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Polaris 600 IQ Widetrak Offroad Vehicle User Manual

1. 108 MAINTENANCE Steering System i Ski Skags WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed snow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter Tip Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the snowmo bile so the skis are approximately 6 inches 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 Skag install a skag 109 MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Release the seat latch and raise the seat to access the battery 2 Disconnect the black
2. 24 Clutches sioen aura stevens OE a 20 Coolant iiie eee ee i i 88 Coolant High Temperature Light 89 Coolant Level 88 Cooling System 88 90 Cooling System Bleeding 90 Cooling System Flushing 89 Coupler Lubrication 82 134 D DC Outlet 12 Volt 33 DEP aps ccs eee erento aah dave 34 Detonation Elimination Technology 34 Digital Display 35 Disabled Operators 14 Drive Belt esc occas hasacen eres 20 Drive Belt Adjustment 99 Drive Belt Condition 98 Drive Belt Deflection 98 Drive Belt Installation 101 Drive Belt Removal 100 Driver Awareness 16 Driving Downhill 18 Driving in Hilly Terrain 19 Driving on Slippery Surfaces 19 Driving Responsibly 22 E Electrical System 96 Emission Control Information 76 Emission Control Label 76 Emission Control Maintenance 76 Emissions Limited Warranty 129 130 Engine Break In 65 66 Engine Restarting 68 Engine Stop Switch 72 Environment Preservation 6 Exhaust System 87 Eye Protection 12 F F l cab hecged tena eee nly 69 Fuel Filter 00 86 Fuel Ling eani tener eines 86 Fuel Pump sesde saytass tas pn asua
3. Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during storage Whenever the snowmobile is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fuel 114 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The snowmobile should be supported off the ground to allow the track to hang freely 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 115 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2877882 VES Gold Plus Synthetic 2 Cycle Engine Oil qt 2877953 VES Go
4. To set up the rear suspension torsion spring preload measure the dis tance between the ground and rear bumper This is measurement X Take the first measurement with no rider and with the rear suspension at full extension Tip The rear bumper may need to be raised slightly to fully extend the rear sus pension Next have the rider drop down hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm See page 51 The ideal amount of sag for this rear suspension is 2 5 inches 6 4 cm X Y 2 5 in 6 4 cm With Rider No Rider 50 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload rotate the three position cam using the engine spark plug tool This adjustment is easier to make if tension is relieved from the spring Exercise extreme caution if you use this method of adjustment and follow the steps below carefully WARNING A sudden release of tension from a spring could result in serious injury Wear eye protection and maintain a firm grip on the spring when removing and installing it 1 Grasp the spring
5. Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is avail able to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty and read the maintenance section of your owner s manual You are responsi ble for ensuring that the specified maintenance is performed Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 76 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 131 The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 miles 800 km and 1000 miles 1600 km These inspections should be per formed by a qualified service technician For continued optimum perfor mance and component life continue maintenance checks at 1000 mile 1600 km intervals All necessa
6. 89 40 27 20 13 6 1 8 15 22 29 36 43 50 57 64 71 78 84 91 45 26 19 12 5 2 9 16 23 30 37 44 5158 65 72 79 86 93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 05 55 25 18 11 4 3 11 18 25 82 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 83 40 48 55 62 69 76 84 07 08 Frostbite in gt gt 30 min 10 min 5 min WIND CHILL CHART C Wind Actual Thermometer Reading C Speed E72 7 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 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 4 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 l 36 30 43 47 60 54 58 62 24 1 3 7 11 15 19 22 26 30 34 38 42 45 49 53 57 61 65 32 0 4 8 12 16 20 24 28 32 36 39 43 47 51 55 59 63 67 40 1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 48 1 5 9 13 18 22 26 l 30 34 38 42 46 50 54 58 62 66 70 56 2 6 10 14 18 22 26 31 35 39 43 47 S 55 59 64 68 72 64 2 6 10 15 19 23 27 31 35 40
7. Pantone 425C POLARIS The Way Out Pantone 425C For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922596 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 100 RECYCLED The text is printed on 100 recycled with 40 post consumer waste PCW 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 instructions and recommendations in this ow
8. Some of the illustrations and photos used in this manual are general rep resentations Your model may differ Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam paign We encourage state and provincial governments across the snow belt to adopt rigorous safety training programs that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organizations are working together to pro tect our environment Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment Noise Level One of the most pub
9. engine operation since manufacture This Li l meter cannot be reset i ENG T Engine Temperature D hr 28e A thermometer measures water temperature giving an indication of engine temperature Air Temperature if equipped The MFD displays actual air temperature in either standard or metric units 1 Enter the Engine Program 2 Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement 41 FEATURES Instrumentation MFD Digital Display Programs Engine Program Altitude if equipped The rider can calibrate the altimeter for current atmospheric conditions Altimeter accuracy will be 300 ft 91 m after adjustment 1 Enter the Engine Program Tip Press and hold the MODE switch for ten sec onds 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 Tip Press and hold the SET button to advance quickly by 100 foot 30 m incre ments 5 Adjust the altitude display to within 50 ft 15 m of current altitude Tip The gauge reads barometric pressure and allows the rider to compensate for daily fluctuations in air pressure The gauge can adju
10. 44 48 52 56 61 65 69 73 72 2 7 11 15 19 23 28 32 36 40 45 49 53 57 61 66 70 74 80 3 7 11 15 20 24 28 33 37 41 45 50 54 58 62 67 71 75 88 3 7 12 16 20 24 29 33 37 42 46 50 55 59 63 67 72 76 96 3 8 12 16 21 25 29 34 38 42 47 51 55 60 64 68 73 77 Frostbite in gt gt 30 min 10 min 5 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 Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Warning This warning decal is found under the hood on the air plenum 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
11. If the sight glass is any color other than black add brake fluid See page 92 59 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock Brake Parking Brake only when you want the snowmo Lever Lever Lock bile to remain stationary for exam ple when parked on an incline for a period of five minutes or less Lock Engagement To engage the lock squeeze the brake lever tightly and push for ward on the lock Hold the lock for ward while releasing the brake lever Tip If the brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock will return to the unlocked position WARNING If the parking brake lever lock is partially or entirely engaged while riding the brakes may overheat resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death Always ensure that the lever lock is completely disengaged before operating the snowmobile 60 PRE RIDE INSPECTIONS Before Starting the E
12. Immediately release the button Press the button again up to five times to advance the reminder in 50 hour increments Tip The maximum interval is 250 hours 5 Press and release the MODE button to save the new settings To disable the service interval reminder 1 Press the SET button once after reaching 250 hours on the display The gauge will display OFF 45 FEATURES Instrumentation 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 2 Tip 46 Remove the plenum from the under side of the hood 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 Cut the plastic cable tie from the outside of the compartment 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 the orientation of the battery before removing it An incorrectly installed battery will not maintain the clock IS FEATURES Instrumentation MFD Battery Replacement 5 Tip Using needle nose pliers grasp the battery and rotate it so the lead ing edge o
13. MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page i50 mi 500mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CHASSIS Ski Toe Alignment l l l Suspension Mounting l l l l l Bolts Steering Fasteners l l l l Cc Rear Suspension l l l l l Fasteners Drive Shaft Bearing 82 L L L l Skags Wear Bars 109 l l l l l Ski Saddle Spindle Bolts l l l l l Hood Straps 58 l l l l l Rear Wheel Idler Bolts 105 l l l l l and Nuts Camber Alignment l l l Handlebar Centering l Track Alignment 106 l l l l l Track Tension 104 l l l l l Front Limiter Strap l l l l l Rail Slide Condition 104 l Gearcase Oil 81 l R I R l Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace 80 L Lubricate MAINTENANCE Lubrication Gearcase Oil Level Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 77 Change the gearcase oil after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally To check the oil level place the snowmobile on a level surface The oil level should be between the safe marks on the dipstick 1 See your Polaris dealer for the recom mended oil for your snowmobile Do not overfill Clean the magnetic plug 2 every 500 miles 800 km and whenever checking
14. level if equipped and either speed or tachometer whichever is selected See page 37 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 distance traveled Both UU odometers can be reset to zero 1 Enter the Performance Program a 2 Press and release the SET button c l 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 38 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 zer
15. negative battery cable first 3 Disconnect the red positive battery cable last 4 Remove the battery 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 112 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 Verify that cables are properly routed Lower the seat and secure the latch Oye es ea 110 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 Tip 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 during 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 ap
16. 2 Push down on the spring to release it from the housing 3 With the wire harness attached to the bulb withdraw the bulb from the housing 4 Grasp the bulb by its metal base and carefully separate the bulb from the harness Harness me 94 MAINTENANCE Lights Installing Halogen Bulbs 1 2 3 4 5 6 Hold the bulb by its metal base and install it into the wire harness Insert the bulb into the housing Connect the spring to the housing Carefully flip the spring back into the housing placing it around the wire harness Reinstall the plenum covering on the headlight assembly Adjust headlight aim See page 31 Replacing Taillight Bulbs 1 ON Oe otk Remove the screws securing the taillight cover and remove the cover Remove the taillight lens Push the bulb in and twist it counterclockwise to remove it Install the new bulb Reinstall the taillight lens Reinstall the taillight cover 95 MAINTENANCE Electrical System 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 Passenger handwarmers Work light Tail lamp Brake lamp Alternator coils Exhaust sensor Accessory projector beam relay Diagnostic plug IGNITION 20A Ignition relay power Cam
17. 86 Fuel Resistor 69 Fuel Safety 20005 64 Fuel System Deicers 69 Fuse Label aon onne nk eee te 96 G Gauge Cleaning 47 Gearcase Oil Level 81 Glove Box 0000000 31 Grab Handle Adjustment 33 H Handlebar Adjustments 54 Headlight Adjusting 31 Helmet suna sanoe aa ada eddies 12 High Temperature Indicator Light 89 Hood Latches 58 l Ice and Snow Build up 18 TPS sae tages tows een ta ea teat 48 Instrumentation 35 47 Intake Filters 0 86 Intake Silencer 20 L Lamps Replacing 94 Light High Temperature Indicator 89 Tights in ooes een e ede 94 95 Limiter Strap Position 52 Low Oil Indicator Light 70 Lubrication 81 83 M Maintenance Interval Table 78 80 Maintenance Program 77 Maneuverability 20 Matte Finish Cleaning 113 MFD Battery Replacement 46 47 MFD Components 35 MFD Digital Display Programs 38 45 MFD Settings 36 37 N IN OIS Girne es Se ates etm een eee 6 0 Oil Filtet saan naserussrasra ures 87 Oil Injection System 66 Oil Levels sharpie ta Gon dee oxen e 70 Ouines s ogc en ered eee 87 Oil Recommendations 66 Oil Gearcase 00000 81 Operating in Deep S
18. Ibs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment yx Rail Slide Wear For ease of inspection all Polaris rail slides have a wear Minim m A limit indicator groove to indi Thickness cate the minimum permissible slide thickness Replace the rail slides if they are worn to the top of the groove at any point along Replace when their length worn to top of NOTICE Failure to replace worn groove rail slides may result in permanent damage to the track or rails 106 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners 107 MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski alignment or camber adjustment See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y Tip If the skis are misaligned we recommend that your dealer correct the align ment since camber adjustment may also be affected 10 in 25 4 cm 10 in 25 4 cm
19. checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on the refer enced pages Look for a checkmark on the referenced pages to locate the pre ride inspection items Item See Page Drive Belt Condition 98 Steering System 58 Brake Fluid 59 Brake Lever Parking Brake Lock 59 60 Brake System 91 Throttle Lever 57 Throttle Safety Switch 57 Auxiliary Shut Off Switch Engine Stop Switch 63 72 Ignition Switch 63 68 Taillight Brakelight Headlight 63 Coolant Level 88 Gearcase Oil Level 81 Injection Oil Level 70 Radiator Cooling Fins clean and remove any debris Suspension Mounting Bolts 62 Skags Wear Bars 62 109 Ski Saddle and Spindle Bolts 62 Hood Straps Latches 58 Seat Latches 57 Rear Wheel Idler Bolts 62 105 Track Alignment Condition 61 106 Rail Slide Condition 106 56 PRE RIDE INSPECTIONS Before Starting the Engine Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start the engine without checking all vehicle components to be sure of proper operation WARNING Operating the vehicle with worn damaged or malfunctioning components could result in serious injury or death Never start the engine without checking all vehicle components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completel
20. defective engine component e Failures caused due to improper adjustments e Failure due to unauthorized service e Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual e Failure due to use of unauthorized parts or modifications e Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage e Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals e Non wear related throttle body parts are covered The fuel pump is covered Clutches and related clutch parts including but not limited to the drive belt are excluded from coverage Electrical components are excluded from coverage e Gearcases and transmissions are excluded from coverage 127 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
21. 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 124 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with cont
22. 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 damage repair
23. install a track having the lug size rec ommended for your model See your Polaris dealer NOTICE 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 WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and sup port the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for break age 4 Replace the track if any rod dam age is found Rods 102 MAINTENANCE Track Lubrication WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for PETE periods on ice and other surfaces that have little or no snow for ubrication 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 Track damage or failure caused by operation on ice or und
24. phase sensor ECU hold on power EFI Forward limit switch RELAY Start relay coil Chassis relay coil EFI Ignition relay coil 20A Fuel pump relay coil Fan relay coil Fuel pump relay power PTO injector MAG injector IGNITION RELAY PTO ignition coil MAG ignition coil FUEL PUMP RELAY Fuel pump FAN RELAY Radiator fan 96 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 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 WARNING 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 NOTICE 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 n
25. riders A decal on the console indicates that the vehicle is designed for one operator and one passenger only WARNING Operating improperly with a passenger could cause loss of control and result in serious injury or death 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 the snowmobile Snowmobiles designed for two riders should never be operated with more than two people on board Slow down Control becomes more dif ficult with two people on board More space is required to make turns and longer distances are necessary for stopping 13 SAFETY Operator Safety Cargo Capacity See page 32 for cargo loading information WARNING Overloading the cargo carrier can cause loss of control resulting in severe injury or death The maximum cargo carrier capacity is 75 lbs 34 kg Never exceed the cargo carrier capacity Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills WARNING Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled persons to operate this vehicle 14 SAFETY Operator Safety Excessive Speed WARNING H
26. the towed object Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 75 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Emission Control Label Your snowmobile is equipped at the time of sale with an emission con trol information ECI label and a factory installed emissions informa tion hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements
