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1. AWARNING 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 PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to Cause cancer and birth defects or other reproductive harm onto the snow on which they operate Keep this engine properly tuned and avoid unnecessary idling and spillage during fueling ZAWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm What s the hottest thing on snow A Polaris owner s Web site designed just for YOU Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out www polarisindustries com owner POLARIS The Way Out Copyright 2003 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 discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions o
2. First Aid Kit 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 Maintenance Items The tools and maintenance items mentioned in this book as well as a long line of other Polaris accessories are available at your Polaris dealer 96 MAINTENANCE Track Maintenance AWARNING 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 correct tension and alignment Tension adjustments should be made only after the track is warmed up and limber 1 Turn the machine 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 distance specified see chart ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is hanging Measurement Measurement Location 10 lbs 4 54 kg 16 ahead of rear idler shaft 3 8 1 2 1 1 3 cm 4 Check for specified slack between the wear surface of the track clip and the plastic Hi fax C If the track needs adjustment 5 Loosen rear idler shaft bolt D 6 Loosen locknu
3. re uncertain about the quality or octane rating of the fuel you use turn your key switch to ON REG The Premium Fuel light will go out This setting will adjust the timing of your engine to run on fuels with 87 octane or higher Polaris does not recommend using fuel with lower than 87 octane Running your machine on ON REG will help protect your engine from damage caused by low octane fuels Fuel Reserve Capacity Mechanical Gauge There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES 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 milliliters per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol See page 110 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deicers or water absorbing additives are not required and should not be used CAUTION Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel 55 OPERATION Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil See page 51 for oil recommendations When the low oil indicator light is on oil should be added before further operation of the snowmobile Visuall
4. 10 cm off the ground Start the engine and allow it to warm up two to three minutes Depress the throttle abruptly and allow the track to rotate several revolutions NOTE It will take longer to warm up the track sufficiently during colder outdoor temperatures Release the throttle apply the brakes shut off the engine and lower the machine to the ground Grasp the skis by their front loops and move them from side to side This will loosen frozen snow from the ski bottoms allowing the machine to move forward more easily The engine drive system and track are now properly warmed up and the machine may be driven following normal safety practices OPERATION Fuel AWARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or ina well ventilated area e Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored e Do not overfill the tank Do not fill the tank neck 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 En gine exhaust fumes are poisonous and can cause loss of con sciousness or death in a short time e Turn the fuel valve off whenever the snowmobile is stored or parked AWARNING The engine e
5. Halogen Bulbs 90 Handlebar Adjustments 38 Handlebar with Riser Block 38 Handlebar Standard 38 Headlight Adjustment 89 HisFax Wear rareo tedd reges eae 103 High Temperature Indicator 82 Hydraulic Brake Inspection 85 l Ice and Snow Build up 15 TES Se esi Os are ts oreo tart ae and ane ere 29 Indy Select Shock 31 Intake Filter 23a esodainrtate urban arg 76 Intake Silencer 0 0 18 INTRODUCTION 5 7 J Jackshaft Bearing Greasing 72 Jetting Guidelines 58 L Lighting Check 0 0 47 Low Oil Indicator 56 Low Oil Level 0000 57 Lubrication 2 isc en Ris ea sie ws 70 73 M MAINTENANCE 65 109 Maintenance Chart 66 67 Maintenance Program 65 Maintenance Log 68 69 Maneuverability 18 Manual Start 0000 48 Mirror Adjustment 47 Moving Parts 000 10 O OA aee A S N 56 57 OEEren A E peck 79 Oil Injection System 51 Oil Level ai e e E e E A 95 Oil Recommendations 51 Operating Area 0 000 47 OPERATION 4 48 64 Operations seni Eae Ee EEE order dee 24 Operator Safety 8 21 P PaSSeN Per aa e naneo ea EER R 22 PERG yora A AER 63 P
6. Polaris has accessory covers and track stands available to fit all mod els See your dealer for more information Towing For your safety do not attempt to using the tow hitch until you ve read the following warnings and understand the proper hitch functions AWARNING 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 hitch 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 a rider on the towed snowmobile to operate the brake and steering when necessary CAUTION 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 sn
7. Replace worn studs and skags to maintain proper balance and vehicle control When studded tracks are used increased wear to the brake pads will result from increased braking Extended wear brake pad kits are available See your dealer for more information CAUTION Aggressive studding patterns may require that you grind protruding stud bolts flush to prevent idler wheel damage Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage Center of stud must be at least 1 1 8 2 86 cm from the outside edge of the track Use only Polaris traction products on your snowmobile Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non Polaris traction products 41 THE PERFECT FIT Accessories Wear Strips To avoid excessive tunnel or cooler damage wear strips must be installed whenever track studding is used See your dealer for more information Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories CAUTION Never add shims to the wear strip Track damage will result due to lack of clearance between upper carrier wheels and track Components as viewed from the rear of the track 1 Top of tunnel 2 Wear strip 3 Track 4 Wear strip mounting holes de 2 CAUTION Whenever wear strips are relocated be sure
8. WIND CHILL CHART C Estimated Wind Speed Actual Thermometer Reading C in KPH 10 15 20 25 Equivalent Temperature C Wind Speeds Greater Little Danger Increasing Than 70 KPH Have Little For Properly Danger Added Effect Clothed Person Danger From Freezing of Exposed Flesh 21 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection 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 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 Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with this guard open Never run engine with drive belt removed Never service clutches yourself see your dealer Airbox Warning This warning decal is found under the hood on applicable models Do not operate above 40 mph with hood to airbox foam removed or engine failure will result Pressure Cap Warning This warning decal i
9. 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 re quired 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 maintenance or part of completing an effective repair The fol
10. and hot exhaust parts Battery Always prepare and maintain the battery as outlined on page 107 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 See illustration Transporting the Snowmobile Whenever the snowmobile is transported 1 Turn the fuel valve clockwise to OFF to shut off the fuel supply 1 Turn the valve counter clockwise to ON to turn the fuel supply on 2 NOTE The fuel valve is located under the hood of your machine 2 Be sure the fuel cap and 1 oil cap are installed correctly 3 Always tie the snowmobile to the transporting unit securely using suitable straps 106 MAINTENANCE Battery AWARNING Battery electrolyte is poisonous It contains acid Serious burns can result from contact with the skin eyes or clothing If contact occurs seek immediate medical attention KEEP OUT OF REACH OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks open flames cigarettes etc away Ventilate when charging or using in closed space Always shield eyes when working near batteries Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The flu
11. coming vehicles when on high beam e When traveling in a group of snowmobiles don t tailgate follow too closely Allow ample stopping distances and keep track of those following you Drive defensively to avoid accidents e Remove the key from the ignition 20 SAFETY Operator Safety Windchill Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding WIND CHILL CHART F Estimated Wind Actual Thermometer Reading F Speed in MPH 40 30 20 10 O 10 20 30 40 50 60 Equivalent Temperature F Calm 50 40 30 20 10 O 10 20 30 40 50 60 5 48 37 27 16 6 5 15 26 36 47 57 68 10 40 28 16 4 9 21 33 46 58 70 83 95 15 36 22 9 5 18 36 45 58 72 85 99 112 20 32 18 4 10 25 39 53 67 82 96 110 124 25 30 16 O 15 29 44 59 74 88 104 118 133 30 28 13 2 18 33 48 63 79 94 109 125 140 35 27 11 4 20 35 49 67 82 98 113 129 145 40 26 10 6 21 37 53 69 85 100 116 132 148 Wind Speeds Great Little Danger Increasing Great er Than 40 MPH For Properly Danger Danger Have Little Added Clothed Person Effect Danger From Freezing of Exposed Flesh
12. 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 wi re harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOT continue to op erate the machine with the throttle safety switch disconnected Return the machine to an authorized Polaris dealer for service as soon as 60 possible OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency Refer to page 59 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES THROTTLE CONDITION AWARNING Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system This overheated condition could cause sudden loss of brakes and or fire resulting in serious injury or death When traveling on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat and result in brake failure 61 OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use Machines equipped with electric start have a recoil for emergency starting On manual start models an emergency start strap is provided for use if the recoil starter system fails AWARNI
13. SOLO located near the base of the shock A This adjustment is the easiest to perform and it should be considered first A clockwise adjustment will increase stiffness in both styles of shock but there are some differences Indy Select Shock The factory setting for this shock is the softest position with the adjusting screw all the way out counterclockwise If bottoming occurs the Indy Select feature should be used to achieve the desired ride The shocks have a wide range of adjustment capability By turning the screw clockwise the compression of the shock increases stiffening the ride When adjusting these shocks we recommend that you turn the screw only 1 4 turn at a time then test ride Always adjust both shocks equally RydeFX SOLO Shock The factory setting for this shock is at medium stiffness with the clicker knob B set at position 4 The clicker can be actuated with the thumb and forefinger If bottoming occurs rotate the clicker clockwise to the next higher number If full shock travel isn t being used rotate the clicker counterclockwise to the next lower number When adjusting these shocks we recommend that you turn the clicker only one click at a time then test ride Always adjust both shocks equally 31 THE PERFECT FIT Front Suspension Adjustments Adjusting Front Shock Spring Preload Increasing spring preload will increase ski to ground pressure Decreasing spring preload will decrease
14. Turn the knob to the left for a softer ride 3b Turn the knob to the right for a stiffer ride 4 Turn the knob to a lower number for less rebound control softer ride or to a higher number for more rebound control stiffer ride 5a Soft Tension long end of cam to front 5b Medium tension short end of cam up 5c Firm tension long end of cam up 36 THE PERFECT FIT Rear Suspension Adjustments Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock Adjustment Locate the adjustment screw A near the base of the shock In half turn increments turn the screw clockwise to increase compression valving and stiffen the ride or counterclockwise to reduce compression and soften the ride There are approximately three full turns of adjustment available If bottoming continues after the screw has been turned fully clockwise the torsion spring should be adjusted see page 36 Return the screw to its original starting position after the torsion spring has been tightened Optional Coil Springs Different rate coil springs are available for some shocks if a firmer ride is desired Contact your dealer for more information 37 THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust the handlebar for a perso
