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Polaris 2009 99 Ranger Offroad Vehicle User Manual

1. 0 98 Carburetor Adjustments 98 Carburetor Protection 126 127 Carburetor Water Sediment Trap 100 Chain Tension 116 Chaincase Oil 92 Chokers saora 3 be dln adhd as das 91 Choke Cable 91 Cleaning and Preservation 125 Clutch Alignment Offset 110 Clutch and Drive System 126 Clutch Center Distance 110 Clutch Cover Warning 21 Clutch Guard 17 Clutch Safety 17 Clutch System 109 Cold Weather Drive Away 16 Controls and Linkage 125 Coolant sioa 60 0808 Maca 99 Coolant Level 100 Cooling System Bleeding 101 Cooling System Flushing 100 Customer Service 139 152 D DE Torre Sl edd kee eens av se 27 Detonation Elimination Technology 27 Disabled Operators 11 Drive Belt 00 17 Drive Belt Adjustment 114 Drive Belt Condition 111 Drive Belt Deflection 114 Drive Belt Installation 113 Drive Belt Removal 112 Drive Chain Tension 102 Driver Awareness 12 Driveshaft Bearing 91 Driving Downhill 15 Driving in Hilly Terrain 16 Driving on Slippery Surfaces 14 Driving Responsibly 19 E Electrical Connections 128 Emission Control Information 82 83 Engine Break In
2. 28 Seat Bucket Warning 21 Shock Components 31 Shock Damping 32 Shock Valving 34 Shock Clicker FOX 40 Shock PPS on duod cata deacon 40 Shock Rear Indy Select 39 Shocks Rear EDGE 39 40 Shock SOLO RydeFX 32 Signal Words 6 Ski Alignment 122 Ski Pressure M10 50 Ski Skags 123 Slide Rail and Track Cooling 66 Snow Conditions 18 INDEX S Snowmobile Engine Emissions Limited Warranty 148 149 Spark Plug Condition 93 Spark Plug Removal 94 Spark Plugs 93 94 Speed ose eie eek kis hans Relate 11 Spring Preload Front 33 Spring Preload Rear IQ 37 Spring Preload Rear M10 47 Spring Overload M10 48 Springs Optional M10 49 Starting the Engine 64 65 Starting Emergency 77 Steering Inspection Adjustment 121 Steering Lubrication 88 Steering System 61 121 124 Stopping Emergency 76 Storage Daily 81 Storage Extended 125 128 Studs 5 deste ios Ae sae BS Sled sees 54 Survival Preparation 10 Suspension Adjustments Rear 35 36 Suspension Adjustments EDGE 37 43 Suspension Adjustments M10 44 51 Suspension Coupling IQ 41 Suspension Inspection P
3. 65 66 Engine Protection 126 127 Engine Safety 8 Engine Stop Switch 74 Environment 5 Exhaust System 99 F FEATURES 5220555 25 29 FRA Position M10 46 Front Rear Scissor Stop 41 Front Springs 34 Front Suspension Adjustments 30 34 Front To Rear Coupling 41 ERSS ds de sengor terta dads 4 Fuel 3 css cS hshaee ge eee 68 70 Fuel Filter 4s eee 95 Fuel Lines 00 95 Fuel Reserve Capacity 70 Fuel System Deicers 70 Fuel Valve siss sees eat ead as 68 G General Maintenance 93 116 H Handlebar Adjustments 52 Headlight Adjustment 106 Headlight Bulb Installation 107 Headlight Bulb Removal 107 High Temperature Indicator Light 100 Hood Latches 62 l Ice and Snow Build up 14 IES erii R 30 31 IFS Adjustment Options 30 31 IFS Components 30 Inadequate Snow Conditions 18 Indy Select Shock 32 Intake Filters 95 Intake Silencer 17 INTRODUCTION 4 5 J Jackshaft Bearing 91 Jetting Guidelines 73 L Low Oil Indicator Light 71 Lubrication 88 92 M MAINTENANCE 82 131 Maintenance Interval Table 85 87 MAINTENANCE LOG 150 151 Maintenance Program
4. Low Oil Level Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous ter rain Always check the oil level when refuel ing Maintain the oil level above the tank s low level line When the oil reaches the low level mark add one U S quart of recommended oil See page 66 for oil rec ommendations NOTE The Polaris oil cap on the oil bot tle is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts 71 OPERATION Carburetion Proper carburetor adjustment is critical A lean mixture too much air too little fuel may result in piston burning bearing failure or complete engine failure A rich mixture too much fuel too little air may foul plugs and cause generally poor engine performance A lean mixture may be caused by things like fuel line restrictions for eign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filter in the air intake system Either condition may be caused by improper carburetor adjustment A WARNING Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage Always have your Polaris dealer perform any carburetor adjustments 72 OPERATION Carburetion Jetting Guidelines Changes in altitude
5. 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove D 3 Reverse the procedure for spark plug installation Torque the spark plug to specification Reinstall the spark plug cap 94 MAINTENANCE General Maintenance Intake Filters CAUTION Operating the snowmobile with the intake filters removed may cause carbu retor icing The result will be poor fuel economy or carburetor malfunction Always reinstall the intake filters before operating the snowmobile The intake foam filter limits snow ingestion into the intake system When operating in loose powder snow check the top of the foam filter periodically to remove any accumulation of snow Fuel Filter Fuel Lines See your Polaris dealer for replacement of the in tank 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 CAUTION Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly 95 MAINTENANCE General Maintenance Oil Filter The oil filter should be changed annually or every 1000 miles 1600 km m S Inspect oil line condition at gt 1
6. 84 Maneuverability 17 MED Components 28 N No Passenger Warning 22 NOISE iii an aaa ten en oe tz 5 0 OM aE A cence Y 71 Ou Filter sia aisa 96 Oil Injection System 66 OilLevelisy sch devas deeds tele 71 Oil Lines 04 95 96 Oil Recommendations 66 OPERATION 64 81 Operation Warning 23 24 Operator Safety 6 20 P Park Brake Lever Lock 60 POLARIS PRODUCTS 132 Premium Fuel Switch 69 Pre Ride Checklist 57 PRE RIDE INSPECTIONS 57 63 Pre Ride Suspension Inspection 124 Pressure Cap Warning 21 R Rail Slide Wear 124 Rear Rear Scissor Stop 42 Rear Shocks IQ 38 Rear To Front Coupling 42 Recoil Rope 00 62 Recommended Maintenance 7 Registration Warranty 141 Reverse Kit Maintenance 115 Reverse Operation 78 80 Reverse Warning 23 Reverse Electronic 79 80 Reverse Mechanical 78 Rider Capacity 11 Riding Apparel 9 Riding Position 9 RERSS oe entitle E etch eee 42 S SAFETY eneco oak oe 6 24 Safety Decals 21 24 Safety Symbols 6 Sag TO esse aaa ei aways 37 Sag M10 006 44 47 Seat Bucket 00 28 Seat Bucket Adjustment
7. DETONATION FLASH indicator will flash The activated sensor reduces engine detonation by retarding the ignition timing This results in decreased engine RPM and perfor mance DET Troubleshooting Use this chart to determine causes and solutions for detonation If none of these conditions exists and the sensor remains activated see your Polaris dealer for diagnosis Possible Cause Solution Poor quality fuel Replace with higher quality fuel Improper engine modifications Do not modify the engine Incorrect jetting Use the correct jetting for your altitude D E T Flash Signals Use this chart to determine the meaning and course of action for each D E T flash signal Type of Flash Cause Action 3 flashes of 1 second each Detonation See DET Troubleshooting Chart Solid 3 second flash off 1 Faulty sensor See your Polaris dealer second repeats until engine is shut down Solid non blinking light High water See your Polaris dealer NOTE temperature If temporary operation is unavoidable drive slowly and stop the engine frequently to allow the engine to cool 27 FEATURES Adjustable Seat Bucket On models equipped with an adjustable seat bucket 1 the bucket can be adjusted for ward or rearward for rider comfort The seat bucket is removable for access to the under seat storage compart ment Do not sit on the seat bucket Do not operate the snowmobil
8. POLARIS The Way Out 2006 EDGE Snowmobiles with 121 track Owner s Manual for Maintenance and Safety 53 POLARIS The Way Out For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9919667 Rev 02 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 PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm onto the snow on which they operate Keep this engine properly tuned and avoid unnecessary idling and spillage during fueling A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris enthusiasts Be sure to visit us online at www polarisindustries com for the latest news new product introduc tions upcoming events career opportunities and more Here at Polaris we proudly produce an exciting line of utility and recre ational products e Snowmobiles e All terr
9. Your Polaris engine is designed to run on 87 octane non oxygen ated or 89 octane oxygenated pump gasoline There s a great deal of variability in the quality of the 87 octane gasoline available across the country so we encourage the use of premium fuel when possible Always use the premium fuel switch when using premium fuel NOTE Some engines require premium fuel See your Owner s Man ual Supplement Premium Fuel Switch If your Polaris snowmobile is equipped with a key function to adjust the timing on the machine as you change fuels it s very important to the life of your engine that you use this feature When using fuels with a pump posted f octane rating of 91 or higher turn the Premium Fuel Setting key switch to ON PREM When the engine is started a yellow Premium Fuel light illuminates on the instrument panel When the key is in this position the fuel must be a minimum of 91 octane Return the key switch to the ON REG position when not using pre mium fuel Regular Fuel Setting ON REG If you re uncertain about the quality or octane rating of the fuel you use turn your key switch to ON REG The Premium Fuel light will go out This setting will adjust the timing of your engine to run on fuels with 87 octane or higher Polaris does not recommend using fuel with lower than 87 octane Running your machine on ON REG will help protect your engine from damage caused by low octane fuels CAUTIO
10. Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Tether Switch If your machine has a tether switch remove the tether from the switch to make sure the engine stops immediately v Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating Mirror Adjustment if equipped Adjust the mirrors so they can be used to their full advantage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the machine 63 OPERATION Starting the Engine A WARNING Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your snowmobile without checking all components to be sure of proper operation See Before Starting the Engine beginning on page 58 Turn th 1 val i urn the fuel valve on See page 68 CHOKE TOGGLE 2 Turn the key to the ON position POSITIONS 3 Pull the engine stop switch up to the RUN position OFF 4 Ifstarting a cold engine flip the choke toggle to FULL ON Do not use the choke if starting a warm HALF ON engine NOTE Do not depress the throttle until FULL ON the engine starts A WARNING Don t pull the starter rope to t
11. Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer 110 MAINTENANCE General Maintenance 1 Drive Belt Condition Periodically check the condition and tension of the drive belt and always carry a spare Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist See Belt Troubleshooting on page 138 For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile The following procedures apply to standard electronic reverse and TEAM driven clutches 111 MAINTENANCE General Maintenance Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse The snow mobile must be stopped after forward motion to prevent damage to compo nents during belt removal SN Aan 2b i 112 Stop the engine after operating in a forward motion Turn the ignition key off Wait for the engine to stop completely Lock the parking brake if equipped Open the hood Remove the clutch guard retain ing pin and open the clutch guard Standard Clutch Skip to step 8 TEAM Clutch Locate the L wrench in the tool kit and install it into the open threaded hole in the outer sheave of the clutch Rotate the wre
