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maintenance - Grand County EMS

1. 81 Intake Silencer 18 L Lights esp tete tes 95 Limiter Strap Position 44 Low Oil Indicator Light 62 Lubrication 75 78 CROKE teer Ys 76 Choke Cable 76 Driveshaft Bearing 76 Front Suspension 75 Rear Suspension 75 Throttle 76 M Maintenance Interval Table 72 74 Maintenance Program 71 Maneuverability 18 MED Components 30 Digital Display 33 Digital Display Programs 34 37 32 eh 6 Oil Filter 82 Oil Injection System 58 Oil Levels doe 62 OIL bimesi keels pce 82 Oil Recommendations 58 Oil 77 Oil 62 Operating in Deep Snow 19 Operation Warning 24 25 P Parking Brake Lever Lock 52 Passenger Warning 23 Polaris Products 112 Pre Ride Checklist 49 55 Pressure Cap Warning 22 R Rail Slide 108 Recoil Rope 51 Reverse Operation 66 67 Reverse Warning 24 Rider Capacity 13 S RA 8 21 Safety Decals
2. 60 25 17 10 3 4 11 19 26 33 40 Frostbite in gt gt 30 min 10 min WIND CHILL CHART C Wind Actual Thermometer Reading C Speed 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature C Cam 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 7 11 14 18 22 25 29 32 36 39 43 46 50 253157 16 2 2 6 40 13 17 21 24 28 32 36 39 43 47 50 54 58 62 24 1 3 7 11 15 9 22 26 30 34 38 42 45 49 53 57 32 4 8 12 16 20 24 28 32 36 39 43 47 51 55 40 1 5 9 13 17 21 25 29 33 37 41 45 49 53 48 1 5 9 13 18 22 26 30 34 38 42 46 50 56 2 6 10 14 18 22 26 31 35 89 43 47 64 2 6 10 15 19 23 27 31 35 40 44 48 72 2 7 41 15 19 23 28 32 36 40 45 80 3 7 11 15 20 24 28 33 37 41 45 88 3 7 12 16 20 24 29 33 37 42 46 16 Frostbite in gt gt 30 min 10 min 21 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protec tion Read and follow the instructions of the deca
3. d 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions NOTE It will take longer to warm up the track sufficiently during colder out door temperatures 4 Release the throttle apply the brakes shut off the engine and lower the snowmobile to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice 59 OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time A WARNING The engine exhaust 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 60 OPERATION Fuel For peak performance Pola
4. Suspension Shock Oil 1 Cooling Fins Shroud 1 1 1 1 1 1 Drive Shaft Bearings 76 L L L Jackshaft Bearings 109 L L L 1 Skags Wear Bars 107 1 1 1 1 1 Ski Saddle Spindle 1 1 1 1 1 Bolts Drive Chain Tension 90 1 l 1 1 Hood Latches 50 1 1 l 1 1 Rear Wheel Idler Bolts 103 l 1 1 1 Idler Bolt Jam Nut 103 l 1 1 l Rear Suspension Pivot 75 L L L Shafts Camber Alignment 1 1 1 Handlebar Centering 1 Tether Switch and Strap 55 1 1 l 1 1 Track Alignment 104 1 l 1 1 103 l 1 1 l Front Limiter Strap l 1 1 1 1 Rail Slide Condition 108 1 Chaincase Oil 77 1 1 1 R Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 74 MAINTENANCE Lubrication Front Suspension The front suspension does not require lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 72 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the sus pension For more information about suspension lubrication and adjust ments see your Polaris dealer 75 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into
5. consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 122 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow mobiles that were Snow Ch
6. Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fuel at all times for assurance against fuel line icing more than normal pulls to start Incorrect throttle SEE YOUR DEALER freeplay or faulty switch Engine requires Poor fuel Replace with fresh winter fuel Not enough fuel get ting to engine SEE YOUR DEALER Engine backfires but fails to start Spark plug wires may be on wrong cylinder Reinstall spark plug wires to the cor responding cylinder 115 TROUBLESHOOTING Suspension Troubleshooting Solution Rear suspension bot toms too easily Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Rides too stiff in rear Check for binding suspension components and grease all pivot points Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Too much weight transfer when climb ing Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Move limiter strap to high position see page 44 Too little weight transfer when climb ing Front end pushes Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Move limiter strap to
7. trol of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary CAUTION Towing a disabled snowmobile with the drive belt in place can result in seri ous damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 68 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Emission Control Label Your snowmobile is equipped at the time of sale with an emission con trol information ECI label and a factory installed emissions informa tion hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a
8. A Accessories 48 Apparel for Riding 12 Avalanches 15 B Brake Components 92 Brake Fluid 93 Brake Inspection 91 Brake Lever 1 51 Brake Lever Travel 51 92 Brake System Bleeding 94 Brakes a c IRI 51 91 94 Break In Engine 57 58 Bulbs 95 C Carburetor 83 84 Carburetor Adjustments 83 Carburetor Protection 600 RMK 110 Carburetor Water Sediment Trap 84 Cargo 28 Chaincase 77 78 Choke Cable 76 Clutch Alignment Offset 96 Clutch Center Distance 96 Clutch Cover Warning 22 Clutch System 96 99 Clutches ex 18 Coolants et crie aset 86 Coolant High Temperature Light 87 Coolant 86 Cooling System 86 89 Cooling System Bleeding 88 89 Cooling System Flushing 87 D DET etn alin tanh ed 29 Detonation Elimination Technology 29 Digital Display 31 Digital Display Programs 33 37 Disabled Operators 13 130 D Drive Belt 18 Drive Belt Adjustment 99 Drive Belt Condition 97 Drive Belt Deflection 99 Drive Belt Installation 97 Drive Bel
9. Hot Surface Warning The hot surface warning is on the rear center of the tunnel WARNING Hot Surface Do Not Touch Burns may result Entire top of tunnel may be hot Install only accessories specifically approved for this model by Polaris Do not place clothing bags or cargo on tunnel Do not cover this label No Passenger Warning Track Warning Hot Surface Warning 23 SAFETY Safety Decals and Locations Reverse Warning Polaris snowmobiles equipped with electric reverse have a reverse warning decal on the console WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Reverse Warning Shift to or from reverse only when stopped Apply throttle slowly Operation Warning NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to forward Operation Warning The operation warning decal is located on the console of all Polaris snowmobiles WARNING To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing con tact a Polaris dealer for a replacement This vehicle is c
10. 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 88 MAINTENANCE Cooling System Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main tenance Table beginning on page 72 Perform the bleeding procedure when the engine is cold 1 2 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 of the heat exchangers 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 bleed 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 exchangers under the running boards If the system is bled properly they ll be warm to the touch If they re not repeat step 5 Lift the front of the machine slightly to assist in the bleeding Replace the pressure cap and carefully lower the front end of the machine 89 MAINTENANCE Drive Chain Tension Check drive chain tens
11. and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor 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 Follow the recommended maintenance program outlined beginning on page 71 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals WARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are capable of traveling at high speeds Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directe
12. 22 25 Sag Settings 43 Sediment 84 Shock Components 40 Shock Compression Valving 45 Shock Spring Preload Front 41 Shock Springs Front 41 Shocks 40 Shocks Standard 40 SKAGS a 107 Ski Alignment 106 Slide Rail and Track Cooling 58 131 INDEX S Snow Build up 16 Snow Conditions 19 Spark Plugs 79 80 tear Aa 5 13 Spring 1 43 Starting the Engine 56 Steering Adjustments 28 Steering Inspection 53 105 Steering System 105 108 Stop Switch 63 65 Storage Daily 68 Storage Extended 109 111 Survival Preparation 11 Suspension Adjustments Front 39 41 Suspension Adjustments Rear 42 45 Suspension Inspection 54 Suspension Lubrication Front 75 Suspension Lubrication Rear 75 Suspension Performance Tips 42 Suspension Front 39 Switch 63 Switch Throttle Safety 63 132 T Tether 48 Throttle Lever 50 64 Throttle Safety Switch 50 63 Torque 99 Torsion Sprin
13. Interval Table The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement parts always use genuine Polaris parts available from your Polaris dealer Item See Frequency Page 150 mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CLUTCH Clutch Alignment Offset 96 1 1 without belt Drive Belt Condition 97 l l 1 Clutches disassemble 96 1 C C Belt Tension 1 I l 1 Clutch Sheaves 96 1 1 1 1 ENGINE COOLING Engine Mounts 1 1 1 Recoil Rope 1 I 1 1 Engine Torque Stop 99 1 1 l Cylinder Head Bolts 1 1 1 Oylinder Base Nuts 1 1 1 1 Ignition Timing 1 l VES System l c c Coolant Level 86 R Coolant Hose 1 1 1 1 Heat Exchangers 89 l 1 l Coolant Circulation 1 1 Coolant Leaks 1 1 1 1 Spark Plug Condition 79 l 1 R 1 Exhaust Pipe 85 1 l Exhaust Retaining 85 1 l 1 Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 72 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 1590 soo mi 1000 mi 2000 mi Pre 240 km 800 km 1600
14. Lubrication Chaincase Oil Oil Change 1 Position the vehicle on a level surface YA 2 Remove the drain plug and drain the ie oil into a drain pan Allow the oil to ESE drain completely 3 Clean off all metal shavings from the and Ly plug 4 Install a new sealing washer on the 2 drain plug Drain Plug NOTE The sealing surfaces on the drain plug 9e CON A 78 and the oil tank should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 6 10 ft 165 8 13 Nm Remove the fill plug Clean off all metal shavings from the plug Add 11 oz 325 ml of the recommended oil Do not overfill Reinstall the fill plug making sure it is seated properly 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 WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection NOTE On carbureted models 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 carbu retor s Refer to the Owner s Manual Supplement or see your dealer Normal Spark Plug The nor
15. NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty CAUTION High speed use on hard packed surfaces is not recommended for models equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequent slow speed intervals for track cooling 101 MAINTENANCE Track Tension A WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine run ning Track tension is critical for maximum efficiency and performance Track tension controls the approach angle of the track to the rail beam in powder snow conditions Deep snow performance will be optimized at the specified tension Looser tensions will cause the track to bunch in front of the rail tips causing improper approach angle and poor perfor mance New tracks will need to be retightened and aligned after the first ride TRACK TENSION DATA CHART Measurement Slack Suspension Weight Location Measurement IQ RMK 10 Ibs 4 54 kg 16 40 cm 3 8 1 2 ahead of rear 1 1 3 cm idler shaft NOTE Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmobile and safely s
16. Synthetic 2 Cycle Engine Oil qt 2871722 Premium Gold Synthetic 2 Cycle Engine Oil gal 2872347 Premium Gold Synthetic 2 Cycle Engine Oil 2 5 gal 2874438 VES II Synthetic 2 Cycle Engine Oil qt 2874439 VES II Synthetic 2 Cycle Engine Oil gal 2874443 VES II Synthetic 2 Cycle Engine Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogel Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 12 oz 2872893 Engine Degreaser 12 oz 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner 112 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Probable Cause Solution Erratic engine oper ating RPM during acceleration or load variations Drive clutch binding SEE YOUR DEALER Driven clutch mal function SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Excessive belt sheave
17. and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number Model number Dealer name Date of purchase Details of trouble experienced Du Bop Length of time and conditions of operation 7 Previous correspondence Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 888 704 5290 Canada 1 204 925 7100 118 WARRANTY Service And Warranty Information Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines Administration 1 Polaris snowmobile owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifying the proper owner when a unit is recovered 119 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 T
18. any specified critical emissions related maintenance is not performed Performance of other scheduled main tenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Polaris recom mendis that you contact an authorized Polaris dealer to perform any service that may be necessary It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law and may result in civil penalties 126 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km 127 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 128 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 129 INDEX
19. becomes disconnected DET Troubleshooting Carbureted Models 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 for diagnosis Possible Cause Solution Poor quality fuel Replace with higher quality fuel Improper engine modifications Do not modify the engine 29 FEATURES Instrumentation MFD Component Identification Item Analog Gauge if equipped Digital Gauge Check Engine Indicator Low Oil Indicator High Temp Indicator Brake Indicator Reverse Indicator m High Beam Indicator uti MSN 30 Instrumentation Digital Display Identification FEATURES Item RPM or Speed Altitude if equi ed Service inte va Electrical System Voltage Level MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute Air Tomp if equipped Engine Temp Degrees Celsius Degrees Fahrenheit Miles Kilometers Hours Trip 1 Trip 2 Trip F Service Label Altitude Label MAX MPH KPH RPM AIR ENG C F MILES KM P 31 FEATURES Instrumentation MFD Settings The MFD Control Switch allows you to set the MFD MODE display to your preferences The rocker switch has a SET MODE button top and a 2 SET
20. button bottom Specific 4 k instructions are outlined on the following pages MFD C ontrol Switch Standard vs Metric The will display either standard or metric units of measurement While viewing a screen that displays measurements MPH km h or temperatures press and hold the MODE switch until the unit of mea surement changes about 10 seconds Speedometer Tachometer To change viewing preferences press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change Option Digital Display Screen Backlight 1 RPM Blue 2 Speed Red 32 FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro grams Performance Engine and History Each program remains active until you cycle to the next program While any program is active press and release the SET button to cycle through the program s screens Performance Program Press and release the MODE button until the performance program screen is active The default display for this screen includes electrical system voltage fuel level if equipped and either speed or tachometer whichever is selected see page 32 Press and release the SET button to cycle through the following screens odometer trip 1 odometer trip 2 odometer fuel trip odometer if fuel is low and clock if equipped Use the following p
21. clearance Replace the drive belt SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec Engine mount bro ken or loose SEE YOUR DEALER Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Check for twisted belt or broken spring SEE YOUR DEALER Track jammed Foreign object may be caught or the rail slide melted to the track clips due to lack of lubrication Track may be iced up or frozen to the ground Chaincase sprocket or chain jammed or broken Chain is loose or broken or chain tightener is loose SEE YOUR DEALER 113 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys tem Broken drive clutch components SEE YOUR DEALER Bearing failure chaincase jackshaft or front drive shaft SEE YOUR DEALER Drive belt surface flat spots nspect and replace as needed Drive chain loose nspect and adjust or replace Drive chain worn sprocket teeth bro ken SEE YOUR DEALER Poor low RPM per formance Worn drive belt nspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Loose torque stop nspect and adjust Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel or higher Engine doesn t tur
22. cool dry location Do not lubricate clutch components except the driven clutch shaft bushing as outlined in the Master Repair Manual See your dealer 109 MAINTENANCE Extended Storage Engine and Carburetor Protection Carbureted Models Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fuel If stabilizer is not used drain the carburetors by removing the water trap drain plugs See page 84 Jet restriction caused by improper storage can cause lean conditions and very poor slow speed driving quality Engine Protection Fuel Injected Models Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container NOTE Do not spray fogging oil into the pl
23. in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2007 Polaris Sales Inc information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2008 Owner s Manual P N 9921554 RMK SHIFT 600
24. km 3200 km Season BRAKES Hose Routing 1 1 l Hose Condition 1 1 1 Fluid Leaks 1 1 1 1 Brake Pads 91 l 1 l Brake Disc 1 1 1 l Parking Brake 52 1 1 l Brake System 51 91 1 Brake Fluid 93 R FUEL MANAGEMENT Pilot Air Screws l 1 1 carbureted models Carburetor carbureted 83 1 1 1 models synchronize Idle RPM 1 1 1 1 Throttle Lever 50 64 1 1 1 1 Oil Pump Lever 1 l 1 synchronize Throttle Cable 76 L L L Choke Cable 76 L L L carbureted models Choke carbureted 76 1 1 1 models Vent Lines l l 1 Throttle Position Sensor l 1 Fuel Lines 82 l 1 l 1 Fuel Filter 82 R R Oil Filter 82 R R Oil Lines 82 l 1 l Air Box Plenum 1 l 1 1 Fuel Injectors 1 1 fuel injected models Drain Water Traps 84 1 1 carbureted models 73 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page isomi soomi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season ELECTRICAL Engine Stop Switch 63 1 1 1 1 Throttle Safety Switch 63 l 1 1 1 Ignition Switch 1 l 1 1 1 Taillight 55 Brakelight 55 l 1 l 1 1 Headlight 55 1 1 1 1 CHASSIS Ski Toe Alignment 1 1 1 Suspension Mounting 1 1 1 1 1 Bolts Steering Fasteners 1 1 l 1 Rear Suspension 1 1 1 1 Fasteners Walker Evans Air See your dealer for service Shocks at 1500 mi 2000 km
25. low position see page 44 Check for worn skags Check for binding front suspension shafts steering compo nents grease all pivot points elevate front of machine Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Increase IFS preload if equipped see page 41 Move limiter strap to high position see page 44 Steering is heavy Make sure spindles and all steering components turn freely Check ski alignment see page 106 Check skags and skis for damage Set static sag see page 43 Machine darts from side to side Check ski alignment see page 106 Check for binding front suspension shafts steering compo nents grease all pivot points elevate front of machine Check for excessive play in steering assembly see dealer Ensure skags are straight on skis Set static sag see page 43 Check rail slide replace if worn see page 108 Install Accu Trak dual skags see your dealer 116 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear Burn Diagnosis Solutions Causes Driving at low RPM Drive at higher RPM 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 low RPM Do not tow in deep snow Use fast aggressive t
26. miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beginning on page 127 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 per formed by a qualified service technician For continued optimum perfor mance and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjust ments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfort able performing these tasks yourself contact an authorized Polaris dealer for service CAUTION Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection 71 MAINTENANCE Periodic Maintenance
27. minimum octane level of 87 R M 2 The emission control system designation per SAE J1930 is EM If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a quali fied dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is available to your qualified service technician Reverse if equipped must not be engaged during engine tune ups 69 MAINTENANCE Emission Control Information Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 125 and read the maintenance section of your owner s manual You are responsible for ensuring that the specified maintenance is per formed including the emission related maintenance outlined in these sections of the manual You must inspect the air intake system on your snowmobile prior to each use including the airbox foam filter and hood foam filters and clean these components as necessary Polaris considers the specified maintenance for the spark plugs oil changes air intake system and exhaust valves to be critical emission related maintenance The speci fied maintenance for the fuel filter is recommended additional emission related maintenance Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 70 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free
