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Polaris Trail RMK User's Manual

1. 24 3 7 11 15 19 22 26 30 34 38 42 45 49 53 57 32 4 8 12 16 20 24 28 32 36 39 43 47 51 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 39 43 47 64 2 6 10 15 19 23 27 31 35 40 44 48 72 2 7 11 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 96 3 8 12 16 21 25 29 34 38 42 Frostbite in gt gt 30 min 22 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protec tion Read and follow the instructions of the decals and other warnings on the snowmobile carefully If any of the decals depicted in this manual differ from the decals on your snowmobile always read and follow the instructions of the decals on the snowmobile If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning This warning decal i
2. Electronic reverse will activate only if the engine is below 4000 RPM If your machine is running at an altitude of over 6000 feet adjust the igni tion setting as described on page 62 Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the vehicle before and while backing Avoid sharp turns Apply throttle slowly Engaging Reverse 1 2 3 Stop the snowmobile and leave the engine idling Make sure the area behind your vehicle is clear Push the yellow reverse button on the left hand control for one sec ond then release The engine will automatically reduce RPM and start a reverse rotation A flashing reverse light on the instrument panel will indicate that the transmission is in reverse Apply the throttle slowly to make sure the transmission is in reverse Tip The maximum engine RPM will be 6000 when in reverse Tip If the engine stops running the snowmobile will be in forward gear when it s restarted 61 OPERATION Electronic Reverse PERC Disengaging Reverse 1 Stop the snowmobile and leave the engine i
3. 25 P Parking Brake Lever Lock 46 Passenger Warning 23 Periodic Maintenance Table 66 69 Polaris Products 109 Pre Ride Checklist 43 Pre Ride Inspections 43 48 R Rail Slide 100 Recoil Rope 47 Reverse Operation 61 62 Reverse Warning 24 Riding Position 12 S Safety a d sues yu be tuus 8 22 Safety Decals 23 25 Safety 5 8 es 34 35 Shock Components 30 Shock Compression Damping 37 Shock Spring Preload 32 Signal Words 8 Ski 98 SkiSkags 99 Slide Rail 53 Snow Conditions 20 Spark Plugs urn garde 74 75 Speed bi Sass e ems AUS eu ud 13 Spring Preload Rear 34 35 Springs 31 Starting the Engine 49 Steering Inspection 97 Steering System 47 97 99 Stop 58 Stopping Emergency 60 129 INDEX S Storage Daily 105 Storage Extended 106 108 Survival Preparation 11 Suspension Adjustments Front 29 32 Adjustments Rear 33 37 Inspections 100 Lubrication Front 70 Lubric
4. 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 Sora E Peas RE s Mad 8 This section describes safe vehicle operation and identifies warning decals and their locations Features and Controls 26 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 29 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 43 This section explains procedures that must be performed before riding Operation icce 23e 49 This section explains proper engine break in operation of features and general operating procedures Maintenance 64 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris 1 lt 109 Suspension Troubleshooting 110 Troubleshooting 111 Warranty 115 Maintenance Log 124 Record maintenance and service in the log for your reference and for future owners of the vehicle INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for c
5. 6 Close and secure the hood and release the parking brake 89 MAINTENANCE 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 1 and apply downward pressure while measuring at point 2 This measurement should be 1 1 4 inches 32 mm Drive Belt Adjustment Belt deflection should be adjusted without removing the clutch from the jackshaft 1 Loosen the 7 16 inch jam nut on the belt width adjuster 2 Using a 1 8 inch Allen wrench adjust the threaded set screw as needed Tip Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the distance 3 Tighten the jam nut 90 Clutch System Torque Stop Periodically check torque stop clearance With clutches in proper alignment the torque stop clearance should be 010 030 inch 25 75 mm from the engine case Adjust if necessary and lock the jam nut Tool Kit A tool kit is included with each machine for emergency and rou tine maintenance Always keep the tool kit with the snowmobile Chain Tension MAINTENANCE 010 030 in 25 75 mm Maintain the proper chain tension as outlined on page 80 Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer 91 MAINTENANCE Track Track Inspection WARNING Brok
6. This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle Polaris Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applica ble U S Environmental Protection Agency emission regulations Polaris warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 200 hours of engine operation 4000 kilo meters 2485 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuelsystem Exhaust gas recirculation systems The following parts are also considered emission related components
7. WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow mobiles that were Snow Checked through an authorized Polaris dealer during the March 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 paperw
8. Rail Slide Condition 100 Chaincase Oil Level 73 Injection Oil Level 55 43 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 checking 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 smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately See page 59 Throttle Safety Switch Test the throttle safety switch system before the machine 15 operated See page 58 44 PRE RIDE INSPECTIONS Before Starting the Engine Brakes Properly functioning brakes are critical to your safety Always check the following it
9. Trail RMK Snowmobile Owner s Manual for Maintenance and n POLARIS The Way Out Pantone 426C 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 9922282 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 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 in this owner s manual Your manual contains instruction
10. This will reduce moisture and rust build up and ensure proper function of the suspension components Grease rear suspension pivots before adjusting the rear suspension See page 71 Track Tension Track adjustment is critical for proper handling Always maintain cor rect tension and alignment Refer to the track tension maintenance sec tion beginning on page 94 33 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the EDGE RMK rear suspension torsion spring preload mea sure the distance between the ground and rear bumper see illustration This measurement should be taken with no rider and the rear suspension at full extension This is measurement X Take the first measurement with no rider and with the rear suspension at full extension Tip The rear bumper may need to be lifted upward slightly to fully extend the rear suspension Next have the rider drop down hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y 34 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method 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 Us
11. abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was 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 control
12. 1 5 11 16 22 28 34 40 46 52 57 63 10 34 27 2111519 4 10 16 22 28 35 41 47 53 59 66 72 15 32 25 1911316 O 7 13 19 26 32 39 45 51 58 64 20 30 24 17 11 4 2 9 15 22 29 35 42 48 55 61 3 1 0 25 29 23 16 4 11 17 24 31 37 44 51 58 30 28 22 15 5 12 19 26 33 39 46 35 28 21 14 7 14 21 27 34 41 48 40 27 20 13 1 8 15 22 29 36 43 50 45 26 19 12 9 16 23 30 37 44 50 26 19 12 3 10 17 24 31 38 45 55 25 18 11 3 11 18 25 32 39 46 60 25 17 10 3 4 11 19 26 33 40 Frostbite in gt gt OH OD N j 1 N WIND CHILL CHART C Wind Actual Thermometer Reading C Spoeg 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature C Calm 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 5 8 3 0 4 7 t 14 18 22 25 29 32 36 39 43 46 50 53 57 16 2 2 6 10 13 17 21 24 28 32 36 39 43 47 50 54 58 62 1 0
13. Use an aerosol lubricant on the steering post support bracket Grease the center steering arms Grease the steering post lower pivot Grease the rear suspension pivot shafts raise the rear of unit A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles See page 109 S 70 MAINTENANCE Lubrication Rear Suspension The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles 800 km initially every 1000 miles 1600 km after that and before off season storage each year Lack of lubrication will adversely affect your ride and the life of the suspension For detailed information about suspension lubrication and adjustments see your Polaris dealer Tip The following illustrations are general representations Your model may dif fer Lubrication points are indicated by a 71 MAINTENANCE Lubrication Jackshaft Bearing The jackshaft bearing on your model may be equipped with a grease fit ting but this component is greased for life at the factory Additional lubrication is not required Driveshaft Bearing Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal approximately two pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate libe
14. a specific stud length See your dealer s studding chart for recommended traction accessories NOTICE Never add shims to the wear strip Track damage will result due to lack of clearance between upper carrier wheels and track Components as viewed from the rear of the track 1 Top of tunnel 2 Wear strip 3 Track 4 Wear strip mounting holes 1 2 E NOTICE Whenever wear strips relocated be sure there s adequate stud clearance to the heat exchangers Lack of clearance may result in damage to heat exchangers 42 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 87 90 Steering System 47 Recoil Rope 47 Parking Brake Lock Brake Lever Brake System 45 46 81 Auxiliary Shut Off Switch Engine Stop Switch 58 Ignition Switch 48 Taillight Brakelight Headlight 48 Suspension Mounting Bolts 100 Skags Wear Bars 41 99 Ski Saddle and Spindle Bolts 100 Hood Straps Latches 47 Throttle Lever Safety Switch 44 58 59 Rear Wheel Idler Bolts 95 100 Tether Switch Strap N A Track Alignment Condition 47 96 Front Torque Arm Limiter Strap Condition