12. In half turn increments turn the screw clockwise to increase compression valving and stiffen the ride or counterclockwise to reduce compression and soften the ride There are approximately three full turns of adjustment available If bottoming continues after the screw has been turned fully clockwise the torsion spring should be adjusted see page 38 Return the screw to its original starting position after the torsion spring has been tightened Adjustment Screw 39 THE PERFECT FIT EDGE Rear Suspension Adjustments Rear Shocks Polaris Position Sensitive Shock There are no external adjustments on the Polaris position sensitive PPS shock There is a performance PPS shock kit available for increasing damping however If you desire to have the internal valving changed consult your dealer or refer to the suspension troubleshooting decal located under the hood or on the clutch guard FOX Position Sensitive Clicker Shock The FOX position sensitive clicker shock is available as an option on some models Adjustments to the compres sion damping are made by turning the clicker knob on the shock reservoir Eight positions are labeled on the knob Position 1 is the softest or least compres sion damping Position 8 is the stiffest or most com pression damping When adjusting we recommend that you turn the clicker only one click at a time then test ride Clicker Knob 40 TH
13. Test the throttle safety switch system before the machine is operated See page 74 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 handgrip than 1 2 1E Aleem 1 3 cm A smaller dis tance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 105 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 104 A WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess 59 PRE RIDE INSPECTIONS Before Starting the Engine Park Brake Lever Lock Use the park brake lever lock only when you want the machine to remain stationary for example when parked on an incline for a period of five minutes or less Brake Lever 2 Park Brake Lever Lock if equipped 3 Master Cylinder Reser voir Cover 4 Fluid Level Indicator Lock Engagement To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever NOTE If the brake lever is squee
14. 2 3 5 16 8 55 8 143 4 4 3 3 250 Ibs 3 3 1 2 5 16 8 59 16 141 4 4 3 3 275 lbs 3 3 1 2 1 2 13 57 16 138 4 4 3 3 300 Ibs 3 3 1 2 1 2 13 53 16 132 4 4 3 3 325 Ibs 3 3 1 2 5 8 16 53 16 132 4 4 3 3 350 Ibs 3 1 2 4 5 8 16 53 16 132 4 4 3 3 375 lbs 4 5 7 8 22 53 16 132 4 4 3 3 Might prefer optional spring rear track Refer to the list on page 49 51 THE PERFECT FIT Handlebar Adjustments Handlebar Angle Follow these steps to adjust handlebar angle at the handle bar block 1 Remove the handlebar cover 1 to expose the handlebar and the four adjuster block bolts 2 2 Using a 7 16 11 mm wrench loosen the four nuts 3 on the bottom of the adjuster block turn handlebar to left or right for access to back nuts NOTE If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be sure handlebars brake lever and throttle lever operate smoothly and do not hit the fuel tank windshield or any other part of the machine when turned fully to the left or right 4 Torque the handlebar adjuster block bolts to 11 13 ft Ibs 15 18 Nm NOTE Torque the front bolts first 5 Reinstall the handlebar cover 52 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 unapprove
15. 3 Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely 4 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe engine doesn t start take the snowmobile to an authorized Polaris dealer for service Excessive freeplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the machine to an authorized Polaris dealer for service If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOT continue to operate the machine with the throttle safety switch disconnected Return the machine to an authorized Polaris dealer for service as soon as possible 75 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 74 for more information about the engine stop switch and throttle safety switch THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Choke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Swi
16. General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles 3200 km To inspect allow the engine and exhaust system to cool completely Open the hood and inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets A WARNING Hot exhaust system parts can cause serious burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running Engine Cooling Liquid Cooled Models The cooling system on liquid cooled models consists of the following major components e Coolant bottle e Water pump e Cylinders Heads e Inlet and outlet manifolds e Pressure cap e Heat exchangers 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 132 for the part numbers of Polaris prod ucts NOTE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system 99 MAINTENANCE General Maintenance Coolant High Temperature Indicator Light The high temperature indicator light is co
17. Maintenance 2000eeeee ee eeeee 82 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris Products 000eeeeees 132 Troubleshooting 0020ee eee eee 133 Warranty tiie obese hers eee ae 139 Maintenance Log 000eeees 150 Indexiin e et ommawes eet ar ee cues 152 INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number right front side of engine crankcase Key Number 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 sold 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 neces sary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding cl
18. and temperature affect air density which is the amount of oxygen available for combustion In low elevations and cold temperatures the air has more oxygen In higher elevations and higher temperatures the air is less dense The carburetors are calibrated for an altitude of 0 2000 ft 0 600 m and ambient temperatures between 10 to 10 degrees F 23 to 12 degrees C Carburetors must be re calibrated if the snowmobile is operated out side this production temperature and or altitude range The main jet installed in production is not correct for all altitudes and or tempera tures See page 98 for more information CAUTION A main jet that s too small will cause a lean operating condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts in your Owner s Manual Supple ment NOTE It s the owner s responsibility to ensure that the correct jets are installed in the machine for a geographical area Be very care ful when jetting down in warm weather As the weather turns colder it will be necessary to re jet upward to prevent engine damage When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encoun tered 73 OPERATION Engine Stop Switch Push down on the engine o stop switch to ground out the ignition and stop the engine quickly Pull the switch up to the ON position to allow restart
19. 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 num ber and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifying the proper owner when a unit is recovered 140 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 warranty period through a Polaris dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be
20. any abnormal wear or chip ping is found Skag Replacement 1 Raise and support the front of the machine so the skis are approxi mately 6 15 2 cm from the ground Remove the attaching nuts and pry the skag downward Remove the rear end of the skag Remove the front end of the skag US eRe Ge oh Reverse the steps to install a skag 123 MAINTENANCE Steering System Rail Slide Wear Measure slide thickness at 7 16 several points along the rail 1 1 cm Have your dealer replace the a A slide when it s worn down to 7 16 1 1 cm Do not oper ate the snowmobile if slide thickness measures less Suspension Maintenance 1 Pre Ride 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 Check suspension mounting bolts for tightness Check rear idler wheel bolts for tightness See page 119 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition Check track tension See page 118 Lubricate all rear suspension components See page 88 Check ski runner skag condition See page 123 Check ski spindle bolts for tightness YYYYYYY YY Check tie rod end nuts for tightness 124 MAINTENANCE Exte
21. are compatible with each other Slide Rail and Track Cooling CAUTION Inadequate cooling and lubrication will lead to overheating of the slide rail and track resulting in premature wear and failure Reduce speeds and fre quently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice hard packed surfaces or roads 66 OPERATION Track Warm Up A WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throt tle during warm up or when the track is free hanging Use a stable rear sup port A WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be about 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 revo lutions NOTE It will ta
22. in the Master Repair Manual See your dealer Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel If stabilizer is not used drain the carburetors by removing the water trap drain plugs See page 97 NOTE Jet restriction caused by improper storage can cause lean con ditions and very poor slow speed driving quality 126 MAINTENANCE Extended Storage Engine and Carburetor Protection Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system If you prefer to drain the fuel tank use the fol lowing procedure l Transfer unused fuel from the fuel tank to an approved fuel con tainer using a siphon pump Do not re use fuel after storage Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward Remove the spark plug s Rotate the engine slowly watching the piston until it s at bottom dead ce
23. performance clean with non oil based cleaners such as isopropyl alcohol A WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not operate the machine until repairs have been made All clutch maintenance and repairs must be performed by an authorized Polaris dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty CAUTION The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings 109 MAINTENANCE General Maintenance Clutch Alignment Offset Clutch center distance and align ment are crucial to maintain ing optimum performance See your Owner s Manual Supplement for the recommended offset between the drive and driven clutches with the belt removed Belt width and length must match the center distance of the clutches and sheave width of the drive clutch For this reason Polaris recommends that only O E M belts be used Other belts may match the dimensions but can drastically change the shift pat tern resulting in poor perfor mance See your dealer for service and adjustments NOTE A worn belt will continue to function but will not deliver maximum perfor mance Always carry a spare belt in case of an emergency
24. riders on rough trails or very aggressive riding The available springs for M 10 suspension are listed below LOCATION SPRING RATE POLARIS PN Front Arm Standard 160 Ibs in 7041671 216 Front Arm Soft 140 Ibs in 7041677 067 Front Arm Firm 180 Ibs in 7041672 067 Rear Arm Standard Rear Arm Soft Rear Arm Firm 210 278 Ibs in 135 240 Ibs in 300 Ibs in 7041935 216 7042010 216 704201 1 067 Overload 1000 Ibs in 7041936 067 49 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Other Ride and Performance Settings Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a rider prefers more ski pressure for improved steering performance adjustments can be made to the front limiter strap and front arm mount 1 Determine if the rider ol 4 prefers comfort or con c 3 trol Lean toward the 4 o2 setting for comfort and 5 1 toward the 3 setting for aggressive riding 2 For full hole adjust ments remove the 5 16 a 2 nut and flat washers from ot 3 the lower attachments of e4 the limiter straps and relocate the straps to the desired position i e move from position 4 to 3 Replace the nut and washer Tighten securely 3 For half hole increments such as 3 4 the limiter straps have slots at the upper pinch bolt These slots allow the bolts to be loosened rather than removed for half step adjustments