15. can See page 110 Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the can running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel HINT For easier starting after extended storage add lubricant to the fuel in the tank at a 40 1 ratio and run the engine for three to five minutes before storage This will lubricate the fuel pump diaphragm to keep it flexible and help prevent loss of prime If stabilizer is not used drain the carburetors by removing the water trap drain plugs see page 78 Catch fuel in a container or shop cloth Reinstall plugs securely Observe all fire safety rules when draining carburetors See gasoline warnings on page 53 Jet restriction caused by improper storage can cause lean conditions and very poor slow speed driving quality 104 MAINTENANCE Extended Storage Controls and Linkage All bushings spindle shafts tie rod ends and cables should receive a light coat of oil or grease 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 See page 110 for part numbers Clutch and Drive System Remove the drive belt and store in a cool dry location Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant See page 110 for part numb
16. clearance Wrong belt for application Clutch alignment out of spec Engine mount bro ken or loose Clutch jammed Track jammed Chaincase sprocket or chain jammed or broken Solution Disassemble drive clutch to inspect shift weights for wear and free operation SEE YOUR DEALER Clean and polish stationary shaft hub Replace ramp buttons and rollers SEE YOUR DEALER Inspect movable sheaves for excessive bushing clearance and replace if necessary SEE YOUR DEALER Replace drive belt SEE YOUR DEALER Replace drive belt Adjust alignment offset Inspect and adjust or replace SEE YOUR DEALER Belt twisted spring broken weights stuck lubricated SEE YOUR DEALER Foreign object caught or Hi fax melted to track clips due to lack of lubrication Machine may be frozen to ground Track may be iced up Chain is loose or broken chain tightener is loose SEE YOUR DEALER 113 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch SEE YOUR DEALER system components Bearing failure SEE YOUR DEALER chaincase jack shaft or front drive shaft Drive belt surface Inspect and replace if necessary flat spots Drive chain loose Inspect and adjust or replace or worn sprocket teeth broken Poor low RPM Worn drive belt Inspect and replace if necessary performance Excessive belt SEE YOUR DEALE
17. decal or page 36 Front end pushes Check for worn skags Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Verify sag dimension see set up decal or page 35 Adjust torsion spring blocks page 36 or install optional torsion springs to achieve correct sag dimensions Increase IFS preload see page 32 Move limiter strap on front torque arm to high position see set up decal or page 36 Steering is heavy Check skags and skis for damage Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Verify sag dimension see set up decal or page 35 Adjust torsion spring blocks page 36 or install optional torsion springs to achieve correct sag dimensions Decrease IFS preload see page 32 Machine darts from Ensure skis are properly aligned see page 101 side to side Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Ensure skags are straight on skis 111 TROUBLESHOOTING Belt Wear Burn Troubleshooting Belt Wear Burn Diagnosis Driving at low RPM Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up 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
18. it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is not limited 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 cellular telephone 11 SAFETY Operator Safety Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer Do not exceed carrier and rack weight limits and do not allow a passenger to sit on the seat back or the cargo carrier Riding Apparel Be aware of the weather forecast and especially the wind chill A wind chill table is provided on page 21 for your reference To better enjoy your ride be prepared be warm and be comfortable AWARNING Loose clothing or long scarves may easily become entangled in moving parts and cause serious personal injury Always wear an approved helmet and eye protection 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 12 SAFETY Operator Safety Excessive Speed AWARNING High speed driving especially at night could result in serious personal injury or death Always reduce speed when driving at night or in i
19. lever and measure the clearance between the lever and handlebar grip This distance called brake lever reserve A should be no less than 1 2 1 3 cm Brake pads must be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer AWARNING 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 85 MAINTENANCE General Maintenance Brake Components Air cooled model Liquid cooled model Brake Caliper Chaincase Brake Disc Backing Plate Brake Pad Material Replace when thickness is less than 1 16 Yh Be Ge bore Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops as described on page 85 the machine should be returned to an authorized Polaris dealer for inspection and adjustment 86 MAINTENANCE General Maintenance Brake Fluid 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 We recommend the use
20. low RPM Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM Lower the gear ratio Remove windage plates from the and slow speed 8000 clutch Reduce RPM Avoid riding in high ambient RPM 10 MPH temperatures Ice and snow build up Warm the engine at least five minutes Take the drive belt off between track and the machine in extremely cold weather and warm it up tunnel Break machine loose from the snow Poor engine Check for carb and choke synchronization fouled plugs performance debris in the carbs and water ice or dirt in the gas tank or fuel line Loading machines onto Skis may gouge into trailers and prevent the drive train from trailers 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 en Use fast aggressive throttle to engage clutch gagement 112 TROUBLESHOOTING Engine Troubleshooting CAUTION Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Erratic engine operating RPM during accelera tion or load variations Harsh drive clutch engagement Drive belt turns over Machine fails to move Probable Cause Drive clutch binding Driven clutch malfunction Drive belt worn or too narrow Excessive belt sheave
21. snowmobile including an area clear of bystanders There s always the possibility of some sideways vehicle movement of applying a little more throttle than intended or of debris being thrown by the track If the surrounding area is clear you before you start you can devote your full attention to operating the snowmobile CAUTION 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 47 OPERATION Starting the Engine AWARNING Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your snowmobile without checking all components to be sure of proper operation Refer to the pre ride inspections section beginning on page 43 Starting a Cold Engine Manual Start Do not depress the throttle until the engine starts 1 2 3 4 5 Turn key to ON Pull kill switch shut off switch up to RUN Flip choke toggle to FULL ON Grasp starter handle and pull slowly until recoil engages then pull abruptly to start the engine 4 amp CAUTION Don t pull the starter rope to full extended position or allow it to snap back into the housing Damage may result To avoid personal injury and or engine damage
22. warranty begins on the date of purchase This warranty is transferrable to another consumer during the war ranty 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 set up of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer set up 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 purposes other than for which it was manufactured The warranty does not cover any damages that oc cur during trailer transi
23. 1 Part No Printed in USA i
24. Bearings esee kori eneg eon easar 105 Before Starting the Engine 43 46 Belt Troubleshooting 112 Bleeding the Cooling System 67 83 Bleeding the Hydraulic Brake System 88 Brake Components 86 Brake Fluid oc 4d006 00 se irasat sas 87 Brake Lever Travel 44 Brake Park 45164 si gob ae thos Ses 45 Brakes Hydraulic 44 Bulb Replacement 90 Cc Carburetion 00 57 58 Carburetor Adjustments 80 Carburetor Information 80 Cargo Overload 12 Chain Tension 95 Chaincase Oil Level 73 Choke and Cable 72 Cleaning and Preservation 104 Clutch Alignment 91 Clutch and Drive System 105 Clutch Center Distance 94 Clutch Cover 00 22 Clutch Guard 00 0 17 Clutch System 0 000 91 Clutch Standard 94 Clutch TEAM 04 94 Chatchesixs ion dam doves da one ditto dace 18 Coil Springs essees set Pere a aa 37 Cold Weather Drive Away 18 Controls o te eee dhe ees 25 26 Controls and Linkage 105 Coolant Level 00 0 82 Coolant Mixture 81 Cooling tueis aes ai ge wi Sa aa 81 83 122 D D E T Flash Signals 28 D E T Troubleshooting 28 Dail
25. CLAIMS 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 transportation 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 perform 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 recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 118 WARRANTY Conditions and Exclusions In order to qualify for warranty the product must have been properly set up and tested by
26. Engine Cooling Liquid Cooled Models The cooling system on liquid cooled models consists of the following major components e Coolant bottle e Inlet and outlet manifolds e Water pump e Pressure cap e Cylinders e Heat exchangers e Heads Coolant Mixture The coolant supplied in the system is a 50 50 mixture of ethylene glycol and distilled water This mixture provides protection against freezing at temperatures to 34 F 37 C If greater protection is required the percentage of antifreeze to water may be increased Use Premium 60 40 anti freeze coolant which is already premixed and ready to use Do not dilute with water Never exceed a 60 antifreeze 40 water mixture Contact you dealer if greater protection is required NOTE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system 81 MAINTENANCE General Maintenance Engine Cooling Liquid Cooled Models Coolant High Temperature Indicator Light The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models If the engine coolant reaches a certain temperature the switch completes a circuit that turns the light on If you must drive your machine after the high temperature indicator light has come on drive slowly and stop frequently to allow the engine to cool down See your dealer Coolant Level The coolant level in the coolant bot
27. ICE 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 Warranty 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 you move to an
28. NG Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure DO NOT wrap the start strap around your hand Keep all bystanders away from the snowmobile when using the emergency starting procedure To use the emergency start strap 1 2 62 Open the clutch guard Push on the inner sheave of the clutch and rotate clockwise slightly to relieve belt tension Starting at one of the tower struts wind the strap counterclockwise around the clutch as shown Pull the strap abruptly so the strap comes free of the clutch while starting the engine acim li O oe OPERATION Reverse Operation Electronic Reverse PERC Electronic reverse will activate only if the engine is below 4000 RPM If your machine is running at an altitude of over 6000 feet adjust the ignition setting as described below Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse 1 Make sure the area behind your vehicle is clear 2 Push the yellow reverse button on the left hand control for one second 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 3 Slowly apply the throttle until movement starts and you re sure the machine is in reverse NOTE The maximum engine RPM will be 6000 when in re