27. 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 Nosepan Skis Front Bumper Hood Headlight Windshield Mountain Bar Handlebar Fuel Filler Cap 10 Seat 11 Backrest 1 2 3 4 5 6 7 8 9 28 Taillights Cargo Carrier Rear Bumper Snow Flap Track Suspension Grab Handle Heater Switch Backrest Adjustment Knob Passenger Grab Handle Seat Latch PO O1 00 Glove Box MFD Display Ignition Switch 12 Volt DC Outlet Shifter Work Light Switch Brake Lever FEATURES Handlebar Grip Warmer Switch Thumbwarmer Switch Throttle Control Engine Stop Switch Electronic Reverse Button MFD Control Switch Headlight Dimmer Switch Parking Brake Lock 29 FEATURES Backrest The backrest is adjustable for either operator or passenger use 1 Loosen the upper adjustment X 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 Seat Latch Release the seat latch and raise the seat to access the battery and under
28. x 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 bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 77 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals AWARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are capable of traveling at high speeds Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobil
29. your snowmobile which could cause loss of control 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 58 PRE RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the 4 2 1 3 handgrip than 1 2 1 3 cm 2em A smaller distance indicates low brake fluid level or air in the hydraulic system See pages 91 93 or see your dealer for service Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Check for the presence of air in the fluid system See pages 91 93 or see your dealer for service WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess Brake Fluid Check the brake fluid in the mas Master Sight ter cylinder before each ride Cylinder Glass View the brake fluid level through the sight glass on the top of the master cylinder The eye will appear dark when the fluid level is full
30. IT 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 e Front shock spring preload e Optional springs e Toe ski alignment see page 108 e Camber see your dealer General Representation 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 retainer to fall off 48 THE PERFECT FIT Rear Suspension Adjustments Rider weight cargo weight riding style trail conditions and vehicle speed all affect suspension actio
31. Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to 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 Yo
32. S Introduction 0000 eee 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 ites Goes tees en chee eae wee 8 This section describes safe vehicle operation and identifies warning decals and their locations Features 6 5 4 25 o0 naa Seid ewe beens 28 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 2 00 eee eee cues 48 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 200005 56 This section explains procedures that must be performed before riding Operation 22 ee snc eees sees eens ea ees 64 This section explains proper engine break in operation of features and general operating procedures Maintenance 0 00eeeeeeeeeeeas 76 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris Products 200000eeee 116 Troubleshooting 000000eeeeee 117 Warranty oesi a a eee eee 122 Maintenance Log 0eeeeeeees 131 INGO aie ss cw Sed eeeds EEA 134 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient ref erence It should remain with the snowmobile when the snowmobile is sold
33. 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 126 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow mobiles that were Snow Checked through an authorized Polaris dealer during the March April Snow Check promotion The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transfer able 120 days after the original purchase date free of charge through any Polaris snow mobile dealer C
34. a Polaris dealer for a replacement This vehicle is capable of high speeds Buried objects or uneven terrain can cause loss of control Reduce speed and use extreme caution when operating in unfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehi cle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control 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
35. able 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 73 OPERATION Electronic Reverse PERC AWARNING 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 trans mission if shifting is attempted when the engine is operating above idle speed e Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle e Look behind the vehicle before and while backing e Avoid sharp turns e Apply throttle slowly Engaging Reverse Tip Electronic reverse will activate only if the engine RPM is below 4000 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one sec ond then release The engine will automatically reduce RPM and start a reverse rotation A flashing reverse light on the instrument panel will indicate that the transmission is in reverse 4 Apply the throttle slowly to make sure the transmission is in reverse The maximum engine RPM will be 6000 when in reverse Tip If the engine stops running the snowmobile will be in forward gear when it s restarted Disenga
36. adjustment 5 Loosen the rear idler shaft bolt 6 Loosen the lock nuts 7 Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track Tip 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 106 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaft bolts Torque to 35 ft lbs 47 5 Nm 105 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
37. 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 Passenger Warning Snowmobiles designed for an operator and one passenger have a warn ing decal on the console For more information on operating with a pas senger 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 25 SAFETY Safety Decals and Locations Reverse Warning Operation Warning Reverse Warning Polaris snowmobiles equipped with standard reverse and will have this decal on the console WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual 26 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
38. 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 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 59 8 Reinstall the gasket and cover 93 MAINTENANCE Lights Removing Halogen Bulbs Tip Do not touch a halogen bulb with bare fingers Oil from skin leaves a resi due causing a hot spot that will shorten the life of the lamp If fingers do touch the bulb clean it with an alcohol moistened towel 1 Remove the plenum cov ering from the headlight Bulb assembly Lift the rubber boot to expose the bulb Spring
39. at has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle Polaris recommends that you contact an autho rized Polaris dealer to perform any service that may be necessary for your vehicle Polaris also recommends that you use only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the Polaris Warranty Department at 1 888 704 5290 130 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
40. ations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 200 hours of engine operation 4000 kilo meters 2485 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems e Aijr induction system e Ignition system e Fuel system e Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions e Aftertreatment devices e Sensors e Crankcase ventilation valves e Electronic control units The following parts are considered emission related components for evaporative emis sions e Fuel Tank e Vacuum Control Diaphragms e Fuel Cap e Control Cables e Fuel Line e Control Linkages e Fuel Line Fittings e Purge Valves e Clamps Vapor Hoses e Pressure Relief Valves e Liquid Vapor Separator e Control Valves e Carbo
41. aves 99 l l l l ENGINE COOLING Engine Mounts l l l l Recoil Rope l l l l Cylinder Head Bolts l l l Cylinder Base Nuts I l l l Ignition Timing BTDC l l l VES System Cc Cc Cc l Coolant Level 88 l l R l Coolant Hose l l l l Coolant Circulation l l l Coolant Leaks l l l l Spark Plugs 84 l l l R l Exhaust Pipe 87 l l Exhaust Retaining 87 l l l l Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 78 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 150mi 500mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 8200 km Season BRAKES Hose Routing l l l l Hose Condition l l l l Fluid Leaks l l l l Brake Pads 91 l l l l Brake Disc l l l l Parking Brakes 60 l l l l Brake System 59 91 l Brake Fluid 59 R FUEL MANAGEMENT Idle RPM l l l Throttle Lever 57 73 l l l l l Oil Pump Lever l l l synchronize Throttle Cable 82 L L L Throttle Position Sensor l l l Fuel Lines 86 l l l l l Fuel Filter 86 R R Oil Filter 87 R R Oil Lines l l l Air Box l l l l l ELECTRICAL Auxiliary Shut Off 63 l l l l l Switch Throttle Safety Switch 72 l l l l l Ignition Switch l l l l l Taillight 63 l l l l l Brakelight 63 l l l l l Headlight 63 l l l l l 79
42. ay also hide your view Always leave yourself a way out O Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you Before riding your snowmobile on a frozen body of water be sure the ice is thick enough to support the snowmobile and its operator as well as the force created by a moving vehicle You may drown if you and the snowmobile break through the ice When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations 16 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain e Take an avalanche class e Travel with experienced people e Travel on designated trails E 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 steepe