25. the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover WARNING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service clutches yourself see your dealer Airbox Warning This warning decal is found under the hood on applicable models Do not operate above 40 mph with hood to airbox foam removed or engine failure will result Pressure Cap Warning This warning decal is found under the hood on the pressure cap of appli cable liquid cooled models Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI Seat Bucket Warning The seat bucket warning is molded into the seat bucket mounting flange It s visible when the bucket is removed DO NOT OPERATE WITH SEAT BUCKET REMOVED 21 SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel 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 No Passenger Warning Some snowmobiles are designed for the operator only while others are designed for the operator and one passenger A warning decal on the console indicates whether it s designed for the operator only 1 Up or the operator and a pas senger 2 Up D
26. the vehicle is stopped and the engine is running at idle before shifting to reverse Engaging Reverse l 2 3 Stop the snowmobile and leave the engine idling Make sure the area behind your vehicle is clear Push the yellow reverse button p x 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 machine is in reverse Apply the throttle slowly to make sure the machine is in reverse NOTE The maximum engine RPM will be 6000 when in reverse NOTE Ifthe engine stops running the snowmobile will be in forward gear when it s restarted 79 OPERATION Reverse Operation Electronic Reverse PERC Disengaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Push the yellow reverse button for one second and release The engine will slow and begin to rotate forward The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the machine is in forward Altitude Setting At higher altitudes above 6000 feet the engine will require a different ignition setting to improve the success of the reverse system To set for a higher altitude start the engine and hold the button down until the light on the instrument panel flashes rapidly then release the button To set the reverse for lower elevations continue holdin
27. 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 setup of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer setup 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 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 wa
28. tighten if necessary 121 MAINTENANCE Steering System Ski Alignment A WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment or camber adjustment See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y NOTE Ifthe skis are misaligned we recommend that your dealer cor rect the alignment since camber adjustment may also be affected Sole gt l lt 122 MAINTENANCE Steering System i Ski Skags A WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed snow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter NOTE Carbide skags must be replaced if
29. 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 2006 Edge 121 Owner s Manual P N 9919667 2 TABLE OF CONTENTS Introduction 0 000 eee ee 4 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 seis eG sath nec EEEa Seeds oe hens 6 This section describes safe vehicle operation and identifies warning decals and their locations PEALUTES core a ee Shei eA ee ies 25 This section identifies the locations of your snowmobile s controls and features The Perfect Fit ia eccsccedex Rete de ive een 30 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 0000000 57 This section explains procedures that must be performed before riding Operation 0 0 es 64 This section explains proper engine break in operation of features and general operating procedures
30. to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS Attributes Moving the RRSS to a higher position will have the following effects on the suspension e Reduced weight transfer Improved chatter bump ride e Improved cornering performance 42 THE PERFECT FIT EDGE Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop RRSS The factory setting is the best for most trail riding condi tions To decrease weight transfer under acceleration for improved comer ing rotate the RRSS to a higher position with the scissor stop tool located in your tool kit To increase weight transfer or ski lift during acceleration move the RRSS to the rearward hole on high posi tion The RRSS may also be rotated to a lower position for even more weight transfer if desired Stock Position This setting is most desirable for trail riding Medium or High Position standard hole location This setting will decrease weight transfer Rearward Upper Position optional hole location This setting will increase weight transfer NOTE Your dealer can help you with initial setup and addi tional setup instructions to help you achieve your opti mum ride Scissor
31. 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 146 WARRANTY Exported Vehicles 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 War ranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be 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 Indust
32. 000 miles 1600 km Polaris oil filters are specially designed for use on Polaris products We strongly recom mend the use of only Polaris replacement parts See page 66 for oil recommendations EDGE models use an oil filter that s built into the oil sending unit located in the bottom of the oil tank After changing the oil filter bleed the oil injection system of all trapped air See your dealer for instruc tions or have your dealer perform the filter change and bleeding opera tion for you NOTE The direction of the arrow indicates the direction of flow through the filters Water Pump Belt Inspection Some liquid cooled models require inspection of the water pump belt at 1500 miles 2400 km Inspect belt width and condition and replace if cracked or worn past the width service limit 250 6 35 mm New belt width is approxi mately 345 8 75 mm See your Polaris dealer if the belt needs to be replaced 96 MAINTENANCE General Maintenance Water Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water sedi ment traps located at the bottom of each carburetor The trap consisting of a hose with a plug should be drained at least every 2000 miles 3200 km and inspected for contamination A WARNING When draining the traps fuel spillage will occur Always work in a well venti lated area away from anything that may cause the fuel to ignite such as open flames spa
33. 4 18 22 26 31 35 39 43 47 64 2 6 10 15 19 23 27 31 35 40 44 48 72 2 7 11 15 19 23 28 32 36 40 45 80 3 7 11 15 20 24 28 33 37 41 45 88 3 7 12 16 20 24 29 33 37 42 46 16 Frostbite in gt gt 30 min 10 min WINDCHILL CHART C Wind Actual Thermometer Reading C Speed 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature C Cam 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 o 7 11 14 18 22l 25 29 32 l 36 39 43 46 50 539 57 16 2 2 6 10 13 17 21 24 28 32 36 39 43 47 50 54 58 62 1 0 20 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 man ual 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
34. E PERFECT FIT EDGE Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the advent of sus pension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other There are two types of rear suspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm causing it to compress and raise the rear suspension up as one allowing the suspension to hit the bump only once and reducing kickback The factory setting is usually adequate for all riders and conditions 41 THE PERFECT FIT EDGE Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop RRSS The rear rear scissor stop RRSS couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen dent movement between the rear torque and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight
35. N Using fuels with a lower than recommended octane or operating with obstructed fuel systems will result in serious and costly engine damage Always use the recommended fuels for your machine 69 OPERATION Fuel Fuel Reserve Capacity Mechanical Gauge There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends the use of Carbon Clean Plus See page 132 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives should not be used CAUTION Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel 70 OPERATION 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 Add oil before further operation of the snowmobile CAUTION Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed
36. NTIES NOT STATED IN THIS WARRANTY 148 WARRANTY Snowmobile Engine Emissions Limited Warranty 340cc and 600cc Engines Only Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This lim ited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical emissions related maintenance is not performed Performance of other scheduled main tenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified repair shop or qualified person may maintain replace or repair the emis sion control devices or systems on your snowmobile Polaris recommends that you con tact an authorized Polaris dealer to perform any service that may be necessary It is a potential violation of the Clean Air Act if a pa
37. Re tighten the pinch bolts 4 There are also two front arm mounting holes in the slide rail that can adjust ski pressure The lower hole 1 increases ski pressure while the upper hole 2 decreases ski pressure NOTE By design the BIASED COUPLE design of the M 10 suspen sion displaces the rear arm as the front arm is compressed This means that when you raise the front limiter strap at some point you will collapse the rear suspension arm which will affect SAG height and reduce rear suspension travel 50 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Initial M 10 Suspension Set up Chart NOTE These positions are only preliminary Experimentation should follow initial set up to obtain optimum results Refer to the sus pension troubleshooting decal for additional set up tips INITIAL SET UP REFERENCE CHART This chart is a guideline to be used for initial suspension set ups Your set up may vary based on your desired riding style FRA Position Dimension pimenslon Rider weight SOFT FIRM Rear Spring Crossover Limiter Ski with full Preload Tube Length Pressure riding gear Settings Settings In mm In mm Light Firm 100 Ibs 1 11 4 0 0 55 8 143 4 4 3 3 125 Ibs 1 11 2 0 O 513 16 148 4 4 3 3 150 Ibs 1 11 2 5 16 8 513 16 148 4 4 3 3 175 Ibs 11 2 2 5 16 8 513 16 148 4 4 3 3 200 Ibs 2 2 1 2 5 16 8 53 4 146 4 4 3 3 225 lbs 2 1
