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Polaris 700 IQ Offroad Vehicle User Manual

1. Engine Lubricants 2874865 Performance Synthetic 4 Stroke PS 4 Oil qt 2874866 Performance Synthetic 4 Stroke PS 4 Oil gal 2876244 Performance Synthetic 4 Stroke PS 4 Plus Oil qt 2876245 Performance Synthetic 4 Stroke PS 4 Plus Oil gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogel Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT4 Brake Fluid 12 oz 2872893 Engine Degreaser 12 oz 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carburetor and Throttle Body Cleaner 151 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Speed RPM or Boost is Limited Probable Cause Engine Management System RPM Reduction Mode is activated Solution See causes on page 38 Jammed clutch Check for twisted belt or broken spring See your dealer Jammed track Remove any foreign objects Slider may be melted to the track clips due to lack of lubrication Track may be iced up or fro ze
2. Ignition relay coil Fuel pump relay coil Fan relay coil Fuel pump relay power PTO injector MAG injector Wastegate IGNITION RELAY PTO ignition coil MAG ignition coil FUEL PUMP RELAY Fuel pump FAN RELAY CAC fan 133 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol A WARNING 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 snowmobile until repairs have been made All clutch maintenance and repairs must be performed by an authorized Polaris dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty CAUTION The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor mance Please see your Polaris dealer if you experience a decrease in performance Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer 134 MAINTENANCE Clutc
3. Snowcross Steep Hill Climbing Only Rider weight is ahead of the center of the snowmobile adding weight to the skis and making the snowmobile heavier in the front These positions are ONLY for snowcross and severe hill climbing 35 FEATURES RIDER SELECT Adjustable Steering System A WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death Always stop the snowmobile before attempting to adjust the steering system 1 Stop the snowmobile 2 Press the release button and move the handlebar forward or rearward to the desired position A WARNING Do not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mecha nism is lubricated for life at the factory A WARNING Some aftermarket accessories including windshields and cargo bags may interfere with the handlebar Such accessories could limit your ability to steer the vehicle and or may contact the brake lever This could lead to loss of con trol resulting in serious injury or death Always be sure that accessories do not contact the handlebar or brake lever at any steering position and at any RIDER SELECT position 36 FEATURES Engine Management System Malfunction Indicator Lamp MIL Iluminated MIL The MIL Check Engine Indicator will i umi
4. 13 RIDER SELECT 34 36 RRSS io uaa aa tae T AGA 61 S Safety eae tut RE ERR 8 23 Safety Decals 24 27 Sag M 10 2 00 63 68 Seat Latches 75 Shock Spring Preload Front 55 Shock Valving 56 SKAGSss ore as ete dy ee ee 73 145 Ski Alignment 144 Ski Pressure M 10 67 68 Snow Build up 18 Snow Conditions 21 Spark Plugs 117 118 Speedas ten ses tenet 15 Spring Preload IQ 58 Spring Preload M 10 66 Springs Front 56 Starting the Engine 85 Starting Emergency 86 88 Steering Inspection 143 Steering System 76 143 145 Stop Switch 0 92 Stopping ooo eassa sasssa naras 95 Storage Daily 96 Storage Extended 149 150 Studs e a E pa a ee 72 Survival Preparation 11 Suspension Adjustment Switch M 10 ACE 30 M 10 ACE 6 42 CHUISED ie ie ee vee ees 69 PRONG secure ts wees ake be 54 56 CO po td Bhai iss 58 62 MIO 335 dae sted eed aks 63 68 M 10 ACE 52 69 R a ennenen oc 57 69 Suspension Coupling IQ 60 Suspension Inspection 80 Suspension Lubrication Front 113 Suspension Lubrication Rear 114 S Suspension Performance Tips 57 Suspension Set up C
5. 10 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control A WARNING Improper riding position may reduce control and could result in serious injury or death Always ride in a position that allows for control of your vehicle Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone Always carry the owner s manual on your snowmobile For added pro tection purchase and carry the following items on your snowmobile as well Spare Drive Belt e Winter Survival Kit e Extra Set of Spark Plugs e Trail Map e Tow Rope e First Aid Kit e Extra Oil e Tool Kit e Fuel Deicer 11 SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can preven
6. 19 Driving Responsibly 22 E Electrical System 133 Emission Control Information 97 98 Emission Control Label 97 Emission Control Maintenance 97 Engine Management System 37 39 Engine Oil 103 111 Engine Stop Switch 92 Environment Preservation 6 Exhaust System 121 Eye Protection 12 F FRA Position M 10 65 Front Rear Scissor Stop 60 Front To Rear Coupling 60 PRS Sess 32s be ood LAA Mel et 60 BUGI et ad pat oo thay Gooey aoe 89 Fuel Filters 0 0 5 0 e040 ue oe 119 Fuel Injectors 119 Fuel bevel ss as sce eae ies 89 Puel Lines 26 oen da e tet aks 119 Fuel Pump 2 2 00 e0005 119 Fuel Safety 83 Fuel System Deicers 89 Fuse Label nts eae ares 133 G Gauge Cleaning 53 Gearcase Oil 115 116 Gearcase Oil Change 116 Gearcase Oil Check 115 Grab Handle Adjustment 33 H Handlebar Adjustments 70 Headlight Adjusting 31 Helmet as 1 s aa a ei et 12 High Temperature Indicator Light 124 Hood Latches 76 171 INDEX l Ice and Snow Build up 18 MES Ahi 3 3 eee teh tee ae a testes log tes 54 Instrumentation 41 53 Intake Filters 119 Intake Silencer 20 J
7. 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 7 11 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 24 1 3 7 11 15 19 22 26 30 34 38 42 45 49 53 57 32 O 4 8 12 16 20 24 28 32 36 39 43 47 51 55 40 1 5 9 13 17 21 25 29 33 37 41 45 49 53 48 1 5 9 13 18 22 26 30 34 38 42 46 50 56 2 6 10 14 18 22 26 31 35 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 16 Frostbite in gt gt 30 min 10 min 23 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
8. Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service T 7 aa reminders When the logged hours 7 j reaches the designated service interval a T set by the user the gauge provides a EnG F reminder that service is due SErVCE j H will flash in the odometer area and GEP YCE eff ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the reminder at the existing interval 1 Enter the History Program 2 Press and release the SET button until the service interval screen is active 3 Press and hold the SET button for ten seconds continuing to hold even after the display begins to flash 4 When the display stops flashing release the button The service interval has been reset 50 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder To reset the reminder at a new interval l 2 3 4 Enter the History Program Press and release the SET button until the service interval screen is active Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button Press the button again up to five times to advance the reminder in 50 hour increments NOTE The max
9. Move the adjuster to the left to lower the headlight beam Move the adjuster to the right to raise the headlight beam Radiator Compartment Access Panel The access panel is provided for cleaning debris from the radiator Cargo Bag Touring The cargo bag is secured to the rear of the tunnel with straps The cargo bag and the passenger seat are removable to provide open storage for transporting larger items The maximum weight capacity for the cargo area is 30 lbs 14 kg Always secure cargo before operating Do not exceed the weight limit Do not allow a passenger to sit on the seat back or the cargo area 1 Push down on the seat latch lever which is located at the lower rear of the passenger seat 2 Lift up the seat and remove it from the chassis 3 Reverse the procedure to reinstall the seat Press down firmly on both sides of the seat to engage the latch Verify that the latch is engaged by firmly pulling the seat upward 31 FEATURES Trunk Passenger Seat Cargo Bag Cruiser The trunk cover is removable to allow installation of the passenger seat and cargo bag The maximum weight capacity for the cargo car rier is 30 lbs 14 kg Always secure cargo before operating Do not exceed the carrier weight limit Do not allow a passenger to sit on the seat back or the cargo area l 32 Adjust the backrest to the for ward operator position See page 30 Release the trunk cover latch Lift t
10. Pantone 7427 C FS 10 Touring FST 10 Touring 10 Cruiser ile Owner s Manual or Maintenance and Safety 7 POLARIS The Way Out Pantone 7427 C For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9921087 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 e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instruc
11. Removal 146 Storage 000 147 Battery Replacement MFD 52 Brake Components 129 Brake Fluid 130 Brake Inspection 129 Brake Lever Feel 77 Brake Lever Travel 77 129 Brake System Bleeding 131 Brakes si3 24 late be 77 129 131 Break In Period 84 Bulbs Replacing 132 Cc Cargo Bag Cruiser 32 Cargo Bag Touring 31 Cargo Overload 0 14 Clutch Alignment Offset 134 Clutch Center Distance 134 Clutch Cover Warning 24 Clutch System 134 137 Clutches i iis diss be See eae ate 20 Coolant 0 0 00 cece eee 122 Coolant High Temperature Light 124 Coolant Level 123 Cooling System 122 127 Cooling System Bleeding 125 127 Cooling System Flushing 125 D DC Outlet 12 Volt 33 Digital Display 4 Disabled Operators 14 Drive Belt 20 135 137 Adjustment 135 Condition 135 Deflection 135 Installation 137 Removal 136 D Drive Chain Tension 128 Driver Awareness 16 Driveshaft Bearing Lubrication 113 Driving Downhill 18 Driving in Hilly Terrain 19 Driving on Slippery Surfaces
12. cooling for the engine adequate snow cover is a requirement for operation of your snowmobile Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine A WARNING Inadequate cooling and lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating for prolonged periods on ice hard packed surfaces or roads Operating in Deep Snow If the snowmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the throttle is opened the snowmobile will be able to climb up and over the snow 21 SAFETY O perator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions may become dangerous if operators drive improperly If you re 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 22 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
13. 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 18 23 ft Ibs 24 31 Nm 5 Release the brake lever lock 128 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 77 Brake pads must be replaced when the brake pad material becomes thin ner than the backing plate approximately 1 16 1 5 mm A kit is avail able for replacing brake pads See your dealer A WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 1 5mm Brake Components Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the snowmobile to an authorized Polaris dealer for inspection and adjustment Brake Disc Bleed Screw Blew Sete Brake Disc Brake Line Brake Line Brake Caliper Eras Brake Pad Material Iper Replace when thickness is less than 1 16 1 5 mm Brake Pad 129 MAINTENANCE Brakes Y Brake Fluid A WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rap
14. Attributes Moving the RRSS to a higher position will have the following effects on the suspension e Reduced weight transfer Improved chatter bump ride Improved cornering performance e Increased load carrying capacity 2 up 61 THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is HIGH by adjusting the rear rear scissor stop LOW LOW RRSS The factory setting is the best for most trail riding conditions MEDIUM To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration rotate the RRSS to a lower position NOTE Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride A scissor stop tool is also available from your dealer 62 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments The M 10 suspension has been designed to be very sensitive to rider weight Changes in rider weight of 25 Ibs 11 kg or more might require appropriate changes in settings The following information has been compiled to assist you in tuning your M 10 suspension to its maximum potential and achieve the best possible ride Please take the time to read and understand all the possible adjustments available with this suspen sion Static Sag and
15. Ifthe MODE button is not pressed within ten seconds the gauge will automatically save the new entry Turbo Boost Turbo models Turbo boost pressure displays in the fuel level area of the gauge The word BOOST will also display when this screen is active 48 FEATURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active This screen will always display electrical system voltage level and fuel level if equipped Press and release the SET button to cycle through the Maximum Vehicle Speed Maximum Engine RPM and Service Interval Reminder screens Maximum Speed Maximum RPM a m The gauge automatically logs the maximum L speed and engine RPM even if the history l A program is not active in the display natiu 1 Enter the History Program 5 2 Press and release the SET button until hr JJ of one of the two screens is active Ss p 42 D m NOTE The MPH and RPM values are both E G Cad reset at the same time Reset the val Tl 1 ues before each run to obtain accurate a a a Cl readings MAX RPM p 3 Press and hold the SET button for three H seconds to reset the recorded maximum be 32 E values for both MPH and RPM NOTE Due to electrical noise the MFD may occasionally display MAX MPH RPM values that are not representa tive of actual values 49 FEATURES
16. K Jump Starting 86 88 Knock Sensor Turbo Models 40 L Lamps Replacing 132 Light High Temperature Indicator 124 LA hts ess ess cis eee Ses Soy 132 Lubrication 113 114 M Maintenance Interval Table 100 102 Maintenance Program 99 Malfunction Indicator Lamp 37 Maneuverability 20 MFD Battery Replacement 52 53 MED Components 41 MFD Digital Display Programs 44 52 MFD Settings 42 43 N NOISES 2 26 gt Gott nec ae ie 6 O Oil Engine 103 111 G arcas ueno ssd sea eer 115 116 Oil Breather Element 112 Oil Breather Filter 120 Oil Change 108 111 Oil in System Check 107 Oil Level Check 104 106 Operating in Deep Snow 21 Operation Warning 27 P Parking Brake Lever Lock 78 Passenger Seat Cruiser 32 Passenger Seat Touring 30 Passenger Warning 25 PSA Othe iss Se taincies tune save sas 103 Polaris Products 151 Pre Ride Checklist 74 82 Pressure Cap Warning 24 172 R Rail Slide Wear 142 Rear Rear Scissor Stop 61 Rear To Front Coupling 61 Relay Label 133 Retainers Optional M 10 66 Reverse Operation 94 95 Reverse Warning 26 Rider Capacity
17. MFD Battery Replacement 5 Using needle nose pliers grasp the battery and rotate it so the lead ing edge of the battery is raised away from the battery holder Pull the battery out gently NOTE The battery will not come out of the holder unless the leading edge of the battery is raised Hold the battery compartment not the wires while removing the battery Pulling on the wires will separate them from the battery holder 6 Install a new battery with fingers only 7 Seal the end of the battery compartment using high strength double sided tape between the two compartment halves or high strength single sided tape around the outside of the compartment 8 Make sure the taped seam of the compartment faces the downward side of the wire harness 9 Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable tie was located Make sure the battery wires are not stretched tight Gauge Cleaning 1 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth 2 Clean the back side of the gauge using a clean cloth and a mild soap and water solution Do not remove the electrical connectors or pro tective rubber boot Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source CAUTION To prevent damage to the lens do not use alcohol for cleaning Do not allow chemicals or sprays to