15. adjust or replace Poor low RPM performance Worn drive belt Inspect and replace if necessary Excessive belt sheave clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t start electric start models Wire connections SEE YOUR DEALER Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inadequate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered crankcase while vehicle was standing or being transported SEE YOUR DEALER to correct cause Drain plug s are located on lower crankcase for emer gency draining 113 TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable Cause Faulty ignition Solution Remove spark plug s and replace with new plug s If engine still fails to start check for spark if no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is ON Check tank level and fill up with cor rect fuel Ice in fuel line filter or pump On the standard Polaris carburetor the choke will not function with the throttle depressed See second item under Probable Cause of Engine contin ually backfires Flooded engine normal situation caused by too much choking Hold throttle open crank engine sev eral times may be necessar
16. all models come with these features See your Owner s Manual Supplement Tip Accessories are available from your Polaris dealer 1 Headlight Dimmer Switch 2 Parking Brake Lock 3 Handlebar Grip Warmer Switch 4 Thumbwarmer Switch 5 Electronic Reverse Button Fuel Valve The fuel valve is located under the hood Turn the fuel valve off when ever the snowmobile is stored or parked 1 Turn the valve clockwise to turn off the fuel supply 2 Turn the valve counter clock wise to turn on the fuel supply 27 FEATURES AND CONTROLS 0 49090 28 Hood Headlight Windshield Handlebar Operator Seat Storage Compartment Taillights Snow Flap Track Suspension Trailing Arm Nosepan Front Bumper do not use for pulling or dragging the snowmobile Skis THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles 240 km and re grease all suspension parts before making any fine tuning adjustments Settings will vary from rider to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The machine should be methodically tested under the same conditions after each adjustment trail and snow conditions vehicle speed riding position etc until the best ride is achieved Adjustments
17. and set the parking brake if equipped Keeping away from the downhill side of the machine pull the rear of the snowmobile around and point the front end and skis downhill Remount the machine restart the engine release the parking brake and descend the hill carefully 17 SAFETY Operator Safety Driving Downhill When riding downhill shift your weight to the rear of the machine and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the machine and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brake failure Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death Clutch Guard Do not operate the engine with the clutch guard removed The clutch guard is designed to protect the operator from metal parts if the clutch should fail Although the chance of failure is extremely remote don t defeat the purpose of the guard by removing it It s pro vided for your 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 re
18. and tips on snowmobile maintenance which may supersede information contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information Serial number Model number Dealer name Date of purchase Details of trouble experienced AAR WH 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 115 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 116 WARRANTY Limited Warranty Polaris Sal
19. and warm it up Break machine loose from the snow Towing at low RPM Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM Lower the gear ratio Remove windage plates from the and slow speed 8000 clutch Reduce RPM Avoid riding in high ambient RPM 10 MPH temperatures Ice and snow build up 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 Loading machines onto trailers Check for carb and choke synchronization fouled plugs debris in the carbs and water ice or dirt in the gas tank or fuel line Skis may gouge into trailers and prevent the drive train 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 engagement Use fast aggressive throttle to engage clutch 111 TROUBLESHOOTING Engine Troubleshooting CAUTION Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Erratic engine operating RPM during acceler ation or load Probable Cause Drive clutch binding Solution Disassemble drive clutch to inspect shift weights for wear and free
20. 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 8 Reinstall the gasket and cover 83 MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro cedure 1 2 3 Tip Place the snowmobile on a level surface with the headlight approxi mately 25 feet 7 6 m from a wall Measure the distance from the floor to the center of the headlight and make a mark on the wall Start the engine and turn the headlight switch to high beam Observe the headlight aim The most intense part of the headlight beam should be aimed two 2 inches 5 1 cm below the mark placed on the wall in step 4 Rider weight must be included on the seat Turn the adjustment nut located inside the hood just below the headlamp opening Turn the knob in or out as needed for proper aim 25 ft 7 6 m Lamp Center Height 2 in 5 1 84 Adjustment Nut MAINTENANCE Lights NOTICE Avoid touching a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot that will shorten the life of the lamp If fin gers do touch the bulb clean it with an alcohol moistened towel Removing Halogen Bulbs 1 Pinch the en
21. can occur without the proper lubrication Check the oil tank level often during the first tankful of fuel If the oil level doesn t go down contact your dealer immediately Oil Recommendations Engine lubrication comes from oil added to the fuel and oil injection systems Polaris recommends the use of Premium 2 Cycle Oil for this engine See page 109 for the part numbers of Polaris products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other 51 OPERATION Track Warm Up WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be approximately 4 inches 10 cm off the ground WARNING A loose track or flying debris could cause serious personal injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up th
22. dealer s responsibility to make sure the correct main jet is installed NOTICE Operating the snowmobile with incorrect jetting can result in serious engine damage Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the carburetor may need adjustment Hard starting Poor idle Overheated pistons and cylinder walls Plug fouling Poor engine response to various throttle valve openings 78 MAINTENANCE Fuel Filter Fuel Lines The fuel filter is located inside the fuel tank This component requires no maintenance Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly Oil Filter The oil filter on your model is assembled into the oil sending unit located in the bottom of the oil tank This component requires no main tenance If service
23. for exhaust emis sions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 122 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WAR
24. from starting If this occurs return the machine to an authorized Polaris dealer for service If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOT continue to operate the machine with the throttle safety switch disconnected Return the machine to an authorized Polaris dealer for service as soon as possible 59 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency Refer to page 58 for more information about the engine stop switch and throttle safety switch THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Choke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All WARNING Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system This overheated condition could cause sudden loss of brakes and or fire resulting in serious injury or death When traveling on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat and result in brake failure 60 OPERATION Electronic Reverse PERC
25. is performed to the oil injection system trapped air must be bled from the system See your dealer for instructions or have your dealer perform this service 79 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles 1600 km To inspect allow the engine and exhaust system to cool completely Open the hood and inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running Drive Chain Tension To obtain correct chain tension 1 Rotate the driven clutch coun terclockwise 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 5 The chain is now tensioned Release the brake lever lock 80 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 45 Brake pads must be replaced when the brake pad material becomes thin ner than the backing plate approximately 1 16 inch 1 5 mm A kit is available for replacing brake pads See
26. lost the ignition switch must be replaced Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number right front side of engine crankcase Key Number SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and 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 indicates the potential for serious injury WARNING A WARNING indicates a potential hazard that may result in serious injury or death CAUTION A CAUTION indicates a potential hazard that may result in minor injury NOTICE A NOTICE indicates a situation that may result in damage to the vehicle SAFETY Operator Safety Follow the recommended maintenance program beginning on page 65 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals A WARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will reduce your alertness and slow your reaction time In most states and provinces it s prohibited by law to drive while intoxicated or under the influence of drugs Polaris produces high performance snowmobiles capable of traveling at high speeds Extra caution must b