28. question Checking pressure without recharging is not possible without loosing pressure If One IFS Shock Feels Soft Check front suspension components for bent parts look closely at rear leg of lower A arm before continuing with shock troubleshooting Look for oil leakage around shaft seal If leaking rebuild with new seal and check for any nicks or dings in shaft Always remove and recharge both IFS shocks together If Both IFS Shocks Feel Soft Remember that at extreme temperature lower than 15 degrees F the IFS may have more free sag and feel slightly softer Always remove and recharge both IFS shocks together If Front Track Shock Feels Soft Remember that at extreme temperature lower than 15 degrees F the IFS may have more free sag and feel slightly softer Check for oil leakage around the shock boot or shaft seal if boot is removed If leaking rebuild with new seal and check for any nicks or dings in shaft Recharge Front Track Shock to specification 40 THE PERFECT FIT IQ Front Suspension Adjustments Standard Shocks The tension at which the shock coil spring is set is called spring preload For the best ride the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming To determine if your machine is using full travel push the jounce bumper down on the shock rod until it contacts the body and test ride the machine The bumper will move up on the
29. rod in relation to the amount of travel that was used dur ing the ride If the travel is full the bumper will be seated at the top of the rod Shock Absorber Components 1 Retainer 2 Bumper 3 Shock Rod 4 Body 5 Threaded Spring Preload Adjuster Nut 6 Spring Front Shock Spring Preload RMK Standard Only Increasing spring preload will increase ski to ground pressure Decreasing spring preload will decrease 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 left Turn it to the right to decrease preload Increasing the spring preload too much may adversely M iuh pon affect the handling of the snowmobile and the perfor mance 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 Front Shock Springs Standard only 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 41 THE PERFECT F
30. secure cargo before operating Do not exceed the cargo weight limit Do not allow a passenger to sit on the seat back or the cargo area Fuel Valve Carbureted Models The fuel valve is located under the hood Turn the fuel valve off when ever the snowmobile is stored or Adjuster parked Turn the valve clockwise to turn off the fuel supply 2 Turn the valve counter clock ON OFF wise to turn on the fuel supply 28 FEATURES Detonation Elimination Technology DET A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel This results in decreased engine RPM and performance Effect of DET The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely If the system senses detonation beyond a preset limit it retards ignition timing and adds fuel to reduce the detonation and prevent engine damage When the detonation returns to a permissible level the system will return spark and fuel to normal allowing the engine to run at rated power levels Sensor Fail Safe The DET includes a sensor fail safe system to prevent the engine from damage if the sensor fails becomes disconnected or is unable to detect detonation The rider will experience a loss in power The sensor must be reconnected or repaired to regain full power NOTE The check engine light will flash six times if the sensor fails or
31. specifically for deep snow applica tions Operation in low snow conditions at high speeds may cause track lug separation Track lug separation is not covered under the Polaris limited warranty policy Polaris does not recommend operation above 70 mph with this track CAUTION High speed use on hard packed surfaces is not recommended for models equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequent slow speed intervals for track cooling 53 PRE RIDE INSPECTIONS Before Starting the Engine Suspension Inspection Loose nuts and bolts can reduce your snowmobile s reliability and cause needless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 103 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness Carrier and bogie wheel bolts Tightness Front torque arm limiter strap Condition Rail slide Condition 108 Track Tension 102 All rear suspension components Lubrication 75 Ski runner skag Condition Ski spindle bolts Tightness Tightness 54 PRE RIDE INSPECTIONS Start the Engine and Check Before starting the engine always refer to
32. the fitting on the speed ometer sensor housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Choke and Choke Cable Lubricate the choke slide and cables 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 possi bility of the choke becoming fro zen 76 Lubrication Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 71 The sight glass is located on the lower rear of the chaincase Maintain the oil level at or slightly below the center of the sight glass Change the chaincase oil after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 112 for the part numbers of Polaris products Oil Check Position the vehicle on a level sur face View the oil level at the sight glass 3 Remove the fill plug and add the recommended oil as needed Do not overfill 4 Reinstall the fill plug making sure it is seated properly MAINTENANCE Sight Glass Maintain Level Here 77 MAINTENANCE
33. the safety switch to activate preventing the engine from starting If this occurs return the snowmobile to an authorized Polaris dealer for service If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOT continue to operate the snowmobile with the throttle safety switch disconnected Return the snowmobile to an authorized Polaris dealer for service as soon as possi ble 64 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 63 for more information about the engine stop switch THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Engine Stop Switch Interrupts ignition circuit All Choke if equipped Floods engine Half throttle or less Throttle Safety Switch Interrupts ignition circuit All Tether Switch if equipped Interrupts ignition circuit All 65 OPERATION Electronic Reverse PERC Electronic reverse will activate only if the engine RPM is below 4000 The maximum engine RPM will be 6000 when in reverse A WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage w
34. this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris control Damage caused by the failure of other components of the snowmobile Failures caused by improper fuel or oil Piston seizures unless caused by a defective engine component Failures caused due to improper adjustments Failure due to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of unauthorized parts or modifications Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related throttle body parts are covered The fuel pump is covered Clutches and related clutch parts including but not limited to the drive belt are excluded from coverage Electrical components are excluded from coverage Gearcases and transmissions are excluded from coverage 123 W
35. vibration or shift pattern see your dealer immediately Do not operate the snowmobile until repairs have been made All clutch maintenance and repairs must be performed by an authorized Polaris dealer Any unauthorized modifications to clutches 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 Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor mance Please see your Polaris dealer if you experience a decrease in performance Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer 96 Clutch System Drive Belt Condition 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 perfor mance See Drive Belt Troubleshooting on page 117 Periodically check the condition and tension of the drive belt and always carry a spare Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these condition
36. warrants that the new engine including all parts of its emission control system is designed built and equipped so it conforms to current U S Environ mental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051 1065 and 1068 at the time of sale to the ultimate purchaser Polaris warrants that the engine is free from defects in materials and workmanship that may keep it from meeting these regulations The warranty period for this emissions certified snowmobile engine starts on the date when the engine is first purchased and continues for 4000 kilometers 2485 miles of vehicle travel 200 hours of operation or 30 calendar months whichever comes first This engine emissions limited warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty This includes compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection components exhaust gas recirculation system components and aftertreatment system components Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WAR
37. 2 ft lbs 24 30 Nm Always carry spare spark plugs 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 it 3 Reverse the procedure for spark plug installation 4 Torque to specification 5 Reinstall the spark plug cap 80 MAINTENANCE Intake Filters 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 Intake Foam Filters Pre filter CAUTION Operating the snowmobile with the intake filters removed may cause intake icing The result will be poor fuel economy or intake malfunction Always rein stall the intake filters before operating the snowmobile 81 MAINTENANCE Fuel Injectors Fuel Injected Models fuel injector service must be performed by an authorized Polaris dealer Do not attempt to clean or service the fuel injectors Fuel Pump fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 72 Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after peri
38. AFETY Operator Safety Inadequate Snow Conditions 4 WARNING Do not drive for prolonged periods on blacktop gravel or ice Doing so could cause irreversible track damage and lead to serious injury Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your snowmobile Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine A CAUTION 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 Operating in Deep Snow If the snowmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the throttle is opened the snowmobile will be able to climb up and over the snow 19 SAFETY perator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions may become dangerous if operators drive improperly If you re ne w to snowmobiling acquaint yourself with the machine and with what it will and won t do under
39. ARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased 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 ser