18. Slide Condition 142 Oil Level check before operating if vehicle was tipped 82 74 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 A WARNING Operating the vehicle with worn damaged or malfunctioning components could result in serious injury or death Never start the engine without check ing all vehicle components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience 1 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 Throttle Safety Switch Test the throttle safety switch system before the snowmobile is operated See page 92 for procedure Seat Latches Ensure that the seat latches are securely in place before every use of the snowmobile 75 PRE R
19. back or the cargo carrier 14 SAFETY Operator Safety Excessive Speed A WARNING High speed driving especially at night could result in serious injury or death Always reduce speed when driving at night or in inclement weather Always observe all state and local laws governing snowmobile opera tion and speed limits Always be alert and pay attention to the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your snowmobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your snowmobile to a stop in the distance illu minated by the headlight 15 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles posts or other obstacles Be especially alert if you re snowmobiling after dark Always be on the alert for wire fences Single strands are especially dangerous since there may be a great distance between posts Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your snowmobile will drown out the sound of approaching vehicles L
20. boot to Spring expose the bulb 3 Push down on the spring Harness to release it from the housing 4 With the wire harness attached to the bulb withdraw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs 1 Hold the bulb by its metal base and install it into the wire harness 2 Insert the bulb into the housing 3 Connect the spring to the housing 4 Carefully flip the spring back into the housing placing it around the wire harness 5 Reinstall the plenum covering on the headlight assembly 6 Adjust headlight aim See page 31 Replacing Taillight Bulbs 1 Remove the screws securing the taillight lens 2 Push the bulb in and twist counterclockwise and replace the bulb 3 Replace the taillight lens 132 Electrical System MAINTENANCE RELAY LABEL FUSE LABEL ITEM POWERED START SOLENOID Ground side of start solenoid RELAY SPARE 20A None ACCESSORY Accessory plugs EMERGENCY CHASSIS SPARE 30A RELAY High beams Low beams CHASSIS Handwarmers 30A Thumbwarmer Tail lamp Brake lamp Alternator coils Exhaust sensor aGEUSOR oane REVERSE SHIFT Reverse shift Accessory projector beam relay Diagnostic plug IGNITION 20A Ignition relay power Cam phase sensor EFI ECU hold on power RELAY Reverse limit switch Forward limit switch Start relay coil EFI Chassis relay coil 20A
21. by a defective engine component Failures caused due to improper adjustments Failure due to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of unauthorized parts or modifications Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related throttle body parts are covered The fuel pump is covered Clutches and related clutch parts including but not limited to the drive belt are excluded from coverage Electrical components are excluded from coverage Gearcases and transmissions are excluded from coverage 164 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 Ind
22. come into contact with the lens Immediately clean off any gasoline that splashes on the gauge during refueling 53 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension IFS Break in the suspension for approximately 150 miles 240 km before making any fine tuning adjustments Settings will vary from rider to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow condi tions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Front shocks and springs 3 Rod ends 4 A arms IFS Adjustment Options Front shock spring preload e Optional springs e Toe ski alignment see page 144 e Camber see your dealer 54 THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions Please see your Polaris dealer for assistance before attempt ing to adjust preload Increasing the spring preload too much may adversely affect the han dling of the snowmobile and the performance of the rear suspension Decreasing the spring preload too much may allow the lower spring r
23. death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed snow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter NOTE Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement NOTE Some models are equipped with single skags Some models are equipped with dual skags 1 Raise and support the front of the snowmobile so the skis are approximately 6 15 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a skag Skag 145 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explo sion 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 Battery Removal 1 Remove the left side panel 2 Disconnect the battery hold down strap 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery ca
24. distance traveled Both odometers can be reset to zero 1 Enter the Performance Program 5 ee 2 Press and release the SET button Z nO until the desired trip screen is active 3 Press and hold the SET button for two seconds to reset the trip odometer to zero 4 Press and release the SET button to cycle through additional screens 44 FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge The fuel symbol and the last fuel bar on the MFD gauge if equipped will blink when the fuel level reaches 1 8 of a tank The Trip F odometer records distance traveled and the fuel symbol continues to blink until enough fuel is added to raise the level above 1 4 of a tank The Trip F odometer will automatically reset to zero after refueling 45 FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting if equipped 1 Enter the Performance Program Lic st 2 Press and release the SET button l Li until the clock screen is active RPM Fm 3 Press and hold the SET button for og five seconds 256 amp 4 When the hour starts flashing press the SET switch once to advance one hour NOTE Press and hold the SET button to advance the hours quickly 5 Press and release the MODE button to save the hour The
25. form prior to delivery may void the warranty Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage Use of the recommended Polaris products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur during the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con sideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components Batteries Circuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal 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 da
26. idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury A WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function CAUTION Brake fluid will damage decals paint and some plastics Always wipe up spills immediately Replace brake fluid at least every two years with Polaris DOT 4 high tem perature brake fluid See page 151 for the part numbers of Polaris products Sight Glass The brake fluid level can be seen through the fluid level indicator a plastic sight glass in the master cyl inder reservoir If the fluid is suffi cient the sight glass will be black If the sight glass is any color other than black add brake fluid 130 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 A 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
27. of your owner s manual You are responsible for ensuring that the specified maintenance is per formed including the emission related maintenance outlined in these sections of the manual You must inspect the air intake system on your snowmobile prior to each use including the airbox foam filter and hood foam filters and clean these components as necessary Polaris considers the specified maintenance for the spark plugs oil changes air intake system and exhaust valves to be critical emission related maintenance The speci fied maintenance for the fuel filter is recommended additional emission related maintenance Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 98 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beginning on page 168 The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 miles 800 km and 1500 miles 2400 km These inspections should be per formed by a qualified service technician For continued optimum perfor mance and component life continue maintenance checks at 1500 mile 2400 km intervals All necessary replacement parts and labor incurred with the exceptio
28. points elevate front of machine Set static sag see page 58 Install single skag see your dealer Increase IFS preload if equipped see page 55 Rotate RRSS to higher position see page 62 Steering is heavy e Make sure spindles and all steering components turn freely Check ski alignment see page 144 Check skags and skis for damage Set static sag see page 58 156 TROUBLESHOOTING M 10 Suspension Troubleshooting Problem Solution Perform only one change at a time Rear suspension e Increase FRA position see page 65 bottoms too easily Install appropriate optional center retainer on rear track shock see page 66 e Increase front track shock coil spring preload by adding washers Revalve rear track shock compression damping see your dealer Check track tension see page 140 Rear suspension rides too stiff Decrease FRA position see page 65 Install appropriate optional center retainer on rear track shock see page 66 Decrease front track shock coil spring preload by adding washers Revalve rear track shock compression damping see your dealer Check track tension see page 140 Front end pushes Check for worn skags Check for binding suspension shafts and grease all pivot points Shorten front limiter strap Install single skags see your dealer Steering is heavy Check skags and skis for damage Check ski alignment see page 144 Make su
29. sensor must be reconnected or repaired to regain full power NOTE The check engine light will illuminate if the sensor fails or becomes dis connected 40 Instrumentation FEATURES MFD Component Identification Item a Analog Gauge Digital Gauge Check Engine Indicator High Temp Indicator Brake Indicator Reverse Indicator N OO oy A OJ N High Beam Indicator Digital Display Identification Item 1 RPM or Speed Altitude if equipped Service Interval 2 Electrical System Voltage Level all models and M 10 ACE Suspension Adjustment RIDE Cruiser only 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute 4 Air Temp if equipped Engine Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers 6 Hours Trip 1 Trip 2 Trip F Service Label Altitude Label 7 Fuel Level FS or Turbo Boost Turbo models l pepa 41 FEATURES Instrumentation MFD Settings The MFD control switch allows you to set the MFD display to your pref erences The rocker switch has a MODE button top and a SET but ton bottom Specific instructions are outlined on the following pages MED settings can be made with the engine running or with the engine off If the engine is off make sure the stop switch is pressed down and turn the
30. standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 148 MAINTENANCE Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 151 for the part numbers of Polaris prod ucts Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The snowmobile should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Battery Maintenance Remove the battery and recharge it as outlined on page 148 Store the battery in a cool dry place Cont
31. the gas tank or fuel line Loading machines onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine com pletely onto the trailer Push and pull it to finish loading if nec essary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch engagement Use fast aggressive throttle to engage clutch Wrong or missing belt Always use the recommended belt Improper break in Always break in a new belt and or clutch by avoiding aggres sive or high speed operation during the break in period 158 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty informa tion contained in this manual Contact your Polaris dealer for replace ment parts service or warranty Your dealer receives frequent updates on changes modifications and tips on snowmobile maintenance which may supersede information contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information a Serial number Model number Dealer name Date of purchase Details of trouble experienced Length of time and conditions of operation ON te ce IND 7 Previous correspondence Use th
32. 3 Shake or pat the filter to clean it or install a new filter Do not attempt to clean the filter with liquids Foam Oil Breather Filter Clean or replace the breather element at each engine oil change See page 112 Clean the element if the snowmobile has been tipped on its left side three times 120 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 100 A WARNING Hot exhaust system parts can cause serious burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Allow the engine and exhaust system to cool completely Open the hood 3 Inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets 4 Replace any damaged or missing components 5 Clean the plastic surfaces next to the muffler with aerosol Carbure tor and Throttle Body Cleaner NOTE See page 151 for the part numbers of Polaris products 6 Close the hood 121 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60 40 mixture of ethylene glycol and distilled water This mixture provides protection against freezing Contact your dealer if greater protection is required Use Premium 60 40 anti freeze coolant which is already premixed and ready to use Do not dilute with water Never exceed
33. 8 Nosepan Skis Front Bumper do not use for pulling or dragging the snowmobile Hood Headlight Windshield Storage Compartment or Cargo Bag Operator Seat Passenger Seat Backrest Passenger Grab Handle Grab Handle Heater Switch Taillights Rear Bumper Snow Flap Track Suspension Ooaron N 10 11 12 13 14 15 16 17 FEATURES MFD Display 1 Mirrors Rider Select Fuel Filler Cap Handlebar Hood Hold Down Straps Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button MFD Control Headlight Dimmer Switch Parking Brake Lock Brake Lever Engine Stop Switch Throttle Control M 10 ACE Suspension Adjustment Switch Cruiser Ignition Switch 29 FEATURES Backrest The backrest is adjustable for either Raise Lower operator or passenger use See page Cj t 32 for passenger seat installation instructions 1 Loosen the upper adjustment knobs to raise or lower the backrest 2 Loosen the lower adjustment knobs to move the backrest for ward for operator use or rear ward for passenger use 3 Always tighten the knobs securely after adjusting M 10 ACE Suspension Adjustment Switch A switch on the console above the ACE Suspension ignition switch allows you to adjust Adjustment Switch the M 10 ACE suspension with the MED control switch See page 69 for instructions Operator Passenger 30 Adjustable Headlights
34. IDE INSPECTIONS Before Starting the Engine Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions Under no circumstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile 1 Steering System A WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage NOTE If your snowmobile is equipped with RIDER SELECT perform this check in both the full up and full down steering positions 76 PRE RIDE INSPECTIONS Before Starting the Engine y Brakes Always check the following items for proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the handgrip than 1 2 1 3 cm A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 131 Brake Lever Feel If the brake lever feels spongy when