27. operation SEE YOUR DEALER Clean and polish stationary shaft hub variations Driven clutch Replace ramp buttons and rollers SEE malfunction YOUR DEALER Inspect movable sheaves for excessive bushing clearance and replace if neces sary SEE YOUR DEALER Harsh drive Drive belt worn or too Replace drive belt clutch engage narrow ment Excessive belt sheave SEE YOUR DEALER clearance Drive belt turns Wrong belt for applica Replace drive belt over tion Clutch alignment out Adjust alignment offset of spec Engine mount broken Inspect and adjust or replace SEE or loose YOUR DEALER Machine fails Clutch jammed Belt twisted spring broken weights to move stuck lubricated SEE YOUR DEALER Track jammed Foreign object caught or rail slide melted to track clips due to lack of lubrication Machine may be frozen to ground Track may be iced up Chaincase sprocket or chain jammed or bro ken Chain is loose or broken chain tight ener is loose SEE YOUR DEALER 112 Engine Troubleshooting Problem Noise in drive system TROUBLESHOOTING Probable Cause Solution Broken drive clutch SEE YOUR DEALER components Bearing failure chain SEE YOUR DEALER case jackshaft or front drive shaft Drive belt surface flat Spots Inspect and replace if necessary Drive chain loose or worn sprocket teeth broken Inspect and
28. pull abruptly to crank the engine Repeat the cranking procedure as needed until the engine starts After the engine starts flip the choke toggle to the OFF position If the engine slows or wants to stop use intermittent choking to the HALF CHOKE position 49 OPERATION Engine Break In No single action on your part is as important to long trouble free machine life as proper break in of a new or rebuilt engine Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel This in addition to the lubrication supplied by the injec tion system will assure proper engine break in NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and machine speeds to reduce friction on all close fitting machined parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the machine 50 OPERATION Engine Break In Oil Injection System Always check and fill the oil tank when refueling See page 55 NOTICE Serious engine damage
29. that the battery is fully charged 2 Place the battery in the battery holder Attach the hold down strap 3 Install the battery vent tube The vent tube must be free of obstruc tions and securely installed Route the vent tube properly to prevent kinks and to allow for proper drainage WARNING Batteries contain gases that can explode If the battery vent tube is pinched or kinked battery gases could accumulate Always ensure that the vent tube is free of obstructions and is securely installed as recommended Whenever removing or installing the battery disconnect the negative black cable first and reinstall the negative cable last to avoid the possibility of explosion 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables and vent tube are properly routed 103 MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more in summer or in winter Remove the battery Charge it to the proper level Store it in a cool dry place Check and or charge monthly Have the battery tested and recharged before reinstalling it in the vehicle If a battery with a low charge freezes the cells could be damaged Always maintain a full charge on a stored battery See the table below Charge condition Will freeze at 10096
30. the protection and preservation 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 Air Pollution Polaris engineers continuously investigate ways to reduce emission lev els of two stroke engines We expect our efforts to lead to the reduction of potential air pollution In addition to our technological research we encourage government agencies manufacturers distributors dealers ecologists and other interested parties to work together to develop data on environmental topics INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are
31. 75 F 59 C 75 24 F 31 C 50 0 F 18 C 25 13 F 11 C 0 18 F 8 104 MAINTENANCE 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 inches 10 cm off the ground Remove the key and cover the machine Tip Polaris has accessory covers and track stands available to fit all models See your dealer for more information 105 MAINTENANCE Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed out of direct sun light and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine part
32. ANCE Battery Battery Connections Keep battery terminals and connections free of corrosion When clean ing is necessary remove the corrosion with a stiff wire brush Wash ter minals and connections with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Battery Removal WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 Disconnect the battery hold down straps Remove the battery vent tube from battery Disconnect the black negative battery cable first Disconnect the red positive battery cable last Carefully lift the battery out of the snowmobile Do not tip it side ways or spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one table spoon baking soda and one cup water to prevent damage to the vehi cle Quero ed 102 MAINTENANCE Battery Battery Installation WARNING Battery electrolyte contains acid Avoid skin contact with electrolyte as severe burns may result Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance 1 Ensure
33. ING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death Replace skags as recommended Check skags weekly to maintain positive steering characteristics Skags must be replaced when worn to half their original diameter Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the machine so the skis are approxi mately 6 15 2 cm from the ground Remove the attaching hardware and pry the skag downward Remove the rear end of the skag Remove the front end of the skag Cosme Scb Reverse the steps to install a skag 99 MAINTENANCE Suspension Maintenance Rail Slide Wear A y For ease of inspection all Polaris rail slides have a Minimum wear limit indicator groove Thickness to indicate the minimum per missible slide thickness Replace the rail slides if they are worn to the top of the groove at any point along their length Failure to do so Replace when may result in permanent worn to top of damage to the track or rails groove Suspension Inspections Loose nuts and bolts can reduce your snowmobile s reliability and cause needless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip Check suspension mounting bolts for tightn
34. Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 milliliters per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol See page 109 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives are not required and should not be used NOTICE Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel 54 OPERATION x Oil 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 If oil is not visible continued opera tion may cause serious engine damage Add oil before further operation of the snowmobile See page 51 for oil recommendations Low Oil Level Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous ter rain Always check the oil level when refueling When the oil reaches the low level mark add one quart 9 1 of recommended oil to the tank See page 51 for oil recommendations NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always
35. RAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle Polaris recommends that you contact an autho rized Polaris dealer to perform any service that may be necessary for your vehicle Polaris also recommends that you use only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of t
36. ation Rear 71 Performance Tips 33 Troubleshooting 110 T Throttle Lever 44 59 Throttle Safety Switch 44 58 Tool Kito ds dd e marker 91 Torque 91 Torsion Spring Preload 36 TOWO es oae EASIER a 63 130 Track Alignment 96 Cooling 53 Damage ooo conse eR 47 92 Lubrication 93 Tension 33 94 95 0 52 Track Seat Warning 24 Traction Products 40 42 Transporting the Snowmobile 108 Troubleshooting Belt Wear 111 Troubleshooting Engine 112 114 Troubleshooting Suspension 110 T ne p cbe cag ROS 91 V W Vehicle Identification Numbers 7 Wear Strips 42 Windchill Temperature Charts 22
37. ause carburetor icing The result will be poor fuel economy or carburetor malfunction Always reinstall the intake filters before operating the snowmobile These illustrations are general representations Your model may differ Foam Filter Intake Foam Filter and Screen Air Intake Box 76 MAINTENANCE Carburetor Water Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water sedi ment traps located at the bottom of each carburetor The trap consisting of a hose with a plug should be drained about every 1000 miles 1600 km and inspected for contamination WARNING When draining the traps fuel spillage will occur Always work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the gasoline warnings found on page 53 Plug Cleaning Procedure 1 Turn the fuel valve off 2 Position a container or shop towels to Clamp catch the contaminated gasoline 3 Slide the clamp away from the drain plug and remove the drain plug from the sediment tube 4 Wipe residue from the plug and reinstall it Reposition and tighten the clamps Drain Continue until all the traps have been Plug emptied 77 MAINTENANCE Carburetor The number stamped in the end of the main jet indicates the jet size The jet installed at the time of manufacture is not necessarily correct for your elevation It s your
38. belt are excluded from coverage Electrical components are excluded from coverage Gearcases and transmissions are excluded from coverage 120 WARRANTY 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 m
39. bs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The 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 119
40. but your dealer will be able to offer advice and assistance NOTICE Installing studs on models without wear strips will result in damage to the cooler or tunnel Always ensure that wear strips are installed before installing studs See your dealer for more details Tip Before equipping your machine with traction products be aware of the laws in your area pertaining to the use of traction products Track studding will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Steering abil ity may be reduced on hard packed snow or ice WARNING Loss of control can result in serious personal injury or death Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice See your dealer for assistance NOTICE Use of studs longer than the recommended length on machines equipped with coolers will result in damage to the cooler or tunnel Always use the recommended length studs 40 THE PERFECT FIT Traction Products A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain The addition of carbide skags is rec ommended with studded tracks to help maintain proper vehicle steering and control Similarly if your machine is equipped with carbide skags or if you re adding them it may be necessar