38. Stop Tool ROTATE Cs Ji wf Rearward Upper 43 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments The M 10 suspension has been designed to be very sensitive to rider weight Changes in rider weight of 25 Ibs 11 kg or more might require appropriate changes in settings The following information has been compiled to assist you in tuning your M 10 suspension to its maximum potential and achieve the best possible ride Please take the time to read and understand all the possible adjustments available with this suspen sion Static Sag and Ride Height Settings Static sag describes the difference in height of the rear bumper from the suspension s fully extended position to its loaded height with the rider seated on the snowmobile A good initial starting point is four inches of sag measured at the rear bumper Too much sag will result in bottoming and too little sag will result in reduced rider comfort Sag travel is used to control ride quality and rebound travel On the M 10 suspension sag is controlled by two settings the full range adjuster FRA position and the rear spring preload 44 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Static Sag and Ride Height Settings l To check sag raise the rear bumper until the suspension is fully extended the rear shock will not extend any further Measure the distance from the ground to the bottom of the bumper dimension X as shown in the il
39. ain 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 owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc RIDER SELECT is a trademark of Polaris Industries Inc M 10 is a registered trademark of FAST Inc Copyright 2005 Polaris Sales Inc All information contained within this publication is based on the latest product information at the
40. ake sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation A WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn off the igni tion
41. and lift the seat bucket to remove it from the seat To reinstall place the bucket sideways onto the bucket mounting flange 2 Rotate the bucket 1 4 turn to its original position Make sure it latches securely CAUTION Movement of heavy loose tools or other objects in the storage compartment may result in damage to the taillights Always secure any loose objects to prevent bouncing and shifting within the compartment 29 THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension IFS Break in the suspension for about 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 machine should be methodically tested one change at a time under the same conditions trail and snow conditions 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 Trailing arms IFS Adjustment Options Shock damping if equipped with Indy Select or RydeFX SOLO shocks Front shock spring preload e Optional springs e Optional shock valving if equipped with RydeFX shocks e Toe ski alignment see page 122 e Camber see your dealer 30 THE PERFECT FIT Fr
42. ca tion SEE YOUR DEALER Track jammed e 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 133 TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive sys tem Probable Cause Solution Broken drive clutch SEE YOUR DEALER components Bearing failure e SEE YOUR DEALER chaincase jackshaft or front drive shaft Drive belt surface flat spots Inspect and replace as needed Drive chain loose Inspect and adjust or replace Drive chain worn sprocket teeth bro ken SEE YOUR DEALER Poor low RPM per formance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t turn Seized engine SEE YOUR DEALER Seizure isa result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered the crank case 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 Engine doesn t start electric start mod els Wire con
43. ction can be adjusted without removing the clutch from the jackshaft 1 Pull the belt into the driven clutch to slightly open the sheaves 2 Loosen the three bolts on the adjustment cam and turn the cam counterclockwise to reduce the distance between the sheaves Do not rotate past the 1 position 3 Torque the bolts to 4 6 ft Ibs 5 4 8 Nm TEAM Clutch 1 Loosen the 7 16 jam nut on the belt width adjuster 2 Using a 1 8 Allen wrench adjust the threaded set screw as needed NOTE Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the distance 3 Tighten the jam nut 114 MAINTENANCE General Maintenance Torque Stop If your snowmobile is equipped 010 030 with an engine torque stop periodi 25 75 mm cally check torque stop clearance With clutches in proper alignment the torque stop clearance should be 010 030 25 75mm from the o engine case Adjust if necessary and lock the S jam nut o he o lt 2 Reverse Kit Maintenance a If your snowmobile is equipped with reverse or if you have a reverse kit installed it s especially important to maintain track tension as specified on page 118 A WARNING Improper track tension can cause serious damage to the snowmobile which can result in loss of vehicle control and serious injury or death Always main tain the track tension as specified Allo
44. d parts and accessories may result in e Non compliance with government industry requirements e Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for ser vice 53 THE PERFECT FIT Traction Products Studs Before equipping your machine with traction products be aware of the laws in your area pertaining to the use of traction products See your dealer about installing studs and or carbides Many tracks with deep lug designs cannot be studded but your dealer will be able to offer advice and assistance Use only Polaris traction products on your snowmobile Track warran ties are void if track damage or failure results from improper or exces sive stud installation or the use of non Polaris traction products See your dealer about installing studs and or carbides CAUTION Always install wear strips before installing studs Failure to install wear strips may result in cooler or tunnel damage See page 56 Never add shims to the wear strip Track damage will result because of lack of clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tun nel Track studdin
45. de the main rear spring Contact is made with this spring only when the crossover tube comes in contact with it toward the end of the travel which reduces bottoming of the rear suspension The correct setting of the crossover tube length enables the M 10 suspension to deliver superior performance in bottoming situa tions This adjustment has no effect on spring pre load or general ride characteristics of the M 10 rear suspension it affects only bottoming resistance To adjust the crossover tube length dimension C in illustra tion and set up chart 1 Use the spanner wrenches located in the tool kit to unlock the upper lock nut from the adjuster collar 2 Turn the adjuster collar to the appropriate or desired dimension for the rider s weight refer to the initial set up reference chart located under the hood of your snowmobile and on page 51 Using the spanner wrenches tighten the upper lock nut firmly against the adjuster collar 48 Other Ride and Performance Settings Optional Springs THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Optional springs have been designed to allow adaptation of the M 10 suspension to your specific needs The 140 Ibs in optional front arm spring would be used when very light load conditions exist such as operation on very smooth trails in deep powder or by very light riders The 300 lbs in rear arm spring option would be used when high load conditions exist such as operation by heavy
46. e between the ground and the rear bumper at the exact location used for measurement X This is mea surement Y lt lt 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 Use the illustration for ref erence The ideal amount of Sag for the EDGE rear suspension is four inches X Y 4 If the rear suspension rides in less than three inches or more than five inches with the torsion spring preload cams at their maximum range of adjustment optional torsion springs softer or stiffer respectively may be required This is only an initial set up and final spring preload may vary based on rider preference and riding conditions 37 THE PERFECT FIT EDGE Rear Suspension Adjustments Torsion Spring Tension To adjust rear torsion spring tension rotate the three position cam using the engine spark plug tool Different rate torsion springs are available if a firmer ride is desired See your dealer for more information a eS Soft Tension Medium Tension Firm Tension 38 THE PERFECT FIT EDGE Rear Suspension Adjustments Rear Shocks Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock which allows for adjustments to the compression valving by turning the adjust ment screw located near the base of the shock Locate the adjustment screw near the base of the shock
47. e IFS preload Ensure use of Accu Trak dual skags Front end pushes Check for worn skags Check for binding suspension shafts and grease all pivot points Increase front IFS preload Shorten front limiter strap Steering is heavy Check ski alignment Check skags and skis for damage Decrease IFS preload Make sure spindles and all steering components turn freely 137 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear Burn Diagnosis Solutions Causes Driving at low RPM Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Towing at low RPM e Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM e Lower the gear ratio Reduce RPM Avoid riding in and slow speed 8000 high ambient temperatures Check for snow ingestion RPM 10 MPH Ice and snow build up between track and tunnel Poor engine performance 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 Check for carburetor and choke synchronization fouled plugs debris in the carburetor s and water ice or dirt in the fuel tank or fuel line Loading machines onto trailers Skis may gouge in
48. e of air bubbles A WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 104 8 Reinstall the gasket and cover 105 MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro cedure 1 Place the snowmobile on a level surface with the headlight approxi mately 25 feet 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall NOTE Rider weight must be included on the seat 5 Turn the adjustment nut located inside the hood just below the headlamp opening Turn the knob in or out as needed for proper aim 25 ft 7 6 m Lamp Center Height T 2 5 1 cm 106 MAINTENANCE General Maintenance NOTE Do not touch a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Bulb Removal 1 Pinch the ends of the spring 1 3 together and lift u
49. e with the seat bucket removed A WARNING Operating or riding the snowmobile with the seat bucket removed or while sit ting on the seat bucket may cause loss of control or ejection from the snow mobile which could result in serious injury or death Never sit on the seat bucket and always make sure the seat bucket is securely installed before operating the snowmobile Seat Bucket Adjustment To adjust the seat bucket press down on the release latch 2 and slide the bucket forward or rearward to the desired position Make sure the bucket locks firmly in position before operating the snowmobile 28 FEATURES Trunk Lock Models equipped with the adjustable seat bucket are also equipped with a trunk lock which is located between the taillights 1 Use the trunk lock keys to lock or unlock the under seat storage compartment If keys are lost or misplaced see your Polaris dealer When the trunk is locked the lock cannot be pressed in and the seat bucket cannot be removed NOTE If the trunk is locked after the bucket has been removed the bucket can still be rein stalled The lock will remain engaged until it s unlocked with the key When reinstalled the bucket will be locked in place Trunk Access The seat bucket must be removed to access the trunk Unlock the trunk using the trunk lock key 2 Press the lock inward and hold while rotating the adjustable seat bucket 1 4 turn Release the lock