35. INTENANCE O Perform Service INITIALLY ak amp X Replace 5 Miles km T gS gt amp we z M of Item Pg Instructions Oo 150 500 1500 see referenced pages 240 800 2400 Coolant Hoses Inspect replace if worn or o o 0 damaged Heat Exchangers Inspect replace if damaged o o o Fuel Lines 119 Inspect replace if worn or o o o damaged Battery 146 Clean terminals test volt o 0 o age Track Tension 140 Verify tension adjust as o o o needed Handlebars Verify alignment adjust as o o o needed Drive Chain 128 Verify tension adjust as EVERY needed Rear Track Shock Inspect covers and caps for EVERY M 10 wear or damage replace as needed Gearcase Oil 115 Check at 500 mi 800 km oO EVERY change every 1000 mi 1000 1600 km 1600 Rear Suspension 114 Lubricate pivot shafts more 0 oO often in wet snow condi tions Bearings 113 Lubricate drive shaft and 0 o 149 jackshaft bearings Throttle Cable 113 Lubricate oO 0 Clutches 134 Verify offset alignment fe o inspect for wear residue loose bushings see your dealer for all service Drive Belt 135 Check tension and condi oO o tion replace if worn or dam aged Air Filter 120 Inspect for oil and dirt 0 o replace as needed Oil Change 108 Replace oil and clean the X x 412 foam oil breather element 101 MAINTENANCE Periodic M
36. LL CHART F SAFETY WIND CHILL CHART C Wind Actual Thermometer Reading F oe 40 35 30 25 20 15 10 5 0 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 1 5 11 16 22 28 34 40 46 52 57 63 10 34 27 21 15 9 3 4 10 16 22 28 35 41 47 53159 66 72 15 32 25 19 13 6 0 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 25 29 23 16 9 3 4 11 17 24 31 37 44 51 58 30 28 22 15 8 1 5 12 19 26 33 39 46 53 35 28 21 14 7 0 7 14 21 27 34 41 48 40 27 20 13 6 1 8 15 22 29 36 43 50 45 26 19 12 5 2 9 16 23 30 87 44 50 26 1912 4 3 10 17 24 31 38 45 4 11 18 60 25 17 10 3 4 11 19 26 33 40 Frostbite in gt gt 30 min 10 min Wind Actual Thermometer Reading C Speed 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature C Calm 5 2 1 4 7 10
37. OTE During bleeding air pockets will bubble to the surface Add coolant after these air pockets have surfaced making sure that the coolant level remains visible in the filler neck 8 With the engine idling and while making sure that the level in the filler neck remains visible observe the bleed return If the system is self bleeding properly coolant will be pumped out of this hole NOTE Coolant flow may be erratic spitting misting for the first few minutes of bleeding but as long as the procedure is followed and coolant is visible in the filler neck the system should bleed properly 126 MAINTENANCE Cooling System Bleeding the Cooling System 9 10 11 While observing the bleed return and making sure the coolant level is visible in the filler neck observe the engine temperature in the digital display The temperature should rise steadily indicating that the system is bleeding properly If the temperature does not rise after approximately one 1 minute repeat steps 8 and 9 Make sure steps 8 and 9 are followed precisely during the entire bleed procedure Reinstall the coolant pressure cap when engine temperature reaches 120 48 C Do not stop the engine at this step NOTE Ifthe engine is stopped before the cap is installed a large amount of 12 13 14 15 16 17 coolant will flow out of the filler neck and the entire bleed procedure will have to be performed again While the eng
38. RCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY 166 WARRANTY Snowmobile Engine Emissions Limited Warranty Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This lim ited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical emissions related maintenance is not performed Performance of other scheduled main tenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified repair shop or qualified person may maintain replace or repair the emis sion control devices or systems on your snowmobile Polaris recommends that you con tact an authoriz
39. Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover WARNING Do not operate with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service clutches yourself See your dealer Pressure Cap Warning This warning decal is found under the hood on the pressure cap of appli cable liquid cooled models WARNING Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI 24 SAFETY Safety Decals and Locations No Passenger Warning Snowmobiles designed for a single rider only have a warning decal on the left console WARNING DR No Passenger This vehicle is designed for Warning a operator only One Passenger NO PASSENGER Warning Passenger Warning Snowmobiles designed for an operator and one passenger have a warning decal on the left console For more information on operating with a passenger see page 13 WARNING This vehicle is designed for operator and ONE passenger only Track Warning 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 S ar SSS Uh wel Track Warni
40. Ride Height Settings Static sag describes the difference in height of the rear bumper from the suspension s fully extended position to its loaded height with the rider seated on the snowmobile Too much sag will result in bottoming and too little sag will result in reduced rider comfort Sag is used to control ride quality and rebound travel On this suspen sion sag is controlled by two settings the full range adjuster FRA position and the rear spring preload 63 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Static Sag and Ride Height Settings 1 To check sag raise the rear bumper until the suspension is fully extended the rear shock will not extend any further Measure the distance from the ground to the bottom of the bumper dimension X as shown in the illustration Record the measurement 2 Have the rider sit on the snowmobile and bounce up and down on the seat a few times to set in the suspension While the rider remains seated measure the distance from the ground to the top of the bumper dimension Y and record it 3 Subtract Y from X and you will have the SAG setting X Y sag setting Example 21 17 4 The correct amount of SAG for the M 10 rear suspension is 3 4 inches 8 10 cm If the measured sag is incorrect adjust the FRA position and rear spring preload See pages 65 and 69 Suspension Recommended Sag Adjustment hae M 10 136 3 4 inches 8 10 cm Rear Spring 66 P
41. a 60 antifreeze 40 water mixture See page 151 for the part numbers of Polaris prod ucts NOTE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part A WARNING Steam and hot liquids will cause serious burns to your skin Never remove the pressure cap when the engine is warm or hot 122 MAINTENANCE Cooling System Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are COLD FILL e Coolant bottle or overflow tank e Filler neck e Pressure cap e Connecting hoses Always maintain the coolant level at the COLD FILL mark on the cool ant tank when the engine is cold CAUTION Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recom mended 123 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool ant temperature becomes too hot for safe continued operation of the engine Stop the snowmobile and allow the engine to cool Place snow on the coolers to help cool the engine If coolant is
42. able beginning on page 100 Always change the oil filter whenever changing oil See page 151 for the part numbers of Polaris products Performance Synthetic 4 Stroke PS 4 Oil Polaris recommends the use of Performance Synthetic 4 Stroke oil PS 4 or PS 4 Plus for this engine PS 4 has been specially formulated for use in Polaris 4 cycle snowmobile engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection Oil may need to be changed more frequently if Polaris PS 4 oil is not used Follow the manufacturer s recommendations for ambient tempera ture operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 103 MAINTENANCE Engine Oil i Oil Level Check NOTE Read the entire oil check procedure before checking the oil level The oil level will rise as engine temperature increases The oil level will be lower when the engine is cold To obtain a proper oil level reading the snowmobile must be on a level surface and the engine coolant tem perature must be between 145 and 160 degrees F 63 71 degrees C NOTE Always check the oil level before operating a snowmobile that has tipped over CAUTION Severe engine damage may occur if procedures for checking the oil level are not followed precisely Always check the oil wi
43. aintenance Interval Table O Perform Service nmay lag amp X Replace 54 Miles km T we gt amp WSs zl of Item Pg Instructions Oo 150 500 1500 see referenced pages 240 800 2400 Engine Mounts Inspect replace if worn or 6 o damaged Spark Plugs 117 Inspect condition gap 0 o replace as needed Exhaust System 121 Check muffler and pipe con oO 0 dition replace damaged or missing components clean plastic surfaces Hoses Inspect for wear damage oO 0 and proper routing replace as needed Brake Pads Disc 129 Inspect replace if worn or oO o damaged Fuel Vent Lines 119 Inspect replace if worn or oO o damaged Ski Toe 144 Verify alignment see your oO o dealer for adjustments Cooling Fins Shroud Inspect and clean oO o Valve Lash See your dealer 1500 2400 FS Specifications a Intake 0 08 0 15 mm EVERY Exhaust 0 15 0 20 mm 10 000 16 000 FST Cruiser Specifications THEREAFTER Intake 0 08 0 15 mm Exhaust 0 18 0 23 mm Cooling System 125 Bleed the cooling system EVERY inspect for leaks and proper 2000 circulation 3200 Fuel Filter 119 Inspect replace as needed EVERY 2000 3200 Rear Suspension See your dealer EVERY Shock Oil l1Q SwitchBack M 10 5200 102 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance T
44. al corrosion or defects in parts components or the snowmobile due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REM EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLI GENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclu sion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 161 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 incons
45. and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage NOTE If your snowmobile is equipped with RIDER SELECT perform this check in both the full up and full down steering positions Driving Downhill When riding downhill shift your weight to the rear of the snowmobile and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the snowmobile and keep it from rolling freely downhill A WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brake failure Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death 18 SAFETY Operator Safety Driving on Slippery Surfaces A WARNING Never attempt an abrupt change of direction when operating on slippery sur faces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces st
46. assistant to help with the oil change 1 Position the vehicle on a level surface 2 Make sure the engine coolant temperature is between 145 and 160 degrees F 63 71 degrees C If necessary start the engine and allow it to idle until the coolant temperature is within the specified range 3 Turn the engine off A CAUTION Hot oil and a hot exhaust system and engine can cause serious burns Do not allow hot oil or hot components to contact skin 4 Open the hood and remove the left side panel NOTE Clamp orientation is critical to the proper operation of the system Be aware of clamp placement and orientation when removing hose clamps Always reinstall hose clamps in the same location and posi tion 108 MAINTENANCE Engine Oil Oil Change 5 6 10 11 12 13 14 15 16 17 Remove the oil return hose from the oil tank Have an assistant place the end of the hose into a drain pan Disconnect the 2 pin WHITE RED and GREEN WHITE starter motor solenoid control switch harness connector located near the battery Rotate the plug 90 degrees and reinstall it with the WHITE RED wire connected Insert the male pin of the jumper harness into the starter solenoid s female port Open the handlebar cover Locate the 3 pin connector with the BROWN and RED WHITE wires Plug this connector into the 3 pin connector of the jumper harness Open the fuse box and remove the 20A EFI fuse from the
47. bile 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 e Each repair visit after the first twelve months of standard warranty coverage is subject to a 50 deductible e The free Second Year Engine Service Contract applies to the first 5 000 miles or two 2 calendar years from date of purchase whichever comes first Tampering with the odometer shall void all warranties service contracts No extensions to coverage under this engine service contract can be given Used snowmobiles are not eligible under this program e Snowmobiles used for commercial purposes or for racing are excluded from coverage Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage 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
48. ble last 5 Lift the battery out of the vehicle Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can dam age the battery and result in a shorter life It can also hinder vehicle per formance Follow the battery charging instructions on page 148 before installing the battery Ensure that the battery is fully charged Set the battery in the battery holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Attach the hold down strap Verify that cables are properly routed pol ee a Reinstall the left side panel 146 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected dur ing the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installa tion o
49. ck cooling 139 MAINTENANCE Track Tension A WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine run ning Track adjustment is critical for proper handling Always maintain cor rect tension and alignment TRACK TENSION DATA CHART Measurement Suspension Slack Measurement Weight Location IQ Comfort 7 8 1 1 8 2 2 2 9 cm 10 Ibs 16 40 cm M 10 136 7 8 1 1 8 2 2 2 9 em 454ko ahead of rear NOTE Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmo bile and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of olbs the center of the rear idler 4 54 kg wheel NOTE Measure at the point where 16 40 cm the weight is hanging 140 MAINTENANCE Track Tension 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide Idler Shaft If the track needs adjustment 5 Loosen the rear idler shaft bolt 6 Loosen the lock nuts 7 Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the trac
50. coolant temperature is at or below 122 F 50 C OR Engine coolant temperature is at or above 203 F 95 C Intake manifold air temperature is at or below 32 F 0 C OR Intake manifold air temperature is at or above 158 F 70 C Overboost condition occurs Check Engine light will flash 38 Fuel octane is too low use the recommended fuel Operator may feel loss of power FEATURES Engine Management System The engine management system is programmed to alert the rider when coolant temperatures reach higher than normal levels The system responds by taking the following sequential steps to alert the rider 1 The High Temperature Indicator on the MFD will flash To cool the engine drive the snowmobile into soft snow so that it comes into contact with the heat exchangers on the snowmobile Alternately you can stop the snowmobile and pack snow or ice onto the heat exchangers to bring the temperature of the engine down 2 The High Temperature Indicator on the MFD will flash and the engine will misfire or stutter If you do not notice the flashing indicator on the MFD or do not suffi ciently cool the snowmobile the engine will misfire to alert you to look at the MFD and take action Again driving the snowmobile into soft snow or packing snow onto the heat exchangers should cool the engine 3 The engine will stop If the engine reaches an extreme temperature where damage becomes possible the
51. ded oil as needed Do not overfill 5 Reinstall the dipstick 115 MAINTENANCE Gearcase Oil Gearcase Oil Change The drain plug is located on the bottom of the gearcase NOTE Polaris does not recommend tip ping the snowmobile onto it s side for service Any time the snowmo bile is tipped onto it s left side always check the oil level and clean the foam oil breather ele ment See page 112 1 Position the vehicle on a level sur face 2 Remove the drain plug and drain the oil into a drain pan Allow the oil to drain completely NOTE The sealing surfaces on the drain plug and the gearcase should be Drain Plug clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 6 10 ft Ibs 8 13 Nm Remove the dipstick Add 9 oz 266 ml of the recommended oil Do not overfill Reinstall the dipstick making sure it is seated properly ON TS 116 MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization CAUTION Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile e Use recommended spark plugs