29. R sheave clearance Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t f Wire connections SEE YOUR DEALER start electric start models Engine doesn t Seized engine SEE YOUR DEALER Seizure is a result turn of poor lubrication inadequate fuel supply broken parts or improper cooling Fuel may have entered crankcase while vehicle was standing or being transported SEE YOUR DEALER to correct cause Drain plug s are located on lower crankcase for emergency draining Hydrostatic lock 114 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine turns Faulty ignition Remove spark plug s and replace with new but fails to start plug s If engine still fails to start check for spark if no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is ON Check tank level and fill up with correct fuel Ice in fuel line filter or pump On the stan dard Polaris carburetor the choke will not function with the throttle depressed See se cond item under Probable Cause of En gine continually backfires Flooded engine Hold throttle open crank engine several normal situation times may be necessary to change plug s caused by too much however the plug s may operate satisfactori choking ly when dried Poor engine com Running too lean a mixture too small a pression main jet will cause seizure resulting in
30. Solid non blinking light High water tem See your Polaris dealer NOTE Iftempo perature rary operation is unavoidable drive slowly and stop the engine frequently to allow the engine to cool 28 THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles 240 km and re grease all suspension parts before fine tuning adjustments are made 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 under the same conditions after each adjustment trail and snow conditions vehicle speed riding position etc until the best ride is achieved Adjustments should be made to one area at a time in order to properly evaluate the change All snowmobile suspensions have a front and a rear suspension each of which has adjustment options Independent Front Suspension IFS The IFS is made up of the skis 1 front shocks and springs 2 and the components that connect these parts to both the steering such as the tie rods 3 and to the machine itself such as the trailing arms 4 Front suspension adjustments include shocks springs toe and camber NOTE Although the front suspension on your machine may not look exactly like the illustration it will have the same parts a
31. aler to make minor adjustments in the driven clutch to achieve correct belt tension 94 MAINTENANCE General Maintenance Torque Stop Your snowmobile is equipped with an engine torque stop 1 Periodically check the torque stop clearance With clutches in proper alignment the torque stop clearance should be a minimum of 010 to a maximum of 030 from the engine case 2 Adjust if necessary and lock the jam nut Tool Kit A tool kit is included with each machine for emergency and routine maintenance Always keep the tool kit with the snowmobile i Topy 2 Your tool kit will contain only the E i tools applicable to your model Se 3 1 Emergency Start Strap eee manual start models o 4 2 Phillips Screwdriver a 3 Tubular Socket ao 4 Tubular Socket Handle 8 5 Wrench 6 ae 6 Flat Screwdriver Sy 7 Shielded Screwdriver models 7 with Indy Select shocks 8 Box End Wrench If necessary a replacement tool kit may be purchased from your Polaris dealer Chain Tension Maintain the proper chain tension as outlined on page 84 Oil Level Maintain the oil level between the safe marks as indicated on the oil bottle see page 57 95 MAINTENANCE General Maintenance For Your Protection For added protection carry the following items on your snowmobile at all times Spare Drive Belt Extra Set of Spark Plugs Tow Rope Extra Oil eFuel Deicer Winter Survival Kit Trail Map eOwner s Manual
32. anty always provide the following information 1 Serial number 5 Details of trouble experienced 2 Model number 6 Length of time and conditions of operation 3 Dealer name 7 Previous correspondence 4 Date of purchase 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 1 763 417 8650 Canada 1 204 925 7100 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 offi cials the owner must call Polaris Customer Service B Owners must provide their name address telephone num ber 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 116 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 repair or replacement of defective parts that are covered by this warranty The
33. anty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc WORKMOBILES UTILITY TASK VEHICLE and PERSONAL TASK VEHICLE are trademarks of Polaris Industries Inc TABLE OF CONTENTS Introduction 2 5 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 Safety scera testes eer antares eeuseed 8 This section describes safe vehicle operation and identifies warning decals and their locations Features and Controls 000eeees 25 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 000ceeeeeeeeceee 29 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 00e000e 43 This section explains procedures that must be performed before riding Operation wisc2 seek tee eee anann isane Sess 48 This section explains proper engine break in operation of features and general operating procedures Maint nanCe siscccae ie ecscewsvetsaeeses 65 This section defines your role and your dealer s role in your snowmobile s reg
34. belt must be performed by your dealer Operation of the engine with the belt removed may result in personal injury or damage to the engine 17 SAFETY Operator Safety 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 dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time especially 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 See Starting a Cold Engine on page 48 Maneuverability Control and maneuverability comes not only through the steering and skis maximum control is achieved by shifting of body weight Maneuverability will change for lighter operators or machines designed to carry a load 18 SAFETY Operator Safety Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles They are normally left open and are located on the front upper and lower hood openings If operatin
35. cover and gasket 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 opening Reinstall the gasket and cover Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air Close the bleeder valve and release the brake lever Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles AWARNING 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 After bleeding is complete refill the reservoir to the proper level Reinstall the gasket and cover MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for 25 7 6 m vertical aim using the following ie procedure 1 Place the snowmobile on a level surface with the headlight Lamp Center approximately 25 feet 7 6 m Height from a wall 2 5 1 cm 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the
36. do not operate the electric starter or pull rope starter while the engine is running 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 ON position 48 OPERATION Starting the Engine Starting a Cold Engine Electric Start Do not depress the throttle until the engine starts CHOKE TOGGLE POSITIONS 1 Flip choke toggle to FULL ON 2 Pull kill switch shut off switch up to RUN 3 Turn key to START and crank engine 4 After the engine starts release the key to ON and flip the choke toggle to OFF If the engine slows or wants to stop use intermittent choking to HALF ON Starting a Warm Engine 1 Turn key to ON 2 Pull kill switch shut off switch up to RUN 3 Grasp starter handle and pull slowly until recoil engages then pull to start If the engine does not start on the first pull slightly depress the throttle with your left hand no more than 1 4 open and pull the rope with your right hand When the engine starts immediately release the throttle 49 OPERATION Engine Break 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 gasoline with one pint of Polaris injection oil for each five gallons of fuel This in addition to the lubrication supplied by the injection system will assure proper engin
37. dures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme caution when handling high pressure service equipment We recommend that this work be performed by a Polaris dealer Front Springs For models without externally adjustable or revalvable shocks the front springs can be changed if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness See your Polaris dealer for more information 33 THE PERFECT FIT Rear Suspension Adjustments Rear Suspensions 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 suspension designs and adjustments involve a compromise or trade off For example a suspension set up for snow cross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bottom out harshly on a snow cross course A decal outlining rear suspension set up options is located either under the hood or on the clutch cover It provides a guideline for initial suspension set up Additional adjustments can be made from this point Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer Suspension Performance Tips e Rider weight usually determines the position at which th
38. e General Carburetor Information 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 CAUTION 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 80 MAINTENANCE General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles 1600 km To inspect allow the engine and exhaust system to cool completely Open the hood and inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets AWARNING Hot exhaust system parts can cause serious burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running
39. e break in CAUTION 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 50 OPERATION Engine Break In Oil Injection System CAUTION Serious engine damage can occur without the proper lubrication Check the oil tank level often during the first tankful of fuel If the oil level doesn t go down contact your dealer immediately Always fill the oil reservoir when refueling Fuel to oil mix ratios are controlled by the oil pump and correspond to the engine s RPM and throttle valve opening Variable Exhaust System All snowmobile engines equipped with variable exhaust valves should use VES 2 Cycle Oil see chart below Oil Recommendations The only source of engine lubrication for your engine comes from lubrication added to the fuel and oil injection systems We highly recommend the use of only Polaris products We re conti
40. e spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride e In deep snow a new Hi fax will offer improved performance over worn Hi fax It can also improve top speed e 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 e Polaris offers track kits for improved flotation in deep snow See your dealer for assistance NOTE 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 See page 70 34 THE PERFECT FIT Rear Suspension Adjustments Rear Suspension 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 this measurement with no rider and with the rear suspension at full extension NOTE The rear bumper may need to be lifted upward slightly to fully extend the 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 be
41. eed screw into the manifold Add coolant to the coolant bottle to the maximum mark Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air Stop the engine and check the coolant bottle level Fill as required Feel the heat exchanger on the rear end of the tunnel If the system is bled properly it will be warm to the touch Ifthey re not warm repeat step 5 Reinstall the pressure cap and carefully lower the front end of the machine CAUTION If coolant flow becomes restricted or plugged coolant loss air lock or engine damage may result Most cooling systems are equipped with a filter that should be periodically inspected or replaced 83 MAINTENANCE General Maintenance Drive Chain Tension To obtain correct chain tension 1 Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut A 3 Finger tighten the adjuster bolt B 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 5 The chain is now tensioned Release the brake lever lock 84 MAINTENANCE General Maintenance Hydraulic Brake Inspection Frequently inspect the brake lever reserve Firmly depress the brake