41. check the oil level when refu eling Add oil as needed The Polaris oil cap on the oil bottle may be vented to allow proper oil flow See your Polaris dealer for recommended replacement parts 55 OPERATION Carburetion Proper carburetor adjustment is critical Always have your Polaris dealer perform any carburetor adjustments A lean mixture too much air too little fuel may result in piston burn ing bearing failure or complete engine failure A rich mixture too much fuel too little air may foul plugs and cause generally poor engine performance A lean mixture may be caused by things like fuel line restrictions for eign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filter in the air intake system Either condition may be caused by improper carburetor adjustment 56 OPERATION Carburetion Jetting Guidelines Changes in altitude and temperature affect air density which is the amount of oxygen available for combustion In low elevations and cold temperatures the air has more oxygen In higher elevations and higher temperatures the air is less dense RMK carburetors are preset to operate at altitudes of 6000 8000 feet 1800 2400 m above sea level see page 78 for more information Car buretors must be re calibrated if the snowmobile is operated outside this production temperature and or altitude range The main jet installed in production is not correct for a
42. chine resulting in serious injury or death Keep the underhood area free of snow and ice Driving on Slippery Surfaces WARNING Driving on ice or hard packed snow reduces steering and braking control which may result in serious injury or death Slow down and use caution If driving on ice or other slippery surfaces is unavoidable use extreme caution and operate at speeds no faster than a walk Never attempt an abrupt change of direction The chance of spin out increases under these conditions 16 SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll over causing serious injury or death Use caution and good judgement when driving in hilly terrain Operating in hilly terrain requires extreme caution to maintain balance and avoid roll over If climbing a hill is unavoidable keep all your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the machine to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine
43. correct main jet is installed in the carburetor s See your Owner s Manual Supple ment Normal Plug The normal 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 The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjust ments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incor rect carburetion adjustments Spark Plug Removal and Replacement 1 Wear protective gloves 2 Remove the spark plug cap 3 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 4 Reverse the procedure for spark plug installation Torque to 18 22 ft 165 24 4 29 8 Nm 5 Reinstall the spark plug cap 75 MAINTENANCE Intake Filter The intake foam filter and screen limits snow ingestion into the intake system When operating in loose powder snow check the top of the foam filter and screen periodically to remove any accumulation of snow NOTICE Operating the snowmobile with the intake filters removed may c
44. d 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 Elevation setting above 6000 feet push and hold for longer than 5 seconds to set Let go of button at desired setting fast flash for high elevation slower flash for low Setting will remain until changed SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present 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 capable of high speeds Buried objects or uneven terrain can cause loss of control Reduce speed and use extreme caution when operating in unfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehi cle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check
45. d out lamps before operating Mirrors if equipped Adjust the mirrors so they can be used to their full advantage Operating Area Before driving check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the machine Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF 48 OPERATION Starting the Engine NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 1 Turn the fuel valve on See page 27 CHOKE POSITIONS 2 Turn the key to the ON position OFF 3 Pull the engine stop switch up to the RUN position 1 2 CHOKE 4 Ifstarting a cold engine flip the choke toggle to FULL CHOKE Do not FULL CHOKE use the choke if starting a warm engine CAUTION Do not depress the throttle until the engine starts CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running 5 Ifequipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts NOTICE Don t pull the starter rope to the fully extended position and don t allow itto snap back into the housing Damage may result 6 Ifnot equipped with electric start grasp starter handle and pull slowly until the recoil engages then
46. dimensions Move limiter strap on front torque arm to low position see page 36 Front end pushes Check for worn skags Check for binding front suspension shafts and steering com ponents grease all pivot points elevate front of machine Verify sag dimension see page 34 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Increase IFS preload see page 32 Move limiter strap on front torque arm to high position see page 36 Steering is heavy Check skags and skis for damage Check for binding front suspension shafts and steering com ponents grease all pivot points elevate front of machine Verify sag dimension see page 34 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Decrease IFS preload see page 32 Machine darts from side to side Ensure skis are properly aligned see page 98 Check for binding front suspension shafts and steering com ponents grease all pivot points elevate front of machine Ensure skags are straight on skis 110 TROUBLESHOOTING Belt Wear Burn Troubleshooting Belt Wear Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather
47. dling NOTICE 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 the 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 Ignition Altitude Setting At higher altitudes above 6000 feet the engine will require a different ignition setting to improve the success of the reverse system To set for a higher altitude start the engine and hold the button down until the light on the instrument panel flashes rapidly then release the button To set the reverse for lower elevations continue holding the button down until the reverse indicator light blinks slowly Once set it s stored in memory until changed whether the machine is running or not 62 OPERATION Towing Do not use the front bumper to pull or drag the snowmobile The front bumper is not designed for this type of use and may detach from the vehicle if force 1s applied For your safety do not attempt to using the 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 o
48. ds of the spring 1 3 together and lift until it releases from the spring retainer 2 Lift spring carefully around 2 T wire harness 2 and flip to out side of housing 3 With the wire harness attached to the bulb 3 withdraw bulb from housing 4 Grasp bulb by metal base and carefully separate bulb from harness Installing Halogen Bulbs 1 Hold bulb by metal base and install into wire harness 2 Insert bulb into housing 3 Carefully flip spring back into housing placing it around wire har ness 4 Squeeze spring together until it is over the spring retainer and release 5 Verify headlight aim 85 MAINTENANCE Clutch System Periodically inspect the clutch sheaves for damage wear or belt resi due To maintain optimum performance clean with non oil based clean ers such as isopropyl alcohol NOTICE If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not operate the machine until repairs have been made All clutch mainte nance and repairs must be performed by an authorized Polaris dealer Any unauthorized modifications to clutches such as adding or remov ing weights will void the warranty The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining opt
49. e Lever 44 59 1 1 1 Oil Pump Lever 1 1 I synchronize Throttle Cable 72 Choke Cable 72 l Vent Lines 1 1 I 1 Throttle Position Sensor 1 1 Choke 72 1 1 Fuel Filter 79 R R Fuel Lines 79 1 1 1 Oil Filter 79 R R Oil Lines 79 1 1 R R 1 Air Box 1 1 1 Drain and Water Traps 77 1 1 I Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 67 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 150 mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season ELECTRICAL Auxiliary Shut Off Switch 48 1 1 1 1 Throttle Safety Switch 44 58 1 1 1 1 Ignition Switch 48 1 1 1 1 Taillight 48 1 1 1 1 Brakelight 48 1 1 1 1 Headlight 48 1 1 1 1 CHASSIS Ski Toe Alignment 1 l Suspension Mounting 1 1 1 1 1 Bolts Steering Fasteners 1 l 1 1 Rear Suspension 1 1 1 I 1 Fasteners Suspension Shock Oil 1 1 l 1 Cooling Fins and Shroud 1 1 l 1 Drive Shaft Bearings 72 L L L 1 Skags Wear Bars 99 1 l 1 1 1 Ski Saddle Spindle Bolts 1 1 1 1 Ski Pivots 70 L L L L 1 Ski Spindle 70 L L L L 1 Steering Arm s 70 L L L L 1 Upper Lower Steering 70 L L L L 1 Post Support Bracket Hood Straps 47 1 1 1 1 1 Battery Fluid Level 101 1 1 1 1 R
50. e isn t sufficient and fur ther adjustment is desired to control suspension stiffness See your Polaris dealer for more information 31 THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski to ground pressure Decreasing spring preload will decrease ski to ground 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 pre load grasp the spring and turn it to the right Turn it to the left to decrease preload Increasing the spring preload too much may adversely affect the han dling of the snowmobile and the per formance 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 Tip Some models do not have shocks with thread adjustable spring preload See your dealer for more information NOTICE Always leave one thread showing above the adjuster nut On models equipped with a plastic adjuster nut if the nut is unscrewed from the threaded body the nut will break Low Preload Preload 32 THE PERFECT FIT Rear Suspension Adjustments Rider weight riding style trail condi