52. difications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation A 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 ser vice and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation A WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments
53. dvent of sus pension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other There are two types of rear suspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm causing it to compress and raise the rear suspension up as one allowing the suspension to hit the bump only once and reducing kickback The factory setting is usually adequate for all riders and conditions 60 THE PERFECT FIT IQ Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop RRSS The rear rear scissor stop RRSS couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen dent movement between the rear torque and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS
54. e distance between the ground and the rear bumper at the exact location used for measure ment X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload Suspension Recommended Sag Adjustment ae IQ Comfort 4 5 inches 10 13 cm Torsion Spring 59 136 Preload NOTE This is only an initial setup and final spring preload may vary based on rider preference and riding conditions NOTE Accessory springs with a higher load rating are available for Touring models with the IQ Comfort rear suspension P N 7043368 left and P N 7043369 right Please see your dealer for availability 58 THE PERFECT FIT IQ Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload rotate the three position cam using the engine spark plug tool Adjustment is easiest when the cam is rotated from low to medium and then to high Rotating directly from low to high will require significantly more effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Soft Medium Firm 59 THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the a
55. e engine See the Engine Overheating troubleshooting section on page 155 See your dealer Drive clutch binding See your dealer Incorrect clutching See your dealer Driven clutch malfunction See your dealer Worn drive belt Replace with the recommended belt Excessive belt sheave clearance See your dealer Loose torque stop Inspect and adjust Other mechanical failure See your dealer 154 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Overheating Probable Cause Solution Inadequate snow conditions Stop and cool the engine Drive into snow frequently to prevent overheating See page 21 Low coolant Stop and cool the engine Check the cool ant level See page 123 Check for leaks Bleed the system if the coolant level is extremely low Restricted air flow to radiator Stop and cool the engine Clean snow and debris from the radiator Harsh Drive Clutch Engagement Probable Cause Solution Worn drive belt Replace with the recommended belt Excessive belt sheave clearance See your dealer Drive Belt Turns Over Probable Cause Solution Incorrect belt Replace with the recommended belt Incorrect clutch alignment See your dealer Broken or loose engine mount See your dealer Drive System Noise Probable Cause Solution Broken drive clutch co
56. e page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 763 417 8650 Canada 1 204 925 7100 159 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 160 WARRANTY Limited Warranty Polaris Sales Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIM ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty The 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
57. eading will be accurate for only one to three minutes after turning off the engine If the oil check isn t completed within three min utes reinstall the dipstick Restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank 105 MAINTENANCE Engine Oil y Oil Level Check Fill mark for oil changes at specified coolant temperature 8 Maintain the oil level in the safe operating range between the upper and lower marks on the dip stick If the level is low add the recommended oil in small increments about 2 ounces 60 ml and recheck the level NOTE Ifthe level is low or when changing the oil add only enough oil to bring the level to the bottom of the safe operating range on the dip stick 9 Ifthe level is high remove 2 ounces 60 ml and recheck the level CAUTION Do not overfill the oil tank Engine damage may occur Always add oil in small increments and recheck the level to avoid overfilling 10 Recheck the oil level if oil was added or removed making sure the coolant temperature is within the specified range If necessary con tinue adding or removing oil until the level is in the safe operating range 106 MAINTENANCE Engine Oil Oil in System Check l 2 Position the vehicle on a level surface Start the engine and allow it to idle 3 5 seconds no more than 5 seconds Turn the engine off Remove the dipstick Clean the dips
58. ealer Suspension Performance Tips e 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 In deep snow a new rail slide will offer improved performance over a worn slide It can also improve top speed e Polaris offers track kits for improved flotation in deep snow See your dealer for assistance NOTE Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension com ponents Grease rear suspension pivots before adjusting the rear sus pension Refer to the suspension lubrication information beginning on page 113 57 THE PERFECT FIT IQ Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the rear suspension torsion spring preload measure the distance between the ground and rear bumper This is measurement X Take the first measurement with no rider and with the rear suspension at full extension lt _x gt NOTE 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 th
59. ease the MODE MLES pS button to increase the ACE set AA 44 ef ting for a firmer ride 5 Press and release the SET button to decrease the ACE setting for a softer ride NOTE Each time the MODE or SET button is pressed the ACE suspension will adjust one position The RIDE display indicates the new position and the former position by flashing the bars between the two positions one bar for each level of adjustment Press and hold the MODE or SET button for 3 or more seconds to adjust the suspension to the fully firm or fully soft position The suspension is fully adjusted when no bars flash in the RIDE display 6 Return the console switch to the gauge setting to operate the MFD gauge 69 THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position See page 34 Use the following steps to adjust handlebar angle at the handlebar block l NOTE If necessary pry the blocks 3 4 5 70 Remove the handlebar cover to expose the handlebar and the four adjuster block bolts Using a 7 16 wrench loosen the four nuts on the bottom of the adjuster block turn han dlebar to left or right for access to back nuts apart with a screwdriver Adjust the handlebar to the desired height Be sure han dlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right T
60. ed Polaris dealer to perform any service that may be necessary It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law and may result in civil penalties 167 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 1500 mi 2400 km 168 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 169 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 170 A Access Panel Radiator Compartment 31 ACCESSOT ES 2 eee eee 71 Adjustable Steering System 34 36 Air Filter Turbo 120 Alternator Belt Inspection 120 Apparel ceea nuina rs Save ceed 12 Avalanches 200 17 B Backrest sit sspsceisd aie ae oes hs s 30 Battery eee eens 146 148 Charging 147 148 Installation 146
61. eering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces Driving in Hilly Terrain A WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the snowmobile downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the snowmobile pull the rear of the snowmobile around and point the front end and skis downhill Remount the snowmo bile restart the engine release the parking brake and descend the hill carefully 19 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed Any serv
62. emperature is between 145 and 160 degrees F 63 71 degrees C 23 Stop the engine 24 Remove the dipstick from the oil tank Clean the dipstick with a clean shop towel and reinstall it screwing it in completely 25 Remove the dipstick and view the oil level Fill mark for oil changes at specified coolant temperature Safe operating range 110 MAINTENANCE Engine Oil Oil Change 26 Add additional oil to bring the level slightly above the lower mark in the safe operating range on the dipstick See the chart for approximate amounts to add at this step DO NOT OVERFILL MODEL OIL TO ADD AT STEP 26 Ounces Milliliters FS 4 to 16 118 to 473 All FST 24 to 32 710 to 496 NOTE Check the oil level often during the fill procedure to avoid overfilling If the filling and checking procedure is not completed within three min utes reinstall the dipstick Restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank Continue adding and checking the oil until the level is slightly above the lower mark in the safe operating range on the dipstick Do not overfill 27 Reinstall the dipstick 111 MAINTENANCE y Foam Oil Breather Element The foam oil breather element absorbs small amounts of liquid to pro tect sensors within the intake system from damage due to oil ingestion Check the element before each ride Clean or replace the breather ele m
63. ends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends the use of Carbon Clean Plus See page 151 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives should not be used 89 OPERATION Track Warm Up A WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throt tle during warm up or when the track is free hanging Be sure the rear sup port is stable A WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile 90 OPERATION Track Warm Up Follow these steps to ensure proper warm up of the engine drive train and track l Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be approximately 4 10 cm off the ground Start the engine and al
64. ent at each engine oil change Clean the element if the snowmobile has been tipped on its left side three times either during service or while riding as oil may leak into the element CAUTION Operating the snowmobile with a clogged foam oil breather element can result in severe engine damage Always clean or replace the element as rec ommended The foam oil breather element is located inside the airbox 1 Open the hood 2 Release the airbox cover retaining clips and remove the cover Element FS 3 Remove the foam breather element Wash the foam element in soapy water then rinse thoroughly and let dry NOTE If soap and water are not readily available remove as much liquid as possible by pressing the foam element in paper towels or a simi lar absorbent material 5 Reinstall the dry foam element or install a new foam element NOTE Always replace a foam element that is brittle cracked crumbling or otherwise damaged For best performance routinely replace the foam element with every other engine oil change 6 Reinstall the airbox cover Secure all retaining clips 112 MAINTENANCE Lubrication Driveshaft Bearing Fitting Inject grease into the fitting on the speed ometer sensor housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Throttle Cable Lubricate the throttle cable li
65. etainer to fall off 55 THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving The shocks can be revalved if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness A WARNING Changing shock valving requires special tools and a sound knowledge of mechanical theory tool use and shop procedures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme cau tion when handling high pressure service equipment We recommend that this work be performed by a Polaris dealer Front Springs The front spring rates can be adjusted by changing the nitrogen pressure The upper chamber adjusts the main spring rate The lower chamber adjusts preload See your Polaris dealer for more information 56 THE PERFECT FIT Rear Suspension Adjustments Rider weight riding style trail conditions and vehicle speed all affect suspension action Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However all sus pension designs and adjustments involve a compromise or trade off For example a suspension set up for snow cross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bot tom out harshly on a snow cross course Make adjustments to one area at a time so you can evaluate the change For further assistance see your d
66. ever tightly The lock will return to the unlocked position A 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 78 PRE RIDE INSPECTIONS Before Starting the Engine 1 Track Inspection A WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of track dam age and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty 79 PRE RIDE INSPECTIONS Before Starting the Engine i Suspension Inspection Loose nuts and bolts can reduce your snowmobile s reliability and cause needless repairs and down time Before beginning any snowmobile trip a visual ins
67. f a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage 147 MAINTENANCE Battery Battery Charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until the battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging A WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging NOTE Always verify battery condition before and 1 2 hours after the end of charging Charge Time State of Voltage Action Using constant current Charge charger
68. f the cooling system has been serviced or replaced including coolers radiator engine coolant lines and oil cooler A cooling system failure occurs resulting in coolant loss A coolant line has been disconnected for any reason e A coolant leak occurs A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 1 Read the entire coolant bleed procedure before beginning After beginning the bleed procedure do not stop the engine until reaching step 14 2 Move the snowmobile into a well ventilated area Allow the engine to cool completely A WARNING Steam and hot liquids will cause serious burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot 125 MAINTENANCE Cooling System Bleeding the Cooling System 3 Open the hood 4 Remove the coolant pressure cap carefully 5 Slowly pour coolant into the filler neck until the coolant level reaches the bleed return hole on the inside of the filler neck Leave the pressure cap off 6 With the cap off start the engine and allow it to idle 7 With the engine idling observe the coolant level in the filler neck Make sure that the coolant level in the filler neck is always visible When the level falls add coolant A rising level is acceptable N
69. fuse block Reinstall the left side panel Have an assistant use the ignition key to turn over the engine Crank the engine for 15 seconds Wait 30 seconds to allow the starter motor to cool down Repeat steps 12 and 13 four more times for a total of five cycles Reconnect the oil return line to the oil tank Make sure the hose and clamp are properly seated Make sure the clamp is in the correct ori entation Refer to the NOTE following step 4 To prevent oil spillage wait 3 to 5 minutes to allow any oil in the oil filter cap to drain out before removing it While waiting remove the foam oil breather element from the airbox See page 112 Inspect the foam element Clean it with soap and water and let it dry Reinstall it or install a new element if the existing element is dam aged or degraded and unable to absorb liquid 109 MAINTENANCE Engine Oil Oil Change 18 Remove the oil filter cap then remove the oil filter Inspect the o ring and replace it if it s worn or damaged 19 Install a new filter then reinstall the cap Tighten the cap to 18 5 ft Ibs 25 Nm 20 Remove the jumper from the starter motor wiring harness Recon nect the solenoid and the originally installed harness Reinstall the 20A EFI Fuse 21 Remove the dipstick from the oil tank Add 2 quarts 1 9 liters of the recommended oil Reinstall the dipstick 22 Start the engine and allow it to idle for 3 5 minutes Make sure the engine coolant t