40. IT Rear Suspension Adjustments Rider weight riding style trail conditions and vehicle speed all affect suspension action Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However all sus pension designs and adjustments involve a compromise or trade off For example a suspension set up for snow cross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bot tom out harshly on a snow cross course Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer Suspension Performance Tips Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride ndeep snow a new rail slide will offer improved performance over a worn slide It can also improve top speed NOTE Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension com ponents Grease rear suspension pivots before adjusting the rear sus pension Refer to the suspension lubrication information beginning on page 76 42 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload S
41. RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY 125 WARRANTY Snowmobile Engine Emissions Limited Warranty Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This lim ited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if
42. RMK 700 RMK 700 DRAGON RMK 800 DRAGON RMK 2 TABLE OF CONTENTS Introduction 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 22 E Gee EN sd neus 8 This section describes safe vehicle operation and identifies warning decals and their locations POCONOS 22513 me x Rede Y dide al RR RR 26 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 39 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 49 This section explains procedures that must be performed before riding Operation ee ete eed 56 This section explains proper engine break in operation of features and general operating procedures 69 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris Products 112 Troubleshooting 113 Warranty ceder REX 118 Maintenance Log 127 Index oss veas wa XR RERIEXXENA LA PE 130 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient ref erenc
43. RMK Shift 600 RMK 100 RMK 700 Dragon RMK 800 Dragon RMK bile Owner s Manual d POLARIS The Way Out Pantone 280 CVC For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921554 Rev 01 Printed in USA A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations
44. RRANTY Conditions and Exclusions In order to qualify for warranty the product must have been properly set up and tested by a Polaris Dealer if applicable Failure of any dealer to perform the required vehicle Pre Delivery Inspection perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage Use of the recommended Polaris products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur during the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con sideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components Batteries Circuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered
45. TY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris snowmobiles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer The cost of 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 rec ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 121 WA
46. all safety warnings pertaining to snowmobile operation Never engage the starter when the engine is running Never start the engine without checking all vehicle components to be sure of proper operation See Before Starting the Engine beginning on page 50 Engine Stop Switch Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Tether Switch If your machine has a tether switch remove the tether from the switch to make sure the engine stops immediately Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advan tage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile 55 OPERATION Starting the Engine CAUTION Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 1 Turn the key to the ON position Pull the engine stop switch up to the RUN position 2 Carbureted models Turn the fuel valve on If starting CHOKE POSITIONS a cold engine flip the
47. apable of high speeds Buried objects or uneven terrain can cause loss of control Reduce speed and use extreme caution when operating in unfamiliar terrain continued on next page 24 SAFETY Safety Decals and Locations Operation Warning continued from previous page Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehi cle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause
48. assure proper engine 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 open ings 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 57 OPERATION Engine Break In Cil Injection System Always fill the oil reservoir when refueling CAUTION Serious engine damage can occur without the proper lubrication Check the oil tank level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately Oil Recommendations This snowmobile is equipped with a variable exhaust system VES Engine lubrication comes from oil added to the fuel and oil injection systems Polaris recommends the use of VES II 2 Cycle Oil for this engine See page 112 for the part numbers of Polaris products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils m
49. ate 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 Soft long end of cam to front Medium short end of cam up Firm long end of cam up Me L Medium Firm Limiter Strap Position The following information is pro vided only as a guideline to be used gh for initial suspension set up Your set up may vary based on your Low desired riding style High Limiter strap in high position increases ski pressure Low Limiter strap in low position decreases ski pressure 44 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving RMK Standard Rear Track Shock The standard RMK rear track shock is an Arvin MPV Select shock that allows for adjustments to the compression valving Adjustments are made by turning the adjustment screw located near the base of the shock In half turn increments turn the screw clockwise to increase compres sion valving and stiffen the ride Turn the screw 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 44 Return the screw to its original starting position after the tor
50. ay also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates Polaris oils are compatible with each other Slide Rail and Track Cooling CAUTION Inadequate cooling and lubrication will lead to overheating of the slide rail and track resulting in premature wear and failure Reduce speeds and fre quently 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 58 OPERATION Track Warm Up A WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throt tle during warm up or when the track is free hanging Be sure the rear sup port is stable A WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up m of the engine drive train and track rA 1 Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be approximately 4 10 cm off the ground n
51. ber adjustment may also be affected 10 in 25 4 cm 10 in 25 4 cm 106 MAINTENANCE Steering System Ski Skags 4 WARNING 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 original 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 before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter NOTE Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement NOTE Some models are equipped with single skags Other models are equipped with dual skags 1 Raise and support the front of the snowmobile so the skis are approximately 6 15 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a skag 107 MAINTENANCE Steering System Rail Slide Wear For ease of inspection all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thick ness Replace
52. brupt change of direction when operating on slippery sur faces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover 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 snowmobile downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the snowmobile pull the rear of the snowmobile around and point the front end and skis downhill Remount the snowmo bile restart the engine release the parking bra
53. choke toggle to FULL OFF CHOKE Do not use the choke if starting a warm engine After the engine starts flip the choke toggle to the OFF position If the engine slows or wants to stop use intermittent chok ing to the HALF CHOKE 1 2 CHOKE FULL CHOKE position NOTE Do not depress the throttle until the engine starts CAUTION Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running 3 Ifequipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts 4 Ifnotequipped with electric start grasp the starter handle and pull slowly until the recoil engages then pull abruptly to crank the engine NOTE It may require as many as eight to ten pulls to prime the fuel system and start the engine if the fuel tank has been completely emptied 5 Repeat the cranking procedure as needed until the engine starts 56 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 injec tion system will
54. d 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 Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or clothing contact the moving part
55. d check the brake fluid level and condition Add fluid as needed See page 93 Check for the presence of air in the fluid system See page 94 for more information or see your dealer for service A WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess 51 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary for example when parked on an incline for a period of five minutes or less 1 Brake Lever 2 Parking Brake Lever Lock 3 Master Cylinder Reservoir Cover 4 Fluid Level Indicator Lock Engagement To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever NOTE Ifthe brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock
56. damage Always maintain the coolant level as recom mended 86 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool ant temperature becomes too hot for safe continued operation of the engine If you must drive your snowmobile after the high temperature indicator light has come on drive slowly and stop frequently to allow the engine to cool down Driving in deep snow will also help cool the engine See your dealer for service Add coolant if the level is low NOTE Engine performance will be reduced if you continue operating when the high temperature light is on Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine drain the system completely every two years and add a fresh mixture of antifreeze and distilled water This service must be performed when the engine is cold Ask your Polaris dealer to check the coolant when he performs the fall tune up on your snowmobile 87 MAINTENANCE Cooling System Bleeding the Cooling System 4 WARNING 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 Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part CAUTION
