostbite in gt gt 30 min A A GH MD N j i N 1 o
20. dealer at specific mileage intervals 17 SAFETY Operator Safety Inadequate Snow Conditions WARNING Do not drive for prolonged periods on blacktop gravel or ice Doing so could cause irreversible track damage and lead to serious injury Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your machine Driving in too lit tle snow will result in excessive wear and damage to the slide rail track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will be able to climb up and over the snow NOTICE When operating on icy surfaces or hard packed snow avoid overheat ing the slide rail and track Lack of lubrication and cooling will cause overheating of the slide rail and track resulting in premature wear and failure If frequently operating in low cooling conditions see your cca an optional wheel kit that will reduce the wear from over eating 18 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions may become dangerous if operators drive improperly If you re new to snowmobiling acquaint yourself with the machine and with what it will and won t do under various conditions Even seasoned driv ers s
21. helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean SAFETY Operator Safety Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone For added protection carry the following items on your snowmobile at all times Spare Drive Belt e Winter Survival Kit e Extra Set of Spark Plugs e Trail Map e Tow Rope e Owner s Manual e Extra Oil e First Aid Kit e Fuel Deicer e Tool Kit 10 SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Rider Capacity Your Polaris snowmobile is designed for a single rider only Do not carry a passenger Excessive Speed WARNING High speed driving especially at night could
22. improper carburetor adjustment WARNING Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage Always have your Polaris dealer perform any carburetor adjustments 54 OPERATION Carburetion Jetting Guidelines Changes in altitude and temperature affect air density which is the amount of oxygen available for combustion In low elevations and cold temperatures the air has more oxygen In higher elevations and higher temperatures the air is less dense The carburetors are calibrated for an altitude of 0 2000 ft 0 600 m and ambient temperatures of 0 to 20 F 18 to 7 C Carburetors must be re calibrated if the snowmobile is operated outside this production temperature and or altitude range The main jet installed in production is not correct for all altitudes and or temperatures See page 74 for more information NOTICE A main jet that s too small will cause a lean operating condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts in your Owner s Manual Supplement Tip It s the owner s responsibility to ensure that the correct jets are installed in the machine for a geographical area Be very careful when jetting down in warm weather As the weather turns colder it will be necessary to re jet upward to prevent engine damage When selecting the proper main jet always use the lowest elevation an
23. or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover WARNING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service clutches yourself see your dealer 21 SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death No Passenger Warning The NO PASSENGER warning decal is on the console below the steering post WARNING This vehicle is designed for operator only NO PASSENGER 22 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the upper console WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Operation Warning Th
24. repair or replacement of defective parts that are covered by this warranty The warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and setup of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer setup will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was manufacture
25. stiff ride on the trail A suspension set up for trail riding would bottom out harshly on a snowcross course Refer to the suspension setup label on your snowmobile or see your Polaris dealer for initial suspension setup information Additional adjustments can be made after initial setup Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer 30 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred setup These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep snow a new rail slide will offer improved performance over worn rail slide It can also improve top speed When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer Polaris offers track kits for improved flotation in deep snow See your dealer for assistance Tip Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension components Grease rear suspension pivots before adjusting the rear suspension Refer to Suspension Maintenance beginning on page 94 Track Tension T
26. the right locknut and tighten the right adjusting bolt 4 After adjustments are com plete tighten the locknuts and torque idler shaft bolts to 35 ft Ibs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 90 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary 91 MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski alignment or camber adjustment See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y Tip If the skis are misaligned we recommend that your dealer correct the align ment since camber adjustment may also be affected x gt o gt lt o lt A v 92 MAINTENANCE Steering System i Ski Skags See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary
27. the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake and steering for proper operation Make sure hood is latched Be seated and in position to control the vehicle Oil injection system Use unmixed fuel only Check oil level when refueling FEATURES OMNOARWN gt Hood Headlight Windshield Handlebar Seat Taillights Rear Bumper Snow Flap Console Storage Compartment if equipped Suspension Track Skis Nosepan Front Bumper do not use for pulling or dragging the snowmobile 25 FEATURES OBNOARWN gt 26 Fuel Filler Cap Dipstick Recoil Starter Handle Reverse Indicator Headlight Adjuster Speedometer Engine Stop Switch Choke Lever Ignition Switch Brake Lever Parking Brake Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button Headlight Dimmer Switch Throttle Control FEATURES Fuel Valve The fuel
28. to add track studs to maintain proper vehicle con trol while turning on hard packed snow or ice WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter Tip Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the machine so the skis are approximately 6 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the rear end of the skag 4 Remove the front end of the skag 5 Reverse the steps to install a skag 93 MAINTENANCE Steering System X Rail Slide Wear Measure slide thickness at several points along the rail 7 16 Have your dealer replace the ir 1 cm k slide when it s worn down to Yo the top of the wear limit indicator groove Do not operate the snowmobile if slide thickness measures less than 7 16 1 1 cm Suspension Maintenance Pre Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile s reliability and cause needless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip Check suspen