42. ers 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 Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system If you prefer to drain the fuel tank use the following procedure 1 Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump Do not re use fuel after storage 2 Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward 3 Remove the spark plug s 4 Rotate the engine slowly watching the piston until it s at bottom dead center BDC the lowest position in the cylinder On twin cylinder models the opposite piston will be up 5 Pour approximately two ounces of Polaris injector oil into the spark plug hole 6 Wait one to two minutes and perform steps 3 to 5 on remaining cylinders 7 Replace the spark plugs and lower the machine to the floor 105 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with dielectric grease and re connect See page 110 for the part numbers of Polaris products Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts
43. etion 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 foreign 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 improper carburetor adjustment AWARNING Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage Always have your Polaris dealer perform any carburetor adjustments 57 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 Carburetors on Polaris Switchback snowmobiles are calibrated for an altitude of 0 2000 ft 0 600 m and ambient temperatures between 10 to 10 F 23 to 12 C RMK carburetors are preset to operate at altitudes of 6000 9000 feet above sea level see page 80 for more information Carburetors must be re calibrated if the snowmobile is operated outside this production temperature and or altitude range The main jet in
44. ft lbs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 98 MAINTENANCE Track Maintenance Track Inspection AWARNING Broken track rods are a serious safety hazard They 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 Using a hoist safely lift and support the 21 3 12 rear of the snowmobile off the ground Rotate the track by hand to check for possible damage Carefully examine the track along the entire length of each rod bending the track and inspecting for breakage The three most common damage areas are shown in the illustration Replace the track if any rod damage is found Track Lubrication AWARNING Operating with insufficient lubrication between the Hi fax 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 requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new Hi fax can cause faster heat build up in limited lubrication resulting in excessive wear NOTE If excessive Hi fax wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more informatio
45. g Abeer n aven 106 Survival Preparation 11 123 INDEX S Suspension AeA E AAA 106 Suspension Maintenance 103 Suspension Performance Tips 34 Suspension Troubleshooting 111 Suspension Front 29 33 Suspension Rear 34 37 Symbols 0 0 0 cece e eee 8 T TABLE OF CONTENTS 4 THE PERFECT FIT 29 42 Throttle Cable 00 000 72 Throttle Lever 0 0 000 60 Throttle Safety Switch 59 ToolKit o s 2 6 ng ds AH as leech node wits 95 Torque Stop 00000 95 Torsion Spring Tension 36 TOWING aoas Eest oh ede es ce eee see 64 Tracki ias sh delay Liae en oe gib lel 106 Track Alignment 98 Track Inspection 46 99 124 T Track Lubrication 99 Track Maintenance 97 99 Track Tension 0 97 Track Warm Up 0 0 52 Track Warning 00 23 Traction Products 40 41 Transporting the Snowmobile 106 TROUBLESHOOTING 111 115 Vv Variable Exhaust System 51 77 Vehicle Identification Numbers 7 WwW Warning Labels 22 24 WARRANTY 116 121 Water Pump Belt Inspection 77 Water Sediment Trap Service 78 Wear SIPS 13 2 ite he dee he 42 WELCOME iemieso aeg leavers 3 Windchill Temperature Charts 2
46. g in deep snow or in extreme cold conditions below 20 F Polaris recommends closing the upper hood closure AWARNING Do not drive for prolonged periods on blacktop gravel or ice Doing so could cause irreversible track damage and lead to serious personal 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 little 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 You may then mount the machine and continue riding ACAUTION When operating on icy surfaces or hard packed snow avoid overheating 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 dealer for an optional wheel kit that will reduce the wear from overheating 19 SAFETY Operator Safety Your Polaris snowmobile is a well engineered and well constructed recreational vehicle Follow the recommended maintenance program outlined beginning on page 65 of this manual to ensure that all critical components on the sno
47. general representations Your model may differ Lubrication points are indicated by a x Forward i 71 MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and Be grease fitting Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal may take only two pumps Push the clutch back onto the shaft and replace the clutch retaining bolt Torque to 18 ft Ibs 24 4 Nm Driveshaft Bearing Greasing Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal approximately two pumps Throttle Cable Lubricate the throttle cable 1 lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Choke and Cable Lubricate the choke slide 2 and cables lightly with oil or grease Before turning the engine off operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen f Siod 72 MAINTENANCE Lubrication Chaincase Oil Level It s the operator s responsibility to check and maintain the proper chaincase oil level To check the oil level place the machine on a level surface The oil level should be between the safe marks on the dipstick A Add Polar
48. h 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 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 AWARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brake 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 Clutch Guard Do not operate the engine with the clutch guard removed The clutch guard is designed to protect the operator from metal parts if the clutch should fail Although the chance of failure is extremely remote don t defeat the purpose of the guard by removing it It s provided for your safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without a
49. has the accessories that will help make each ride more enjoyable See your dealer for a list of accessories NOTE The accessory tether switch is available for all models See your Polaris dealer Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in e Non compliance with government industry requirements e Voiding of warranty e Personal injury to self or others This applies to but is not limited to the following areas brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use ap proved Polaris parts Please see your Polaris dealer for service 39 THE PERFECT FIT Accessories Traction Products Another way to tailor your machine is to install traction products See your dealer about installing studs and or carbides Many tracks with deep lug designs cannot be studded but your dealer will be able to offer advice and assistance CAUTION Installing studs on models without wear strips will result in damage to the cooler or tunnel Always ensure that wear strips are installed before installing studs Always install the Polaris approved Switchback Wear Strip Kit before installing studs on a Switchback See your dealer for more details NOTE Before equipping your machine with traction products be aware of the laws in your area pertaining to the use of traction products Track studding will enhance brak
50. hrottle lever and the throttle cable or valves do not return to the normal closed position AWARNING 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 59 OPERATION Throttle Lever AWARNING 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 lever does not work properly DO NOT start the engine If the engine stops abruptly when the throttle lever is released 1 2 3 4 5 Turn the ignition switch to OFF Visually inspect the throttle cable and carburetor s to determine what caused the safety switch to activate Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely If the throttle lever operates properly turn the ignition switch on and go through normal starting procedures If the engine doesn t start take the snowmobile to an authorized Polaris dealer for service Excessive free play in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs
51. id level should be kept between the upper 1 and lower 2 level marks 107 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion When cleaning is necessary remove the corrosion with a stiff wire brush Wash terminals and connections with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry with clean shop towels Coat the terminals with dielectric grease or petroleum jelly CAUTION Tap water contains minerals that will damage a battery and shorten its life Use only distilled water to refill your battery Never allow cleaning solution or tap water to enter the battery Battery Removal AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Disconnect battery hold down straps Remove battery vent tube from battery Disconnect black negative battery cable first Disconnect red positive battery cable second Carefully lift the battery out of the snowmobile Do not tip it sideways or spill electrolyte 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle Be a 108 MAINTENANCE Ba
52. ile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will reduce your alertness and slow your reaction time In most states and provinces it s prohibited by law to drive while intoxicated or under the influence of drugs Polaris produces high performance snowmobiles capable of traveling at high speeds Extra caution must be observed to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times We strongly recommend that the operator 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 become 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 Away From Moving Parts AWARNING Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious personal injury
53. ing items to assure proper operation before starting the engine Brake Lever Travel When the brake lever is squeezed it should move no closer to the handgrip than 1 2 1 3 cm A A distance less than this indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 88 Lever Feel A hydraulic system multiplies the force of your hand squeezing the brake lever Proper operation depends on an adequate supply of air and moisture free hydraulic brake fluid in the system If the brake lever feels spongy when squeezed check the level and condition of the fluid Also check for the presence of air in the fluid system Refer to page 88 for more information or see your dealer for service Replace brake fluid at least every two years All DOT 3 brake fluid is not alike We recommend the use of Polaris DOT 3 high temperature brake fluid See page 110 for the part numbers of Polaris products AWARNING 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 44 PRE RIDE INSPECTIONS Before Starting the Engine Park Brake Lever Lock Your snowmobile may have a park brake lever lock located over the brake lever Use the brake lever lock only when you want the machine to remain stationary for example when parked on an incline for a period of five min
54. ing control on hard packed snow or ice but extreme caution is still required on such surfaces Steering ability may be reduced on hard packed snow or ice AWARNING 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 CAUTION Use of studs longer than the recommended length on machines equipped with coolers will result in damage to the cooler or tunnel Always use the recommended length studs 40 THE PERFECT FIT Accessories Traction Products 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 The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control Similarly if your machine is equipped with carbide skags or if you re adding them it may be necessary to add track studs to maintain proper vehicle control Proper balance must be maintained between the number of studs and the length of the carbide on skags The more studs used the longer the carbide on the skags should be See your dealer s track studding chart for recommended studding and skags Inspect skags and studs frequently Worn studs or skags may reduce steering and braking control on hard packed snow and ice
55. ing of system components Every 1000 to 2000 miles bring the machine to an authorized Polaris dealer to have the V E S disassembled inspected and cleaned NOTE To ensure maximum performance and minimize required maintenance follow the oil recommendation chart on page 51 The use of other lubricants may cause improper function of the valve mech anism and increase the frequency of required cleaning due to excessive build up of carbon deposits Water Pump Belt Inspection Liquid cooled RMK and Switchback models require inspection of the water pump belt at 1500 miles 2400 km Inspect belt width A and condition and replace if cracked or worn past the width service limit 250 6 35mm New belt width is approximately 345 8 75 mm See your Polaris dealer if the belt needs replacement 77 MAINTENANCE General Maintenance Water Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water sediment 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 AWARNING When draining 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 gasoline warnings found on page 53 Plug Cleaning Procedure 1 Turn the fuel tank