70. ghtly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Front Suspension The front suspension and steering components do not require lubrica tion 113 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 100 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the sus pension For more information about suspension lubrication and adjust ments see your Polaris dealer M 10 136 ACE Rear Suspension 114 MAINTENANCE Gearcase Oil 1 Gearcase Oil Check Check and change the gearcase oil at the intervals outlined in the Periodic Maintenance Table beginning on page 100 Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 151 for the part numbers of Polaris products The dipstick is located on the lower front side of the gearcase Maintain the oil level in the safe operating range between the upper and lower marks on the dipstick 1 Position the vehicle on a level surface 2 Remove the dipstick and wipe it dry with a clean cloth Reinstall SAFE Range the dipstick 3 Remove the dipstick and view the oil level Add the recommen
71. h When connecting jumper cables always connect the negative usually black cable last When removing jumper cables always disconnect the negative usually black cable first A WARNING Loose fitting clothing can get caught in the engine when the vehicle is run ning with the hood open This can cause serious injury or death Remove or control all items that could catch in the engine including scarves gloves jackets and clothing straps and hooks NOTE Ifa car or truck battery will be used to jump start the snowmobile turn the engine off A running engine will put out too much electrical current for the snowmobile battery NOTE Never attempt to jump start a discharged battery that is frozen 86 OPERATION Emergency Starting 1 Always wear eye protection when jump starting your vehicle 2 Keep bystanders away from the vehicles 3 Perform the emergency starting procedure in a well ventilated area 4 Position the vehicles close enough for the jumper cables to reach easily between the batteries but do not allow the vehicles to touch each other 5 Lock the parking brakes on both vehicles to prevent accidental movement 6 Open the hood and remove the left side panel 7 Decide which of the jumper cables will be positive usually red or yellow and which will be negative usually black NOTE Never connect a jumper cable to the fuel system or fuel lines 8 Pull back the red plastic boot covering the posit
72. h System 1 Drive Belt Condition Periodically check the condition and tension of the drive belt and always carry a spare Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 158 For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile Drive Belt Deflection Straight Measure belt deflection with both Measure Edge clutches at rest and in their full A neutral position Place a straight edge on the belt and apply downward pressure while measuring at point A This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment TEAM Clutch 1 Loosen the 7 16 jam nut on the belt width adjuster 2 Using a 1 8 Allen wrench adjust the threaded set screw as needed NOTE Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the distance 3 Tighten the jam nut 135 MAINTENANCE Clutch System Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse The snow mobile must be stopped after forward motion to prevent damage to compo nents during belt removal 1 Stop the engine after operating in a forward motion NOTE For easier accessibility make sure the clutch t
73. hart M 10 68 Suspension Front 54 Switch Stop Switch 92 Suspension Adjustment Switch 30 Throttle Safety Switch 92 T Throttle Cable Lubrication 113 Throttle Lever 75 93 Throttle Safety Switch 75 92 Tip Over Inspections 82 Torsion Spring Preload IQ 59 TOWING wcies ceec esc s ges nes pane 96 Track Alignment 142 Track Inspection 79 138 Track Lubrication 139 Track Replacement 138 Track Tension 140 141 Track Warm Up 90 91 Track Warning 25 INDEX T Traction Products 72 73 Transporting the Snowmobile 150 Troubleshooting Drive Belt Wear Burn 158 Engine and Drive Train 152 155 IQ Suspension 156 M 10 Suspension 157 Trunk Cruiser 4 32 Turbo Noise FST 93 V Vehicle Identification Numbers 7 W Warning Labels Decals 24 27 Warranty Engine Emissions 166 167 Wear Strips 0 0 000 73 Weight Transfer 62 Windchill Temperature Charts 23 173
74. he trunk assembly upward and rearward to remove it Install the passenger seat securely Install the cargo bag and secure the straps to the cargo carrier sides Adjust the backrest to the rear passenger position poLARis a FEATURES Passenger Grab Handle On some models the position of the passenger grab handles can be adjusted for rider preference Knob Assembly 1 Unscrew and remove the knob assemblies that secure the grab handles 2 Reposition the grab handles to one of the three available posi tions on the grab handle tube between the operator seat and the passenger seat 3 Reinstall the knob assemblies and tighten securely 12 Volt DC Outlet If equipped use the outlet to power a global positioning sensor GPS heated helmet shield utility light cell phone or other accessories The 12 volt DC outlet is installed in the recoil pocket next to the right hood hold down If you install an accessory outlet on your model always install it in the recoil pocket The fuel filter is installed in the upper console area Do not install an outlet on the upper console 12 Volt DC Outlet A WARNING Serious injury could occur if sparks ignite a fuel supply Do not install an accessory 12 volt DC outlet on the upper console Install the outlet in the recoil pocket 33 FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system if equipped allow
75. heir efforts and operate your snowmobile with consideration for 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 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 lost the ignition switch must be replaced Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number on valve cover Key Number SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bol
76. hicle only outdoors or in well ventilated areas 83 OPERATION Break In Period The break in period for your new Polaris snowmobile is the first 500 miles 800 km of operation No single action on your part is as impor tant as following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient per formance and longer life for these components CAUTION Excessive heat build up during the first 500 miles 800 km of operation will damage close fitting engine parts Do not operate at full throttle or high speeds for extended periods during the break in period Use of non recommended oil may cause serious engine damage Always use the recommended oil for your Polaris snowmobile 1 Fill the fuel tank with the recommended fuel See page 89 2 Check the oil level in the oil tank See page 104 Add oil if neces sary to maintain at the recommended level 3 Drive slowly at first Vary the throttle positions Do not operate at sustained idle 4 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 74 5 During the break in period change both the oil and the filter at 500 miles or before seasonal storage whichever comes first 84 OPERATION Starting the Engine CAUTION Engaging the starter when the engine is running WILL result in serious engine damage especially if the t
77. horized Polaris dealer Do not attempt to clean or service the fuel injectors Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 100 Fuel Lines 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 CAUTION Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly 119 MAINTENANCE Alternator Belt Inspection Inspect the alternator belt condition and tension before each ride 1 Stop the engine 2 Open the hood 3 Inspect the belt for wear cracks or other damage If the belt is worn or damaged install a new belt 4 Grasp the alternator belt and attempt to twist it 5 Ifthe belt rotates 1 4 turn 90 degrees or more as own tighten the belt or install a new belt Air Filter Turbo Inspect the air filter for oil and dirt accumulation at the intervals out lined in the Periodic Maintenance Table beginning on page 100 1 Open the airbox 2 Remove the air filter
78. icing that requires operation without a belt must be performed by your dealer Operation of the engine with the belt removed may result in injury or damage to the engine Intake Silencer Do not operate the engine with the intake silencer or filter removed Damage to the engine may occur if the intake silencer or filter are removed Clutches Do not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the snowmobile into motion but always operate within safety limits and on 2 up machines with respect for a passenger Maneuverability While much control and maneuverability is achieved through the steer ing system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or snowmobiles designed to carry a load or a passenger 20 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models
79. ignition key to the START position briefly to activate the gauge The gauge will illuminate for about 90 seconds Standard vs Metric The MFD will display either standard or metric units of measurement While viewing a screen that displays measurements MPH km h or temperatures press and hold the MODE switch until the unit of mea surement changes about 10 seconds ca mIRE meme a E IF L I Li 5 LI mH lt i P KPH J R 7 a 7 F MILES KM z x J AAN N AANAND T 000033 Diei E E E Uh Wa i ACE Suspension Adjustment IQ Cruiser The MFD control switch also operates the M 10 ACE rear suspension adjustment When the blue ACE adjustment switch on the console is in the GAUGE position the MFD control switch functions the same as on all other FST models When the switch is in the ACE position you may use the MFD control switch to adjust the rear suspension See page 69 for instructions NOTE The engine must be running to make suspension adjustments with the MFD control switch 42 FEATURES Instrumentation MFD Settings Speedometer Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display If the analog display is set to show speedometer read ings the digital screen will automatically display the tachometer option 1 If the analog is set to show the tachometer the digital screen will show the speedometer option 2 To change view
80. imum interval is 250 hours 2 Press and release the MODE button to save the new settings To disable the service interval reminder l Press the SET button once after reaching 250 hours on the display The gauge will display OFF 51 FEATURES Instrumentation MFD Digital Display Programs M 10 ACE Suspension Adjustments Cruiser A switch on the console Adjustment Switch above the ignition switch allows you to adjust the GAUGE M 10 ACE suspension with the MFD control ACE switch See page 69 for 4 instructions MFD Battery Replacement Models equipped with the clock feature have a battery to power the clock If the clock function of the MFD isn t working properly replace the battery Replace ment batteries are available from your dealer 1 Remove the plenum from the under side of the hood 2 Locate the black battery compart ment It has a red wire and a brown wire with a white stripe It s located about three inches down the main harness from the point where the harness connects to the MFD 3 Cut the plastic cable tie from the outside of the compartment 4 Carefully cut the bottom of the compartment opposite the wires to separate the heat sealed seams Squeeze the corners of the compart ment inward so the battery is visible NOTE Note the orientation of the battery before removing it An incorrectly installed battery will not maintain the clock 52 FEATURES Instrumentation
81. ine temperature is rising allow the engine to idle until the temperature reaches approximately 220 F 104 C Do not stop the engine at this step Feel the coolers at the rear of the snowmobile rear cooler de icers grippers as equipped These components should be warm to the touch indicating the thermostat is open and the entire cooling sys tem is bleeding If coolant is still flowing from the bleed return and there is coolant in the filler neck the system has been bled properly Stop the engine Allow it to cool completely Restart the engine and allow it to idle until the temperature reaches 120 F 49 C Stop the engine Keeping your face and other exposed skin clear of the bleed screw on the PTO side of the head loosen the screw about 1 4 turn You should hear hot air escape Tighten the screw immediately when coolant begins to escape Torque the screw to 9 ft lbs 12 Nm Remove the coolant overflow tank cap Add coolant to the COLD FILL mark on the tank Reinstall the cap 127 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension 1 Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 3 Finger tighten the adjuster bolt until it can no longer be adjusted by hand then back off
82. ing preferences press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change See table below Option Analog Digital Analog Digital P Display Display Screen Screen 1 Speed RPM Blue MPH Blue Backlight 2 RPM Speed Red Red X100RPM Backlight 43 FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro grams Performance Engine and History Each program remains active until you cycle to the next program While any program is active press and release the SET button to cycle through the program s screens Performance Program Press and release the MODE button until the performance program screen is active The default display for this screen includes electrical system voltage unless equipped with ACE suspension adjustment fuel level if equipped and either speed or tachometer whichever is selected See page 43 Press and release the SET button to cycle through the following screens odometer trip 1 odometer trip 2 odometer fuel trip odometer if fuel is low and clock if equipped Use the following procedures to make changes to these screens Odometer Setting The odometer records the vehicle s total distance traveled since manufacture The odometer cannot be reset Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of
83. ion dis places the rear arm as the front arm is compressed This means that when you raise the front limiter strap at some point you will collapse the rear suspension arm which will affect SAG height and reduce rear suspension travel Initial M 10 Suspension Set up Chart These charts are a guideline to be used for initial suspension set ups Your set up may vary based on your desired riding style M 10 136 Rider s Weight with Gear Suggested FRA Range Ibs kg lower number is softer Under 100 45 1 to 11 2 100 150 45 68 1 1 2 to 2 150 200 45 90 2 to 2 1 2 200 250 90 113 2 1 2 to3 250 300 1 13 136 3 to 3 1 2 300 350 136 159 3 1 2 to 4 350 159 4to5 You may prefer an optional rear track middle spring retainer See page 66 68 THE PERFECT FIT FAST M 10 ACE Rear Suspension Adjustments MFD Suspension Adjustments Cruiser A switch on the console Adjustment Switch above the ignition switch allows you to adjust the GAUGE M 10 ACE suspension with the MFD control ACE switch 4 NOTE The engine must be running to make suspension adjust ments with the MFD control switch 1 Place the console rocker switch on the gauge setting 2 Press and release the MODE Ride Setting Display switch until the RIDE icon appears in the voltage display m md area 1 I s 3 Place the console rocker m ae switch on the ACE setting RPM fa 4 Press and rel