29. you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance see page 104 110 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle Polaris Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped s
30. 6 Carburetor Water Sediment Trap 75 Chaincase Oil 68 69 Choke e scat anasa 2h she ed baat 67 Choke Cable 67 Choke Operation 47 Cleaning and Preservation 95 Clutch Alignment Offset 82 Clutch and Drive System 96 Clutch Center Distance 82 Clutch Cover Warning 21 Clutch Safety 0 17 Clutch System 82 85 Cold Weather Drive Away 17 Controls and Linkage 95 Coolant 29 ine eta as 73 Cooling System 73 Customer Service 104 116 D Disabled Operators 11 Drive Belti a lt zeae ks rroan 17 84 Drive Belt Adjustment 85 Drive Belt Condition 83 Drive Belt Deflection 85 Drive Belt Installation 84 Drive Belt Removal 83 Drive Belt Troubleshooting 103 Drive Chain Tension 76 Driver Awareness 12 Driveshaft Bearing 67 Driving Downhill 15 Driving in Hilly Terrain 16 Driving on Slippery Surfaces 14 Driving Responsibly 19 E Electrical Connections 97 Engine Break In 48 49 Engine Protection 96 Engine Safety 8 Engine Stop Switch 56 Environment 00 5 Exhaust System 73 F Front Rear Scissor Stop
31. RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased War ranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If
32. RATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris snowmobiles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer The cost of transpor tation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to per form warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polaris if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 107 WARRANTY Conditions and Exclusions In order to qualif
33. RNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard SAFETY Operator Safety Follow the recommended maintenance program beginning on page 62 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals AWARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are capable of traveling at high speeds Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may bec
34. Replace L Lubricate 65 MAINTENANCE Lubrication Front Suspension The front suspension does not require lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles 800 km initially every 1000 miles 1600 km after that and before off season storage each year Lack of lubrication will adversely affect your ride and the life of the suspension For more infor mation about suspension lubrication and adjustments see your Polaris dealer 66 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Choke and Choke Cable Lubricate the choke slide and cables oe lightly with oil or grease Before ey turning the engine off operate the Pas choke intermittently to draw mois ture out of the choke plunger area and reduce the possibility of the choke becoming frozen 67 MAINTENANCE Lubrication Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 62 The sight glass 1 1s located on the lower rear of the chaincase Maintain the
35. additional wheel kits are available See your dealer for more information Tip Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty 87 MAINTENANCE Track Maintenance WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine running Track Tension Track adjustment is critical for proper handling Always maintain cor rect tension and alignment TRACK TENSION DATA CHART Suspension Weight Measurement Slack p g Location Measurement 1Q T0 Ibs 4 54kg 16in 40 cm 718 1 1 8 in ahead of rear 2 2 2 9 cm idler shaft Tip Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the machine and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel Measure at the point where the weight is hanging 88 MAINTENANCE Track Maintenance Track Tension 4 Check for specified slack between the wear surface of the track clip and the plastic slider Refer to the Track Tension Data Chart on page 88 If the track needs adjustment 5 Loosen the rear idler shaft bolt 6 Loos
36. age Daily 95 Storage Extended 95 97 Survival Preparation 10 Suspension Coupling IQ 34 35 Suspension Inspection Pre Ride 94 Suspension Maintenance 94 Suspension Performance Tips 31 Suspension Front Lubrication 66 Suspension Rear Lubrication 66 117 INDEX T Taillight Brakelight Replacement 81 Throttle Cable 67 Throttle Lever 41 57 Throttle Safety Switch 41 56 Torque Stop 000 85 Torsion Spring Preload IQ 33 TOWING ak vs tuera aa gale 60 TAC oncy seca tacks aad seg ee 44 Track Alignment 90 Track Care for Storage 97 Track Inspection 86 Track Lubrication 87 Track Maintenance 86 90 Track Safety 00 8 Track Tension 31 88 Track Warm Up 50 Track Waming 22 Traction Products 37 Transporting the Snowmobile 97 Troubleshooting Drive Belt 103 Troubleshooting Engine 99 101 Troubleshooting Rear Suspension 102 Tune Ups ciren es wake r ane 95 118 V Vehicle Identification Numbers 4 WwW Weight Transfer 36 Windchill asss ge caa gees eed es 20 Windchill Temperature Charts 20
37. ailures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle Polaris recommends that you contact an autho rized Polaris dealer to perform any service that may be necessary for your vehicle Polaris also recommends that you use only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the Polaris Warranty Department at 1 888 704 5290
38. ble for replacing brake pads See your dealer WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16 1 5 mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the machine to an autho rized Polaris dealer for inspec tion and adjustment 77 MAINTENANCE Brakes Brake Fluid WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury The brake fluid level can be seen through a plastic sight glass in the brake reservoir If the fluid is sufficient the sight glass will be black If the sight glass is any color other than black add brake fluid Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged mov
39. d The warranty does not cover any dam ages that occur during trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the snowmobile due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARIS ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 106 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DU
40. d parts and accessories may result in e Non compliance with government industry requirements e Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Tip Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service 37 THE PERFECT FIT Handlebar Adjustments When making handlebar adjustments always be sure the handlebars brake lever and throttle lever operate smoothly and do not contact the fuel tank windshield or any other part of the vehicle when the handle bars are turned fully to the left or right Handlebar Position Follow these steps to adjust handlebar position 1 Remove the handlebar cover 2 Loosen the four upper and four lower adjuster block bolts 3 Adjust the handlebar to the desired position 4 Torque the front bolts first then torque the rear bolts Torque the bolts to 15 17 ft Ibs 20 23 Nm 5 Reinstall the handlebar cover 38 THE PERFECT FIT Handlebar Adjustments Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block l 2 3 4 5 Remove the handlebar cover Loosen the four upper adjuster block bolts Adjust the handlebar to the desired angle Torque the bolts to 15 17 ft Ibs 20 23 Nm Reinstall the handlebar cover 39 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all