56. ing the vehicle Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death 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 with inadequate lubrication could severely damage track rods break track edges and cause other track damage Examples of inadequate lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused by operation on ice or under poor lubrication conditions voids the track warranty Check for Securely Latched Hood 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 46 PRE RIDE INSPECTIONS Start the Engine and Check jn Engine Stop Switch Check the auxiliary shut off switch for proper operation Push down to stop the engine Pull up to release and start the engine i Lighting Check Check the headlight high and low beam taillight and brake light for normal operation Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advantage Check Surroundings to Verify Clear Operating Area Make sure you have a clear area all around your
57. is synthetic chaincase oil through the dipstick opening Do not overfill See page 110 for the part numbers of Polaris products Flush the chaincase after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally Clean the magnetic plug B whenever checking or changing lubricant 73 MAINTENANCE General 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 fouling and engine malfunctioning In selecting a spark plug heat range for production a manufacturer assumes that the engine will be operated under extreme heavy duty conditions and selects a spark plug that will protect the engine from internal damage if the purchaser actually does operate the engine in this manner This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure Refer to your Owner s Manual Supplement for the specific spark plug to be used in your machine CAUTION A spark plug with a heat range too high will always cause engine damage 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 preservative added during the assembly pr
58. loss of power SEE YOUR DEALER This indi cates a major engine problem that must be repaired before engine is run Engine lacks Fouled or defective Change and test operation power spark plug Fuel filter loss of Check fuel filter flow Disconnect hose and high RPM power drain about 1 2 cup Fuel flow should be steady and encompass the entire diameter of fuel line If not replace filter Incorrect clutching SEE YOUR DEALER Carburetor and fuel There s no adjustment to change power out pump put SEE YOUR DEALER Engine Faulty plug s Change plug s continually backfires Carburetor Dirt or ice in fuel system Deicer should be added to non ethanol fuel at all times for as surance against fuel line icing Engine requires Poor gasoline or Replace with fresh winter fuel more than not enough fuel normal pulls to getting to engine start 115 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual Contact your Polaris dealer for replacement parts service 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 service or warr
59. lowing 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 en gine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjust ment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermar ket 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 dam aged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 119 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March April Snow Check promotion The free Second Year Engine Se
60. lug Cleaning oere y eiee rioei a 78 POLARIS PRODUCTS 110 Powder Snow Operation 19 PRE RIDE INSPECTIONS 43 47 Premium Fuel Switch 54 Premium Fuel Switch 55 Pressure Cap 2 0 0 000005 22 R Reyers afc andes ards es areas 23 63 Riding Apparel 0 12 Riding Position 0 11 RydeFX SOLO Shock 31 S SAFERY vae r e IEN EN 8 24 Safety Decals and Locations 22 24 SAG OAE EE ches tener tues EE TEUN 35 Seat Warning Aos ev eleare cere eros 23 Second Year Engine Service Contract 120 Service and Warranty Information 116 Shock Absorber Components 30 Shock Damping 31 Shock Spring Preload Front 32 Shock Valving 0 000 33 Shock Rear serret r ak ee as 37 Signal words 0 000000 8 Skag Replacement 102 Ski Alignment 0 101 Ski Skag s wie ech oe che eek eee 102 Spark Plugs 04 74 75 Spring Preload 0 0 35 Start the Engine and Check 47 Starting sinc kage ewe ee tae 62 Starting a Cold Engine 48 49 Starting a Warm Engine 49 Starting the Engine 48 Steering Adjustment 100 Steering Inspection 100 Steering System 46 100 102 Stopping 0 00 00 61 Storage 6 0 0 0 euo 64 104 105 Storage oie re ec
61. n NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty 99 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check fasteners and tighten if necessary Specific fasteners that should be checked are marked with a in the following illustrations Edge IFS Steering System 100 MAINTENANCE Steering System Ski Alignment AWARNING 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 greater than at point Y NOTE Ifthe skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected Edge IFS Steering System 101 MAINTENANCE Steering System Ski Skags AWARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the origi
62. nal equipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed snow or ice Check skags weekly to maintain positive steering characteristics Skags must be replaced when worn to half their original diameter NOTE 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 forward portion of the skag Reverse this procedure for new skag installation 102 MAINTENANCE Hi Fax Wear Check Hi fax wear by measuring the thickness at several points along the rail A Replace Hi fax when a thickness of 7 16 is reached Take the machine to your dealer for Hi fax replacement If excessive Hi fax wear occurs due to poor snow conditions additional wheel kits are available from your dealer 7 16 1 1 cm Minimum Thickness Suspension Maintenance 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 following items on a weekly basis or before any long trip Check rear idler wheel bolts for tightness Check rear idler adjusting bolt locknuts for
63. nal fit 1 2 NOTE It may be necessary to pry the adjuster blocks apart with a screwdriver 3 4 a Remove the handlebar cover to access the four adjuster block bolts A Using a 7 16 11 mm wrench loosen the four nuts on the bottom of the adjuster block turn the handlebar either left or right for access to the rear nuts Adjust the handlebar to the desired angle Be sure the handlebar brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when the handlebar is turned fully to the left or right Torque the handlebar adjuster block bolts to 11 13 ft lbs 15 17 6 Nm Replace the handlebar cover ongiena with Riser Block 38 Remove the handlebar cover to expose the handlebar mounting hardware Using a 1 2 wrench loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser depending on the type of adjustment required Adjust the handlebar to the desired angle Be sure the handlebar brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when the handlebar is turned fully to the left or right Torque the handlebar adjuster block bolts to 11 13 ft Ibs 15 17 6 Nm Replace the handlebar cover THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile From map light to electric start Polaris
64. nclement weather Observe all state and local laws governing snowmobile operation They ve been established for your protection Always be alert and pay attention to the trail ahead Multiplying speed MPH by 1 5 will equal the approximate number of feet per second 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 seconds 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 illuminated by the headlight 13 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 highways Steep embankments may also hide your view Always leave yourself a way ou
65. nd functions as 2 3 those illustrated IFS Adjustment Options Shock damping if equipped with RydeFX SOLO shocks e Front shock spring preload e Optional springs e Optional valving if equipped with RYDE FX shocks e Indy Select if equipped 29 THE PERFECT FIT Front Suspension Adjustments AWARNING Always verify ski alignment before making adjustments to the IFS See page 101 to check alignment If the skis are misaligned see your dealer as the camber adjustment may also be affected The tension at which the shock coil spring is set is called spring preload For the best ride the spring preload should be set as low as possible to use the full travel of the ski shock with occasional light bottoming To determine if your machine is using full travel of the ski shock push the jounce bumper down as far as it will go on the shock rod and test ride the machine The bumper will move up on the rod in direct relation to the amount of travel If the shock travel is full the bumper will be seated at the top of the shock Shock Absorber Components 1 1 Retainer H 2 Shock Rod eer 3 Jounce Bumper 4 Body 3 5 Threaded Spring Preload Adjuster Nut _ ee 4 el 5 ny 30 THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw Select or actuator
66. ng Technician Date Mileage Type of Service 69 MAINTENANCE Lubrication Lubricate the suspension and steering components with Polaris Premium All Season Grease at 500 miles 800 km and annually or every 1000 miles 1600 km thereafter See page 110 for the part numbers of Polaris products The illustration shows the location of suspension and steering components A indicates a grease point or fitting Grease the left and right spindles Raise the front end of the ma chine to permit better grease entry into the spindle area Lubricate both of the front ski pivots at the fittings as shown Grease the jackshaft and driveshaft clutch side bearings Use an aerosol lubricant on the steering post support bracket Grease the center steering arms Grease the steering post lower pivot Grease the rear suspension pivot shafts raise the rear of unit A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles See page 110 70 MAINTENANCE Lubrication The suspension pivot shafts should be lubricated 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 detailed information about suspension lubrication and adjustments see your Polaris dealer NOTE The following illustrations are
67. nowmobile when obtaining insurance and when ordering replacement parts In the event your snowmobile is stolen these numbers are essential to its recovery and identification 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 If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your snowmobile s ID numbers and key number in the spaces provided Tunnel VIN lower right side of the tunnel Vehicle Model Number Engine Serial Number right front side of engine crankcase Key Number 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 symbols are used Become familiar with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury AWARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 4 CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety AWARNING Driving a snowmob
68. nuously testing lubricants and provide the highest performance products available for your snowmobile s engine Refer to the table below to determine the recommended oils for use in your Polaris snowmobile Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage They 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 Premium Premium VES 2 Cycle Gold 2 Cycle Fan Cooke NA Liquid Cooled NA 51 OPERATION AWARNING A loose track or flying debris could cause serious personal 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 Be sure the rear support is stable AWARNING 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 Track Warm Up Follow these steps to ensure proper warm up of the engine drive train and track 1 52 Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be approximately 4