43. components Lubrication 83 Ski runner skag Condition Ski spindle bolts Tightness Tie rod end nuts Tightness 62 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 Y Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advan tage i Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile 63 OPERATION Fuel Safety AWARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonou
44. current Charge charger 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 At least 20 hours desulfating charger 112 MAINTENANCE Matte Clear Coat Cleaning if equipped Matte finish products are prone to trapping dirt oils and other contami nants Polaris Industries recommends cleaning with warm water and a mild dish detergent Use a soft sponge to gently rub the surface and rinse with clean warm water For stubborn stains such as grease or oil use a citrus based cleaner 3M Citrus Base Cleaner recommended Spray onto the area to be cleaned and rub with a soft sponge Allow to sit for a couple of minutes and wash away with clean warm water Repeat as necessary to clean the surface NOTICE Never use a polishing buffing wax or any sponge that has an abrasive surface These products will buff the matte surface of the finish resulting in a glossy finish It is not recommended that you clean matte finishes with a pressure washer as this will further imbed contaminants into the clear coat and possibly damage the decals Extended Storage Off season or extended storage of your sno
45. damage This is especially important when the machine is operated in mountainous ter rain Always check the oil level when refueling When the oil reaches the low level mark add one quart 9 liters of recommended oil to the tank See page 66 for oil recommendations NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling Add oil as needed The Polaris oil cap on the oil bottle is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts Always maintain the oil level between the add mark and the bottle neck Do not fill the bottle neck See page 66 for oil recommendations Add Mark 2 1 Immediately stop the engine if the low oil indicator light comes on 2 Open the left side panel 3 View the oil level in the oil bottle 4 Add oil as needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling Add oil as needed The oil bottle cap is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts 70 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 snowmobile and the moving track Never hold the snowmobile up or stand behind it while warming up th
46. e Slows jackshaft All Engine Stop Switch Interrupts ignition circuit All Fuel For peak performance Polaris recommends the use of 91 octane fuel or higher Although 87 octane fuel is usable some engine performance 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 Never use E85 in your snowmobile NOTICE Operating with obstructed fuel systems will result in serious engine damage Always perform maintenance as recommended NOTICE Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel 68 OPERATION Fuel Resistor This snowmobile is equipped with a feature that allows the engine controller to select the proper operating software based on the type of fuel being used 10 ETHANOL 24 OHM The proper fuel resistor must be installed to match the type of fuel you are using The snowmobile comes from the NONETHANOL factory with the resistor installed 160 OHM that should be used when run ning fuel containing up to 10 ethanol The resistor is labeled 10 Ethanol 24 OHM A picture of the resistor is shown below The resistor is installed into the wiring harness on the left side of the snow mobile just above the top of the oil bottle If the snowmobile is run with non ethanol fuel be sure to install the resistor labeled Non Ethanol 160 OHM Thi
47. e air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury 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 NOTICE Brake fluid will damage decals paint and some plastics Always wipe up spills immediately Check the brake fluid in the mas Master Sight ter cylinder before each ride Cylinder Glass View the brake fluid level through the sight glass on the top of the master cylinder The eye will appear dark when the fluid level is full If the sight glass is any color other than black add brake fluid 1 Position the handlebars so the master cylinder is level 2 Remove the master cylinder cover 3 Add DOT 4 brake fluid only Do not overfill See page 116 for the part numbers of Polaris products 92 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action Bleed the system before operating the snowmobile WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever During the bleeding procedure keep the brake handle as level
48. e 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 CAUTION Operation of the engine with the belt removed may result in personal injury or damage to the engine Any servicing that requires operation without a belt must be performed by your dealer Intake Silencer Do not operate the engine with the intake silencer or filter removed NOTICE 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 Warm the drive belt by allow ing the engine to idle in neutral for several minutes 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 Maneuv
49. e sure spindles and all steering components turn freely Check ski alignment see page 108 Check skags and skis for damage Set static sag see page 50 Machine darts from side to side Check ski alignment see page 108 Check for binding front suspension shafts steering compo nents grease all pivot points elevate front of machine e Check for excessive play in steering assembly see dealer e Ensure skags are straight on skis e Set static sag see page 50 e Check rail slide replace if worn see page 106 120 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 the gas tank or fu
50. e track Do not use excessive throttle dur ing warm up or when the track is free hanging Be sure the rear support is sta ble AWARNING Use of traction products such as studs ice growsers etc will increase the possi bility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 Use an appropriate stand to securely support the rear of the snow mobile at the rear bumper The track should be approximately 4 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions Tip It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the snowmobile to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice 71 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 Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valv
51. ebar angle at the handlebar block 1 Remove the mountain bar 2 Remove the handlebar cover Mountain 3 Using a 7 16 wrench loosen Bar the four nuts on the bottom of the adjuster block Turn the handlebar to the left or right for bay evra access to the back nuts If nec essary pry the blocks apart with a screwdriver 4 Adjust the handlebar to the desired height Be sure the han dlebar 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 5 Torque the front bolts first then torque the rear bolts Torque the bolts to 15 17 ft Ibs 20 23 Nm 6 Reinstall the handlebar cover i Adjuster Qe Block Bolts 7 Reinstall the mountain bar 54 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 e Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service 55 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all items on the
52. ecessary see your dealer 97 MAINTENANCE Clutch System 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 121 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 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 98 MAINTENANCE Clutch System Drive Belt Adjustment Belt deflection should be adjusted without removing the clutch from the jackshaft 1 Loosen the 7 16 inch jam nut on the belt width adjuster 2 Using a 1 8 inch Allen wrench adjust the threaded set screw as needed Tip Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the distance 3 Tighten the jam nut 99 MAINTENANCE Clutch System Drive Belt Removal NOTICE Do not attempt to remove the drive belt after operating in reverse The snowmobile must be stopped after forward motion to prevent damage to compone
53. el 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 121 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 j i Serial number Model number Dealer name Date of purchase Details of trouble experienced DUPY NY Length of time and conditions of operation 7 Previous correspondence Use the page provided nea
54. er other poor lubrication conditions will void the track warranty NOTICE High speed use on hard packed surfaces is not recommended for models equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequent slow speed intervals for track cooling 103 MAINTENANCE Track Tension WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine running Track adjustment is critical for proper handling Always maintain cor rect tension and alignment TRACK TENSION DATA CHART Suspension Slack Measurement Weight Measurement Location Widetrak IQ 3 4 1 19 25 mm 10 Ibs 16 40 cm 4 54 kg ahead of rear idler shaft Tip Tip 104 Tension adjustments should be made only after the track is warmed up and limber Turn the engine off Lift the rear of the snowmo bile and safely support it off the ground Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel Measure at the point where the weight is hanging MAINTENANCE Track Tension 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide Idler Shaft Bolt If the track needs