41. d temperature that is likely to be encoun tered 55 OPERATION y Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly Pull the switch up to the ON position to allow restart ing y Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exert ing pressure on the pivot pin in the direction shown in the illustra tion 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine 56 OPERATION Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control which could result in serious injury or death If the throttle l
42. dlight aim 80 MAINTENANCE Lights Taillight Brakelight Replacement l 2 3 Remove the screws securing the taillight lens Remove the lens Push the bulb inward and turn it counterclockwise to remove it Install a new bulb Push the bulb inward and turn it clockwise to secure it Reinstall the taillight lens 81 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol NOTICE If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not operate the machine until repairs have been made All clutch maintenance and repairs must be performed by an autho rized Polaris dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor mance See your dealer for service and adjustments A special tool is required to check for proper alignment Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer 82 MAINTENANCE Clutch Syst
43. e failure Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death 15 SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll over causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the machine to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the machine pull the rear of the snowmobile around and point the front end and skis downhill Remount the machine restart the engine release the parking brake and descend the hill carefully 16 SAFETY Operator Safety Drive Belt Do not operate th
44. e engine with the drive belt removed Any servicing that requires operation without a belt must be performed by your dealer Operation of the engine with the belt removed may result in injury or damage to the engine Intake Silencer Do not operate the engine with the intake silencer or filter removed Damage to the engine may occur if the intake silencer or filter are removed Clutches Do not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this pre cision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the machine into motion but always operate within safety limits Maneuverability While much control and maneuverability is achieved through the steer ing system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or machines designed to carry a load Maintenance Follow the recommended maintenance program beginning on page 62 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your
45. e on some snowmobiles but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control WARNING Improper riding position may reduce control and could result in secs injury or death Always ride in a position that allows for control of your vehicle SAFETY Operator Safety Riding Apparel Be prepared be warm and be com fortable when riding Be aware of the Perne weather forecast especially the wind chill and dress accordingly See the chart on page 20 WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 031039 granted approval The ape number and serial 0006 31 number will also be displayed on the label i Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof
46. e operation warning decal is located on the lower console See page 24 for the text Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to forward 23 SAFETY Safety Decals and Locations Operation Warning 24 To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing con tact a Polaris dealer for a replacement This vehicle is capable of high speeds Buried objects or uneven terrain can cause loss of control Reduce speed and use extreme caution when operating in unfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehi cle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control
47. e snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubri cation would include frozen bodies of water without snow cover icy trails and no snow conditions Tip Track damage or failure caused by operation on ice or poor lubrication con ditions voids the track warranty 44 PRE RIDE INSPECTIONS Before Starting the Engine Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions Under no circumstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your Polaris dealer for replacement 45 PRE RIDE INSPECTIONS Start the Engine and Check Before starting the engine always refer to all safety warnings pe
48. ealer Check track tension see page 88 Machine darts from e Check ski alignment see page 92 side to side Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag see page 32 Check rail slide replace if worn see page 94 Install Accu Trak dual skags see your dealer Front end pushes e Check for worn skags Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Set static sag see page 32 Install single skag see your dealer Increase IFS preload if equipped see page 28 Rotate RRSS to high position see page 36 Steering is heavy e Make sure spindles and all steering components turn freely Check ski alignment see page 92 Check skags and skis for damage Set static sag see page 32 102 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear Burn Diagnosis Causes Solutions Driving at low RPM e Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up e Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Towing at low RPM e Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM e Lower the gear ratio
49. ee position cam using the engine spark plug tool Adjustment is easiest when the cam is rotated from low to medium and then to high Rotating directly from low to high will require significantly more effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Soft Medium Firm Limiter Strap Position Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a rider prefers more ski pressure for improved steering performance adjustments can be made to the front limiter straps Tighten the straps to increase ski pressure Loosen the straps to reduce ski pressure 1 Remove the nuts and flat washers from the upper limiter straps 2 Relocate the straps to the desired position 3 Reinstall the nuts and washers Tighten securely 33 THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the advent of sus pension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other There are two types of rear suspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS This type of coupling is available as an accessory for your model The front rear scissor