51. e observed to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times We strongly rec ommend that the operator check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from opera tion with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynami cally unstable at speeds higher than those for which it is designed Loss of con trol 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 attem
52. e the illustration for ref erence The ideal amount of Sag for the this rear suspension is four inches X Y 4 If the rear suspension rides in less than three inches or more than five inches with the torsion spring preload cams at their maximum range of adjustment optional torsion springs softer or stiffer respectively may be required This is only an initial set up and final spring preload may vary based on rider preference and riding conditions 35 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 Soft Low Tension COPS tool Different rate torsion Long end to front springs are available if a firmer ride is desired See Se your dealer for more TUN information Short end up The following informa tion is provided only as a guideline to be used for initial suspension set up High Firm Tension Your set up may vary Long end up based on your desired riding style Optional Torsion Springs Track Soft Standard Firm 136 Not applicable 7041627 067 7041628 067 7041629 067 7041630 067 347 77 359 77 Limiter Strap Position The following information is pro vided only as a guideline to be High used for initial suspension set up Your set up may vary based on Low your desired riding style High Limiter strap in high posi tion increases ski pressure Low L
53. e track Do not use excessive throttle during warm up or when the track is free hanging Be sure the rear support is stable 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions Tip It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the machine to the ground 5 Grasp the skis by their front loops and move them from side to side This will loosen frozen snow from the ski bottoms allowing the machine to move forward more easily 6 The engine drive system and track are now properly warmed up and the machine may be driven following normal safety practices 52 OPERATION Slide Rail and Track Cooling NOTICE Inadequate cooling and lubrication will lead to overheating of the slide rail and track resulting in premature wear and failure Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice hard packed surfaces or roads Fuel 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 n
54. ear Wheel Idler Bolts 95 1 1 l 1 and Nuts Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace 68 L Lubricate MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 150 mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CHASSIS Rear Suspension Pivot 71 L L L Shafts Camber Alignment 1 1 1 Radius Rod Bushings 1 Handlebar Centering 1 Track Alignment 96 1 1 l 1 Track Tension 94 1 1 1 Front Limiter Strap 1 l 1 1 Rail Slide Condition 100 1 Chaincase Oil 73 1 1 R 1 Gearcase Oil N A l 1 1 R 1 Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 69 MAINTENANCE Lubrication Front Suspension Lubricate the suspension and steering components with Polaris Pre mium All Season Grease at 500 miles 800 km and annually or every 1000 miles 1600 km thereafter See page 109 for the part numbers of Polaris products The illustration shows the location of suspension and steering compo nents A indicates a grease point or fitting Grease the left and right spindles Raise the front end of the machine to permit better grease entry into the spindle area Lubricate both of the front ski pivots at the fittings as shown Grease the driveshaft clutch side bearing
55. ems to assure proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the handgrip than 1 2 inch 1 3 cm A smaller distance indi 1 2 inch 1 3 cm cates low brake fluid level or A air in the hydraulic system See pages 82 83 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Also check for the presence of air in the fluid sys tem See pages 82 83 or see your dealer for service 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 45 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever Use the brake lever lock only when you want the machine to remain sta tionary 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 NOTICE If the brake lever is squeezed tightly enough the lock will move freely into place Do not force the loc
56. en track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and support the rear of the snowmobile off the ground 2 Rotate the track by hand to check for possible damage 3 Carefully examine the track along the entire length of each rod X Bend the age track to check for break ER 4 Replace the track if any rod damage is found 92 MAINTENANCE Track Track Lubrication WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication The slide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear Tip If excessive rail slide wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information Tip Track damage or failure caused by operation on ice or under other poor lubrication conditi
57. es Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIM ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty The 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
58. ess Check rear idler wheel bolts for tightness See page 95 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition Check track tension See page 94 Lubricate grease all suspension components See page 70 Check ski runner skag condition See page 99 Check ski spindle bolts for tightness Check tie rod end nuts for tightness NN N NN NN YY 100 MAINTENANCE Battery AWARNING Battery electrolyte is poisonous It contains acid Serious burns can result from contact with the skin eyes or clothing If contact occurs seek immediate medi cal attention KEEP OUT OF REACH OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks open flames cigarettes etc away Ventilate when charging or using in closed space Always shield eyes when working near batteries Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks Upper Mark NOTICE Tap water contains minerals that will damage a battery and shorten its life Use only distilled water to refill your battery Never allow cleaning solution or tap water to enter the battery 101 MAINTEN
59. ght for access to the rear 7 nuts If necessary pry the R blocks apart with a screw driver Adjust the handlebar to the desired angle Be sure the handlebar brake lever and Nuts throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when the handlebar is turned fully to the left or right Torque the front bolts first then torque the rear bolts Torque the bolts to 11 13 ft 165 15 18 Nm Reinstall the handlebar cover THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile From map light to electric start Polaris has the accessories that will help make each ride more enjoyable See your dealer for a list of accessories 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 Voiding of warranty Personal injury to self or others This applies to but is not limited to the following areas brakes clutches fuel systems and exhaust systems Tip Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service 39 THE PERFECT FIT Traction Products Another way to tailor your machine is to install traction products See your dealer about installing studs and or carbides Many tracks with deep lug designs cannot be studded
60. he vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the Polaris Warranty Department at 1 888 704 5290 123 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 TECHNICIAN SERVICE PERFORMED COMMENTS KM 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km 124 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 125 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 126 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 127 INDEX A Accessories 39 Air Box Waming 23 Air Pollution 6 Apparel i esce sies Em pes 12 15 Battery 101 104 Connections 102 s ce em 101 Installation 103 102 Sotal ces
61. ich could cause loss of control resulting in serious injury or death Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time with inadequate lubrication could severely damage track rods break track edges and cause other track damage Examples of inade quate lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions Track damage or failure caused by operation on ice or under poor lubri cation conditions voids the track warranty Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions Under no circumstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your Polaris dealer for replacement 47 PRE RIDE INSPECTIONS Start the Engine and Check 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 Lighting Check the headlight high and low beam taillight and brake light Replace burne
62. imiter strap in low position decreases ski pressure 36 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Damping Your snowmobile is equipped with the Indy Select rear shock which allows for adjustments to the compression valving 1 Locate the adjustment screw near the base of the shock 2 Adjust the screw 1 2 turn clockwise to increase compression valv ing and stiffen the ride Test ride the snowmobile before making further adjustments Tip An excessive adjustment can result in damage to the shock When adjust ing these shocks we recommend that you turn the screw only 1 2 turn at a time then test ride 3 Adjustthe screw 1 2 turn counterclockwise to reduce compression and soften the ride There are approximately three full turns of adjustment available If bot toming continues after the screw has been turned fully clockwise the torsion spring should be adjusted see page 36 Return the screw to its original starting position after the torsion spring has been tightened Adjustment Screw 37 THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust handlebar angle at the handlebar block 1 38 Remove the handlebar cover to expose the handlebar and the four adjuster block bolts Cover Using a 7 16 inch wrench loosen the four nuts on the bottom of the adjuster block Bolts ma turn the handlebar either left or ri