69. ocess Avoid prolonged idle speeds which cause plug fouling and carbonization Use recommended spark plugs with the proper gap Refer to your Owner s Manual Supplement for specific information e Spark plug torque is 18 22 ft Ibs 24 4 29 8 Nm e Always carry spare spark plugs in case of an emergency CAUTION Using non recommended spark plugs can result in serious engine damage Always use the recommended spark plugs 74 MAINTENANCE General Maintenance 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 AWARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection NOTE 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 Supplement or see your dealer 1 Normal The normal insulator tip is gray tan or light 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 NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an impr
70. of Polaris DOT 3 high temperature brake fluid See page 110 for the part numbers of Polaris products AWARNING 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 severe injury AWARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function CAUTION Brake fluid will damage decals paint and some plastics Always wipe up spills immediately 87 MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action Bleed the system before operating the snowmobile AWARNING 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 possible The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent 1 2 88 Remove brake master cylinder reservoir
71. onic Reverse Button 26 FEATURES AND CONTROLS Features NOaRWONM gt Hood Headlight Windshield Handlebar Seat Storage Compartment Taillights Snow Flap Track Suspension Trailing Arm Nosepan Front Bumper Skis 27 FEATURES AND CONTROLS Features Detonation Elimination Technology D E T Some Polaris snowmobiles are equipped with a detonation sensor that monitors the engine and responds to detonation by automatically reducing the engine timing When activated the DETONATION FLASH indicator A will flash in the lower right hand area of the tachometer The activated sensor reduces engine detonation by retarding the ignition timing This results in decreased engine RPM and performance D E T Troubleshooting Use this chart to determine causes and solutions for detonation If none of these conditions exists and the sensor remains activated see your Polaris dealer Possible Cause Solution Poor quality fuel Replace with higher quality fuel Improper jetting Verify and adjust per jetting chart Improper engine modifications Do not modify the engine D E T Flash Signals Use this chart to determine the meaning and course of action for each D E T flash signal Type of Flash Cause Action 3 flashes of 1 second See DET Troubleshooting Chart each Solid 3 second flash off Faulty sensor See your Polaris dealer 1 second repeats until engine is shut down
72. oper spark plug or incorrect carburetion adjustments 2 Wet Fouled 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 incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation 4 Torque to 18 22 ft lbs 24 4 29 8 Nm 5 Install spark plug cap 75 MAINTENANCE General Maintenance Intake Filter The intake foam filter limits snow ingestion into the intake system When operating in loose powder snow check the top of the foam filter periodically to remove any accumulation of snow NOTE These illustrations are general representations Your model may differ in appearance 1 Intake Foam Filter 2 Air Intake box CAUTION Operating the snowmobile with the intake filters removed may cause carburetor icing The result will be poor fuel economy or carburetor malfunction Always reinstall the intake filters before operating the snowmobile 76 MAINTENANCE General Maintenance Variable Exhaust System V E S Maintenance of the V E S is limited to a periodic inspection and clean
73. or death We recommend having your dealer perform track service and alignment procedures Be alert when riding and remain properly seated to stay clear of the track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation Serious injuries may result if hands feet or clothing become entangled in the track AWARNING If fingers or clothing contact the moving parts of an engine serious injury can result Always stop the engine before attempting adjustments Never attempt adjustments with the engine running Turn off the ignition raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation 10 SAFETY Operator Safety Riding Position AWARNING Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death Always be properly seated and in position to control your vehicle Operating a snowmobile requires skill and balance for proper control Rider positions may vary from person to person as each becomes more skilled but under most conditions the proper position is to be seated with feet on the running boards and comfortably positioned for proper throttle brake and steering control 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
74. other 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 116 121 INDEX A ACCESSOTIES 6 eee eee 39 42 ADOR ete facts nA ARAE tassced 4 22 B Battery stents eee age a 106 108 Battery Connections 108 Battery Fluid 0 107 Battery Installation 109 Battery Removal 108 Battery Storage 0 109
75. owmobile before towing 64 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and service checks outlined in this manual The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 miles 800 km and 1000 miles 1600 km These inspections should be performed by a qualified service technician For continued optimum performance 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 registered 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 adjust your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfortable performing these tasks yourself contact an authorized Polaris dealer for service 65 MAINTENANCE Maintenance Chart 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 u
76. p 5 TEAM Clutch Rotate the L wrench to tighten the sheaves Remove the wrench and store in the tool kit Close the clutch guard and reinstall the retaining pin Close and secure the hood and release the parking brake 93 MAINTENANCE General Maintenance Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the belt A and apply downward pressure while measuring at point B This measurement should be 1 1 4 Drive Belt Adjustment Polaris Standard Clutch Belt deflection can be adjusted without removing the clutch from the jackshaft 1 Pull the belt into the driven clutch to slightly open the sheaves 2 Loosen the three bolts on the adjustment cam and turn the cam counterclockwise to reduce the distance between the sheaves Do not rotate past the 1 position 3 Torque the bolts to 4 6 ft Ibs 5 4 8 1 Nm TEAM Clutch 1 Loosen the 7 16 jam nut on the belt width adjuster 2 Using a 1 8 Allen wrench adjust the threaded set screw as needed NOTE Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the distance 3 Tighten the jam nut Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer Due to tolerances in belt length it may be necessary for your de
77. r inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2 WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Polaris Recreational Vehicles e Snowmobiles e All terrain vehicles ATVs e Watercraft e RANGER utility vehicles e Victory motorcycles Polaris Professional Series Workmobiles e Utility Task Vehicles UTVs e Personal Task Vehicles PTVs e All Surface Loaders ASLs We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience 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 your 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 service needs during and after the warr
78. r low Setting will remain until changed 23 SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing contact 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 unex pected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehicle 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 cloth ing while operating this vehicle This vehicle is designed for adult use only Check local laws for age re quirements 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 the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Red
79. rvice Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date free of charge through any Polaris snowmobile 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 registration form This form is your proof of warranty Consumer Exclusions e Each repair visit after the first twelve months of standard warranty coverage is subject to a 50 deductible e 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 e Snowmobiles used for commercial purposes or for racing are excluded from cover age 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 additional 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 includes e Damage due to accident fire explosion
80. s found under the hood on the pressure cap of liquid cooled models Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI Passenger Warning Your Polaris snowmobile is designed for a single rider only A decal on the console indicates single rider operation This vehicle is designed for operator only NO PASSENGER 22 Safety Decals and Locations Track Seat Warning The track seat warning decal is on the rear of the tunnel Stay clear of track Do not sit on seat back Entanglement with the track ora fall from seat back may result in severe injury or death Reverse Warning Some Polaris snowmobiles are equipped with electric reverse and will have this decal on the console Reverse operation even at low speeds may cause loss of control resulting in serious injury or death To avoid loss of control always e Look behind before and while backing e Avoid sharp turns e Shift to or from reverse only when stopped e Apply throttle slowly NOTE For more information see your Owner s Manual If electric reverse e Machine stopped and engine at idle push yellow button on LH control to reverse Flashing light on dash indicates reverse opera tion e Push button again to return to forward e Elevation setting above 6000 feet push and hold for longer than 5 seconds to set Let go of button at desired setting fast flash for high elevation slower flash fo
81. s steering and braking control which may result in serious injury or death Slow down and use caution Excessive shifting of operator body weight when turning on hard packed snow or ice may lead to loss of vehicle control and result in serious injury or death Slow down to maintain control under these conditions It s dangerous to drive on ice or other slippery surfaces If it s unavoidable use extreme caution and operate at speeds no faster than a walk Never attempt an abrupt change of direction The chance of spin out increases under these conditions 15 SAFETY Operator Safety Driving in Hilly Terrain AWARNING 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 Operating in hilly terrain requires extreme caution to maintain balance and avoid roll over If climbing a hill is unavoidable keep all 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 enoug
82. se Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz 2871372 2871322 2871423 2871329 Dielectric Grease Nyogel 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt 110 TROUBLESHOOTING Suspension Troubleshooting Problem Solution perform only one change at a time Rear suspension Verify sag dimension see set up decal or page 35 Adjust bottoms too easily torsion spring blocks page 36 or install optional torsion springs to achieve correct sag dimensions Increase shock compression damping page 37 Rear suspension Check for binding suspension components and grease all rides too stiff pivot points Verify sag dimension see set up decal or page 35 Adjust torsion spring blocks page 36 or install optional torsion springs to achieve correct sag dimensions Decrease shock compression damping see page 37 Too much weight Verify sag dimension see set up decal or page 35 Adjust transfer when torsion spring blocks page 36 or install optional torsion climbing springs to achieve correct sag dimensions Move limiter strap on front torque arm to high position see set up decal or page 36 Too little weight Verify sag dimension see set up decal or page 35 Adjust transfer when torsion spring blocks page 36 or install optional torsion climbing springs to achieve correct sag dimensions Move limiter strap on front torque arm to low position see set up