50. ecal text found on 1 up models WARNING This vehicle is designed for operator only NO PASSENGER 22 SAFETY Safety Decals and Locations Reverse Warning Some Polaris snowmobiles are equipped with reverse These models have a reverse warning decal on the lower dash WARNING Reverse operation even at low speeds can cause loss of con trol resulting in serious injury or death To avoid loss of con trol always Look behind before and while backing up e Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse e Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation e Push button again to return to forward e Elevation setting above 6000 feet push and hold for longer than 5 seconds to set Let go of button at desired setting fast flash for high elevation slower flash for low Setting will remain until changed Operation Warning The operation warning decal is located on the console 23 SAFETY Safety Decals and Locations Operation Warning The operation warning decal is located on the console of all Polaris snowmobiles e To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing con tact a Polaris dealer for a replacement e T
51. eet per second If you look back for only two sec onds your machine will travel about 120 feet If your speed is 60 MPH your machine will travel about 180 feet in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your machine to a stop in the distance illumi nated by the headlight 11 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles posts or other obstacles Be especially alert if you re snowmobiling after dark Always be on the alert for wire fences Single strands are especially dangerous since there may be a great distance between posts Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your machine will drown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or high ways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Avoid travel ling on frozen bodies of water 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 t
52. eeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2870990 DOT 3 Brake Fluid 12 oz 2872893 Engine Degreaser 12 oz 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner 132 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 Disassemble drive clutch to inspect shift weights for wear and free operation SEE YOUR DEALER Clean and polish stationary shaft hub Driven clutch mal function Replace ramp buttons and rollers SEE YOUR DEALER Inspect movable sheaves for exces sive bushing clearance and replace if necessary SEE YOUR DEALER Harsh drive clutch Drive belt worn or e Replace the drive belt engagement too narrow Excessive belt e SEE YOUR DEALER sheave clearance Drive belt turns over Wrong belt for appli e Replace the drive belt cation Clutch alignment out of spec Adjust alignment offset SEE YOUR DEALER Engine mount bro ken or loose Inspect and adjust or replace SEE YOUR DEALER Machine fails to move Clutch jammed e Check for twisted belt broken spring sticking weights lubri
53. emove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary CAUTION Towing a disabled snowmobile with the drive belt in place can result in seri ous damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 81 MAINTENANCE Emission Control Information 340cc and 600cc Engines Only Emission Control Label Your snowmobile is equipped at the time of sale with an emission con trol information ECI label and a factory installed emissions informa tion hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 The emission control system designation per SAE J1930 is EM If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a quali fied dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is available to your
54. en reinstalling the battery always connect the negative black cable last Disconnect battery hold down straps Remove battery vent tube from battery Disconnect black negative battery cable first Disconnect red positive battery cable second ie ee Carefully lift the battery out of the snowmobile Do not tip it side ways or spill electrolyte CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 130 MAINTENANCE Battery Battery Installation A WARNING Batteries contain gases that can explode If the battery vent tube is pinched or kinked battery gases could accumulate Whenever removing or installing the battery disconnect the negative black cable first and reinstall the nega tive cable last to avoid the possibility of explosion Battery electrolyte contains acid Avoid skin contact with electrolyte as severe burns may result Place the battery in its holder Attach the hold down strap 2 Install the battery vent line It must be free from obstructions and securely installed Route the vent line properly to prevent kinks and to allow for proper drainage 3 Connect and tighten the red positive cable first 4 Connect and tighten the black negative cable last 5 Verify that cables and vent hose are properly routed Battery Storage When your snowmobile is placed in storage for one mo
55. en the snowmobile is stopped and when engine speed is at idle e Look behind the vehicle before and while backing e Avoid sharp turns Apply throttle slowly Mechanical Reverse Make sure the shift lever is shifted completely into forward or reverse position Some models are equipped with a reverse indicator light that will help you make that determination Do not force the shift lever into reverse if resistance is felt The gears may not always be aligned for shifting into reverse and forcing the lever may cause damage If resistance is felt gently apply the throttle to move the gears to a different position and try to shift again The transmission may not always be in the gear indicated by the shift lever Apply the throttle slowly until you re sure which gear is engaged Sometimes the drive belt will drag in the drive clutch causing slight tension in the transmission and making it hard to shift Shutting the engine off will remove this tension and ease shifting This should only happen during the break in of a new belt or when the drive driven clutch center distance is too long If this is the case belt tension adjustments should be made by your dealer 78 OPERATION Reverse Operation Electronic Reverse PERC Electronic reverse will activate only if the engine RPM is below 4000 If your machine is running at an altitude of over 6000 feet adjust the igni tion setting as described below Always make sure
56. ension is new it may take from 25 to 200 miles 40 300 km to properly break in the springs and shocks at which time the suspension will be softer and may require FRA re adjustment AG Oo CD 46 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Static Sag and Ride Height Settings Rear Spring Preload The top section of the crossover tube the tube at the top of the rear shock has a threaded collar on it The rear spring has a lock tab that fits into the collar to allow easy spring preload adjustment Refer to the ini tial set up chart on page 51 1 To increase preload use the tool kit spanner wrench to rotate the crossover toward the left side of the snowmobile clockwise when viewed from below Rotate toward the right side to decrease preload counter clockwise when viewed from below Be sure the aluminum lock nut and adjuster collar are locked against each other before starting the adjustment 2 While adjusting keep in mind that spring preload is a fine tuning adjustment Coarse adjustments should be made using the FRA NOTE Preload is set softest when the preload dimension B in illus tration and set up chart is equal to zero Adjusting spring pre load beyond this could cause damage to the threads 47 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Other Ride and Performance Settings Overload Spring The overload spring is located insi
57. eplace filter backfires Incorrect clutching e SEE YOUR DEALER Carburetor and fuel SEE YOUR DEALER pump Engine continually Faulty plug s e Change plug s Carburetor Fuel System Dirt or ice may be in the fuel sys tem add deicer to non ethanol fuel at all times to prevent icing Incorrect throttle freeplay or faulty switch SEE YOUR DEALER 135 TROUBLESHOOTING EDGE Suspension Troubleshooting Problem Solution Rear suspension bot Increase torsion spring preload toms too easily e Increase rear shock compression damping by turning screw clockwise e Increase torsion spring wire diameter see your dealer Rides too stiff in rear Check for binding suspension shafts and grease all pivot points e Decrease torsion spring preload adjustments e Decrease rear shock compression valving by turning screw counterclockwise if equipped with optional Indy Select shock e Change to lighter valving if if equipped with FOX shocks e Check for proper track tension Machine darts from e Make sure skis are aligned properly side to side e Make sure spindles and all steering components are free turning e Make sure skags are straight on skis e Check rail slide and replace if worn e Reduce ski pressure A Reduce IFS spring preload B Reduce rear torsion spring preload Front end pushes e Check for worn skags e Check for binding suspension shafts and grease all pivot
58. f the machine 101 MAINTENANCE General Maintenance Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension l 102 Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly Loosen the adjuster bolt jam nut 1 Finger tighten the adjuster bolt 2 until it can no longer be adjusted by hand then back off 1 4 turn Tighten the jam nut while holding the adjuster bolt Torque to 21 ft Ibs 28 Nm Release the brake lever lock MAINTENANCE General Maintenance 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 A kit is available for replacing brake pads See your dealer A WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the machine to an authorized Polari
59. ffort and greatly affect the ride In deep snow a new rail slide will offer improved performance over worn rail slide It can also improve top speed When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer Polaris offers track kits for improved flotation in deep snow See your dealer for assistance NOTE Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension components Grease rear suspension pivots before adjusting the rear suspension See page 88 Track Tension Track adjustment is critical for proper handling Always maintain cor rect tension and alignment Refer to the track tension maintenance sec tion beginning on page 118 36 THE PERFECT FIT EDGE Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the EDGE rear suspension torsion spring preload measure the distance between the ground and rear bumper This is measurement X Take the first measurement with no rider and with the rear suspension at full extension lt x gt NOTE The rear bumper may need to be lifted upward slightly to fully extend the rear 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 distanc
60. g Always maintain cor rect tension and alignment TRACK TENSION DATA CHART A Measurement Slack Suspension Weight Location Measurement EDGE 10 Ibs 4 54kg 16 ahead of 3 8 1 2 rear idler shaft 1 1 3 cm M 10 10 Ibs 4 54 kg 16 ahead of 7 8 1 1 8 rear idler shaft 2 2 2 9 cm NOTE Tension adjustments should be made only after the track is warmed up and limber Turn the engine off 2 Lift the rear of the machine and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is hanging 118 MAINTENANCE Track Maintenance Track Tension 4 Check for specified slack between the wear surface of the track clip and the plastic slider Refer to the Track Tension Data Chart on page 118 If the track needs adjustment 5 Loosen the rear idler shaft bolt 6 Loosen the locknuts Locknut Slack Adjusting Screw Measurement 10 Ibs 4 54 kg 7 Tighten or loosen the track adjusting screws 4 to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track NOTE Check more frequently when the machine is new 9 Start the machine and slowly rotate the track at least five revolu tions Let the track come to a stop do not apply brakes 10 Check track alignme