84. is not removable once installed so a new insert is needed when installing a new retainer 66 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Static Sag and Ride Height Settings Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a rider prefers more ski pressure for improved steering performance adjustments can be made to the front limiter strap and front arm mount 1 Determine if the rider _ 4 prefers comfort or con a trol Lean toward the 4 setting for comfort and toward the 3 setting for aggressive riding 2 For full hole adjust ments remove the 5 16 Se nut and flat washers from ot 3 the lower attachments of C4 the limiter straps and relocate the straps to the desired position i e move from position 4 to 3 Replace the nut and washer Tighten securely 3 For half hole increments such as 3 4 the limiter straps have slots at the upper pinch bolt These slots allow the bolts to be loosened rather than removed for half step adjustments Re tighten the pinch bolts 67 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Static Sag and Ride Height Settings Ski Pressure 4 There are also two front Upper arm mounting holes in the slide rail that can adjust ski pressure The lower hole increases ski pressure while the upper hole decreases ski pressure NOTE By design the BIASED COUPLE design of the M 10 suspens
85. istent with controlling state law How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris snowmobiles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polaris if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 162 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
86. itch 81 fail see your dealer for ser O Throttle Safety Switch 92 vice 0 Taillight 81 Test for proper operation 0 Brakelight 31 replace bulbs as needed O Headlight 81 oO Skags Wear Bars 145 Inspect for wear or damage O replace when worn Fluid Leaks Inspect for fluid leaks 6 Parking Brake 78 Test for proper engagement O and release see your dealer for service Brake Lever 77 Check lever travel and lever O feel Coolant 123 Inspect level add as oO Brake fluid 730 needed CHANGE EVERY 2 YEARS Hood Latches 76 Secure properly replace if 0 Seat Latches 75 damaged oO Rail Slide 142 Inspect for wear or damage O replace when worn Foam Oil Breather 112 Check pre ride clean or 0 o o o Element replace with each oil change Clean after tipping 3 times onto left side Front and Rear Sus 80 Inspect for missing or loose WEEKLY BEFORE LONG TRIPS pension and Steering bolts and fasteners tighten Fasteners or replace as needed Front Limiter Strap Inspect for wear damage WEEKLY BEFORE LONG TRIPS and missing or loose fasten ers replace as needed Oil Lines Inspect replace if worn or 0 o o o damaged Alternator Belt 120 Check tension and condi oO o o o tion replace if worn or dam aged Throttle Lever 75 Verify smooth and proper oO o o oO 93 Operation Track Alignment 142 Verify alignment adjust as 0 o o o Periodic Maintenance Interval Table MA
87. itch to activate preventing the engine from starting If this occurs return the snowmobile to an authorized Polaris dealer for service Turbo Noise Turbo models Under some conditions when the throttle lever is released the boost pressure dump valve will release pressure and you may hear the sound of escaping air This is a normal occurrence on turbo charged models 93 OPERATION Electronic Reverse PERC 4 Electronic reverse will activate only when the vehicle is stopped and engine speed is below 2500 RPM Maximum vehicle speed when oper ating in reverse will be approximately 12 MPH 19 km h A WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the gearcase or transmission if shifting is attempted when the engine is operating above idle speed e Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle e Look behind the snowmobile before and while backing Avoid sharp turns Apply throttle slowly CAUTION Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your snowmobile is clear 3 Push the yellow reverse but ton on the lef
88. ive terminal of the weak battery Connect one end of the positive jumper cable to the positive terminal of the weak battery 9 Connect the other end of the positive jumper cable to the positive terminal of the charged battery NOTE Make sure that the end of the negative cable by the weak battery is not contacting the snowmobile battery or chassis 10 Connect the other negative end of the jumper cable to the negative terminal of the charged battery 11 Connect the end of the negative jumper cable by the weak battery to the CHASSIS of the snowmobile There may be a small spark when this is done but this is normal NOTE Always be sure that the jumper cables do not interfere with the belts pulleys or clutches on either vehicle 87 OPERATION Emergency Starting 12 Make sure that the engine stop switch is in the UP position 13 Attempt to start the vehicle 14 If the engine does not turn over crank over wait 30 to 60 seconds and attempt to start the engine again If the engine does not start wait another to 2 minutes and attempt to start the engine again 15 If the engine still does not start try adjusting the clips on the jumper cable ends to ensure that they have a good electrical connections Repeat step 14 16 If the engine still does not start remove the jumper cables as out lined in step 17 and transport the snowmobile to an authorized Polaris dealer for service 17 Carefully remove the jumper cables i
89. k 8 Repeat the measurement on the other side of the track NOTE Check more frequently when the snowmobile is new 9 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check track alignment see page 142 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaft bolts Torque to 35 ft lbs 47 5 Nm 141 MAINTENANCE y Track Alignment Periodically check that the track is centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rail 1 Safely support the rear of the snowmobile with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns slowly at least five com plete revolutions Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten locknuts and torque idler shaft bolts to 35 ft lbs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment x Rail Slide Wear For ease of inspection all j Polaris rail slides have a wear limit indicator groove Minimum
90. k plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Exhaust manifold leak Inspect and repair or see your dealer 153 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Runs Irregularly Stops or Loses Power Probable Cause Solution Engine Management System RPM Reduction Mode is activated See causes on page 38 Low battery voltage Recharge the battery to 12 8 VDC Water is present in fuel See your dealer Poor quality or low octane fuel Replace with fresh recommended fuel Loose ignition connections Check all connections and tighten Incorrect spark plug gap or heat range Set gap to specs or replace plug Fouled or defective spark plug Inspect clean and or replace spark plug Kinked or plugged fuel vent line Inspect and replace Clogged air filter Inspect and clean or replace Air flow through intake is too warm Turbo models Engine management system failure Boost is limited until cooler air flows through the intake See your dealer Engine overheating Fuel in crankcase Stop and cool th
91. 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 6 8 cm below the lip of the reservoir open ing Reinstall the gasket and cover 3 Slip arubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles A WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 130 8 Reinstall the gasket and cover 131 MAINTENANCE Lights Removing Halogen Bulbs NOTE Do not touch a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot that will shorten the life of the lamp If fin gers do touch the bulb clean it with an alcohol moistened towel 1 Remove the plenum cov ering from the headlight Bulb assembly 2 Lift the rubber
92. low in the coolant overflow bottle add coolant to the coolant bottle Do not open the radia tor pressure cap A WARNING Steam and hot liquids will cause serious burns to your skin Never remove the pressure cap when the engine is warm or hot or if any part of the cooling system is warm or hot CAUTION Operating the snowmobile when the high temperature indicator light is illumi nated can result in serious engine damage Always stop the snowmobile and cool the engine when the high temperature indicator light illuminates Drive in adequate snow to prevent overheating If you must drive your snowmobile after the high temperature indicator light has illuminated drive in deep snow Drive slowly and stop frequently to allow the engine to cool down Engine performance will be reduced if you continue oper ating when the high temperature light is illuminated 124 MAINTENANCE Cooling System Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine the system should be completely drained every two years and a fresh mix ture of antifreeze and distilled water should be added Have your Polaris dealer perform this service Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main tenance Table beginning on page 100 In addition bleed the cooling sys tem any time one or more of the following conditions exist e A component o
93. low it to warm up two to three minutes Depress the throttle abruptly and allow the track to rotate several revo lutions NOTE It will take longer to warm up the track sufficiently during colder out 4 door temperatures Release the throttle apply the brakes shut off the engine and lower the snowmobile to the ground Grasp the skis by their front loops and move them from side to side to loosen snow and ice 91 OPERATION y Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly Pull the switch up to the RUN position to allow restarting y Throttle Safety Switch The throttle safety switch is designed to limit engine speed to 2400 RPM whenever all pressure is removed from the throttle lever and the throttle cable or throttle valves do not return to the normal closed posi tion If the throttle lever is depressed with a throttle valve error the Mal function Indicator Lamp will come on and vehicle speed will be limited to 18 MPH 29 km h See page 38 for more information about conditions that will cause vehi cle speed and engine speed to be limited A WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not limit engine speed to 2400 RPM when all pressure is removed from the throttle lever during a throttle malfunction immediately push d
94. ls and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tun nel 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 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 CAUTION Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage Center of stud must be at least 1 1 8 2 86 cm from the outside edge of the track 72 THE PERFECT FIT Traction Products i Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain Use carbide skags with studded tracks to help maintain proper vehicle steering and control See page 145 If your snowmobile has carbide skags it may be necessary to add track studs to maintain proper vehicle control Maintain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags sho
95. ly prohibited Printed in U S A 2008 FS IQ Touring FST IQ Touring IQ Cruiser Owner s Manual P N 9921087 2 TABLE OF CONTENTS Introduction 000 ce eee ee 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 sc beter tetesle sues ered Petes 8 This section describes safe vehicle operation and identifies warning decals and their locations POSLUTES 24 206 chee ea wee owe 28 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 0 000 cece eeeuee 54 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 0200005 74 This section explains procedures that must be performed before riding Operation 2656 seca bikes Belew cede ees 83 This section explains proper engine break in operation of features and general operating procedures Maintenance voce he end wae dice cee ewes 97 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris Products 000eeeeees 151 Troubleshooting 0220e seen eee 152 Warranty o oes duuran eee ee ee eee 159 Maintenance Log 000ee0es 168 INGO wie tee oe oie eee eee eee wie 171 INTRODUCTION Important Notes for Owners and Driver
96. m the vehicle if force is applied For your safety do not attempt to use a tow hitch until you ve read the following warnings and understand the proper hitch functions A WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed on a tobog gan or sled make sure the pole is at least four feet 1 2 meters long to pre vent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain con trol of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary CAUTION Towing a disabled snowmobile with the drive belt in place can result in seri ous damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 96 MAINTENANCE Emission Control Informa
97. mage 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 163 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 mo
98. me alcohol or drugs before or while operating this vehi cle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause 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 27 FEATURES w AOLA 10 11 12 13 14 15 16 17 2
99. minutes will begin flashing 6 Set the minutes in the same manner 7 When finished press and release the MODE button to save the new setting NOTE Ifthe MODE button is not pressed within ten seconds the gauge will automatically save the new entry 46 FEATURES Instrumentation MFD Digital Display Programs Engine Program Press and release the MODE button until the engine program screen is active The default display for this screen includes engine hours electri cal system voltage level fuel level if equipped and either engine cool ant temperature air temperature accessory or altimeter accessory Press and release the SET button to cycle through the following screens hour meter engine temperature air temperature available as an acces sory altimeter available as an accessory and turbo boost if equipped Hour Meter a The hour meter records the total hours of A Li engine operation since manufacture This Li l m meter cannot be reset FE ENG F Engine Temperature az hr agf A thermometer measures water temperature giving an indication of engine temperature Air Temperature if equipped am aD 3 The MFD displays actual air temperature in L LI either standard or metric units Li l E 1 Enter the Engine Program AIR oF F 2 Press and hold the MODE switch for ten PF seconds to switch between standard and metric units of measurement 47 FEATURES Instrumenta
100. mponents See your dealer Bearing failure chaincase jackshaft or front drive shaft See your dealer Flat spots on drive belt surface Inspect and replace as needed Loose drive chain Inspect and adjust or replace Worn drive chain broken sprocket teeth See your dealer 155 TROUBLESHOOTING IQ Comfort Suspension Troubleshooting Problem Solution Rear suspension bot Adjust torsion spring preload to achieve proper static sag toms too easily see page 58 e Change torsion spring to stiffer optional spring see your dealer e Rotate RRSS to higher position see page 62 Rides too stiff in rear Check for binding suspension shafts and grease all pivot points Adjust torsion spring preload to achieve proper static sag see page 58 Change torsion spring to softer optional spring see your dealer Check track tension see page 140 Rotate RRSS to lower position see page 62 Machine darts from e Check ski alignment see page 144 side to side Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag see page 58 Check rail slide replace if worn see page 142 Install Accu Trak dual skags see your dealer Front end pushes e Check for worn skags Check for binding front suspension shafts and steering components grease all pivot
101. n 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 NOTE Polaris does not recommend tipping the snowmobile onto it s side for service Any time the snowmobile is tipped onto it s left side always check the oil level and clean the foam oil breather element See page 112 CAUTION Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled if you must tip the snowmobile on its side for service or inspection 99 MAINTENANCE Periodic Maintenance Interval Table O Perform Service 100 needed INITIALLY 3 amp X Replace 5 Miles km T ue zE we zl M o Item Pg Instructions Oo 150 500 1500 see referenced pages 240 800 2400 Engine Stop Switch 81 Test for proper operation 6 Pe Do not operate if switches Ignition Sw