57. e It should remain with the snowmobile when the snowmobile is sold Some of the illustrations and photos used in this manual are general rep resentations 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 Protect and preserve your right to ride by joining your local trail riding clubs 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 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam paign We encourage state and provincial governments across the snow belt 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 pro tect our environment Please support their efforts and operate your snowmobile with consideration for the protection and pre
58. e engine Rail and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten the locknuts and torque idler shaft bolts to 35 ft lbs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 104 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners TEN _ M Ld M peut FI 105 MAINTENANCE Steering System Ski Alignment 4 WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment or camber adjustment See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y NOTE Ifthe skis are misaligned we recommend that your dealer correct the alignment since cam
59. e engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer A Stop 4 Switch i Test the throttle safety switch system daily before operation 1 Sit on the seat Lock the parking brake Start the engine and allow it to idle PS exerting pressure on the pivot pin in the direction shown in the illustration Hold the throttle lever pin stationary by i 1 S N 5 Apply a slight amount of throttle A properly functioning switch must shut down the engine 63 OPERATION Throttle Lever A WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control which could result in serious injury or death If the throttle lever does not work properly DO NOT start the engine If the engine stops abruptly when the throttle lever is released 1 Turn the ignition switch to OFF 2 Visually inspect the throttle cable and throttle body to determine what caused the safety switch to activate 3 Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely 4 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe engine doesn t start take the snowmobile to an authorized Polaris dealer for service NOTE Excessive freeplay in the throttle cable may cause
60. e the SET button to advance the reading in 50 foot 15 m increments or press and hold the button to advance quickly Adjust the altitude display to within 50 ft 15 m of the current alti tude NOTE The gauge reads barometric pressure and allows the rider to compen sate for daily fluctuations in air pressure The gauge can adjust the displayed altitude to 1300 ft 396 m from the preset value It will adjust up to 1300 ft 396 m above the calibrated altitude Once the 1300 ft 396 m offset has been reached the next adjustment is 1300 ft 396 m from the calibrated altitude and 50 ft 15 m will be added to the altitude each time the SET button is pressed 6 Press the MODE button to hold the reading at the adjusted value If the MODE button is not pressed within five seconds the gauge will automatically save the new setting 35 FEATURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active This screen will always display electrical system voltage level and fuel level if equipped Press and release the SET button to cycle through the following screens maximum vehicle speed maximum engine RPM and service interval reminder Maximum Speed Maximum RPM The gauge automatically logs the maximum speed and engine RPM even if the history program is not active in the display MAX MPH 1 Enter the History Program 2 Pres
61. ecked through an authorized Polaris dealer during the March April Snow Check promotion The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transfer able 120 days after the original purchase date free of charge through any Polaris snow mobile dealer Coverage on Snow Check units is automatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty reg istration form This form is your proof of warranty Consumer Exclusions Each repair visit after the first twelve months of standard warranty coverage is subject to a 50 deductible The free Second Year Engine Service Contract applies to the first 5 000 miles or two 2 calendar years from date of purchase whichever comes first Tampering with the odometer shall void all warranties service contracts No extensions to coverage under this engine service contract can be given Used snowmobiles are not eligible under this program Snowmobiles used for commercial purposes or for racing are excluded from coverage Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate
62. een includes engine hours electri cal system voltage level fuel level if equipped and either engine cool ant temperature air temperature accessory or altimeter accessory Press and release the SET button to cycle through the following screens hour meter engine temperature air temperature available as an acces sory and altimeter available as an accessory Hour Meter The hour meter records the total hours of engine operation since manufacture This meter cannot be reset Engine Temperature A thermometer measures water temperature giving an indication of engine temperature 34 Instrumentation MFD Digital Display Programs Engine Program Air Temperature accessory The MFD displays actual air temperature Press and hold the MODE switch for ten sec onds to switch between standard and metric units of measurement Altimeter accessory The rider can calibrate the altimeter for cur rent atmospheric conditions Altimeter accu racy will be 300 ft 91 m after adjustment NOTE When ALt FT displays the program is in the standard mode If only ALt displays the program is in the metric mode 1 Enter the Engine Program 2 Press and release the SET button until the altimeter screen is active 3 Press and hold the SET button for five seconds rr FEATURES AIR F LILILI Aut When the digits begin to flash release the SET button 5 Press and releas
63. enum Remove the plenum and spray the fogging oil into the boost box Continue spraying until the engine stops Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fuel See page 68 110 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The machine should be supported off the ground to allow the track to hang freely Transporting the Snowmobile Whenever the snowmobile is transported 1 Turn the fuel valve off See page 28 2 Besure the fuel cap and oil cap are installed correctly 3 Always tie the snowmobile to the transporting unit securely using suitable straps 4 Remove the ignition key to prevent loss 111 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2871098 Premium 2 Cycle Engine Oil qt 2871097 Premium 2 Cycle Engine Oil gal 2871240 Premium 2 Cycle Engine Oil 2 5 gal 2871721 Premium Gold
64. etting 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 x gt 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 between the ground and the rear bumper at the exact location used for measure ment X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X Sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm See illustration The ideal amount of sag for this rear suspension is five inches 12 7 cm X Y 5 in 12 7 cm If the rear suspension rides in less than four inches or more than six 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 43 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload rotate the three position cam using the engine spark plug tool Different r
65. 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 posi tion to control the vehicle Cil injection system Use unmixed fuel only Check oil level when refueling 25 FEATURES 26 ouwognsom Front Bumper do not use for pulling or dragging the snow mobile Hood Headlight Windshield Mountain Bar if equipped Handlebar Seat Taillights 10 11 12 13 14 15 16 Rear Bumper Snow Flap Track Suspension Tunnel Side Panel Ski Nosepan FEATURES 1 Fuel Filler Cap 9 Parking Brake 2 Ignition Switch 10 Handlebar Grip Warmer 3 MFD Multi Function Display Switch 4 Engine Stop Switch 11 Thumbwarmer Switch 5 Throttle Control 12 Electronic Reverse Button 6 Recoil Starter Handle 13 MFD Control 7 Hood Hold Down Straps 14 Headlight Dimmer Switch 8 Brake Lever 27 FEATURES Adjustable Headlights Move the adjuster to the left to lower the headlight beam Move the adjuster to the right to raise the headlight beam Adjustable Steering The adjustable steering system allows you to adjust the handlebar position to fit your style of riding See page 47 Accessory Cargo System The maximum weight capacity for the rear cargo area is 15 Ibs 7 kg Always
66. following conditions the carburetor may need adjustment Hard starting Poor idle Overheated pistons and cylinder walls Plug fouling Poorengine response to various throttle valve openings 83 MAINTENANCE Carburetor Carbureted Models Carburetor Water Sediment Trap Most Polaris snowmobiles contain patented carburetor bowl water sedi ment traps located at the bottom of each carburetor The trap consisting of a hose with a plug should be drained about every 1000 miles 1600 km and inspected for contamination A WARNING When draining the traps fuel spillage will occur Always work in a well venti lated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the fuel warn ings on page 60 Cleaning Procedure Turn the fuel valve off 2 Place container or shop towels below the plug to catch drained fuel 3 Slide the clamp away from the drain plug and remove the drain plug from the sedi ment tube 4 Wipe residue from the plug and reinstall it Reposition and tighten the clamp 5 Repeat the draining proce dure for any remaining traps 84 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 71 A WARNING Hot exhaust system parts can cause serious burns Allow adequate time for the exhaust
67. for pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the snowmobile due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE 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 NEGLI GENCE 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 120 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILI
68. g Preload 44 DROWN Sires S oec esc sitive ets 68 Track Alignment 104 Track Care for Storage 111 Track Inspection 53 100 Track Lubrication 101 Track Replacement 100 Track Tension 102 103 Track Warm Up 59 Track 23 Track Deep Lug 53 Transporting the Snowmobile 111 Troubleshooting Drive Belt 117 Troubleshooting Engine 113 115 Troubleshooting Rear Suspension 116 V Vehicle Identification Numbers 7 W Warning Labels Decals 22 25 Warranty Engine Emissions 125 Windchill Temperature Charts 21