61. g the button down until the reverse indicator light blinks slowly Once set it s stored in memory until changed whether the machine is running or not 80 OPERATION Daily Storage At the end of each ride park the snow mobile on a level surface and support it at the rear with an appropriate track stand The track should be suspended approximately 4 10 cm off the ground Remove the key and cover the machine 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 A WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed 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 per son riding in the towed object Braking distances increase when towing loads Slow down to maintain con trol of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components R
62. g will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Steering abil ity may be reduced on hard packed snow or ice When studded tracks are used increased wear to the brake pads will result from increased braking Extended wear brake pad kits are avail able See your dealer CAUTION Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage The center of the stud must be at least 1 1 8 2 86 cm from the outside edge of the track 54 THE PERFECT FIT Traction Products Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain Use carbide skags with studded tracks to help maintain proper vehicle steering and control See page 123 If your machine has carbide skags it may be necessary to add track studs to maintain proper vehicle control Maintain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Inspect skags and studs frequently Worn studs or skags may reduce steering and braking control on hard packed snow and ice Replace worn s
63. ge is sub ject 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 cover age 144 WARRANTY Polaris Second Year Engine Service Contract 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 e Damage due to accident fire explosion theft or other causes beyond Polaris con trol Damage caused by the failure of other components of the snowmobile e Failures caused by improper fuel or oil e Piston seizures unless caused by a defective engine component e Failures caused due to improper adjustments 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 seaso
64. gm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function CAUTION Brake fluid will damage decals paint and some plastics Always wipe up spills immediately 104 MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action Bleed the system before operating the snowmobile A WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever During the bleeding procedure keep the brake handle as level as possi ble The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent Remove the 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 a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air Close the bleeder valve and release the brake lever Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream fre
65. he fully extended position and don t allow it to snap back into the housing Damage may result To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running 5 Ifequipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts 6 Ifnot equipped with electric start grasp the recoil rope handle and pull slowly until the recoil engages then pull abruptly to crank the engine Repeat the cranking procedure as needed until the engine starts After the engine starts flip the choke toggle to the OFF position If the engine slows or wants to stop use intermittent choking to the HALF ON position 64 OPERATION Engine Break In No single action on your part is as important to long trouble free machine life as proper break in of a new or rebuilt engine Premix the first tank of 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 CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle open ings and machine speeds to reduce friction on all close fitting machined parts allowing them to break in slowly wi
66. hem to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses 12 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain e Take an avalanche class Travel with experienced people Travel on designated trails l e Make sure each person is equipped with a shovel probe and avalanche beacon You don t have to be snowmobiling on a slope for an avalanche to occur Be aware that all of the snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in moun tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information For more information about avalanche training and avalanche condi tions contact local law enforcement in your area or visit either the American Avalanche Association online at www americanavalancheas sociation org or the U S Forest Service National Avalanche Center at www avalanche org 13 SAFETY Operator Safety Ice and Snow Build up A WARNING Ice and snow build up may interfere with the steering of your machine result ing in serious injury or death Keep the underhood area free of snow a
67. his 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 e 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 e Never consume alcohol or drugs before or while operating this vehi cle e 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 e Always wear an approved helmet eye protection and adequate clothing while operating this vehicle e This vehicle is designed for adult use only Check local laws for age requirements e 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 e 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 e 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 e Repeated stops from high speed may cause fading or sudden loss of braking ability e Parking brake may relax when used for long per
68. ich could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of track dam age and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty 61 PRE RIDE INSPECTIONS Before Starting the Engine Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions Under no circumstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your Polaris dealer for replacement y Transmission Make sure the transmission is not in reverse before starting the engine if equipped with reverse 62 PRE RIDE INSPECTIONS Start the Engine and Check Engine Stop Switch
69. ile unattended 19 SAFETY Operator Safety Windchill Temperature Charts The following information is provided to help you determine when tem peratures become dangerous for riding WINDCHILL CHART F Wind Actual Thermometer Reading F Speed 70 T35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 MPH Equivalent Temperature F Calm 40 35 30 25 20 15 10 5 0 5 10 15 20 25 80 85 40 45 5 36 31 25 19 43 7 1 5 11 16 22 28 34 40 46 52 57 63 10 34 27 21 15 9 4 10 16 22 28 35 41 47 53 59 66 72 15 32 25 19 13 6 0 7 13 19 26 32 30 45 51 58 64 20 30 24 17 11 4 22 3 1 0 25 29 23 16 9 4 30 28 22 15 8 5 35 28 21 14 7 7 40 27 20 13 6 1 8 45 26 19 12 5 2 9 50 26 19 12 4 3 10 55 25 18 11 4 3 11 60 25 17 10 3 4 11 Frostbite in gt gt 24 3 7 11 15 19 22 26 30 34 38 42 45 49 53 57 32 4 8 12 16 20 24 28 32 36 39 43 47 51 55 40 1 5 9 13 17 21 25 29 33 37 41 45 49 53 48 1 5 9 13 18 22 26 30 34 38 42 46 50 56 2 6 10 1
70. ine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color A WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection NOTE Incorrect fuel mixture can often cause a spark plug to appear too dark or too light in color Before changing spark plug heat ranges be sure the correct main jet is installed in the carbure tor s Refer to the Owner s Manual Supplement or see your dealer 93 MAINTENANCE General Maintenance Spark Plugs 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incor rect carburetor throttle body adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incor rect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap
71. ing Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position A WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a 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 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine 74 OPERATION Throttle Lever A WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control which could result in serious injury or death If the throttle lever does not work properly DO NOT start the engine If the engine stops abruptly when the throttle lever is released Turn the ignition switch to OFF 2 Visually inspect the throttle cable and carburetor to determine what caused the safety switch to activate
72. iods Do not leave brake engaged for more than five minutes e Before starting 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 24 O ON D OTR ON gt FEATURES Hood Headlight Windshield Handlebar Seat Storage Compartment Trunk Taillights Rear Bumper Snow Flap Track Suspension Ski Nosepan Front Bumper Adjustable Seat Bucket select models 25 FEATURES Some Polaris snowmobiles are equipped with special features such as a reverse indicator light electronic fuel gauge temperature light and elec tric shock control gauge Not all models come with these features Refer to your Owner s Manual Supplement for the features on your machine OCONAAARWNY gt 26 Choke Headlight Dimmer Switch Park Brake Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button Electronic Shock Control Button Fuel Filler Cap Ignition Switch Brake Lever Speedometer Tachometer Engine Stop Switch Throttle Control Hood Hold Down Straps Recoil Starter Handle FEATURES Detonation Elimination Technology D E T Some Polaris snowmobiles are equipped with a detonation sensor that monitors the engine and responds to detonation by automatically reducing the engine timing When activated the
73. ions 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 143 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow mobiles that were Snow Checked through an authorized Polaris dealer during the March April Snow Check promotion The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transfer able 120 days after the original purchase date free of charge through any Polaris snow mobile dealer Coverage on Snow Check units is automatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty reg istration form This form is your proof of warranty Consumer Exclusions e Each repair visit after the first twelve months of standard warranty covera
74. ke longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the machine to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice 67 OPERATION Fuel Valve Turn the fuel valve clockwise to OFF to shut off the fuel 5 supply Turn the valve OFF n counter clockwise to ON to turn the fuel supply on ON Fuel A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the snowmobile is stored or parked A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 68 OPERATION Fuel
75. l 103 Brake Fluid 104 R UEL MANAGEMENT Pilot Air Screws l l l Carburetor 98 l l l synchronize Idle RPM l l l Throttle Lever 75 l l l l l Oil Pump Lever l l l synchronize Throttle Cable 91 L L L Choke Cable 91 L L L Choke 91 l l l Vent Lines l l l l Throttle Position l l l Sensor Fuel Lines 95 l l l l l Fuel Filter 95 R R Oil Filter 96 R R Oil Lines l l I Oil Change R R Air Box l l l l l Drain and Water Traps 97 l l l ELECTRICAL Auxiliary Shut Off 63 l l l l l Switch Throttle Safety Switch 74 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 86 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 7c0 mi 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 8200 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 Fas l l l l l teners Suspension Shock Oil l l l l Cooling Fins and l l l l Shroud Drive Shaft Bearing 91 L L L l Jackshaft Bearings 126 L L L l Skags Wear Bars 123 l l l l l Ski Saddle Spindle l l l l l Bolts Ski Pivots 88 L L L L l Ski Spindle 88 L L L L l Steering Arm s l Upper Lower Steering 88 L L L L l Post Support Bracket Drive Chain Ten