102. n this order A B C D Remove the negative end of the jumper cable from the snowmobile chassis Remove the negative end of the jumper cable from the charged battery Remove the positive end of the jumper cable from the charged battery Remove the positive end of the jumper cable from the weak battery 18 Reinstall the left side panel 19 Close and secure the hood 88 OPERATION Fuel For peak performance Polaris recommends the use of 91 octane or higher fuel Although 87 octane fuel is usable some engine perfor mance will be lost and fuel economy will decrease Do not use lower than 87 octane fuel Do not use fuel containing more than 10 ethanol including E85 CAUTION Operating with obstructed fuel systems will result in serious engine damage Perform maintenance as recommended Damage to the fuel pump will occur if the snowmobile is operated with an empty fuel tank Do not allow the snowmobile to run out of fuel Always refuel when the level is low Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel Level The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank There will be approximately one gallon of fuel remaining Refuel as soon as possible Do not allow the snowmo bile to run out of fuel Fuel System Deicers If you use non oxygenated fuel Polaris recomm
103. n to the ground Jammed or broken chaincase sprocket or chain See your dealer Mechanical failure See your dealer Engine Doesn t Turn Over Probable Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine stop switch is off Lift the stop switch to the ON position Fusible link malfunction See your dealer Fuse panel malfunction Check condition of fuses Replace blown fuses then see your dealer Main relay panel malfunction See your dealer Mechanical failure See your dealer 152 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Turns Over Fails to Start Probable Cause Solution Out of fuel Refuel Water is present in fuel See your dealer Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug See your dealer Water or fuel in crankcase See your dealer Clogged fuel filter Replace the filter Low battery voltage Recharge the battery to 12 8 VDC Poor engine compression See your dealer Mechanical failure See your dealer Engine Backfires Probable Cause Solution Weak spark from spar
104. nate when a problem with engine management system components is detected 1 Turn the engine off and restart it If the light goes off continued operation is permissible 2 Ifthe light illuminates again determine whether engine RPM or vehicle speed is limited then check the charts on page 38 to identify the cause NOTE If you are unable to determine the cause of an illuminated MIL please see your Polaris dealer Flashing MIL Turbo The MIL will flash if an error with the turbo boost regulation system is detected CAUTION If you are unable to determine and correct the cause of a flashing MIL or high temperature indicator serious engine damage may occur with continued operation See your Polaris dealer 1 Verify that all electrical connections are secure 2 Check battery voltage on the gauge and install a new battery if volt age is low see page 52 3 Verify that engine temperature is within the recommended operating range See the Turbo Boost chart on page 38 A flashing MIL may also be caused by damaged or disconnected hoses between the turbocharger and wastegate solenoid pulse valve located on the engine side of the airbox or between the wastegate actuator located under the turbocharger and wastegate solenoid pulse valve If the hose has no damage and is not disconnected see your dealer imme diately CAUTION Serious engine damage may occur if the wastegate reference line is removed or m
105. ng 25 SAFETY Safety Decals and Locations Reverse Warning Operation Warning Reverse Warning Polaris snowmobiles equipped with electric reverse and will have this decal on the console 26 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 e Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to forward 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 consu
106. odified DO NOT remove or modify the wastegate reference line 37 FEATURES Engine Management System To protect the engine the engine management system will limit engine RPM vehicle speed or turbo boost if equipped if the following condi tions are encountered Under extreme overheating conditions the sys tem will also stop the engine entirely to prevent engine damage Vehicle Speed is Limited Cause Function Maximum Speed Result MPH km h Reverse is selected Reverse 12 19 Defective rollover switch Rollover 37 59 T e Throttle stuck throttle Throttle stuck throttle 18 29 vehicle speed lever depressed safety switch high Maximum vehicle speed Max speed limiter 186 299 Engine Speed is Limited Cause Function Maximum RPM Result Reverse is selected Reverse 5300 speed sensor error Defective rollover Rollover 6000 switch speed sensor Engine will mis error fire at higher engine speed Throttle stuck throttle Throttle stuck throttle 5450 lever depressed speed safety switch high sensor error Throttle stuck throttle Throttle stuck throttle 2400 lever at idle position safety switch low Maximum vehicle speed Max speed limiter 8800 speed sensor error Reverse failure Reverse 2500 ECU cannot determine if reverse or for ward selected Turbo Boost is Limited Turbo Indication Result Illuminated High Temperature Indicator Engine
107. ook ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Avoid travelling on frozen bodies of water 16 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain e Take an avalanche class Travel with experienced people Travel on designated trails e Make sure each person is equipped i 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 mountainous 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 17 SAFETY Operator Safety Ice and Snow Build up A WARNING Ice
108. ool access hole is visible between the 11 00 and 2 00 positions of the clutch sheave 2 Turn the ignition key off Wait for the engine to come to a complete stop Access Hole Lock the parking brake Open the hood Remove the left side panel Install an L wrench into the open threaded access hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt Dy ON re 8 136 MAINTENANCE Clutch System Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack NOTE To ensure satisfactory belt life install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the wrench Reinstall the side panel 5 Close and secure the hood 137 MAINTENANCE Track Replacement When replacing the track always install a track having the lug size rec ommended for your model See your Polaris dealer CAUTION Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel Always install a track having the lug size recommended for your model Track Inspection A WARNING Broken
109. orque the front bolts first then torque the rear bolts Torque the bolts to 15 17 ft Ibs 20 23 Nm Reinstall the handlebar cover THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in e Non compliance with government industry requirements e Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service 71 THE PERFECT FIT Traction Products Studs Before equipping your snowmobile with traction products be aware of the laws in your area pertaining to the use of traction products 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 See your dealer about installing studs and or carbides CAUTION Always install wear strips before installing studs Failure to install wear strips may result in cooler or tunnel damage See page 73 Never add shims to the wear strip Track damage will result because of lack of clearance between upper carrier whee
110. own the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Stop Switch This four stroke snowmobile has a self diagnostic check of the throttle safety switch The switch operation is checked through the engine con trol unit for correct operation If a defective switch is detected by the self diagnostics system the MIL will illuminate Take your snowmobile to an authorized Polaris dealer for diagnosis and repair if the MIL is illu minated 92 OPERATION yx Throttle Lever A WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control which could result in serious injury or death If the throttle lever does not work properly DO NOT start the engine If the engine speed limits at 2400 RPM when the throttle lever is released 1 Turn the ignition switch to OFF 2 Visually inspect the throttle cable and throttle body to determine what caused the safety switch to activate 3 Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely 4 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe engine doesn t start take the snowmobile to an authorized Polaris dealer for service NOTE Excessive freeplay in the throttle cable may cause the safety sw
111. pection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 141 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness Carrier and bogie wheel bolts Tightness Front torque arm limiter strap Condition Rail slide Condition 142 Track Tension 140 All rear suspension components Lubrication 114 Ski runner skag Condition Ski spindle bolts Tightness Tie rod end nuts Tightness 80 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 Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF vy Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating yw Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advan tage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile 81 PRE RIDE INSPECTIONS y Tip Over Inspections In the event of a tip over or rollover check the oil level before operating the snowmobile CAUTION Failure to check
112. quired 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 159 165 WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris stan dard limited warranty for snowmobiles Polaris Industries Inc warrants that at the time it is first purchased this emissions certified snowmobile engine meets current U S Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051 1065 and 1068 Polaris warrants that the engine is free from defects in materials and workmanship that would ca
113. ransmission is in reverse Never engage the starter when the engine is running 1 Turn the key to the ON position 2 Pull the engine stop switch up to the RUN position 3 Do not apply throttle when starting the engine unless extremely cold temperatures below 15 F 26 C prevent the engine from start ing NOTE Under these conditions attempt to start the engine without using the throttle If two to three attempts are unsuccessful apply 1 8 to 1 4 throttle while cranking the engine Ease off the throttle immediately when the engine starts Continue to apply just enough throttle to keep the engine running until it idles smoothly 4 Tur the key to START to crank the engine Release the key to the ON position when the engine starts 5 Repeat the cranking procedure as needed until the engine starts NOTE Always allow the engine to warm up to full operating temperature 150 F 65 C before shutting it down Avoid starting and stopping the engine with less than 5 minutes of run time when the engine is cold 85 OPERATION Emergency Starting If the battery is too weak to start the engine and a battery charger is not available the engine can be started using jumper cables and a charged battery from another vehicle Carefully read and follow the instructions on the following pages A WARNING Improperly connecting or disconnecting jumper cables can result in an explo sion and cause serious injury or deat
114. re spindles and all steering components turn freely Verify sag dimension see page 63 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Adjust IFS preload see page 55 Adjust RIDER SELECT see page 34 Machine darts from side to side Check ski alignment see page 144 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer e Make sure skags are straight on skis e Set static sag see page 63 e Install dual skags 157 TROUBLESHOOTING Drive Belt Wear Burn Cause Solution Driving at low RPM Drive at higher RPM Gear the machine down Check belt deflection Insufficient warm up Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Towing at low Do not tow in deep snow Use fast aggressive throttle to engage RPM clutch Riding with high Lower the gear ratio Reduce RPM Avoid riding in high ambi RPM and slow ent temperatures Check for snow ingestion speed 8000 RPM 10 MPH Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine perfor mance Check for fouled plugs or water ice or dirt in
115. reload NOTE Thisis only an initial setup and final spring preload may vary based on rider preference and riding conditions 64 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear suspension adjustment It will have the MOST effect on the rear suspension performance To adjust the FRA 1 Refer to the initial set up reference chart see page 68 to determine the desired FRA position 2 To adjust see page 69 NOTE When the M 10 suspension is new it will take from 25 to 200 miles 40 300 km to properly break in the springs and shocks at which time the suspension will be softer and may require FRA re adjustment 65 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Static Sag and Ride Height Settings Rear Spring Preload If FRA position alone does not allow the setup of the proper amount of sag the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and change the sag See your Polaris dealer for assistance OPTIONAL RETAINERS Retainer Insert standard on M 10 136 Part Number Retainer Part Number Preload Sag 5135077 Least Most 5436109 standard on M 10 128 5134923 Middle Middle 5135080 Most Least NOTE Whenever ordering any of the retainers listed in the chart always order the retainer insert as well The insert
116. rider operation Driving 2 Up Some Polaris snowmobiles are designed for up to two riders A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only A WARNING Control becomes more difficult with two people on board More space is required to make turns and longer distances are needed for stopping Make sure the passenger remains seated behind the driver facing forward with both feet placed firmly on the running boards Slow down and avoid jumping your snowmobile Snowmobiles designed for two riders should never be operated with more than two people on board When traveling with a passenger it s the driver s responsibility to operate the snowmobile safely Slow down Control becomes more difficult with two people on board More space is required to make turns and longer distances are necessary for stopping 13 SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills A WARNING Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled persons to operate this vehicle 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
117. rols and Linkage Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 100 Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All Season Grease or a similar high quality grease to prevent corrosion Clutch and Drive System Remove the drive belt and store in a cool dry location Do not lubricate clutch components except the driven clutch shaft bushing as outlined in the service manual See your dealer 149 MAINTENANCE Extended Storage Engine Protection Fogging the engine is not recommended for this model CAUTION Fogging the engine improperly can result in damage to the sensors Fogging is not recommended Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The snowmobile should be supported off the ground to allow the track to hang freely See illustration Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Always tie the snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition key to prevent loss 150 POLARIS PRODUCTS Part No Description