55. erability 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 cooling for the engine adequate snow cover is a requirement for operation of your snowmobile NOTICE Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine 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 imprope
56. es are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from opera tion with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynami cally unstable at speeds higher than those for which it is designed Loss of con trol may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur if
57. es do not return to the normal closed position Test the throttle safety switch system daily before operation WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pres sure on the pivot pin in the direction shown in the illustration Stop Switch 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine 72 OPERATION y Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control which could result in serious injury or death If the throttle lever does not work properly DO NOT start the engine If the engine 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 c
58. eser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization NOTICE 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 with the proper gap e 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 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 84 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 Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments 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 elect
59. f the battery is raised away from the battery holder Pull the battery out gently 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 remov ing the battery Pulling on the wires will separate them from the battery holder Install a new battery with fingers only 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 Make sure the taped seam of the compartment faces the downward side of the wire harness 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 2 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth 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 NOTICE To prevent damage to the lens do not use alcohol for cleaning Do not allow chemicals or sprays to contact the lens Immediately clean off any gasoline that splashes on the gauge during refueling 47 THE PERFECT F
60. fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments 10 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control 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 e 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 De
61. firmly with both hands 2 Maintain a firm grip on the spring and carefully remove the long leg from the guide block Be prepared for a sudden release of tension 3 Carefully allow the leg to unwind and relieve tension from the cam 4 Rotate the cam to the desired setting 5 Rewind the long leg of the spring Maintain a firm grip on the spring while reinstalling it into the guide block Tip Different rate torsion springs are available if a firmer ride is desired Contact your dealer for more information The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style Soft long end of cam to front Medium short end of cam up Firm long end of cam up 2 Q Soft Medium Firm 51 THE PERFECT FIT Rear Suspension Adjustments Limiter Strap Position Ski Pressure The following information is provided only as a guideline to High be used for initial suspension set up Your set up may vary Low based on your desired riding style High Limiter strap in high position increases ski pressure Low Limiter strap in low position decreases ski pressure 52 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving The rear track shocks for this model are gas charged shocks The valv ing on the gas charged shocks is pre set 53 THE PERFECT FIT Handlebar Adjustments Use the following steps to adjust handl
62. ging Reverse 1 Stop the snowmobile and leave the engine idling NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 2 Push the yellow reverse button for one second and release The engine will slow and begin to rotate forward The light on the instru ment panel will shut off 3 Apply the throttle slowly to make sure the transmission is in for ward 74 OPERATION Daily Storage At the end of each ride park the snowmobile on a level surface and sup port it at the rear with an appropriate track stand The track should be suspended approximately 4 10 cm off the ground Remove the key and cover the snowmobile Towing For your safety do not attempt to use a tow hitch until you ve read the following warnings and understand the proper hitch functions WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed ona toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in
63. he engine and check the coolant bottle level Fill as required 7 Feel the heat exchangers under the running boards If the system is bled properly they ll be warm to the touch If they re not repeat step 5 Lift the front of the machine slightly to assist in the bleeding 8 Replace the pressure cap and carefully lower the front end of the machine 90 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 59 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 WARNING Brake failure during operation can result in serious injury or death 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 e Brake Caliper e Gearcase e Brake Disc e Backing Plate e Brake Pad Material Replace when thickness is less than 1 16 1 5 mm Gearcase Backing Plate Brake Disc Brake Pad Brake Material Caliper 91 MAINTENANCE Brakes Y Brake Fluid AWARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from th
64. his 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 WARNING Never attempt an abrupt change of direction when operating on slippery surfaces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the snowmobile downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill sid
65. icer 11 SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be prepared be warm and be com fortable when riding Be aware of EEEN POLARIS the weather forecast especially the windchill and dress accordingly See the chart on page 23 WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Always wear an s approved helmet and eye protection 12 SAFETY Operator Safety Rider Capacity Your snowmobile is designed for up to two
66. igh 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 Look ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments m
67. ion and don t allow it to snap back into the housing Damage may result 5 Ifthe engine does not start after several attempts slightly depress the throttle no more than 1 4 open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running NOTICE Operating the vehicle immediately after cold starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle If cold drive away is attempted the engine RPM may stumble slightly to protect the engine 67 OPERATION Restarting an Engine If the rider stops the engine by pushing the engine stop switch down restart the engine using the normal starting procedure If the engine fails to start using the normal procedure 1 Push the engine stop switch down to the OFF position 2 Turn the key to the OFF position 3 With both switches OFF squeeze and hold the throttle in the wide open position 4 Crank the engine several times to clear the engine 5 Release the throttle 6 Restart the engine using the normal starting procedure Stopping the Snowmobile The following chart lists methods for stopping the snowmobile See page 72 for more information about the engine stop switch THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit All Brak
68. istration 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 material corrosion or
69. ker or flash momentarily Check Engine Light Status Indicates Solid or Flickering Detonation detected Severe detonation detected RPM will Flashin 3 be limited You may notice decreased engine RPM and performance when DET is activated but in most cases DET activation is temporary and the timing will return to normal automatically If severe detonation occurs the check engine light will begin to flash The engine will enter a limp home mode and RPM will be limited to 6500 RPM and stay in this mode until the engine is shut down and restarted The most likely causes of severe detonation are shown in the table below Refer to the table for troubleshooting information DET Troubleshooting Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol non ethanol fuel resistor installed Verify correct fuel resistor for fuel type in tank Low fuel no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter See your Polaris dealer for service Alcohol based fuel additive used with Ethanol fuel Do not add de icers or additives that contain any form of alcohol while using up to 10 ethanol fuel Improper engine modifications Do not modify the engine 34 Instrumentation FEATURES MFD Component Identification Item Analog Gauge if e