76. lt in loss of balance and machine roll over 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 machine to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the machine pull the rear of the snowmobile around and point the front end and skis downhill Remount the machine restart the engine release the parking brake and descend the hill carefully Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the machine into motion but always operate within safety limits 16 SAFETY Operator Safety Drive Belt Do not operate the engine with the dri
77. lustration Record the measurement Have the rider sit on the snowmobile and bounce up and down on the seat a few times to set in the suspension While the rider remains seated measure the distance from the ground to the top of the bumper dimension Y and record it Subtract Y from X and you will have the SAG setting X Y sag setting Example 21 17 4 The correct amount of SAG for the M 10 rear suspension is 3 5 inches If the measured sag is incorrect adjust the FRA position and rear spring preload See pages 44 47 Le SN sae F SS X y ree 2G I al 0 45 THE PERFECT FIT FAST M 10 Rear Suspension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear suspension adjustment It will have the MOST effect on the rear suspension performance To adjust the FRA 1 Refer to the initial set up reference chart located under the hood of your snowmobile and on page 51 to determine the desired FRA position 2 To adjust loosen the hex bolts 1 attaching the rear lower shock cross shaft to the rail beam 3 Using a 9 16 wrench loosen the jam nuts 2 on the preload bolts 4 Adjust the preload bolts 3 to the desired FRA position 5 Tighten the jam nuts NOTE Make sure the preload bolt contacts the slide block before tight ening the jam nut 6 Tighten the hex bolts and torque to 35 ft Ibs 47 Nm NOTE When the M 10 susp
78. me cold conditions below 20 F Polaris recommends closing the upper hood closure A WARNING Do not drive for prolonged periods on blacktop gravel or ice Doing so could cause irreversible track damage and lead to serious injury Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your machine Driving in too lit tle snow will result in excessive wear and damage to the slide rail track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will be able to climb up and over the snow A CAUTION When operating on icy surfaces or hard packed snow avoid overheating the slide rail and track Lack of lubrication and cooling will cause overheating of the slide rail and track resulting in premature wear and failure If frequently operating in low cooling conditions see your dealer for an optional wheel kit that will reduce the wear from overheating 18 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions may become dangerous if operators drive improperly If you re new to snowmobiling acquaint yourself with the machine and with what it will and won t do under various conditions Even sea
79. n pivot shafts raise the rear of unit o 3 88 Lubrication EDGE Rear Suspension MAINTENANCE 89 MAINTENANCE Lubrication Other Rear Suspensions 90 MAINTENANCE Lubrication Jackshaft Bearing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fit ting Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal may take only two pumps Push the clutch back onto the shaft and replace the clutch retaining bolt Torque to 18 ft lbs 24 4 Nm Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Choke and Choke Cable O Lubricate the choke slide and cables ER e lightly with oil or grease Before ict turning the engine off operate the iia u choke intermittently to draw mois ture out of the choke plunger area and reduce the possibility of the choke becoming frozen 91 MAINTENANCE Lubrication 1 Chaincase Oil Check the chaincase oil level at the intervals outlined in the mainte nance charts beginning on page 84 Change the chainca
80. n storage as listed in the owner s manual e Failure due to use of unauthorized parts or modifications Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage e Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage e Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related throttle body parts are covered The fuel pump is covered e Clutches and related clutch parts including but not limited to the drive belt are excluded from coverage e Electrical components are excluded from coverage e Gearcases and transmissions are excluded from coverage 145 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to
81. nch until the sheaves open far enough to remove the belt Firmly grasp the belt midway between the clutches and pull upward and rearward to remove See illustration MAINTENANCE General Maintenance Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack NOTE To ensure satisfactory belt life install belts so they operate in the same direction of rota tion by positioning the identification numbers so that you can read them If required sep arate the sheaves as outlined in the belt removal procedures 2 Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves 3 Hold the belt down between the sheaves and roll the bot tom portion over the outer clutch sheave Work the belt to the outer edge of the sheave 4 Standard Clutch Skip to step 6 5 TEAM Clutch Rotate the L wrench to tighten the sheaves Remove the wrench and store in the tool kit Close the clutch guard and reinstall the retaining pin Close and secure the hood and release the parking brake 113 MAINTENANCE General Maintenance Y Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge 1 on the belt and apply downward pres sure while measuring at point 2 This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment Standard Clutch Belt defle
82. nd 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 on Slippery Surfaces A WARNING Never attempt an abrupt change of direction when operating on slippery sur faces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces 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 14 SAFETY Operator Safety Driving Downhill When riding downhill shift your weight to the rear of the machine and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the machine and keep it from rolling freely downhill A WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brake failure Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death 15 SAFETY Operator Safety Driving in Hilly Terrain A WARNING Climbing a hill or crossing the face of a slope may resu
83. nded Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 132 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 sur faces before beginning preservation with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed out of direct sun light and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Controls and Linkage Lubricate bushings spindle shafts tie rod ends and cables as outlined in the Periodic Maintenance Table beginning on page 85 125 MAINTENANCE Extended Storage 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 Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant Do not lubricate clutch components except the driven clutch shaft bush ing as outlined
84. nections SEE YOUR DEALER Engine requires more than normal pulls to start Poor fuel Replace with fresh winter fuel Not enough fuel get ting to engine SEE YOUR DEALER 134 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition TROUBLESHOOTING Install new spark plug s If engine still fails to start check for spark If there s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on Use the choke See page 64 Make sure fuel tank contains fuel Ice may be in fuel line filter or pump Add isopropyl alcohol to fuel system On the standard Polaris carburetor the choke will not function with the throttle depressed See second item under Probable Cause of Engine Contin ually Backfires Flooded engine too much choke used Hold throttle open crank engine several times may be necessary to change plug s Poor engine com pression Mixture is too lean A main jet that is too small will cause seizure resulting in loss of power This indicates a major engine problem that must be repaired before operat ing SEE YOUR DEALER Engine lacks power Fouled or defective Replace the plug s spark plug s Fuel filter loss of e Check fuel filter flow Disconnect high RPM power hose and drain 1 2 cup Fuel flow should be steady and encompass the entire diameter of fuel line If not r
85. ng on page 150 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 per formance and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjust ments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfort able performing these tasks yourself contact an authorized Polaris dealer for service CAUTION Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection 84 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 pa
86. nment agencies manufacturers distributors dealers ecologists and other interested parties to work together to develop data on environmental topics SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety Follow the recommended maintenance program beginning on page 84 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals A WARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are capable of traveling at high speeds Use extra caution to ensure operator safety M
87. nt see page 120 and adjust as necessary 11 Tighten the locknuts 12 Tighten the idler shaft bolts 13 Torque idler shaft bolts to 35 ft lbs 47 5 Nm 119 MAINTENANCE Track Maintenance 1 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 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen the F A A idler shaft bolts then ARA loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen the right locknut and tighten the right adjusting bolt 4 After adjustments are com plete tighten the locknuts Od and torque idler shaft bolts to 35 ft lbs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 120 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and
88. nter BDC the lowest position in the cylinder On twin cyl inder models the opposite piston will be up Pour approximately two ounces of Polaris injector oil into the spark plug hole Wait one to two minutes and perform steps 3 5 on remaining cylin ders Replace the spark plugs and lower the machine to the floor 127 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with dielectric grease and re connect Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Battery Always prepare and maintain the battery as outlined on page 131 Track and Suspension Moderate track tension should be maintained during summer storage The machine should be supported off the ground to allow the track to hang freely Transporting the Snowmobile Whenever the snowmobile is transported Turn the fuel valve off See page 68 2 Be sure the fuel cap and oil cap are installed correctly 3 Always tie the snowmobile to the transporting unit securely using suitable straps 4 Remove the ignition key to prevent loss 128 MAINTENANCE Battery Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often Maintain the fluid level between the upper and lo
89. nth or more e Remove the battery Charge it to the proper level e Store it in a cool dry place e Check and or charge monthly Before using the battery take it to your dealer for testing and recharging Batteries may freeze if not fully charged resulting in cell damage Charge condition Will freeze at 100 75 F 59 C 75 24 F 31 C 50 0 F 18 C 25 13 F 11 C 0 18 F 8 C 131 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2871098 Premium 2 Cycle Engine Oil qt 2871097 Premium 2 Cycle Engine Oil gal 2871240 Premium 2 Cycle Engine Oil 2 5 gal 2871721 Premium Gold Synthetic 2 Cycle Engine Oil qt 2871722 Premium Gold Synthetic 2 Cycle Engine Oil gal 2872347 Premium Gold Synthetic 2 Cycle Engine Oil 2 5 gal 2874438 VES II Synthetic 2 Cycle Engine Oil qt 2874439 VES II Synthetic 2 Cycle Engine Oil gal 2874443 VES II Synthetic 2 Cycle Engine Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogel Coolant 2871323 Anitfr