118. s After reading this manual store it in the snowmobile for convenient ref erence It should remain with the snowmobile when the snowmobile is sold Some of the illustrations and photos used in this manual are general rep resentations Your model may differ Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam paign We encourage state and provincial governments across the snow belt to adopt rigorous safety training programs that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organizations are working together to pro tect our environment Please support t
119. s you to adjust the handlebar position to fit your style of riding Some models have five 5 adjustment positions Other models have seven 7 positions A WARNING If your snowmobile has five adjustment positions do not remove the RIDER SELECT lockout Your Polaris snowmobile has been engineered for this range of adjustability Removing this lockout and using RIDER SELECT posi tion 6 or 7 will result in the handlebars and brake lever contacting other com ponents and interfering with steering and braking This could lead to loss of control resulting in serious injury or death Always be sure that the handle bars and brake lever do not contact any other snowmobile components at any steering position AND at any RIDER SELECT position Do not use RIDER SELECT positions 6 or 7 unless riding conditions require it Operation in position 6 or 7 can reduce vehicle handling for other types of riding and result in serious injury or death 34 FEATURES RIDER SELECT Adjustable Steering System Choosing the Best RIDER SELECT Position Position Riding Style Relaxed Trail Riding Rider weight is slightly behind the center of the snowmobile for comfortable and relaxed riding General Trail Riding Boondocking Deep Snow Riding Rider weight is centered on the snowmo bile providing balance comfort and con trol for both novice and experienced riders This is the recommended position for most riding situations
120. s are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 99 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 or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are capable of traveling at high speeds Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any mo
121. squeezed check the brake fluid level and condition Add fluid as needed See page 130 1 2 1 3 cm Check for the presence of air in the fluid system See page 131 for more information or see your dealer for service A WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess 77 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary for example when parked on an incline for a period of five minutes or less 1 Brake Lever 2 Parking Brake Lever Lock 3 Master Cylinder Reservoir Cover 4 Fluid Level Indicator Lock Engagement To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever NOTE Ifthe brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake l
122. system will stop the engine This condition will occur only after the system has taken both previous steps to alert the rider to the extreme engine temperature If the engine stops and you attempt to restart it while before it has cooled sufficiently the engine will restart and run for two seconds but will immediately stop again NOTE The engine management system will also turn the engine off if the engine reaches an extreme temperature while idling 39 FEATURES Knock Sensor Turbo Models A knock sensor monitors the engine and responds to detonation by auto matically reducing the engine timing and adding fuel This results in decreased engine RPM and performance NOTE Engine performance will be reduced if fuel with a lower octane than 91 is used See fuel recommendations on page 89 Effect The knock sensor system prevents damage to the engine from detona tion while developing the maximum power of the engine safely If the system senses detonation beyond a preset limit it retards ignition timing and adds fuel to reduce the detonation and prevent engine damage When the detonation returns to a permissible level the system will return spark and fuel to normal allowing the engine to run at rated power levels Fail Safe The knock sensor includes a sensor fail safe system to prevent the engine from damage if the sensor fails becomes disconnected or is unable to detect detonation The rider will experience a loss in power The
123. t a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be prepared be warm and be com fortable when riding Be aware of the weather forecast especially the windchill and dress accordingly See the chart on page 23 A WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Always wear an approved helmet and eye pro tection 12 SAFETY Operator Safety Rider Capacity Driving 1 Up Some Polaris snowmobiles are designed for a single rider only A decal on the console of these models indicates single
124. t hand control for one second then release NOTE A reverse light on the instrument panel will indicate that the transmis sion is in reverse 4 Apply the throttle slowly to make sure the transmission is in reverse NOTE Ifthe engine stops running the transmission will be in forward gear when it s restarted i Reverse Button 94 Electronic Reverse PERC 4 Disengaging Reverse 1 Stop the snowmobile and leave the engine idling OPERATION 2 Push the yellow reverse button for one second and release The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in for ward Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 92 for more information about the engine stop switch THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Engine Stop Switch Interrupts ignition circuit All 95 OPERATION Daily Storage At the end of each ride park the snowmo bile on a level surface and support it at the rear with an appropriate track stand The track should be suspended approximately 4 10 cm off the ground Remove the key and cover the snowmobile X 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 fro
125. th the snowmobile positioned on a level surface Always check the oil level when the coolant temperature is within the specified range 104 MAINTENANCE Engine Oil Oil Level Check NOTE The oil level in the oil bottle may drain below the level of the dipstick if 4 NOTE Check the oil level within three 7 the engine has not run for more than a week If you re not sure if there is oil in the system you must first check to make sure oil is in the sys tem before checking the oil level Perform the Oil in System Check procedure on page 107 before performing the oil level check Position the vehicle on a level surface If the engine is cold start the engine and allow it to idle until the engine coolant temperature reaches the specified range Proceed to step 4 If the engine has been running stop the engine and verify that cool ant temperature is within the specified range for performing the oil check Allow the engine to cool if necessary When the coolant is within the specified range restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank Turn the engine off minutes before the coolant tem perature and oil level begin to drop Remove the dipstick from the oil tank Clean the dipstick with a clean shop towel and reinstall it screw ing it in completely Remove the dipstick and view the oil level gt Dipstick NOTE The oil level r
126. the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer set up will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for 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 materi
127. the oil after a tip over can result in serious engine damage Always check the oil level before operating a snowmobile that has tipped over or rolled over NOTE In the event of a tip over or rollover the engine will stop To restart the engine turn the key to the OFF position then restart A WARNING Operating a snowmobile with accident damage can result in serious injury or death Do not operate the snowmobile if vehicle components have been damaged in a collision or tip over Have the snowmobile inspected by an authorized Polaris dealer 82 OPERATION Fuel Safety A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this ve
128. tick with a clean shop towel and reinstall it screwing it in completely Remove the dipstick and ver ify that oil is present anywhere on the dipstick If oil is present continue with the oil level check procedure begin ning on page 104 If oil is not present add 1 2 quart 47 1 of the recommended oil Reinstall the dipstick start the engine for no more than 5 seconds stop the engine and recheck for the presence of oil If oil is present continue with the oil level check procedure begin ning on page 104 If oil is not present add another 1 2 quart 47 1 of oil Reinstall the dipstick start the engine for no more than 5 seconds stop the engine and recheck for the presence of oil If no oil is present on the dipstick check the oil system for leaks and proper operation or see your Polaris dealer 107 MAINTENANCE Engine Oil Oil Change Always change the oil at the intervals outlined in the Periodic Mainte nance Table beginning on page 100 Clean the foam oil breather element with each engine oil change See page 112 Always use the recommended oil See page 104 or see your Polaris dealer about oil change kits which contain a new filter and the recom mended oil NOTE A special jumper harness is required for changing the oil on this vehi cle Please see your Polaris dealer to purchase the harness which will allow you to use the ignition key to turn over the engine without start ing it You may also need an
129. tion Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Emission Control Label Your snowmobile is equipped at the time of sale with an emission con trol information ECI label and a factory installed emissions informa tion hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 The emission control system designation per SAE J1930 is MFI If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a quali fied dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is available to your qualified service technician Reverse if equipped must not be engaged during engine tune ups 97 MAINTENANCE Emission Control Information Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 166 and read the maintenance section
130. tion MFD Digital Display Programs Engine Program Altitude if equipped 7 7 7 s The rider can calibrate the altimeter for current Laas atmospheric conditions Altimeter accuracy fae ae Yay will be 300 ft 91 m after adjustment 1 Enter the Engine Program wl NOTE Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement When ALt displays the program is in the metric mode 2 Press and release the SET button until the altimeter screen is active 3 Press and hold the SET button for five seconds When the digits begin to flash release the button 4 Press and release the SET button once to advance 50 feet 15 m NOTE Press and hold the SET button to advance quickly by 100 foot 30 m increments 5 Adjust the altitude display to within 50 ft 15 m of current altitude NOTE The gauge reads barometric pressure and allows the rider to compen sate for daily fluctuations in air pressure The gauge can adjust the displayed altitude to 1300 ft 896 m from the preset value It will adjust up to 1300 ft 896 m above the calibrated altitude Once the 1300 ft 396 m offset has been reached the next adjustment is 1300 ft 396 m from the calibrated altitude and 50 ft 15 m will be added to the altitude each time the SET button is pressed 6 Press and release the MODE button to set the reading at the adjusted value m e a i NOTE
131. tions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc RIDER SELECT is a trademark of Polaris Industries Inc Copyright 2007 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 express
132. to indicate the minimum per Thickness missible slide thickness A 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 142 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners 143 MAINTENANCE Steering System Ski Alignment A WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment or camber adjustment See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected 10 in 25 4 cm 10 in 25 4 cm 144 MAINTENANCE Steering System i Ski Skags A WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or
133. track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and sup port the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for break age 4 Replace the track if any rod dam age is found 138 MAINTENANCE Track Lubrication A WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other surfaces that have lit tle or no snow for lubrication The slide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty CAUTION High speed use on hard packed surfaces is not recommended for models equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequent slow speed intervals for tra
134. uld be See your dealer s track studding chart Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used Install the appropriate wear strip kit See your dealer Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories CAUTION Whenever wear strips are relocated be sure there s adequate stud clearance to the heat exchangers Lack of clearance may result in damage to heat exchangers 73 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 over Item See Page Drive Belt Condition 135 Steering System 76 Parking Brake Lock Brake Lever Brake System 77 78 129 Throttle Lever 75 Throttle Safety Switch 75 Auxiliary Shut Off Switch Engine Stop Switch 81 95 Ignition Switch 81 95 Taillight Brakelight Headlight 81 Coolant Level 123 Gearcase Oil Level 115 Engine Oil Level 104 Foam Oil Breather Element 112 Suspension Mounting Bolts 80 Skags Wear Bars 73 145 Ski Saddle and Spindle Bolts 80 Hood Straps Latches 76 Seat Latches 75 Rear Wheel Idler Bolts 80 141 Track Alignment Condition 79 142 Rail
135. use it to fail to meet these regulations The warranty period for this emissions certified snowmobile engine starts on the date when the engine is first purchased and continues for 4000 kilometers 2485 miles of vehicle travel 200 hours of operation or 30 calendar months whichever comes first This engine emissions limited warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty This includes compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection components exhaust gas recirculation system components and aftertreatment system components Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE 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 CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WAR RANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF ME
136. ustries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to 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 re
137. with the proper gap Use only resistor type spark plugs e Torque spark plugs to 18 20 ft lbs 24 27 Nm Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds If a plug is fouled replace the plug with a new plug A WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 117 MAINTENANCE Spark Plugs Normal Spark 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 NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil or rich fuel mixture 118 MAINTENANCE Intake Filters 7 is x The intake foam filter limits snow SN ingestion into the intake system y When operating in loose powder Se snow check the top of the foam i filter periodically to remove any ni 4 mss accumulation of snow Fuel Injectors All fuel injector service must be performed by an aut
138. your operating experience Before allowing someone else to use your snowmobile know the extent of their operating skills Check to see if they ve taken a snow mobile safety course and have an operator s certificate For their pro tection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowmobile is not intended for this kind of use Be courteous to oncoming traffic by dimming your headlights and reducing your speed When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic around your vehicle Drive defen sively to avoid accidents Remove the key from the ignition when you leave the snowmobile unattended Operator Safety Windchill Temperature Charts The following information is provided to help you determine when tem peratures become dangerous for riding WIND CHI

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