63. imum 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 86 MAINTENANCE 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 Belt Troubleshooting on page 111 Periodically check the condition and tension of the drive belt and always carry a spare Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist Tip A worn belt will continue to function but will not deliver maximum perfor mance Always carry a spare belt in case of an emergency For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile 87 MAINTENANCE Clutch System Drive Belt Removal 1 Stop the engine after operating in a forward motion NOTICE Do not attempt to remove the drive belt after operating in reverse The 88 snowmobile must be stopped after forward motion to prevent damage to componen
64. inning on page 124 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 NOTICE Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmo bile on its side for service or inspection 65 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement part
65. ium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogel 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 109 SUSPENSION TROUBLESHOOTING Problem Solution perform only one change at a time Rear suspension bot toms too easily Verify sag dimension see page 34 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Increase shock compression damping see page 37 Rear suspension rides too stiff Check for binding suspension components and grease all pivot points Verify sag dimension see page 34 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Decrease shock compression damping see page 37 Too much weight transfer when climb ing Verify sag dimension see page 34 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Move limiter strap on front torque arm to high position see page 36 Too little weight transfer when climb ing Verify sag dimension see page 34 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag
66. k or it may break The brake light will illuminate if the parking brake lever lock is set while the engine is running It will also illuminate when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock will return to the 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 46 PRE RIDE INSPECTIONS Before Starting the Engine Steering System WARNING Ice and snow build up may interfere with the steering of your machine resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Make sure all greasable components are properly lubricated Track WARNING Always inspect the track for damage before using the vehicle Operating the snowmobile with a damaged track increases the possibility of track failure wh
67. ling state law 117 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN 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 cau
68. ll altitudes and or temperatures NOTICE A main jet that s too small will cause a lean operating condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts See your Owner s Manual Supplement Tip It s the owner s responsibility to ensure that the correct jets are installed in the machine for a geographical area Be very careful when jetting down in warm weather As the weather turns colder it will be necessary to re jet upward to prevent engine damage When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encoun tered 57 OPERATION Engine Stop Switch Push down on the engine Stop Switch stop switch to stop the engine in an emergency This will ground out the ignition and bring the engine to a quick stop To restart the engine the switch must be pulled up to the ON position Throttle Safety Switch 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 Test the throttle safety switch system daily before operation WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety Switch does not shut off the engine during a carburetor throttle system malfunction im
69. 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 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 Oil injection system Use unmixed fuel only Check oil level when refueling 25 FEATURES AND CONTROLS Fuel Filler Cap may include a fuel gauge Ignition Switch Brake Lever Speedometer may include indicator warning lights Reverse Indicator Mountain Bar accessory Engine Stop Switch see page 58 Throttle Control Choke 0 Recoil Starter Handle o9eouoorom 26 FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features Controls for these features are illustrated on this page Not
70. mediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pres sure on the pivot pin in the direction shown in the illustration S 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine 58 OPERATION Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control which could result in serious injury or death If the throttle 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 carburetor s to determine what caused the safety switch to activate 3 Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely 4 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe engine doesn t start take the snowmobile to an authorized Polaris dealer for service Excessive free play in the throttle cable may cause the safety switch to activate preventing the engine
71. ment 6 Exhaust ot cua rtr EUR 53 Exhaust 80 F Fuel tuis hace bs th era 53 54 Fuel Filter 79 PE elEimnes d ctore 79 Fuel Recommendations 54 Fuel Reserve 54 Fuel System Deicers 54 27 H Handlebar Adjustments 38 Headlight Adjustment 84 Hood 47 l Ice and Snow Build up 16 IFS Adjustment Options 29 IFS Components 29 Ignition Altitude Settings 62 Intake 76 Intake Silencer 19 J Jetting 57 L Lights 84 85 Headlight Adjustment 84 Installing Halogen Bulbs 85 Removing Halogen Bulbs 85 Lubrication Choke and Cable 72 Driveshaft Bearing 72 Front Suspension 70 Jackshaft Bearing 72 Rear Suspension 71 Throttle Cable 72 M Maintenance Program 65 Maneuverability 19 N NOISQ x PR Si se aie 6 need 55 Oil Filter 79 Oil Indicator Light 55 Oil Levels uv dau 55 Oil Level Chaincase 73 Oil Recommendations 51 Operating in Deep Snow 20 Operation Warning
72. moved may result in personal injury or damage to the engine 18 SAFETY Operator Safety Intake Silencer Do not operate the engine with the intake silencer or filter removed Damage to the engine may occur if the intake silencer or filter are removed Clutches Do not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is 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 machine into motion but always operate within safety limits See Starting the Engine on page 49 Maneuverability Control and maneuverability comes not only through the steering and skis maximum control is achieved by shifting of body weight Maneu verability will change for lighter operators or machines designed to carry a load 19 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your machine NOTICE Driving in too little snow will re
73. nd steering control 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 11 SAFETY Operator Safety Riding Apparel Be prepared be warm and be JE AN PELARIS comfortable when riding Be aware of the weather forecast especially the windchill and dress accordingly See the chart on page 22 WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Eye Protection 051039 0006 31 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 protec
74. nd the use of Polaris DOT 4 high temperature brake fluid See page 109 for the part numbers of Polaris products NOTICE Brake fluid will damage decals paint and some plastics Always wipe up spills immediately Replace brake fluid at least every two years 82 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action Bleed the system before operating the snowmobile WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever During the bleeding procedure keep the brake handle as level as possi ble The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent 1 Remove brake master cylinder reservoir cover and gasket 2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 inch 6 8 cm below the lip of the reservoir opening Reinstall the gasket and cover 3 Slip arubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air
75. nect See page 109 for the part numbers of Polaris products Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Battery Always prepare and maintain the battery as outlined on page 101 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 2 Be sure 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 108 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 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 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 Prem
76. nowmobilers 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 information 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 Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered check for ice and snow build up that may be obstructing the steering linkage Snow screens and bib kits are available through your dealer to help reduce snow and ice build up WARNING Ice and snow build up may interfere with the steering of your ma
77. ons will void the track warranty 93 MAINTENANCE Track AWARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine run ning Track Tension Track adjustment is critical for proper handling Always maintain cor rect tension and alignment Tension adjustments should be made only after the track is warmed up and limber WARNING Improper track tension can cause serious damage to the snowmobile which can result in loss of vehicle control and serious injury or death Always maintain the track tension as specified 1 Turn the engine off 2 Lift the rear of the machine and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the distance specified see chart ahead of the center of the rear idler wheel 4 Measure at the point where the weight is hanging Weight Measurement Measurement Location 10 Ibs 4 54 kg 16 inches 41 cm ahead of 3 8 1 2 inch 1 1 3 cm rear idler shaft 5 Check for specified slack between the wear surface of the track clip and the plastic rail slide 94 Track Track Tension If the track needs adjustment 6 Loosen the rear idler shaft bolt Loosen the locknuts 8 Tighten or loosen the track adjusting screws as necessary to pro vide equal adju
78. onvenient ref erence It should remain with the snowmobile when the snowmobile is sold 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 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 Some of the illustrations and photos used in this manual are general rep resentations Your model may differ 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