50. em Drive Belt Condition Periodically check the condition and tension of the drive belt and always carry a spare Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 103 For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile Drive Belt Removal NOTICE Do not attempt to remove the drive belt after operating in reverse The snowmobile must be stopped after forward motion to prevent damage to components during belt removal 1 Stop the engine after operating in a forward motion 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Open the hood 5 Remove the left side panel 6 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt 83 MAINTENANCE Clutch System Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack Tip To ensure satisfactory belt life install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt
51. ement of brake fluid below the diaphragm may be restricted altering brake function Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid See page 98 for the part numbers of Polaris products NOTICE Brake fluid will damage decals paint and some plastics Always wipe up spills immediately 78 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action Bleed the system before operating the snowmobile WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever During the bleeding procedure keep the brake handle as level as possi ble The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent 1 Remove the brake master cylinder reservoir cover and gasket 2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 6 8 cm below the lip of the reservoir open ing Reinstall the gasket and cover 3 Slip arubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps
52. en the locknuts Adjusting Screw Lock Nut Slack Measurement t __ 10 Ibs 16 40 cm 4 54 kg 7 Tighten or loosen the track adjusting screws to provide equal adjust ment on both sides of the track 8 Repeat the measurement on the other side of the track Tip Check more frequently when the machine is new 9 Start the machine and slowly rotate the track at least five revolu tions Let the track come to a stop do not apply brakes 10 Check track alignment see page 90 and adjust as necessary 11 Tighten the locknuts 12 Tighten the idler shaft bolts 13 Torque idler shaft bolts to 35 ft lbs 47 5 Nm 89 MAINTENANCE Track Maintenance Track Alignment Periodically check that the track is centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rail 1 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen the idler shaft bolts then loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen
53. ervice or warranty always provide the fol lowing information Serial number Model number Dealer name Date of purchase Details of trouble experienced Nn BW WN Length of time and conditions of operation 7 Previous correspondence Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 888 704 5290 Canada 1 204 925 7100 104 WARRANTY Service and Warranty Information Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines Administration 1 Polaris snowmobile owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifying the proper owner when a unit is recovered 105 WARRANTY Limited Warranty Polaris Sales Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIM ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship This warranty covers the parts and labor charges for
54. ever 2 Parking Brake Lever Lock 3 Master Cylinder Reser voir Cover 4 Fluid Level Indicator Lock Engagement To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever Tip If the brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The brake light will illuminate if the parking brake lever lock is set while the engine is running It will also illuminate when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock will return to the unlock position WARNING If the parking brake lever lock is partially or entirely engaged while riding the brakes may overheat resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death Always ensure that the lever lock is completely disengaged before operating the snowmobile 43 PRE RIDE INSPECTIONS Before Starting the Engine KX Steering System Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage y Track WARNING Operating th
55. ever does not work properly DO NOT start the engine If the engine stops abruptly when the throttle lever is released 1 Turn the ignition switch to OFF 2 Visually inspect the throttle cable and carburetor to determine what caused the safety switch to activate 3 Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely 4 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe engine doesn t start take the snowmobile to an authorized Polaris dealer for service Excessive freeplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the machine to an authorized Polaris dealer for service If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOT continue to operate the machine with the throttle safety switch disconnected Return the machine to an authorized Polaris dealer for service as soon as possible 57 OPERATION Electronic Reverse PERC Electronic reverse will activate only if the engine RPM is below 4000 If your machine is running at an altitude of over 6000 feet adjust the igni tion setti
56. f Polaris Premium Blue or VES II 2 cycle oil for this engine See page 98 for the part numbers of Polaris products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other Slide Rail and Track Cooling NOTICE Inadequate cooling and lubrication will lead to overheating of the slide rail and track resulting in premature wear and failure Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice hard packed surfaces or roads 49 OPERATION Track Warm Up WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throttle during warm up or when the track is free hanging Use a stable rear support WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train a
57. g 1 Open the hood and inspect the muffler and pipes for cracks or dam age 2 Check for weak or missing retaining springs or damper support grommets 3 Check for loose clamps on the pipe covers 73 MAINTENANCE Carburetor The number stamped in the end of the main jet indicates the jet size The jet installed at the time of manufacture is not necessarily correct for your elevation It s your dealer s responsibility to make sure the correct main jet is installed NOTICE Operating the snowmobile with incorrect jetting can result in serious engine damage Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the carburetor may need adjustment e Hard starting e Poor idle e Overheated pistons and cylinder walls e Plug fouling e Poor engine response to various throttle valve openings 74 MAINTENANCE Carburetor Water Sediment Trap Most Polaris snowmobiles contain patented carburetor bowl water sedi ment traps located at the bottom of each carburetor The trap consisting of a hose with a plug should be drained about every 1000 miles 1600 km and inspected for contamination WARNING When draining
58. ght brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incor rect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap Rotate the spark plug counterclockwise to remove it Reverse the procedure for spark plug installation Torque to 18 22 ft Ibs 24 30 Nm Reinstall the spark plug cap DN ee 71 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system When operating in loose powder snow check the foam filters period ically to remove any accumulation of snow NOTICE Operating the snowmobile with the intake filters removed may cause carburetor icing The result will be poor fuel economy or carburetor mal function Always reinstall the intake filters before operating the snowmobile Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter The oil f