83. se genuine Polaris parts available from your Polaris dealer Weekly or 150 500 1000 See before miles miles miles Page long trip 240 km 800 km 1600 km Check brake operation and Daily 43 85 adjustment Frestenginesopswieh bay _ _ 7 Presteterseep pay _ 7 Temone aeyn oa _ 39 Pthotteeveroperaion Daily _ _ 8 59 Ee a a S taillight brakelight Chock park vrake tno bay __ C E check mackatgnmen x __ ___ Seorngamand ios x Check and tighten loose suspension mounting bolts Tighten ski saddle and spindle bolts Check front limiter strap condition tighten bolts Check ski skags replace when worn to half original diameter Check Hi fax thickness replace when worn Dealer Tighten rear idler wheel bolts A a 5 o Eo A 92 94 66 MAINTENANCE Maintenance Chart Weekly or 150 500 1000 See before miles miles miles Page long trip 240 km 800 km 1600 km Tighten idler adjusting bolt jam X nuts Inspect coolant filter replace if X X X 83 necessary orses OOO t x x x 7 ae oe Lubricate steering post support 70 bracket and pivot aerosol Check cylinder base stud torque X X X on all Polaris engines Specifica tion 32 ft lbs 2 ft lbs Dealer EEE F Grease lower steering post pivot Grease driveshaft bearing always perform before storage X X X Cheskanddainvaertap e a a X X Ti Ee ae
84. shafts a o x xX gt N gt ee N Grease jackshaft bearing 72 always perform before storage Lubricate throttle cable Lubricate choke slide and cable ooo Cx r Check ernen alignment oi __ ay gt lt Ka r i a a specific gravity Fnspetoitfiterandrepie Inspec oil Tine condon __ Inspect fuel fter and repe O cheek brake midi __ Inspect fuel nes and epee __ Inspect exhaust system for weak or missing retaining springs Inspect exhaust pipe for cracks or damage Inspect clutch sheaves for damage wear belt residue O y fja KoF on KoF Re oO 67 MAINTENANCE Maintenance Log Present this section of your manual to your dealer each time your snowmobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile 150 Mile 240 km Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 500 Mile 800 km Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 1000 Mile 1600 km Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 68 MAINTENANCE Maintenance Log Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servici
85. ski to ground pressure When adjusting be sure the springs on both the left and right sides of the machine are at the same adjustment To increase front shock spring preload grasp the spring and turn it to the right Turn it to the left to decrease preload Illustration B indicates high preload and illustration C indicates low preload 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 preload beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make sure at least two turns of preload are holding the spring between the retainer on top of the shock and the threaded spring preload adjuster nut on the shock body NOTE Some models do not have shocks with thread adjustable spring preload See your dealer for more information ACAUTION Always leave one thread showing above the adjuster nut On models equipped with a plastic adjuster nut if the nut is unscrewed from the threaded body the nut will break 32 THE PERFECT FIT Front Suspension Adjustments Shock Valving RydeFX or RydeFX SOLO shocks can be revalved if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness AWARNING Changing shock valving on RydeFX and RydeFX SOLO shocks requires special tools and a sound knowledge of mechanical theory tool use and shop proce
86. stalled in production is not correct for all altitudes and or temperatures CAUTION 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 NOTE 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 and temperature that is likely to be encountered 58 OPERATION Engine Stop Switch Push down on the engine stop switch A to stop the engine in an emergency This will ground out the ignition and bring the engine to a quick stop To restart the engine the switch must be pulled up to the ON position Throttle Safety Switch Test the throttle safety switch system daily before operation While seated in a normal riding position and with the engine idling hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration B Apply a slight amount of throttle A properly functioning switch must shut down the engine The throttle safety switch is designed to stop the engine whenever all pressure is removed from the t
87. supply valve off 2 Position a container or shop towels to catch the contaminated gasoline 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube 4 Wipe residue from the plug and reinstall it Reposition and tighten the clamps Continue until z all the traps have been emptied vy 78 MAINTENANCE General Maintenance Fuel Filter Fuel Lines Inspect the in tank fuel filter 1 and fuel lines regularly Give special attention to the system s fuel line condition after periods of storage Normal deterioration from weather 1 and fuel compounds may occur CAUTION 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 Oil Filter The oil filter should be changed annually or every 1200 miles 1920 km Inspect oil line condition at 1000 miles 1600 km Polaris oil filters are specially designed for use on Polaris products We strongly recommend the use of only Polaris replacement parts Edge models use an oil filter that s built into the oil sending unit located in the bottom of the oil tank After changing the oil filter bleed the oil injection system of all trapped air See your dealer for instructions or have your dealer perform the filter change and bleeding operation for you See page 51 for oil recommendations 79 MAINTENANCE General Maintenanc
88. t Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you Before riding your machine on a frozen body of water be sure the ice is thick enough to support the machine and its operator as well as the force created by a moving vehicle You may drown if you and the snowmobile break through the ice 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 sponsored by local or state organizations 14 SAFETY Operator Safety Ice and Snow Build up AWARNING 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 check for ice and snow build up that may be obstructing the steering linkage Snow screens and bib kits are available through your dealer to help reduce snow and ice build up Driving on Slippery Surfaces AWARNING Driving on ice or hard packed snow reduce
89. t 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 punc turing of upholstery material corrosion or defects in parts components or the snowmo bile 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 REM EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEG LIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclu sion 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 117 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DIS
90. the belt and warm it to room temperature Reinstall it before starting the snowmobile The following procedures apply to standard electronic reverse and TEAM driven clutches Drive Belt Removal 1 92 Be sure the key switch is off and the engine has come to a complete stop Apply the brake or lock the parking brake if equipped Open the hood remove the clutch guard retaining pin and open the clutch guard Standard Clutch Skip to step 4 TEAM Clutch Locate the L wrench in the tool kit and install it into the open threaded hole in the outer sheave of the clutch Rotate the wrench until the sheaves open far enough to remove the belt Firmly grasp the belt midway between the clutches and pull upward and rearward to remove See illustration MAINTENANCE General Maintenance Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack A NOTE 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 removal procedures Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave B Work the belt to the outer edge of the sheave Standard Clutch Skip to ste
91. theft or other causes beyond Polaris control e Damage caused by the failure of other components of the snowmobile e Failures caused by improper fuel or oil e Piston seizures unless caused by a defective engine component e Failures caused due to improper adjustments Failure due to unauthorized service e 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 e Failure due to use of unauthorized parts or modifications e 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 e Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage e Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals e Non wear related throttle body parts are covered The fuel pump is covered e Clutches and related clutch parts including but not limited to the drive belt are ex cluded from coverage e Electrical components are excluded from coverage e Gearcases and transmissions are excluded from coverage 120 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERV
92. there s adequate stud clearance to the heat exchangers Lack of clearance may result in damage to heat exchangers 42 PRE RIDE INSPECTIONS Before Starting the Engine AWARNING 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 We ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling Check Throttle and Brake for Proper Operation The throttle and brake are the primary controls of your snowmobile If either should malfunction loss of control could result Make sure the throttle lever compresses evenly and smoothly The lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly DO NOT start the engine Have the throttle serviced immediately The need for a properly functioning brake is critical Your snowmobile is equipped with the highest quality brake system available Check the brakes for correct operation before starting the engine Throttle Safety Switch Test the throttle safety switch system daily before the machine is operated 43 PRE RIDE INSPECTIONS Before Starting the Engine Hydraulic Brakes Properly functioning brakes are critical to your safety Always check the follow
93. tightness Check front torque arm limiter strap condition Check slide rail Hi fax condition greatly affects performance have your dealer replace when worn to minimum thickness Check track tension beginning on page 97 Lubricate grease all suspension components see page 70 YAA AW AAS Check ski runner skag condition 103 MAINTENANCE 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 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 surfaces 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 sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the prevention 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
94. tle must be maintained at the full cold line on the coolant bottle when the engine is cold CAUTION Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine the system should be completely drained every two years and a fresh 50 50 or 60 40 mixture of antifreeze and distilled water should be added This service must be done when the engine is cold Ask your Polaris dealer to check the coolant when he performs the fall tune up on your snowmobile 82 MAINTENANCE General Maintenance Engine Cooling Liquid Cooled Models Bleeding the Cooling System If the pressure cap needs replacement contact your dealer for the correct part Use of a non standard pressure cap will not allow the cooling system to function properly NA AWARNING Steam and hot liquids will cause serious burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark Elevate the front end of the machine slightly to aid in bleeding Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bl
95. ts A 7 Tighten or loosen the track adjusting screws B as necessary to provide equal adjustment on both sides of the track C Track 97 MAINTENANCE Track Maintenance If the track needs adjustment continued 8 Repeat measurement on the other side of the track NOTE Check more frequently when machine is new 9 Start machine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check track alignment see page 98 and adjust as necessary 11 Tighten locknuts A 12 Tighten idler shaft bolts D and torque to 35 ft Ibs 47 5 Nm 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 A are evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten locknuts and torque idler shaft bolts to 35
96. ttery Installation AWARNING Batteries contain gases that can explode If the battery vent tube is pinched or kinked battery gases could accumulate Whenever removing or installing the battery disconnect the negative black cable first and reinstall the negative cable last to avoid the possibility of explosion Battery electrolyte contains acid Avoid skin contact with electrolyte as severe burns may result 1 Place the battery in its holder Attach the hold down strap 2 Install the battery vent line It must be free from obstructions and securely installed Route the vent line properly to prevent kinks and to allow for proper drainage 3 Connect and tighten the red positive cable first 4 Connect and tighten the black negative cable last 5 Verify that cables and vent hose are properly routed Battery Storage When your snowmobile is placed in storage for one month or more e Remove the battery e Charge it to the proper level e Store it in a cool dry place e Check and or charge monthly Before using the battery take it to your dealer for testing and recharging NOTE Batteries may freeze if not fully charged which would result in cell damage Charge Condition Will Freeze At 100 15 F 59 C WE GEO FF CRO AFF CEO 0 18 F 8 109 POLARIS PRODUCTS Part No Description 287079 2871098 2871097 2871721 2871722 2874438 2874430 Chaincase Lubricants 2873105 Synthetic Chainca