70. km as Tip The direction of the arrows indicates the direction of flow through the filter Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 78 CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Allow the engine and exhaust system to cool completely 2 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 See page 116 for the part numbers of Polaris products 6 Close the hood 87 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60 40 mixture of ethylene glycol and distilled water This mixture provides protection against freezing Contact your dealer if greater protection is required Use Premium 60 40 anti freeze coolant which is already premixed and ready to use Do not dilute with water Never exceed a 60 antifreeze 40 water mixture See page 116 for the part numbers of Polaris prod ucts Tip 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 p
71. ld Plus Synthetic 2 Cycle Engine Oil 2 qt 2877883 VES Gold Plus Synthetic 2 Cycle Engine Oil gal 2877884 VES Gold Plus Synthetic 2 Cycle Engine Oil 2 5 gal It 2877887 VES Gold Plus Synthetic 2 Cycle Engine Oil Itr 2877888 VES Gold Plus Synthetic 2 Cycle Engine Oil 4 Itr 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 116 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Probable Cause Solution Erratic engine oper ating RPM during acceleration or load variations Drive clutch binding e SEE YOUR DEALER Driven clutch mal function e SEE YOUR DEALER Harsh d
72. licized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter machines we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly Air Pollution Polaris engineers continuously investigate ways to reduce emission lev els of two stroke engines We expect our efforts to lead to the reduction of potential air pollution In addition to our technological research we encourage government agencies manufacturers distributors dealers ecologists and other interested parties to work together to develop data on environmental topics INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Tunnel VIN
73. n Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions However all suspen sion 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 please see your Polaris dealer 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 e In deep snow anew 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 Tip Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension components Grease rear suspension pivots before adjusting the rear suspension Refer to the suspension lubrication information beginning on page 82 49 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method
74. n Canister e Control Solenoids e Canister Mounting Brackets e Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 129 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine th
75. ncrease your risk of losing con trol Loads should be centered Cargo Carrier carried as low as possible and firmly secured to the carrier Be careful if load extends over the side of the carrier The maximum weight capacity for the cargo carrier is 75 lbs 34 1 kg Do not allow a passenger to sit on the seat back or in the cargo carrier NOTICE Do not drive aggressively or jump your vehicle when operating with heavy loads in the cargo carrier This may cause vehicle damage 32 FEATURES Passenger Grab Handle The position of the passenger grab handles can be adjusted for rider preference Adjustment Bolt 1 Remove the adjustment bolt 2 Reposition the grab handles to one of the two adjustment positions on the grab handle tube between the operator seat and the passenger seat 3 Reinstall the adjustment bolt and tighten securely 12 Volt DC Outlet Use the 12 volt DC outlet to power a global positioning sen sor GPS heated helmet shield utility light cell phone or other accessories The 12 volt DC outlet is located on the console near the shift lever fy f gt Vi od Yih f f LY 7 Uy K 12 Volt DC Outlet 33 FEATURES Detonation Elimination Technology DET The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active When excessive detonation is detected the check engine light will illuminate flic
76. ne damage can occur without the proper lubrication Check the oil bottle level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately Oil Recommendations This snowmobile is equipped with a variable exhaust system VES Engine lubrication comes from oil added to the fuel and oil injection systems Polaris recommends the use of VES Gold Plus Synthetic 2 cycle oil for this engine See page 116 for the part numbers of Polaris products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other 66 OPERATION Starting the Engine 1 Turn the key to the ON position NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission Is in reverse Never engage the starter when the engine is running 2 Pull the engine stop switch up to the RUN position 3 If equipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts 4 If not equipped with electric start grasp the starter handle and pull slowly until the recoil engages then pull abruptly to crank the engine TIP Don t pull the starter rope to the fully extended posit
77. ner 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 THE WAY OUT are registered trademarks of Polaris Industries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 600 Widetrak Owner s Manual P N 9922596 TABLE OF CONTENT
78. ng 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 SAFETY The following information is provided to help you determine when tem peratures become dangerous for riding WIND CHILL CHART F Wind Actual Thermometer Reading F Speed 70T 35 30 25 20 15 10 5 0 5 10 15 20 25 80 35 40 45 MPH Equivalent Temperature F Calm 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 5 36 31 25 19 13 7 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 63 59 66 72 15 32 25 19 13 6 0 7 13 19 26 32 30 45 51 58 64 F777 20 30 24 17 11 4 2 9 15 22 29 35 42 48 65 61 68 74 81 25 29 23 16 9 3 4 11 17 24 31 37 44 51 58 64 71 78 84 30 28 22 15 8 1 5 12 19 26 33 39 46 53 60 67 73 80 87 35 28 21 14 7 0 7 14 21 27 34 41 48 55 62 69 76 82
79. ngine Track Inspection 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 WARNING Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty 61 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 inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 105 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness a Carrier and bogie wheel bolts Tightness e Front torque arm limiter strap Condition Rail slide Condition 106 Track Tension 104 All rear suspension
80. now 21 Operation Warning 27 P Parking Brake Lever Lock 60 Passenger Warning 25 Polaris Products 116 Pre Ride Checklist 56 Pressure Cap Warning 24 R Rail Slide Wear 106 Relay Label 20 00 isa Shee eee 96 ROVeOrse scsi Sue Snicket adie seers 74 Reverse Warning 26 Rider Capacity 13 S Safety a aiaa teal ied ae ak 8 23 Safety Decals 24 27 Seat Latch 04 30 57 Seat Storage 0 00 30 Shock Compression Valving 53 Shock Spring Preload Front Suspension 48 Skagen savcaed ay sls det sect 109 Ski Alignment 108 Ski Pressure 00 52 Snow Build up 18 Snow Conditions 21 Spark Plugs 84 85 PCC sa cecal dered en esha tiers Soke oe ay 15 Spring Preload IQ 50 135 INDEX S Starting the Engine 67 Starting the Engine Restarting 68 Steering Inspection 107 Steering System 58 107 109 Stop Switch 0000 72 Stopping the Engine 68 Stopping the Snowmobile 68 Storage Daily 75 Storage Extended 113 115 Storage Under Seat 30 Survival Preparation 11 Suspension Adjustments Front 48 Suspension Adjustments Rear 49 53 Sus
81. nts during belt removal 1 Stop the engine after operating in a forward motion 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Open the hood 5 Remove the left side panel 6 Rotate the driven clutch counterclockwise 1 4 turn by hand to ensure forward engagement before attempting to remove the belt 7 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 8 Turn the wrench clockwise until the sheaves open far enough to remove the belt If the wrench does not turn readily rotate the driven clutch counterclockwise an additional 1 4 turn by hand and try again 9 Grasp the belt at the lower edge and remove it 100 MAINTENANCE Clutch System Drive Belt Installation 1 Tip Drop the drive belt over the drive clutch and pull back the slack 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 from the left side of the vehicle If required separate the sheaves as outlined in the belt removal procedures Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves Remove the wrench Reinstall the side panel Close and secure the hood 101 MAINTENANCE Track Replacement When replacing the track always
82. o after refueling 39 FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting if equipped GD 1 Enter the Performance Program L L j i 2 Press and release the SET button aL z until the clock screen is active RPM f 3 Press and hold the SET button for l five seconds 2 58 E 4 When the hour starts flashing press the SET switch once to advance one hour Press and hold the SET button to advance the hours quickly 5 Press and release the MODE button to save the hour The 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 If the MODE button is not pressed within ten seconds the gauge will automatically save the new entry 40 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 9 The hour meter records the total hours of L Li a