59. hould spend some time getting the feel for a machine before attempting ambitious maneuvers e A snowmobile depends on the rider s body position for proper bal ance in executing turns traversing hills etc Always start on a smooth level area to begin building your operating experience Before allowing someone else use your snowmobile know the extent of their operating skills Check to see if they ve taken a snowmobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowmobile is not intended for this kind of use e Be courteous to oncoming traffic by dimming your headlights and reducing your speed e When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic around your vehicle Drive defen sively to avoid
60. icals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 51 OPERATION Fuel Your Polaris engine is designed to run on 87 octane non oxygenated or 89 octane oxygenated pump gasoline There s a great deal of variability in the quality of the 87 octane gasoline available across the country so we encourage the use of premium fuel when possible Do not use fuel containing more than 10 ethanol including E85 NOTICE Using fuels with a lower than recommended octane or operating with obstructed fuel systems will result in serious and costly engine dam age Always use the recommended fuels for your machine Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends the use of Carbon Clean Plus See page 98 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives should not be used Fuel Valve Turn the fuel valve clockwise to OFF to shut off the fuel supply Turn the valve counter clockwise to ON to turn the fuel supply on OFF 52 OPERATION x Oil Low Oil Indicator Light
61. ide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Avoid travel ling on frozen bodies of water When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses 12 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain e Take an avalanche class Travel with experienced people e Travel on designated trails e Make sure each person is equipped with a shovel probe and avalanche beacon You don t have to be snowmobiling on a slope for an avalanche to occur Be aware that all of the snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in moun tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information For more information about avalanche training and avalanche condi tions contact local law enforcement in your area
62. ilter is located at the side of the oil tank Have your dealer change the oil filter and bleed the system annually or every 1000 miles 1600 a km Tip The direction of the arrows indicates the direction of flow through the fil ter Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump 72 MAINTENANCE Fuel Filter Fuel Lines See your Polaris dealer for replacement of the under tank fuel filter every 1000 miles or annually Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly Cooling System Inspect the fan intake and outlet edge seal at the input and output for cracks loosening of duct and blockage or obstructions Make any neces sary repairs promptly Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles 3200 km Always allow the engine and exhaust system to cool completely before inspecting CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine runnin
63. iodically check torque stop P i clearance With clutches in 010 030 ae q proper alignment the torque 25 75 mm stop clearance should be 010 030 25 75 mm from the engine case Adjust if necessary and lock o the jam nut 85 MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and support the rear of the snow mobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for breakage 4 Replace the track if any rod damage is found 86 MAINTENANCE Track Maintenance Track Lubrication WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication The slide rail needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear Tip If excessive rail slide wear occurs due to poor snow conditions
64. ion of our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be wel come to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter machines we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly Air Pollution Polaris engineers continuously investigate ways to reduce emission lev els of two stroke engines We expect our efforts to lead to the reduction of potential air pollution In addition to our technological research we encourage government agencies manufacturers distributors dealers ecologists and other interested parties to work together to develop data on environmental topics SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WA
65. items on the checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on the ref erenced pages Look for a checkmark on the referenced pages to locate the pre ride inspection items Item See Page Drive Belt Condition 83 85 Steering System 44 Recoil Rope 45 Cooling System Seal 73 Parking Brake Lock Brake Lever Brake System 42 43 77 Auxiliary Shut Off Switch Engine Stop Switch 46 Ignition Switch 46 Taillight Brakelight Headlight 46 Suspension Mounting Bolts 94 Skags Wear Bars 93 Ski Spindle Bolts 94 Hood Straps Latches 45 Seat Latches if equipped N A Throttle Lever Safety Switch 56 57 Rear Wheel Idler Bolts 89 Tether Switch Strap accessory 46 Track Alignment Condition 44 90 Rail Slide Condition 94 Chaincase Oil Level 68 Injection Oil Level 53 40 PRE RIDE INSPECTIONS Before Starting the Engine WARNING Worn damaged or malfunctioning components may cause serious injury or death Before starting the engine check all components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make s
66. l Snow Check promotion The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transfer able 120 days after the original purchase date free of charge through any Polaris snow mobile dealer Coverage on Snow Check units is automatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty reg istration form This form is your proof of warranty Consumer Exclusions Each repair visit after the first twelve months of standard warranty coverage is subject to a 50 deductible The free Second Year Engine Service Contract applies to the first 5 000 miles or two 2 calendar years from date of purchase whichever comes first Tampering with the odometer shall void all warranties service contracts No extensions to coverage under this engine service contract can be given Used snowmobiles are not eligible under this program Snowmobiles used for commercial purposes or for racing are excluded from coverage Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage i