97. tween the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm Use the illustration or the decal found under the hood for reference The ideal amount of sag for the EDGE RMK and Switchback rear suspensions is four inches X Y 4 If the rear suspension rides in less than three inches or more than five inches with the torsion spring preload cams at their maximum range of adjustment optional torsion springs softer or stiffer respectively may be required This is only an initial setup and final spring preload may vary based on rider preference and riding conditions 35 THE PERFECT FIT Rear Suspension Adjustments Rear Torsion Spring Tension To adjust rear torsion spring tension rotate the three position cam using the engine spark plug tool Different rate torsion springs are available if a firmer ride is desired Contact your dealer for more information The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style 1 Turn screw clockwise to stiffen compression 2a Limiter strap in high position increases ski pressure 2b Limiter strap in low position decreases ski pressure 3a
98. uce speed and al low 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 the engine check throttle brake and steering for proper operation Make sure hood is latched Be seated and in position to con trol the vehicle Oil injection system Use unmixed fuel only Check oil level when refueling 24 FEATURES AND CONTROLS Controls SOLO ON ON Re hor Fuel Filler Cap may include a fuel gauge Ignition Switch Brake Lever Speedometer may include indicator warning lights Tachometer may include indicator warning lights Engine Stop Switch see page 59 Throttle Control Recoil Starter Handle Choke 25 FEATURES AND CONTROLS Controls Some Polaris snowmobiles are equipped with special features Controls for these features are illustrated on this page Not all models come with these features Refer to your Owner s Manual Supplement for a list of features on your machine Accessories are available from your Polaris dealer 1 Headlight Dimmer Switch 2 Position 2 Park Brake 3 Handlebar Grip Warmer Switch 4 Thumbwarmer Switch 5 Electr
99. ular maintenance Troubleshooting 2 0eeeeeeeeeeee 111 This section is a quick reference guide to solving problems Warranty nin itt eae eee eee ee ea 116 This section outlines specific warranty information Late E ati ceivaiaadeialeten SiGe teeee es 122 INTRODUCTION Important Notes for Owners and Drivers i After reading this manual store it in the snowmobile for convenient reference It should remain with the snowmobile when sold i The illustrations and photos used in this manual are general representations Your model may differ 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 necessary to ensure warranty coverage i 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 campaign We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organizations are working together to protect our environment Please support their efforts and operate your snowmobile
100. utches such as adding or removing weights will void the warranty CAUTION 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 Periodically inspect the clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol Clutch Alignment and Offset Clutch center distance and alignment A are crucial to maintaining optimum performance See your Owner s Manual Supplement for the recommended offset between the drive and driven clutches with the belt removed The drive belt is a very important part of the drive system Belt width and length must match the center distance of the clutches and sheave width of the drive clutch For this reason Polaris recommends that only O E M belts be used Other belts may match the dimensions but can drastically change the shift pattern resulting in poor performance See your dealer for service and adjustments NOTE A worn belt will continue to function but will not deliver maximum performance Al ways carry a spare belt in case of an emergency 91 MAINTENANCE General Maintenance Periodically check the condition and tension of the drive belt and always carry a spare belt For improved drive away during extremely cold temperatures remove
101. utes or less To apply the lock squeeze the brake handle and push forward on the brake lever lock Hold the lock forward and release the brake handle If the brake handle is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break To release the lock squeeze the brake handle until the lever returns to the unlock position The park brake light on the console will light up when the park brake lever lock is set and the engine is running It will also be lit when the service brake is in use If the park brake light does not come on when the park brake or service brake is in use have it serviced by your dealer 1 Brake Handle 2 Park Brake Lever Lock 3 4 3 Master Cylinder Reservoir 2 gt re Cover A ae 4 Fluid Level Indicator Ze JEN BQ 3 AWARNING If the park brake lever lock is partially or entirely engaged while riding overheating of the brakes could occur resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death 45 PRE RIDE INSPECTIONS Before Starting the Engine Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left If any difficulty is encountered check for ice and snow build up that may be obstructing the steering linkage Make sure all greasable components are properly lubricated Track Inspection AWARNING Always inspect the track for damage before us
102. verse NOTE If the engine stops running the snowmobile will be in for ward gear when it s restarted 4 amp CAUTION Operating the electric starter or the recoil while the engine is running can result in personal injury and or engine damage Do not operate the electric or pull rope starter while the engine is running Disengaging Reverse Push the yellow reverse button on the left hand control for one second and release The engine will slow and and begin to rotate forward The light on the instrument panel will shut off Make sure the area around your vehicle is clear and apply throttle slowly until you re sure the machine is in forward gear 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 63 OPERATION Daily Storage At the end of each ride park the snowmobile on a level surface and support it at the rear with an appropriate track stand The track should be suspended approximately 4 20 cm off the ground Remove the key and cover the machine NOTE
103. wall in step 2 NOTE Rider weight must be included on the seat 5 Turn the adjustment nut A located inside the hood just below the headlamp opening Turn the knob in or out as needed for proper aim 89 MAINTENANCE General Maintenance NOTE Avoid touching a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot that will shorten the life of the lamp Removing Halogen Bulbs 1 Pinch the ends of the spring 1 together and lift until it releases from the spring retainer 2 2 Lift spring carefully around wire Se Z harness 2 and flip to outside of 8 housing 3 With the wire harness attached 1 to the bulb 3 withdraw bulb from housing 4 Grasp bulb by metal base and carefully separate bulb from harness Installing Halogen Bulbs 1 Hold bulb by metal base and install into wire harness 2 Insert bulb into housing 3 Carefully flip spring back into housing placing it around wire harness 4 Squeeze spring together until it is over the spring retainer and release 5 Verify headlight aim 90 MAINTENANCE General Maintenance Clutch System AWARNING 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 authorized Polaris dealer Any unauthorized modifications to cl
104. with consideration for the protection and preservation of our environment Respect your snowmobile respect your environment and you will earn the respect of everyone 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 welcome 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 levels 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 INTRODUCTION Vehicle Identification Numbers The tunnel vehicle identification number VIN and engine serial number are important for model identification when registering your s
105. wmobile are thoroughly inspected by your dealer at specific mileage intervals Driving Responsibly Every snowmobile handles differently and even the most docile conditions 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 drivers should 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 ex tent of their operating skills Check to see if they ve taken a snow mobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safe ty course Everyone can benefit from the course Don t jump your snowmobile Jumping may injure your back be cause of spinal compression The seat and suspension of your snow mobile have been designed to provide protection 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 Your snowmobile is equipped with a high out put headlamp system that may cause discomfort to operators of on
106. xhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 53 OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used 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 Premium Fuel Switch Your Polaris snowmobile is equipped with a key function to adjust the timing on the machine as you change fuels It s very important to the life of your engine that you use this feature When using fuels with a pump posted octane rating of 91 or higher turn the key switch to ON PREM When the engine is started a yellow Premium Fuel light illuminates on the instrument panel When the key is in this position the fuel must be a minimum of 91 octane Most high performance machines require the use of premium fuels Substituting other fuels may cause Regular Fuel Setting engine damage CAUTION Using fuels with a lower than recommended octane or operating with obstructed fuel systems will result in serious and costly engine damage Always use the recommended fuels for your machine 54 OPERATION Fuel Premium Fuel Switch If you
107. y Storage 0000 64 Detonation Elimination Technology 28 Disabled Operators 12 Drive Belts oeieo eop er ee sees 17 Drive Belt Adjustment 94 Drive Belt Deflection 94 Drive Belt Installation 93 Drive Belt Removal 92 Drive Chain Tension 84 Driver Awareness 0 14 Driveshaft Bearing Greasing 72 Driving Downhill 17 Driving in Hilly Terrain 16 Driving on Slippery Surfaces 15 Driving Responsibly 20 E Electric Start 00000 49 Electrical Connections 106 Emergency Starting 62 Emergency Stopping 61 Engine Carburetor Protection 104 105 Engine Break In 50 Engine Stop Switch 47 59 Engine Troubleshooting 113 115 Excessive Speed 0 00 13 Exhaust System 0 81 F Fall Tune Up 2 hice ieee Ae ee 96 Features serani reriyi eira otai 27 28 FEATURES AND CONTROLS 25 28 Flushing the Cooling System 82 For Your Protection 96 Front Springs 0000 33 FUG cre 2s vies din astdrnouns diay itera 53 55 FUCL Filter ies Ser ets ole aa glad elie gues ou ee 79 Fuel LMS oe erate faves cin endene 79 Fuel Reserve Capacity 55 Fuel System Deicers 55 G General Maintenance 74 96 H
108. y check the oil level in the bottle The engine may be operated as long as oil is visible in the oil tank If oil is not visible continued operation may cause serious engine damage Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage They 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 Always maintain the oil level above the tank s low level line This is especially important when the machine is operated in mountainous terrain Maintaining the proper oil level will prevent system aeration and possible loss of pumping action which could result in engine damage CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris 2 cycle oils for your snowmobile Never mix brands CAUTION Operating the snowmobile without proper engine lubrication can result in serious engine damage Always check the oil level when refueling 56 OPERATION Oil Low Oil Level Always do a visual check of the oil level when refueling When the oil reaches the low level mark add one U S quart of recommended oil to the tank See page 51 for oil recommendations The Polaris oil cap on the oil tank may be vented to allow proper oil flow See your Polaris dealer for recommended replacement parts Carbur

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