83. old the MODE switch until the unit of mea surement changes about 10 seconds 36 FEATURES Instrumentation MFD Settings Speedometer Tachometer If your model is equipped with both analog and digital displays the speedometer and tachometer can be viewed in either display If the ana log display is set to show speedometer readings 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 viewing preferences press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change 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 37 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
84. or changing lubricant Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 116 for the part numbers of Polaris products NOTICE Mixing brands or using non recommended lubricants could result in excessive wear to chain sprockets and bearings Always use Polaris recommended products for your vehicle 81 MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the han dlebars to the left and lubri cate liberally as shown Front Suspension The front suspension and steering components do not require lubrica tion Coupler Lubrication eae Using a needle point grease gun grease the driveshaft cou pler only The jackshaft on this S model is a one piece jackshaft B that requires no lubrication 5 Driveshaft 82 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 78 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 83 MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the pr
85. overage 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 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 e Damage caused by the failure of other components of the snowmobile e Failures caused by improper fuel or oil e Piston seizures unless caused by a
86. pension Coupling IQ 53 Suspension Inspection 62 Suspension Lubrication Front 82 Suspension Lubrication Rear 83 Suspension Performance Tips 49 Suspension Front 48 Switches Auxiliary Shut Off Switch 63 Engine Stop Switch 63 72 Ignition Switch 63 Location 28 29 MFD Control Switch 36 Throttle Safety Switch 57 72 136 T Throttle Cable Lubrication 82 Throttle Lever 57 73 Throttle Safety Switch 57 72 Torsion Spring Preload IQ 51 TOWINg 0 eee eee eee eee 75 Track Alignment 106 Track Inspection 61 102 Track Lubrication 103 Track Replacement 102 Track Tension 104 105 Track Warm Up 0 71 Track Warning 25 Transporting the Snowmobile 115 Troubleshooting Drive Belt Wear Burn 121 Eg sz ns eats dou at 117 119 Suspension 120 V Vehicle Identification Numbers 7 Ww Warning Labels Decals 24 27 Windchill Temperature Charts 23
87. ply only to the installa tion of 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 111 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 Tip 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 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 Tip Always verify battery condition before and 1 2 hours after the end of charg ing State of Charge Time Voltage Action Using constant
88. quipped Digital Gauge Check Engine Indicator High Temp Indicator Brake Indicator Reverse Indicator N OD 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 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 90003 LILILILI Re J 35 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 ignition key to the START position briefly to activate the gauge The gauge will illuminate for about 90 seconds Standard vs Metric MFD Control MODE Switch SET 4 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 h
89. r 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 WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving Downhill When riding downhill shift your weight to the rear of the snowmobile and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the snowmobile and keep it from rolling freely downhill 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 T
90. r the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 888 704 5290 Canada 1 204 925 7100 122 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 123 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 the Warranty Reg
91. ressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part CAUTION Steam and hot liquids will cause burns to your skin Never remove the pressure cap when the engine is warm or hot Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are e Coolant recovery bottle e Coolant reservoir e Pressure cap e Connecting hoses Always maintain the coolant level at the COLD FILL mark on the coolant recovery bottle when the engine is cold NOTICE Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended 88 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool ant temperature becomes too hot for safe continued operation of the engine If you must drive your machine after the high temperature indi cator light has come on drive slowly and stop frequently to allow the engine to cool down Driving in deep snow will also help cool the engine See your dealer for service Add coolant if the level is low Engine performance will be reduced if you continue operating when the high temperature light is on Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine the s
92. rive clutch engagement Drive belt worn or too narrow Replace the drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount bro ken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Track jammed Check for twisted belt or broken spring SEE YOUR DEALER Foreign object may be caught or the rail slide melted to the track clips due to lack of lubrication Track may be iced up or frozen to the ground Chaincase sprocket or chain jammed or broken Chain is loose or broken or chain tightener is loose SEE YOUR DEALER 117 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch SEE YOUR DEALER system components Bearing failure e SEE YOUR DEALER gearcase jackshaft or front drive shaft Drive belt surface e Inspect and replace as needed flat spots Drive chain loose e Inspect and adjust or replace Drive chain worn e SEE YOUR DEALER sprocket teeth bro ken Poor low RPM Worn drive belt e Inspect and replace as needed performance Excessive belt sheave clearance e SEE YOUR DEALER Sticky clutch e SEE YOUR DEALER Poor fuel quality e Use 87 89 octane fuel Engine doesn t turn Sei
93. rly 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 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 drivi
94. rodes are not worn General causes of fouling are excessive oil or rich fuel mixture 85 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system When operating in loose powder snow check the foam filters periodically to remove any accumulation of snow NOTICE Operating the snowmobile with the intake filters removed may cause intake icing The result will be poor fuel economy or intake malfunction Always reinstall the intake filters before operating the snowmobile Intake Filter Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump Fuel Filter Fuel Lines See your Polaris dealer for replacement of the fuel filter every 1000 miles or annually Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly 86 MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter The oil filter is located at the side of the oil tank Have your dealer change the oil filter and bleed the system annually or every 1000 miles 1600
95. rolling 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 125 WARRANTY Conditions and Exclusions In order to qualify for warranty the product must have been properly set up and tested by a Polaris Dealer if applicable Failure of any dealer to perform the required vehicle Pre Delivery Inspection perform all applicable service bulletins and have the consumer sign the PDI form prior to
96. ry replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjust ments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfort able performing these tasks yourself contact an authorized Polaris dealer for service NOTICE Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection 77 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement parts always use genuine Polaris parts available from your Polaris dealer Item See Frequency Page i50 mi 500 mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CLUTCH Clutch Alignment Offset 97 l l l without belt Clutches 97 l l l l Drive Belt 98 Cc Cc c Belt Tension Ga l l l l Clutch She
97. s and can cause loss of consciousness or death in a short time AWARNING The engine exhaust from this product contains chemicals known to cause can cer birth defects or other reproductive harm Operate this vehicle only outdoors or 64 in well ventilated areas OPERATION Engine Break In No single action on your part is as important to long trouble free snow mobile life as proper break in of a new or rebuilt engine Premix the first tank of fuel with one pint of Polaris injection oil for each five gal lons of fuel This in addition to the lubrication supplied by the injection system will assure proper engine break in NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and vehicle speeds to reduce friction on all close fitting machined parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the snowmobile 65 OPERATION Engine Break In Oil Injection System Always check and fill the oil bottle when refueling See page 70 NOTICE Serious engi