69. g brake Open the hood Remove the left side panel Qv ud Locate the L wrench in the tool kit Install the wrench into the open threaded access hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt 98 Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the belt and apply downward pressure while measuring at point A This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment MAINTENANCE Straight Measure Edge 1 Install the L wrench into the open threaded hole in the outer sheave of the clutch see page 98 Turn the wrench clockwise slightly to remove pressure from the sheaves 2 Loosen the 7 16 jam nut 3 Usinga 1 8 Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves or outward counter clockwise to decrease the distance 4 Tighten the jam nut Store the L wrench in the tool kit Torque Stop Periodically check torque stop clear ance With clutches in proper align ment measure rear torque stop clearance from the engine case Rear torque stop clearance should be 010 030 25 75mm Adjust if neces sary Secure the nut 010 030 25 75 mm lem oe 99 MAINTENANCE Track Replacement When replacing the track a
70. g style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow condi tions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components Ski Front shock and spring Rod ends Upper control arms DAC bot pasos Lower control arms IFS Adjustment Options Shock spring preload e Shock valving Optional springs Toe ski alignment see page 106 Camber see your dealer 39 THE PERFECT FIT IQ Front Suspension Adjustments Walker Evans Air Shocks Walker Evans Air shocks are oil filled shocks that use nitrogen pressure for spring force These shocks are tuned for high performance riding in a wide range of winter riding conditions You will notice slight differ ences in ride height and spring rate at high and low temperature extremes Sled will sit higher at room temperature on showroom floor This will not affect the overall shock tuning or ride quality Always have your Walker Evans Air Shocks serviced annually to replenish the Nitrogen charge and refresh the oil Troubleshooting See your dealer for any damaged parts or service items Always install foam sleeve on IFS for service and trailering Your dealer must always recharge both IFS shocks if charge pressure is in
71. he yellow reverse button for one second and release The engine will slow and begin to rotate forward The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in for ward 67 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 10 cm off the ground Remove the key and cover the snowmobile Towing Do not use the front bumper to pull or drag the snowmobile The front bumper is not designed for this type of use and may detach from the vehicle if force is applied For your safety do not attempt to use a tow hitch until you ve read the following warnings and understand the proper hitch functions WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed on a tobog gan or sled make sure the pole is at least four feet 1 2 meters long to pre vent 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 con
72. his warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty The warranty begins on the date of purchase This warranty is transferable to another consumer during the 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
73. hrottle to engage clutch Riding with high RPM Lower the gear ratio Reduce RPM Avoid riding in and slow speed 8000 high ambient temperatures Check for snow ingestion RPM 10 MPH Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance Check for carburetor and choke synchronization fouled plugs debris in the carburetor s and water ice or dirt in the fuel tank or fuel line Loading machines onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch engage ment Use fast aggressive throttle to engage clutch 117 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty informa tion contained in this manual Contact your Polaris dealer for replace ment 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
74. ill occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed Shiftto or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the snowmobile before and while backing Avoid sharp turns Apply throttle slowly CAUTION Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 66 OPERATION Electronic Reverse PERC Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your snow mobile is clear 3 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 rota tion Reverse Button NOTE Areverse light on the instrument panel will indicate that the transmis sion is in reverse 4 Apply the throttle slowly to make sure the transmission is in reverse NOTE Ifthe engine stops running the snowmobile will be in forward gear when it s restarted Disengaging Reverse 1 Stop the snowmobile and leave the engine idling CAUTION Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 2 Push t
75. ion weekly and before each long trip To obtain correct chain tension 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 3 Finger tighten the adjuster bolt until it can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft 165 28 Nm 5 Release the brake lever lock 90 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever travel before each use of the snowmobile See page 51 Brake pads must be replaced when the brake pad material becomes thin ner than the backing plate approximately 1 16 1 5mm A kit is avail able for replacing brake pads See your dealer 4 WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 1 5mm 91 MAINTENANCE Brakes Brake Components Brake Disc Bleed Screw Brake Line Brake Caliper Brake Pad Material Replace when thickness is less than 1 16 1 5mm Excessive Lever Travel Hydraulic brakes are self adjusti
76. judgement and physical skills WARNING Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled persons to operate this vehicle Rider Capacity Your Polaris snowmobile is designed for a single rider only Do not carry a passenger Excessive Speed WARNING High speed driving especially at night could result in serious injury or death Always reduce speed when driving at night or in inclement weather Always observe all state and local laws governing snowmobile opera tion and speed limits Always be alert and pay attention to the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your snowmobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m 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 snowmobile to a stop in the distance illu minated 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 es
77. ke and descend the hill carefully 17 Operator Safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without a belt must be performed by your dealer Operation of the engine with the belt removed may result in injury or damage to the engine Intake Silencer Do not operate the engine with the intake silencer or filter removed Damage to the engine may occur if the intake silencer or filter are removed Clutches Do not attempt to service the clutches clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the snowmobile into motion but always operate within safety limits and on 2 up machines with respect for a passenger Maneuverability While much control and maneuverability is achieved through the steer ing system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or snowmobiles designed to carry a load or a passenger 18 S
78. ke system will cause spongy brake lever action Bleed the system before operating the snowmobile WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever During the bleeding procedure keep the brake handle as level as possi ble The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent 1 Remove brake master cylinder reservoir cover and gasket 2 Fillthe master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 6 8 cm below the lip of the reservoir open ing Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 93 8 Rei
79. ls 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 The clutch cover warning decal is under the hood on the clutch cover WARNING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service clutches yourself See your dealer Pressure Cap Warning The pressure cap warning decal is found under the hood on the pressure cap of applicable liquid cooled models WARNING Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI 22 Safety Decals and Locations No Passenger Warning Snowmobiles designed for only a single rider have a warning decal on the console below the steering post WARNING This vehicle is designed for operator only NO PASSENGER Track Warning The track warning decal is on the rear of the tunnel WARNING Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death
80. lways install a track having the lug size rec ommended for your model See your Polaris dealer CAUTION Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel Always install a track having the lug size recommended for your model Track Inspection 4 WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and sup port the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for breakage 4 Replace the track if any rod dam age is found 100 MAINTENANCE Track Lubrication A WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other surfaces that have lit tle or no snow for lubrication The slide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear
81. ly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately Throttle Safety Switch Test the throttle safety switch system before the snowmobile is operated See page 63 for procedure Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions Under no circumstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile 50 PRE RIDE INSPECTIONS Before Starting the Engine Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your Polaris dealer for replacement y Brakes Always check the following items for proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the 4 2 1 8 handgrip than 1 2 1 3 cm 1 3 A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 94 Brake Lever Feel If the brake lever feels spongy when squeeze
82. m 53 Recoil Rope 51 Parking Brake Lock Brake Lever Brake System 51 52 91 Throttle Lever 50 Throttle Safety Switch 50 Auxiliary Shut Off Switch Engine Stop Switch 55 65 Ignition Switch 55 65 Taillight Brakelight Headlight 55 Coolant Level 86 Gearcase Oil Level N A Engine Oil Level 77 Suspension Mounting Bolts 54 Skags Wear Bars 107 Ski Saddle and Spindle Bolts 54 Hood Straps Latches 50 Seat Latches if equipped N A Rear Wheel Idler Bolts 54 103 Tether Switch Strap 55 Track Alignment Condition 53 104 Rail Slide Condition 108 Chaincase Oil Level 77 Oil Level 62 49 PRE RIDE INSPECTIONS Before Starting the Engine Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start the engine without checking all vehicle components to be sure of proper operation WARNING Operating the vehicle with worn damaged or malfunctioning components could result in serious injury or death Never start the engine without check ing all vehicle components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smooth