79. ork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes 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
80. ot smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the snowmobile is stored or parked Exhaust 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 53 OPERATION Fuel Fuel Recommendations Your Polaris engine is designed to run on 87 octane non oxygenated or 89 octane oxygenated pump gasoline There s a great deal of variability in the quality of the 87 octane gasoline available so we encourage the use of premium fuel when possible Do not use lower than 87 octane fuel Do not use fuel containing more than 10 ethanol including E85 NOTICE Using fuels with a lower than recommended octane or operating with obstructed fuel systems will result in serious and costly engine dam age Always use the recommended fuels for your machine Fuel Reserve Capacity Mechanical Gauge There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES Fuel System Deicers If you use non oxygenated fuel
81. port the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward 3 Remove the spark plug s 4 Rotate the engine slowly watching the piston until it s at bottom dead center BDC the lowest position in the cylinder On twin cyl inder models the opposite piston will be up 5 Pour approximately two ounces of Polaris injector oil into the spark plug hole 6 Wait to two minutes and perform steps 3 to 5 on remaining cyl inders 7 Replace the spark plugs and lower the machine to the floor Controls and Linkage All bushings spindle shafts tie rod ends and cables should receive a light coat of oil or grease Bearings Grease the drive shaft clutch side bearing with Polaris Premium All Season Grease or a similar high quality grease to prevent corrosion See page 109 for part numbers Clutch and Drive System Remove the drive belt and store in a cool dry location Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant See page 109 for the part numbers of Polaris products Do not lubricate clutch components except the driven clutch shaft bushing as outlined in the Master Repair Manual See your dealer 107 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with dielectric grease and re con
82. pt adjustments with the engine running Turn off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments 10 SAFETY Operator Safety Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone For added protection carry the following items on your snowmobile at all times Spare Drive Belt Winter Survival Kit Extra Set of Spark Plugs Trail Map Tow Rope Owner s Manual Extra Oil First Aid Kit Fuel Deicer Tool Kit 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 a
83. r death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have a rider on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 63 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 label and a factory installed emissions informa tion hang tag These items are required by U S Environmen
84. rally as shown Choke and Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke intermittently to draw mois ture out of the choke plunger area and reduce the possibility of the choke becoming frozen 72 MAINTENANCE Lubrication Chaincase Oil Level Check the chaincase oil level at the intervals outlined in the mainte nance charts beginning on page 66 Change the chaincase oil after the first 500 miles 800 km then every 1000 miles 1600 km or season ally Maintain the oil level between the safe marks on the dipstick Clean the magnetic plug on the dipstick whenever checking or changing oil Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 109 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the dipstick and view the oil level on the dipstick 3 Add the recommended oil as needed Do not overfill 4 Clean the magnetic plug 5 Reinstall the dipstick 73 MAINTENANCE Spark Plugs It s very important to use the correct spark plug for your machine A spark plug with a heat range too high will cause engine damage A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning In selecting a spark plug heat range for production a manufacturer assumes that the engine will be operated under extreme heavy du
85. s always use genuine Polaris parts available from your Polaris dealer Item See Frequency Page 7 150 500 1000 2000 240 800 1600 3200 CLUTCH Clutch Offset Alignment 86 1 1 1 without belt Drive Belt Condition 87 1 1 1 1 Clutches disassemble 86 C C C Belt Tension 1 1 1 1 Clutch Sheaves 90 1 1 1 1 ENGINE Engine Mounts l 1 1 1 Recoil 47 1 1 1 1 Engine Mounting Plate l 1 1 Engine Torque Stop 91 1 1 1 1 Cylinder Head Bolts 1 1 1 Cylinder Base Nuts l 1 1 1 Ignition Timing 1 1 1 Spark Plug Condition 74 1 1 1 1 1 Exhaust Pipe 80 1 1 Exhaust Retaining 80 1 1 1 1 Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 66 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 150 mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season BRAKES Hose Routing 1 1 I 1 Hose Condition 1 1 1 Fluid Leaks 1 1 1 Brake Pads 81 1 1 l 1 Brake Disc 1 1 1 Parking Brakes 46 1 l 1 1 Brake System 45 81 1 Brake fluid 82 R FUEL MANAGEMENT Pilot Air Screws 1 1 Carburetor synchronize 56 1 1 1 Idle RPM 1 1 Throttl
86. s 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 can See page 107 Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the can running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Tip For easier starting after extended storage add lubricant to the fuel in the tank at a 40 1 ratio and run the engine for three to five minutes before stor age This will lubricate the fuel pump diaphragm to keep it flexible and help prevent loss of prime If stabilizer is not used drain the carburetors by removing the water trap drain plugs see page 77 Catch fuel in a container or shop cloth Rein stall plugs securely Observe all fire safety rules when draining carbure tors See gasoline warnings on page 53 Tip Jet restriction caused by improper storage can cause lean conditions and very poor slow speed driving quality 106 MAINTENANCE Extended Storage Engine and Carburetor Protection Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system If you prefer to drain the fuel tank use the fol lowing procedure 1 Transfer unused fuel from the fuel tank to an approved fuel con tainer using a siphon pump Do not re use fuel after storage 2 Securely sup
87. s for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 Trail RMK Owner s Manual P N 9922282 2 TABLE OF CONTENTS Introduction
88. s found under the hood on the clutch cover WARNING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with this guard open Never run engine with drive belt removed Never service clutches yourself see your dealer Air Box Warning This warning decal is found under the hood on applicable models CAUTION Do not operate above 40 mph with hood to air box foam removed or engine failure will result Passenger Warning Your Polaris snowmobile is designed for a single rider only A decal on the console indicates single rider operation WARNING This vehicle is designed for operator only NO PASSENGER 23 SAFETY Safety Decals and Locations Track Seat Warning The track seat 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 Reverse Warning Polaris snowmobiles equipped with electric reverse and will have this decal on the console 24 WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stoppe
89. se 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 around your vehicle Drive defen sively to avoid accidents Remove the key from the ignition when you leave the snowmobile unattended 21 SAFETY Operator Safety Windchill Temperature Charts The following information is provided to help you determine when tem peratures become dangerous for riding WIND CHILL CHART F Wind Actual Thermometer Reading F Speed 40 35 30 25 20 15 10 5 O 5 10 15 20 25 30 35 40 45 MPH Equivalent Temperature F Calm 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 5 36 31 25 19 13 7
90. se 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 118 WARRANTY 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 bul
91. ses ER 104 BAK CS 45 81 83 Components 81 ossis 82 Inspection 81 Lever Feel 45 Lever 45 System Bleeding 83 Break In Period 50 51 C Carburetion 56 57 Carburetor 77 78 Carburetor Adjustments 78 Carburetor Protection Storage 106 107 Carburetor 7 argo 13 Chain Tension 91 Choke 49 Cleaning the Vehicle 106 Clutch Alignment 86 Clutch Center Distance 86 Clutch Cover Warning 23 Clutch Guard sas casaua aroase 18 Clutch System 86 91 Clutches 00 000 19 Cold Weather Drive Away 19 128 D Disabled Operators 13 Drive Belt Safety eo lee ler rre ls 18 Adjustment 90 87 Deflection 90 89 Removal 88 Drive Chain Tension 80 Driver Awareness 14 Driving Downhill 18 Driving in Hilly Terrain 17 Driving on Slippery Surfaces 16 Driving Responsibly 21 E Emission Control Information 64 Emissions Limited Warranty 122 123 Engine Break In 50 51 Engine Care for Storage 106 107 Environ
92. should be made to one area at a time in order to properly evaluate the change IFS Components 1 Skis 2 Front shocks and springs 3 Rod ends 4 Trailing arms IFS Adjustment Options Front shock spring preload Optional springs 29 THE PERFECT FIT Front Suspension Adjustments WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Always verify ski alignment before making adjustments to the IFS See page 98 to check alignment Do not attempt to change the ski alignment or camber adjustment See your Polaris dealer The tension at which the shock coil spring is set is called spring preload For the best ride the spring preload should be set as low as possible to use the full travel of the ski shock with occasional light bottoming To determine if your machine is using full travel of the ski shock push the jounce bumper down as far as it will go on the shock rod and test ride the machine The bumper will move up on the rod in direct relation to the amount of travel If the shock travel is full the bumper will be seated at the top of the shock Shock Components 1 Retainer 1 Shock Rod Jounce Bumper 2 Body Threaded Spring Preload Adjuster Nut 3 f 30 THE PERFECT FIT Front Suspension Adjustments Front Springs For models without externally adjustable or revalvable shocks the front springs can be changed if spring preload alon