98. s resistor is provided in the tool kit NOTICE Engine damage may occur if ethanol fuel is used while the non ethanol fuel resistor is installed The machine may also display the check engine light in this condition as this could cause detonation If you are unsure of the type of fuel you are using make sure the 10 Ethanol 24 OHM resistor is installed This is the preferred default and will provide the most engine protection Fuel System Deicers If you use non ethanol fuel sometimes labeled non oxygenated Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent damage resulting from fuel system icing Never use deicers or additives containing methanol Polaris also recommends the use of Carbon Clean Plus See page 116 for the part numbers of Polaris prod ucts If you use fuel with up to 10 ethanol sometimes labeled oxy genated do not add deicers or additives that contain any form of alcohol 69 OPERATION x Oil Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low Visually check for oil in the bottle If oil is not visible continued opera tion may cause serious engine damage Add oil before further operation of the snowmobile Low Oil Level Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine
99. seat storage area Raise Lower Operator Passenger Check the seat latch before each use of the snowmobile Push downward on the seat near the seat latch then attempt to raise the seat by pulling upward on the right hand passenger grab handle Make sure the latch is secure before riding Under Seat Storage When using the under seat storage area to transport supplies and other items pack the items securely to prevent them from moving around in the storage area Smaller items should be placed in bags or containers to keep them secure Storage Area 30 FEATURES Adjustable Headlights Move the headlight adjuster to raise or lower the headlight beam e Move the adjuster to the left to lower the beam e Move the adjuster to the right to raise the beam Glove Box The glove box is a heated dry storage area intended for drying wet gloves Do not use the glove box for items that could be damaged by heat Turn the knob to release the glove box cover latch and open the cover 31 FEATURES Cargo Carrier WARNING Overloading or towing improperly can alter vehicle ha ndling and can cause loss of control Do not exceed the cargo carrier capacity Always reduce speed and allow greater distance for braking and turning when carrying cargo or a passenger or when towing Always secure cargo before operating vehicle Overloading or carrying tall off center or unsecured loads will i
100. snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 1500 mi 2400 km 131 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 132 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 133 INDEX A Accessories 00 008 55 Air Pollution 6 Apparel 00 12 Avalanches 004 17 B Backtestit torte ak ook eee ee et 30 Battery Charging 111 112 Installation 110 Removal 110 50 1 a a ee PaE 111 Battery Replacement MFD 46 Brake Components 91 Brake Fluid 59 92 Brake Inspection 91 Brake Lever Feel 59 Brake Lever Travel 59 Brake System Bleeding 93 BrakeS oi esnce ne nana eet 59 91 93 Bulbs Replacing 94 Cc Cargo Capacity 14 Cargo Carrier 4 32 Cargo Overload 14 Cargo Rack 005 32 Cleaning for Matte Finishes 113 Clutch Alignment Offset 97 Clutch Center Distance 97 Clutch System 97 101 Clutch Warning
101. st the displayed altitude to 1300 ft 896 m from the preset value It will adjust up to 1300 ft 396 m above the calibrated altitude Once the 1300 ft 396 m offset has been reached the next adjustment is 1300 ft 396 m from the calibrated altitude and 50 ft 15 m will be added to the altitude each time the SET button is pressed 6 Press and release the MODE button to set the reading at the adjusted value If the MODE button is not pressed within ten seconds the gauge will automatically save the new entry 42 Instrumentation MFD Digital Display Programs History Program FEATURES 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 The gauge automatically logs the maximum speed and engine RPM even if the history program is not active in the display 1 Enter the History Program 2 Press and release the SET button until one of the two screens is active Tip The MPH and RPM values are both reset at the same time Reset the values before each run to obtain accurate readings 3 Press and hold the SET button for three seconds to reset the recorded maximum values for both MPH and RPM Tip Due to electrical noise the MFD ma
102. than normal pulls to start Poor fuel e Replace with fresh winter fuel Not enough fuel get ting to engine e SEE YOUR DEALER 119 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension e Set static sag see page 50 Adjust torsion spring blocks or bottoms too easily install optional torsion springs to achieve correct sag dimensions Rides too stiff in rear Check for binding suspension components and grease all pivot points Set static sag see page 50 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Too much weight Set static sag see page 50 Adjust torsion spring blocks or transfer when install optional torsion springs to achieve correct sag climbing Move limiter strap to high position see page 52 Too little weight Set static sag see page 50 Adjust torsion spring blocks or transfer when install optional torsion springs to achieve correct sag climbing Move limiter strap to low position see page 52 Front end pushes Check for worn skags Check for binding front suspension shafts steering compo nents grease all pivot points elevate front of machine Set static sag see page 50 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Increase IFS preload if equipped see page 48 Move limiter strap to high position see page 52 Steering is heavy Mak
103. u may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance see page 122 128 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle Polaris Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applica ble U S Environmental Protection Agency emission regulations Polaris warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regul
104. wmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 116 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 113 MAINTENANCE Extended Storage Battery Maintenance Remove the battery and recharge it as outlined on page 112 Store the battery in a cool dry place Controls and Linkage Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 78 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 Engine Protection
105. y and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience Y 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 72 for procedure 1 Seat Latch Check the seat latch before each use of the snowmobile Push downward on the seat near the seat latch then attempt to raise the seat by pulling upward on the right hand passenger grab handle Make sure the latch is secure before riding 57 PRE RIDE INSPECTIONS Before Starting the Engine i 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 Steering System WARNING Ice and snow build up may interfere with the steering of
106. y occa sionally display MAX MPH RPM values that are not representative of actual values meee hr 3e J 53 hr 33 J m 43 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service e 7 jel reminders When the logged hours W reaches the designated service interval a m set by the user the gauge provides a n F reminder that service is due SErV CE will flash in the odometer area and 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 44 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder To reset the reminder at a new interval 1 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
107. ystem 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 89 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION Steam and hot liquids will cause burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part NOTICE If coolant flow becomes restricted or plugged coolant loss air lock or engine damage may result Most cooling systems are equipped with a filter that should be periodically inspected or replaced Perform the bleeding procedure when the engine is cold 1 Position the vehicle so that the top of the tunnel is level Elevate the front of the vehicle slightly if necessary 2 Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark 3 Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed screw into the manifold 4 Add coolant to the coolant bottle to the maximum mark 5 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air 6 Stop t
108. zed engine e SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered the crankcase while the vehicle was standing or being transported SEE YOUR DEALER to correct the cause Drain plug s are located on the lower crankcase for emergency draining 118 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition TROUBLESHOOTING Install new spark plug s If engine still fails to start check for spark If there s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on Make sure the fuel tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system Poor engine com pression This indicates a major engine prob lem that must be repaired before operating SEE YOUR DEALER Engine lacks power Engine continually backfires Fouled or defective Replace the plug s spark plug s Fuel filter loss of e SEE YOUR DEALER high RPM power Incorrect clutching e SEE YOUR DEALER Faulty plug s e Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fuel at all times for assurance against fuel line icing Incorrect throttle freeplay or faulty switch e SEE YOUR DEALER Engine requires more

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