67. l l Fuel Filter 73 R R Oil Filter 72 R R Oil Lines 72 l l l Air Box l l l l l Drain and Water Traps 75 l l l ELECTRICAL Auxiliary Shut Off 56 l l l l l Switch Throttle Safety Switch 56 l l l l l Ignition Switch l l l l l Taillight 46 l l l l Brakelight 46 l l l l l Headlight 46 l l l l l 64 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 750 mi 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CHASSIS Ski Toe Alignment l l l Suspension Mounting l l l l l Bolts Steering Fasteners l l l l Cc Rear Suspension Fas l l l l l teners Suspension Shock Oil l l l l Cooling System 73 l l l l Drive Shaft Bearing 67 L L L l Jackshaft Bearings 96 L L L l Skags Wear Bars 93 l I l l l Ski Saddle Spindle l l l l l Bolts Steering Arm s l Drive Chain Tension 76 l l l l l Hood Latches 45 l l l l l Rear Wheel Idler Bolts 89 l l l l l Idler Bolt Jam Nut 89 l l l l l Rear Suspension Pivot 66 L L L Shafts Camber Alignment l l l Handlebar Centering l Tether Switch and Strap 46 l l l l l Track Alignment 90 l l l l l Track Tension 88 l l l l l Front Limiter Strap l l l l l Rail Slide Condition 94 l Chaincase Oil 68 l l l R l Inspect clean adjust tighten lubricate replace if necessary C Clean R
68. maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 108 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow mobiles that were Snow Checked through an authorized Polaris dealer during the March Apri
69. method for controlling weight transfer during acceleration is HGH by adjusting the rear rear scissor stop LOW LOW RRSS The factory setting is the best for most trail riding conditions MEDIUM To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration rotate the RRSS to a lower position Tip Your dealer can help you with initial setup and additional setup instruc tions to help you achieve your opti mum ride A scissor stop tool is also available from your dealer 36 THE PERFECT FIT Traction Products Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain Inspect skags frequently Worn skags may reduce steering and braking control on hard packed snow and ice Replace worn skags to maintain proper balance and vehicle control WARNING Loss of control can result in serious personal injury or death Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice See your dealer for assistance Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only Polaris parts and accessories on your Polaris snowmobile Use of unapprove
70. ncludes Damage due to accident fire explosion theft or other causes beyond Polaris control Damage caused by the failure of other components of the snowmobile Failures caused by improper fuel or oil Piston seizures unless caused by a defective engine component Failures caused due to improper adjustments Failure due to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of unauthorized parts or modifications Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related throttle body parts are covered The fuel pump is covered Clutches and related clutch parts including but not limited to the drive belt are excluded from coverage Electrical components are excluded from coverage Gearcases and transmissions are excluded from coverage 109 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR
71. nd track 1 Use an appropriate stand to securely sup port the rear of the snowmobile at the rear bumper The track should be about 4 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions Tip It will take longer to warm up the track suffi ciently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the machine to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice 50 OPERATION Fuel AWARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the snowmobile is stored or parked A WARNING The engine exhaust from this product contains chem
72. ng and engine malfunctioning Change the spark plugs every 2000 2500 miles 3200 4000 km NOTICE A spark plug with a heat range too high will always cause engine dam age if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See your Owner s Manual Supplement A new engine can cause temporary spark plug fouling due to the preser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization e Use recommended spark plugs with the proper gap e Use only resistor type spark plugs e Torque spark plugs to 18 22 ft lbs 24 30 Nm e Always carry spare spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Tip Incorrect fuel mixture can often cause a spark plug to appear too dark or too light in color Before changing spark plug heat ranges be sure the correct main jet is installed in the carburetor s Refer to the Owner s Manual Sup plement or see your dealer 70 MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray tan or li
73. ng as described on page 59 Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse Tip The engine will activate a misfire mode and begin to stutter after 45 sec onds in reverse This feature protects the engine from overheating and will reset when it is shifted into forward or when the engine is stopped and restarted WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed e Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle e Look behind the vehicle before and while backing e Avoid sharp turns Apply throttle slowly 58 OPERATION Electronic Reverse PERC Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one sec ond then release The engine will automatically reduce RPM and start a reverse rotation A flashing reverse light on the instrument panel will indicate that the machine is in reverse 4 Apply the throttle slowly to make sure the machine is in reverse Tip The maximum engine RPM will be 6000 when in reverse Tip If the engine stops running the snowmobile will be in forward gear when it s restarted
74. o it conforms with applica ble U S Environmental Protection Agency emission regulations Polaris warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 200 hours of engine operation 4000 kilo meters 2485 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems e Aur induction system e Ignition system e Fuel system Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions e Aftertreatment devices e Sensors e Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank e Vacuum Con
75. oil level at or slightly below the center of the sight glass 2 Change the chaincase oil after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 98 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level sur face View the oil level at the sight glass 3 Remove the fill plug 3 and add the recommended oil as needed Do not overfill 4 Reinstall the fill plug making sure it is seated properly 68 MAINTENANCE Lubrication Chaincase Oil Oil Change 1 Position the vehicle on a level surface 2 Remove the drain plug 4 and drain the oil into a drain pan Allow the oil to drain completely 3 Clean off all metal shavings from the plug 4 Install a new sealing washer on the drain plug Tip The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain plug Torque to 6 10 ft lbs 8 13 Nm 6 Remove the fill plug Clean off all metal shavings from the plug 7 Add 9 oz 265 ml of the recommended oil Do not overfill 8 Reinstall the fill plug making sure it is seated properly 69 MAINTENANCE Spark Plugs It s very important to use the correct spark plug for your machine A spark plug with a heat range too high will cause engine damage A spark plug with a heat range too low will cause excessive fouli
76. ome aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience and the features availabl
77. our vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited
78. rack adjustment is critical for proper handling Always maintain cor rect tension and alignment Refer to the track tension maintenance sec tion beginning on page 86 31 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the rear suspension torsion spring preload measure the distance between the ground and rear bumper This is measurement X Take the first measurement with no rider and with the rear suspension at full extension Tip The rear bumper may need to be lifted upward slightly to fully extend the rear suspension Next have the rider drop down hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y lt x gt To determine sag commonly referred to as ride in subtract mea surement Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload Suspension Recommended Sag Adjustment Bae IQ 121 4 5 inches 10 13 cm Torsion Spring 33 Preload Tip This is only an initial setup and final spring preload may vary based on rider preference and riding conditions 32 THE PERFECT FIT IQ Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload rotate the thr
79. result in serious injury or death Always reduce speed when driving at night or in inclement weather Always observe all laws governing snowmobile operation and speed limits Always be alert and pay attention to the trail ahead Multiplying speed MPH by 1 5 will equal the approximate number of feet per sec ond your machine travels If your speed is 40 MPH your machine is traveling about 60 feet per second If you look back for only two sec onds your machine will travel about 120 feet If your speed is 60 MPH your machine will travel about 180 feet in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your machine to a stop in the distance illumi nated by the headlight 11 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles posts or other obstacles Be especially alert if you re snowmobiling after dark Always be on the alert for wire fences Single strands are especially dangerous since there may be a great distance between posts Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your machine will drown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or high ways Steep embankments may also h
80. rtaining to snowmobile operation Never start your snowmobile without check ing all components to be sure of proper operation See Before Starting the Engine beginning on page 41 Engine Stop Switch Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF 1 Tether Switch if equipped If your machine has a tether switch remove the tether from the switch to make sure the engine stops immediately vy Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating Mirrors if equipped Adjust the mirrors so they can be used to their full advantage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the machine 46 Starting the Engine NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never OPERATION engage the starter when the engine is running Turn the fuel valve on See page 27 Turn the key to the ON position Pull the engine stop switch up to the RUN position If starting a cold engine flip the choke toggle to FULL CHOKE Do not use the choke if starting a warm engine Do not depress the throttle until the engine s
81. s 800 km and 1000 miles 1600 km These inspections should be per formed by a qualified service technician For continued optimum perfor mance and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjust ments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfort able performing these tasks yourself contact an authorized Polaris dealer for service NOTICE Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmo bile on its side for service or inspection 62 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement parts always use genuine Polaris parts available from your Polaris dealer Springs
82. should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is avail able to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty and read the maintenance section of your owner s manual You are responsi ble for ensuring that the specified maintenance is performed Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 61 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beginning on page 113 The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 mile
83. sion mounting bolts for tightness Check rear idler wheel bolts for tightness See page 89 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition Check track tension See page 88 Lubricate all rear suspension components See page 66 Check ski runner skag condition See page 93 Check ski spindle bolts for tightness Check tie rod end nuts for tightness YYYYYYY YY 94 MAINTENANCE Daily Storage At the end of each ride park the snowmo bile on a level surface and support it at the rear with an appropriate track stand The track should be suspended approximately 4 10 cm off the ground Remove the key and cover the machine Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer His experienced and trained service technician will keep your machine in peak operating condition Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 98 for the part numbers of Polaris products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from
84. stment To change front shock spring preload grasp the spring and rotate it Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension Never exceed one inch of pre load beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make ee High sure at least two turns of preload are hold ing the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body Failure to do so could cause the retainer to fall off when the suspension is fully extended Tip Not all models have shocks with thread adjustable spring preload See your dealer for more information NOTICE On some models equipped with a plastic adjuster nut the nut will break if it is unscrewed from the threaded body Do not force the nut if resistance suddenly increases while you re turning it Preload Preload 29 THE PERFECT FIT Rear Suspension Adjustments Rider weight riding style trail conditions and vehicle speed all affect suspension action Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However all sus pension designs and adjustments involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very
85. stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm causing it to compress and raise the rear suspension up as one allowing the suspension to hit the bump only once and reducing kickback The factory setting is usually adequate for all riders and conditions 34 THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling Rear To Front Coupling and the Rear Rear Scissor Stop RRSS The rear rear scissor stop RRSS couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen dent movement between the rear torque and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS Attributes Moving the RRSS to a higher position will have the following effects on the suspension e Reduced weight transfer Improved chatter bump ride Improved cornering performance 35 THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration The preferred