83. mal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates 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 improper spark plug or incorrect carburetor throt tle body adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incor rect carburetion adjustments 79 MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization Change the spark plugs every 2000 2500 miles 3200 4000 km CAUTION Using non recommended spark plugs can result in serious engine damage 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 Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 2
84. n Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered the crankcase while the vehicle was standing or being transported SEE YOUR DEALER to correct the cause Drain plug s are located on the lower crankcase for emergency draining 114 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition TROUBLESHOOTING Install new spark plug s If engine still fails to start check for spark If there s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on Use the choke See page 56 Make sure the fuel tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system Poor engine com pression Mixture is too lean main jet that is too small will cause seizure result ing in loss of power This indicates a major engine problem that must be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective Replace the plug s spark plug s Fuel filter loss of SEE YOUR DEALER high RPM power Incorrect clutching SEE YOUR DEALER Carburetor and fuel pump There is no adjustment to change power output SEE YOUR DEALER Engine continually backfires Faulty plug s Change plug s Carburetor
85. ng but if excessive brake pad clearance develops see page 91 bring the snow mobile to an authorized Polaris dealer for inspection and adjustment 92 Bleed Screw Brake Disc Brake Line Brakes Brake Fluid 4 WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rap idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury WARNING 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 Replace brake fluid at least every two years with Polaris DOT 4 high tem perature brake fluid See page 112 for the part numbers of Polaris products Sight Glass The brake fluid level can be seen through a plastic sight glass in the brake reservoir If the fluid is suffi cient the sight glass will be black If the sight glass is any color other than black add brake fluid 93 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic bra
86. nstall the gasket and cover 94 MAINTENANCE Lights Removing Halogen Bulbs NOTE Do not touch a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot that will shorten the life of the lamp If fin gers do touch the bulb clean it with an alcohol moistened towel Remove the plenum cov Bulb ering from the headlight assembly Spring Lift the rubber boot to expose the bulb Harness 4 Push down on the spring to release it from the housing With the wire harness attached to the bulb with draw the bulb from the housing Grasp the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs 1 Hold the bulb by its metal base and install it into the wire harness 2 Insert the bulb into the housing 3 Connect the spring to the housing 4 Carefully flip the spring back into the housing placing it around the wire harness 5 Reinstall the plenum covering on the headlight assembly 6 Adjust headlight aim See page 28 Replacing Taillight Bulbs nagd 1 Remove the screws securing the taillight lens 2 Remove the bulb and install a new bulb 3 Reinstall the lens 95 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol 4 WARNING If you become aware of higher than normal clutch engagement or an unusual
87. nterval 1 Enter the History Program 4 Press and release the SET button until the service interval screen is active Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button Press the button again up to five times to advance the reminder in 20 hour increments NOTE The maximum interval is 200 hours To disable the service interval reminder press the SET button once after reaching 200 hours on the display The gauge will display OFF 37 FEATURES Instrumentation Gauge Cleaning 1 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth 2 Clean the back side of the gauge using a clean cloth and a mild soap and water solution Do not remove the electrical connectors or pro tective rubber boot Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source CAUTION To prevent damage to the lens do not use alcohol for cleaning Do not allow chemicals or sprays to contact the lens Immediately clean off any gasoline that splashes on the gauge during refueling 38 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension IFS Break in the suspension for approximately 150 miles 240 km before making any fine tuning adjustments Settings will vary from rider to rider depending on rider weight vehicle speed ridin
88. obile See page 58 for oil recommendations CAUTION Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed Low Oil Level Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous ter rain Maintain the oil level at the bottom of the filler neck Always check and fill the oil tank when refueling Never operate the engine if oil is not vis ible in the tank NOTE The Polaris oil cap on the oil bottle is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts 62 OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly Pull the switch up to the RUN position to allow restarting Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position A WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a throttle system malfunction immedi ately push down th
89. ods of storage Normal dete rioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly 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 Cil Lines Inspect oil line condition at the intervals outlined in the Periodic Main tenance Table beginning on page 72 Oil Filter Have your dealer change the oil filter and bleed the system at the intervals outlined in the Periodic Maintenance Table beginning on page 72 NOTE The direction of the arrows indi ER cates the direction of flow through the filter 82 MAINTENANCE Carburetor Carbureted Models 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
90. ormation For more information about avalanche training and avalanche condi tions contact local law enforcement in your area or visit the American and Canadian online avalanche centers at www avalanche org 15 SAFETY Operator Safety Ice and Snow Build up 4 WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving Downhill When riding downhill shift your weight to the rear of the snowmobile 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 snowmobile and keep it from rolling freely downhill A WARNING 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 16 SAFETY Operator Safety Driving on Slippery Surfaces 4 WARNING Never attempt an a
91. pecially 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 snowmobile 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 out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Avoid travelling on frozen bodies of water 14 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain Take an avalanche class Travel with experienced people Travel on designated trails Make sure each person is equipped with a shovel probe and avalanche beacon You don t have to be snowmobiling on a slope for an avalanche to occur Be aware that all of the snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in moun tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability inf
92. perator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be prepared be warm and be com fortable when riding Be aware of the weather forecast especially the windchill and dress accordingly See the chart on page 21 WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Always wear an approved helmet and eye pro tection s 12 SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires good
93. ris recommends the use of 91 octane or higher fuel Although 87 octane fuel is usable some engine perfor mance will be lost and fuel economy will decrease Do not use lower than 87 octane fuel Do not use fuel containing more than 10 ethanol including E85 CAUTION Operating with obstructed fuel systems will result in serious engine damage Perform maintenance as recommended Damage to the fuel pump will occur if the snowmobile is operated with an empty fuel tank Do not allow the snowmobile to run out of fuel Always refuel when the level is low Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends the use of Carbon Clean Plus See page 112 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives should not be used 61 OPERATION Cil Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low Visually check for oil in the bottle Add oil before further operation of the snowm
94. rocedures to make changes to these screens Odometer Setting up XD AE The odometer records the vehicle s total l L J distance traveled since manufacture The 1 l D AD S ADOS odometer cannot be reset Trip Settings Trip 1 and Trip 2 are odometers used to TE n check fuel mileage or to keep track of Lu distance traveled Both odometers can be 1 Enter the Performance Program e 1 2 Press and release the SET button until the desired trip screen is active 3 Press and hold the SET button for two seconds to reset the trip odometer to zero 4 Press and release the SET button to view another trip screen if desired FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is 1 ft r ft equipped with an electronic fuel gauge i The fuel symbol and the last fuel bar on ae the MFD gauge if equipped will blink RPM when the fuel level reaches 1 8 of a tank D The Trip F odometer records distance F 0 0 traveled the fuel symbol continues to blink until enough fuel is added to raise the level above 1 4 of a tank The Trip F odometer will automatically reset to zero after refueling Engine Program Press and release the MODE button until the engine program screen is active The default display for this scr
95. s and release the SET button until he 33 one of the two screens is active m m a RA NOTE The MPH and RPM values are both ll I f 12 reset at the same time Reset the val NINI ues before each run to obtain accurate am a readings MAX RPM 3 Press and hold the SET button for three seconds to reset the recorded maximum 3 0 values for both MPH and RPM NOTE Due to electrical noise the MFD may occasionally display MAX MPH RPM values that are not representative of actual values 36 Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders When the logged hours reaches the desig nated service interval set by the user the gauge provides a reminder that service is due SErVCE will flash in the odometer area and ENG will flash in the icon area FEATURES 5Er Vt for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the reminder at the existing interval 1 Enter the History Program 2 Press and release the SET button until the service interval screen is active 3 Press and hold the SET button for ten seconds continuing to hold even after the display begins to flash 4 When the display stops flashing release the button The service interval has been reset To reset the reminder at a new i