93. stment on both sides of the track 9 Repeat the measure ment on the other side of the track Tip Check more frequently when machine is new 10 Start the engine and slowly rotate the track MAINTENANCE Slack Measurement Locknut Idler Shaft Bolt Adjusting Screw Track 16 in 40 cm 10 Ibs 4 54 kg at least five revolutions Let the track come to a stop do not apply brakes 11 Check track alignment see page 96 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts Torque to 35 ft 165 47 5 Nm 95 MAINTENANCE Track 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 96 Safely support the rear of the machine with the track off the ground Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions Stop the engine and let the track come to a stop do not apply brakes 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
94. sts or other obstacles Be especially alert if you re snowmobiling after dark Always be on the alert for wire fences Single strands are especially dangerous since there may be a great distance between posts Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your machine will drown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or high ways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you Before riding your machine on a frozen body of water be sure the ice is thick enough to support the machine and its operator as well as the force created by a moving vehicle You may drown if you and the snowmobile break through the ice When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations 14 SAFETY Operator Safety Avalanches S
95. sult in excessive wear and damage to the slide rail track and or engine Do not drive for prolonged periods on blacktop gravel or ice If frequently operating in low cooling condi tions see your dealer for an optional wheel kit that will reduce the wear from overheating Operating in Deep Snow If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will be able to climb up and over the Snow 20 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions may become dangerous if operators drive improperly If you re new to snowmobiling acquaint yourself with the machine and with what it will and won t do under various conditions Even seasoned driv ers should spend some time getting the feel for a machine before attempting ambitious maneuvers 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 cour
96. tal 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 hang tag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is avail able to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty and read the maintenance section of your owner s manual You are responsi ble for ensuring that the specified maintenance is performed Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 64 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beg
97. tighten the right adjusting bolt Rails After adjustments are complete tighten locknuts and torque idler shaft bolts to 35 ft Ibs 47 5 Nm Repeat steps 2 and 3 to verify proper alignment MAINTENANCE Steering System Steering Inspection Each week or before a long ride check fasteners and tighten if neces sary Specific fasteners that should be checked are marked with a in the illustration 97 MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski alignment or camber adjustment See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 1 4 inch 3 6 mm greater than at point Y Tip If the skis are misaligned we recommend that your dealer correct the align ment since camber adjustment may also be affected E 10 in 25 4 cm 98 MAINTENANCE Steering System Ski Skags See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add track studs to maintain proper vehicle con trol while turning on hard packed snow or ice WARN
98. tions 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 condi tions However all suspension designs and adjustments involve a com promise or trade off For example a suspension set up for snow cross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bottom out harshly on a snow cross course See your Polaris dealer for initial suspension setup information Addi tional adjustments can be made after initial setup Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer 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 n deep snow a new rail slide will offer improved performance over a worn rail slide It can also improve top speed Whenriding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer Polaris offers track kits for improved flotation in deep snow See your dealer for assistance Tip Keep the suspension pivot points lubricated
99. tive eye wear is kept clean 12 SAFETY Operator Safety Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer Do not exceed carrier and rack weight limits and do not allow a passenger to sit on the seat back or the cargo carrier Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Excessive Speed 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 machine to a stop in the distance illumi nated by the headlight 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 13 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles po
100. ts during belt removal Turn the ignition key off Wait for the engine to stop completely Lock the parking brake if equipped Open the hood Remove the clutch guard retain ing pin and open the clutch guard Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forward engagement before attempting to remove the belt Locate the L wrench in the tool kit and install it into the open threaded hole in the outer sheave of the clutch Rotate the wrench until the sheaves open far enough to remove the belt Firmly grasp the belt midway between the clutches and pull upward and rearward to remove See illustration MAINTENANCE Clutch System Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack Tip To ensure satisfactory belt life install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves 3 Hold the belt down between the sheaves and roll the bot tom portion over the outer clutch sheave Work the belt to the outer edge of the sheave 4 Rotate the L wrench to tighten the sheaves Remove the wrench and store in the tool kit 5 Close the clutch guard and reinstall the retaining pin
101. ty con ditions and selects a spark plug that will protect the engine from internal damage if the purchaser actually does operate the engine in this manner This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure NOTICE A spark plug with a heat range too high will always cause engine dam age if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See your Owner s Manual Supplement A new engine can cause temporary spark plug fouling due to the preser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization Use recommended spark plugs with the proper gap See your Owner s Manual Supplement Spark plug torque is 18 22 ft 165 24 4 29 8 Nm Always carry spare spark plugs 74 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 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Tip Incorrect fuel mixture can often cause a spark plug to appear too dark or too light in color Before changing spark plug heat ranges be sure the
102. ust show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to 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 115 121 WARRANTY U S A EPA Emissions Limited Warranty
103. y to change plug s however the plug s may operate satisfactorily when dried Poor engine compression Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEALER This indicates a major engine problem that must be repaired before engine is run Engine lacks power Fouled or defective Change and test operation spark plug Fuel filter loss of high Check fuel filter flow Disconnect RPM power hose and drain about 1 2 cup Fuel flow should be steady and encompass the entire diameter of fuel line If not replace filter Incorrect clutching SEE YOUR DEALER Carburetor and fuel pump There s no adjustment to change power output SEE YOUR DEALER Engine continu ally backfires Faulty plug s Change plug s Carburetor Dirt or ice in fuel system Deicer should be added to non ethanol fuel at all times for assurance against fuel line icing Engine requires more than nor mal pulls to start Poor gasoline or not enough fuel getting to engine Replace with fresh winter fuel 114 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
104. y to add track studs to main tain proper vehicle control Proper balance must be maintained between the number of studs and the length of the carbide on skags The more studs used the longer the carbide on the skags should be See your dealer s track studding chart for recommended studding and skags Inspect skags and studs frequently Worn studs or skags may reduce steering and braking control on hard packed snow and ice Replace worn studs and skags to maintain proper balance and vehicle control See page 99 When studded tracks are used increased wear to the brake pads will result from increased braking Extended wear brake pad kits are avail able See your dealer for more information NOTICE Aggressive studding patterns may require that you grind protruding stud bolts flush to prevent idler wheel damage Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage Center of stud must be at least 1 1 8 inches 2 86 cm from the outside edge of the track Use only Polaris traction products on your snowmobile Track warran ties are void if track damage or failure results from improper or exces sive stud installation or the use of non Polaris traction products 41 THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel or cooler damage wear strips must be installed whenever track studding is used See your dealer for more information Wear strips are designed for
105. your dealer WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 inch 1 5 mm Brake Components 1 Brake Caliper 2 cedar 2 Chaincase P 3 Brake Disc 4 Backing Plate H 5 Brake Pad Material Z 5 4 if Replace when thickness is less than 1 16 inch 1 5 mm V 9 a MN ULUR 81 MAINTENANCE Brakes Brake Fluid WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury The brake fluid level can be seen through a plastic sight glass in the brake reservoir If the fluid is sufficient the sight glass will be black If the sight glass is any color other than black add brake fluid Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function We recomme

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