86. sur faces before beginning preservation with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed out of direct sun light and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Mainte nance Table beginning on page 63 95 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All Season Grease or a similar high quality grease to prevent corrosion Clutch and Drive System Remove the drive belt and store in a cool dry location Do not lubricate clutch components except the driven clutch shaft bushing as outlined in the Master Repair Manual See your dealer Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to r
87. tarts CHOKE POSITIONS OFF 1 2 CHOKE FULL CHOKE CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running NOTICE Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result If equipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts 5 6 If not equipped with electric start grasp the starter handle and pull slowly until the recoil engages then pull abruptly to crank the engine Repeat the cranking procedure as needed until the engine starts After the engine starts flip the choke toggle to the OFF position If the engine slows or wants to stop use intermittent choking to the HALF CHOKE position 47 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 56 for more information about the engine stop switch and throttle safety switch THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Choke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All Tether Switch accessory Interrupts ignition circuit All Engine Break
88. tch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 60 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Emission Control Label Your snowmobile is equipped at the time of sale with an emission con trol information ECI label and a factory installed emissions informa tion hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label
89. the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Tunnel VIN H right side of the tunnel Engine Serial Number on recoil housing Key Number Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient ref erence It should remain with the snowmobile when the snowmobile is sold Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is neces sary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam paign We encourage governments to adopt rigorous safety training pro grams that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organizations are working together to pro tect our environment Please support their efforts and operate your snowmobile with consideration for the protection and preservat
90. the traps fuel spillage will occur Always work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the fuel warnings on page 51 Cleaning Procedure l 2 Turn the fuel valve off Place a container or shop 1 towels below the plug to catch drained fuel Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube Wipe residue from the plug and reinstall it Reposition and tighten the clamp Repeat the draining procedure for any remaining traps 75 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension 1 Rotate the driven clutch counter clockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly Loosen the adjuster bolt jam nut 1 3 Finger tighten the adjuster bolt 2 until it can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft Ibs 28 Nm 5 Release the brake lever lock 76 MAINTENANCE Brakes Hydraulic Brake Inspection riage brake lever travel before each use of the snowmobile See page Brake pads must be replaced when the brake pad material becomes thin ner than the backing plate approximately 1 16 A kit is availa
91. trol Diaphragms e Fuel Cap e Control Cables e Fuel Line e Control Linkages e Fuel Line Fittings e Purge Valves e Clamps Vapor Hoses e Pressure Relief Valves Liquid Vapor Separator e Control Valves e Carbon Canister e Control Solenoids e Canister Mounting Brackets e Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 111 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes f
92. un out of fuel If stabilizer is not used drain the carburetors by removing the water trap drain plugs See page 75 Tip Jet restriction caused by improper storage can cause lean conditions and very poor slow speed driving quality 96 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The machine should be supported off the ground to allow the track to hang freely Transporting the Snowmobile Whenever the snowmobile is transported 1 Turn the fuel valve off See page 27 2 Besure the fuel cap and oil cap are installed correctly 3 Always tie the snowmobile to the transporting unit securely using suitable straps 4 Remove the ignition key to prevent loss 97 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 0z 355 ml Aerosol 2875035 Premium Synthetic Blend Blue 2 Cycle Oil qt 95 I 2875036 Premium Synthetic Blend Blue 2 Cycle Oil gal 3 8 I 2875037 Premium Synthetic Blend Blue 2 Cycle Oil 2 5 gal 9 5 I 2874438 VES II Synthetic 2 Cycle Oil qt 95 1 2874439 VES II Synthetic 2 Cycle Oil gal 3 8 1 2874443 VES II Synthetic 2 Cycle Oil 2 5 gal
93. ure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately Throttle Safety Switch Test the throttle safety switch system before the machine is operated See page 56 41 PRE RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the n handgrip than 1 2 1 3 cm MEERN A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 79 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 78 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess 42 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the machine to remain stationary for example when parked on an incline for a period of five minutes or less 1 Brake L
94. valve is located under the hood Turn the fuel valve off when ever the snowmobile is stored or parked OFF 1 Turn the valve clockwise to turn off the fuel supply 2 Turn the valve counter clock wise to turn on the fuel supply Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left or right 27 THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension IFS Break in the suspension for about 150 miles 240 km before making any fine tuning adjustments Settings will vary from rider to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The machine should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Front shocks and springs 3 Rod ends 4 A arms IFS Adjustment Options Front shock spring preload e Optional springs e Optional shocks 28 THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski to ground pressure Decreasing spring preload will decrease ski to ground pres sure When adjusting be sure the springs on both the left and right sides of the machine are at the same adju
95. y for warranty the product must have been properly set up and tested by a Polaris Dealer if applicable Failure of any dealer to perform the required vehicle Pre Delivery Inspection perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage Use of the recommended Polaris products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur during the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con sideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components Batteries Circuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal

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