96. s exist NOTE A worn belt will continue to function but will not deliver maximum per formance Always carry a spare belt in case of an emergency For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack 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 2 Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the wrench and store it in the tool kit Reinstall the side panel 5 Close and secure the hood 97 MAINTENANCE Clutch System Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse The snow mobile must be stopped after forward motion to prevent damage to compo nents during belt removal 1 Stop the engine after operating in a forward motion NOTE For easier accessibility make sure the clutch tool access hole is visible between the 11 00 and 2 00 positions of the clutch sheave 2 Turn the ignition key off Wait for the engine to come to a complete stop Access Hole Lock the parkin
97. s of an engine Always stop the engine before attempting adjustments 10 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control 4 WARNING Improper riding position may reduce control and could result in serious injury or death Always ride in a position that allows for control of your vehicle Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone Always carry the owner s manual on your snowmobile For added pro tection purchase and carry the following items on your snowmobile as well Spare Drive Belt Winter Survival Kit Extra Set of Spark Plugs Trail Map Tow Rope First Aid Kit Extra Oil Tool Kit Fuel Deicer 11 SAFETY O
98. sen top bolts to adjust handlebar angle Handlebar Angle 1 Loosen the four bolts on the top of the adjuster block NOTE If necessary pry the blocks apart with a screwdriver 2 Adjust the handlebar forward or rearward to the desired angle 3 Tighten the bolts Loosen bottom bolts to adjust handlebar position 47 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements e Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service Tether Switch The accessory tether switch is available for all models Order part num ber 2870668 48 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on the refer enced pages Look for a checkmark on the referenced pages to locate the pre ride inspection items Item See Page Drive Belt Condition 97 Steering Syste
99. servation of our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be 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 INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in the spaces provided below The key number is stamped on the spare key The number on the rubber coated key is in the form of raised dots Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key num ber and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number on valve cover Key Number SAFETY Operator Safety The following signal words and symbols appear throughout this manual
100. sion spring has been adjusted Adjustment Screw 45 THE PERFECT FIT Handlebar Adjustments A WARNING Some aftermarket accessories including windshields and cargo bags may interfere with the handlebar Such accessories could limit your ability to steer the vehicle and or may contact the brake lever This could lead to loss of con trol resulting in serious injury or death Always be sure that accessories do not contact the handlebar or brake lever at any handlebar position Handlebar position and handlebar angle can be adjusted to rider prefer ence The optimum position for the proper vehicle balance is with the riser block aligned with the steering post After making handlebar adjustments check to make sure wires are not pinched or kinked Make sure the handlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the vehicle when the handlebars are turned fully to the left or right When adjustments are complete torque the front adjuster block bolts first then torque the rear bolts Torque the bolts to 11 13 ft Ibs 15 18 Nm 46 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1 Loosen the four bolts on the bottom of the adjuster block NOTE If necessary pry the blocks apart with a screwdriver 2 Adjust the handlebar forward or rearward to the desired position 3 Tighten the bolts Loo
101. system to cool Never perform this procedure with the engine running Always allow the engine and exhaust system to cool completely before inspecting 1 Open the hood and inspect the muffler and pipes for cracks or dam age 2 Check for weak or missing retaining springs or damper support grommets 3 Check for loose clamps on the pipe covers 85 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60 40 mixture of ethylene glycol and distilled water This mixture provides protection against freezing Contact your dealer if greater protection is required 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 See page 112 for the part numbers of Polaris prod ucts 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 Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are e Coolant bottle or overflow tank Filler neck Pressure cap Connecting hoses Always maintain the coolant level between the minimum and maximum marks on the coolant bottle when engine is cold to prevent overheating and serious engine damage CAUTION Operating the snowmobile with insufficient coolant will result in overheating and serious engine
102. t Removal 98 Drive Belt Troubleshooting 117 Drive Chain Tension 90 Driver Awareness 14 Driving Downhill 16 Driving in Hilly Terrain 17 Driving on Slippery Surfaces 17 Driving Responsibly 20 E Electrical Connections 111 Emission Control Information 69 70 Emission Control Label 69 Emission Control Maintenance 69 Engine Break In 57 58 Engine Protection 600 110 Engine Protection DRAGON 110 Engine Stop Switch 63 Engine Starting 56 Environment Preservation 6 Exhaust System 85 Eye Protection 12 F Fuel Filter 82 Fuel 82 EuelLin S 4 2 82 Fuel 82 Fuel Recommendations 61 Fuel 60 Fuel System Deicers 61 Fuel Valve assiste dale hii 28 G Gauge Cleaning 38 H Handlebar Adjustments 46 47 Handlebar Angle 47 Handlebar Position 47 Headlight Adjustments 28 Helmet Recommendations 12 Hood Latches 50 Hot Surface Warning 23 Ice and Snow Build up 16 TES ases p RUNS 39 Instrumentation 30 38 Intake
103. the rail slides if they are worn to the top of the groove at any point along their length Failure to do so may result in permanent damage to the track or rails 108 Minimum Thickness Replace when worn to top of groove 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 See page 112 for the part numbers of Polaris prod ucts 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 snowmobile 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 Controls and Linkage Lubricate all bushings spindle shafts tie rod ends and cables as outlined in the Periodic Maintenance Table beginning on page 72 Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All Season Grease or a similar high quality grease to prevent corrosion Clutch and Drive System Remove the drive belt and store in a
104. und your vehicle Drive defen sively to avoid accidents Remove the key from the ignition when you leave the snowmobile unattended Operator Safety Windchill Temperature Charts The following information is provided to help you determine when tem peratures become dangerous for riding SAFETY WIND CHILL CHART F Wind Actual Thermometer Reading F 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 Equivalent Temperature F 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 85 40 45 5 36 31 25 19 18 1 5 11 16 22 28 34 40 46 52 57 63 34 27 21 15 9 8 4 10 16 22 28 35 41 47 53159 66 72 15 32 25 19 13 6 0 7 13 19 26 32 39 45 51 58 64 20 30 24 17 1 4 2 9 15 22 29 35 42 48 55 61 25 29 23 16 9 8 4 11 47 24 31 37 44 51 58 30 28 22 15 8 1 5 12 19 26 88 89 46 53 35 28 21 i4 7 0 7 14 21 27 84 41 48 40 27 20 13 6 1 8 15 22 29 86 43 50 45 26 19 12 5 2 9 46 23 30 37 44 50 26 19 12 4 3 10 17 24 31 88 45 4 11 18
105. upport it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is placed 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide 102 MAINTENANCE Track Tension Canay Idler Shaft Bolt crew 16 40 cm If the track needs adjustment 5 Loosen the rear idler shaft bolt 6 Loosen the lock nuts 7 Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track NOTE Check more frequently when the snowmobile is new 9 Start the engine 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 104 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaft bolts Torque to 35 ft lbs 47 5 Nm 103 MAINTENANCE Track Alignment Periodically check that the track is centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rail 1 Safely support the rear of the snowmobile 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 com Window plete revolutions Stop th
106. various conditions Even seasoned driv ers should spend some time getting the feel for a machine before attempting ambitious maneuvers 20 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 to use your snowmobile know the extent of their operating skills Check to see if they ve taken a snow mobile safety course and have an operator s certificate For their pro tection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowmobile is not intended for this kind of use Be courteous to oncoming traffic by dimming your headlights and reducing your speed When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic aro
107. vicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance see page 118 124 WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris stan dard limited warranty for snowmobiles Polaris Industries Inc
108. will return to the unlocked position WARNING If the parking brake lever lock is partially or entirely engaged while riding the brakes may overheat resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death Always ensure that the lever lock is completely disengaged before operating the snowmobile 52 PRE RIDE INSPECTIONS Before Starting the Engine Steering System Manually turn the skis completely to the right and to the left If any dif ficulty is encountered remove any ice and snow build up that may be obstructing the steering linkage Track Inspection A WARNING 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 Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubri cation would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty Deep Lug Tracks if equipped The 2 4 powder track is designed

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