90. ntil it releases from the spring retainer 2 Lift the spring carefully around 2 se the wire harness 2 and flip it to the outside of the housing 3 With the wire harness attached to the bulb 3 withdraw the 1 bulb from the housing 4 Grasp the bulb by its metal base and carefully separate the bulb from the harness Headlight Bulb Installation 1 Hold the bulb by its metal base and install it into the wire harness 2 Insert the bulb into the housing 3 Carefully flip the spring back into the housing placing it around the wire harness 4 Squeeze the spring together until it s over the spring retainer and release 5 Verify headlight aim See page 106 107 MAINTENANCE General Maintenance Taillight Brakelight Replacement To replace a bulb on most EDGE models remove the taillight lens screws and remove the lens to access the bulbs On models with the adjustable seat bucket 1 Remove the two sets of fasteners at the rear corners of the seat base 2 Tilt the rear of the seat upward to access the bulbs from under the seat 3 Twist the bulb socket slightly and pull it from the assembly 4 Replace the bulb and reinstall the socket into the assembly Lower the seat and reinstall the fasteners Test the taillight and brakelights for proper operation 108 MAINTENANCE General Maintenance Clutch System Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum
91. ntrolled by a switch in the engine cooling system on liquid cooled models If the engine coolant reaches a certain temperature the switch completes a circuit that turns the light on If you must drive your machine after the high temperature indicator light has come on drive slowly and stop frequently to allow the engine to cool down See your dealer Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are e Coolant bottle or overflow tank Engine filler neck e Pressure cap on some models e Connecting hoses Always maintain the coolant level between the minimum and maximum marks on the coolant bottle when engine is cold to prevent overheating and serious engine damage CAUTION Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recom mended Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine drain the system completely every two years and add a fresh mixture of antifreeze and distilled water This service must be performed when the engine is cold Ask your Polaris dealer to check the coolant when he performs the fall tune up on your snowmobile 100 MAINTENANCE General Maintenance Bleeding the Cooling System A WARNING Steam and hot liquids will cause serious burns to your skin Never bleed the cooling
92. ont Suspension Adjustments Independent Front Suspension IFS A WARNING Always verify ski alignment before making adjustments to the IFS See page 122 to check alignment If the skis are misaligned see your dealer as the camber adjustment may also be affected For the best ride the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming To determine if your machine is using full travel push the jounce bumper down on the shock rod until it contacts the body and test ride the machine The bumper will move up on the rod in relation to the amount of travel that was used dur ing the ride If the travel is full the bumper will be seated at the top of the rod Shock Components The front springs can be changed if spring preload alone isn t sufficient and further _ adjustment is desired to control suspension 2 stiffness See your Polaris dealer for more information 3 1 Retainer 4 2 Shock Rod 3 Jounce Bumper 4 Body oe 5 Threaded Spring Preload Adjuster Nut 31 THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiff ness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw Select or actuator SOLO located near the base of the shock This adjustment is the easi est to perform and it should be consid ered first A clockwise adjustment will increase stiffness in bo
93. points Increase IFS spring preload by adjusting cam or threaded adjuster e Decrease front limiter strap length Steering is heavy e Check ski alignment e Check skags and skis for damage e Reduce ski pressure A Increase front track spring preload B Reduce IFS spring preload by adjusting cam C Reduce rear torsion spring preload Setting up for deep e Change worn Hi fax snow operation e Move front track shock assembly to upper position 136 TROUBLESHOOTING M 10 Suspension Troubleshooting Problem Solution Rear suspension bot toms too easily Increase FRA position see setup decal under hood for ini tial position Increase X over tube length see setup decal under hood Increase rear track shock coil spring preload Increase front track shock coil spring preload Change to optional stiff rear track shock compression spring see your dealer Revalve rear track shock compression damping see your dealer Check track tension Rides too stiff in rear Decrease FRA position see setup decal under hood Decrease rear track shock coil spring preload Change to optional soft rear track shock compression spring see your dealer Revalve rear track shock compression damping see your dealer Check track tension Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components turn freely Make sure skags are straight on skis Increas
94. purchased and continues for 4000 kilometers 2485 miles of vehicle travel 200 hours of operation or 30 calendar months whichever comes first This engine emissions limited warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty This includes compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection components exhaust gas recirculation system components and aftertreatment system components Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WAR RANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRA
95. qualified service technician Reverse if equipped must not be engaged during engine tune ups 82 MAINTENANCE Emission Control Information 340cc and 600cc Engines Only Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 148 and read the maintenance section of your owner s manual You are responsible for ensuring that the specified maintenance is per formed including the emission related maintenance outlined in these sections of the manual You must inspect the air intake system on your snowmobile prior to each use including the airbox foam filter and hood foam filters and clean these components as necessary Polaris considers the specified maintenance for the spark plugs oil changes air intake system and exhaust valves to be critical emission related maintenance The speci fied maintenance for the fuel filter is recommended additional emission related maintenance Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 83 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 beginni
96. r Front Springs For models without externally adjustable or revalvable shocks the front springs can be changed if spring preload alone isn t sufficient and fur ther adjustment is desired to control suspension stiffness See your Polaris dealer for more information 34 THE PERFECT FIT Rear Suspension Adjustments Rider weight riding style trail conditions and vehicle speed all affect suspension action Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However all sus pension designs and adjustments involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bot tom out harshly on a snowcross course Refer to the suspension setup label on your snowmobile or see your Polaris dealer for initial suspension setup information Additional adjustments can be made after initial setup Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer 35 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred setup These adjustments are easy to make involve very little time or e
97. r damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for breakage 4 Replace the track if any rod damage is found Track Lubrication A WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended peri ods on ice and other surfaces that have little or no snow for lubrication The slide rail needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear NOTE If excessive rail slide wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty 117 MAINTENANCE Track Maintenance A WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all mov ing parts Never perform track measurement or adjustments with the engine running Track Tension Track adjustment is critical for proper handlin
98. r 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 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 imperfect
99. raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation A WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience and the features available on some snowmobiles but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control A WARNING Improper riding position may reduce control and could result in serious injury or death Always ride in a position that allows for control of your vehicle Riding Apparel Be prepared be warm and be com fortable when riding Be aware of the weather forecast especially the lis windchill and dress accordingly Pers See the chart on page 20 x P A WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Always wear an approved helmet and eye protection SAFETY Operator Safety Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to
100. re Ride 124 Suspension Lubrication 88 90 Suspension Lubrication EDGE 89 Suspension Lubrication M10 89 Suspension Lubrication Rear 90 Suspension Maintenance 124 Suspension Performance Tips 36 154 T TABLE OF CONTENTS 3 Taillight Brakelight Replacement 108 THE PERFECT FIT 30 56 Throttle Cable 91 Throttle Lever 58 75 Throttle Safety Switch 58 74 TOO WK tied ay sale eos ck guava 116 Torque Stop 115 Torsion Spring Tension 38 Towing 002 eee 81 ATACK 6534 506965 956 wage ned 61 Track Alignment 120 Track Care for Storage 128 Track Inspection 117 Track Lubrication 117 Track Maintenance 117 120 Track Safety 8 Track Tension 36 118 Track Warm Up 67 Track Warning 22 Traction Products 54 56 Transporting the Snowmobile 128 TROUBLESHOOTING 133 138 Troubleshooting Drive Belt 138 Troubleshooting Engine 133 135 Troubleshooting IQ Suspension 136 Troubleshooting M10 Suspension 137 Trunk Access 04 29 Trunk Lock 00 29 Tune Up arice aea sorarsa i 116 V Vehicle Identification Numbers 4 Ww WARRANTY 139 149 Water Pump Belt 96 Water Sediment Trap Service 97 Wear Strips 0 56 Weigh
101. ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone For added protection carry the following items on your snowmobile at all times e Spare Drive Belt e Winter Survival Kit e Extra Set of Spark Plugs e Trail Map e Tow Rope e Owner s Manual e Extra Oil e First Aid Kit e Fuel Deicer 10 SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Rider Capacity Your Polaris snowmobile is designed for a single rider only Do not carry a passenger Excessive Speed A WARNING High speed driving especially at night could result in serious injury or death Always reduce speed when driving at night or in inclement weather Always observe all laws governing snowmobile operation and speed limits Always be alert and pay attention to the trail ahead Multiplying speed MPH by 1 5 will equal the approximate number of feet per sec ond your machine travels If your speed is 40 MPH your machine is traveling about 60 f
102. ries 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 139 147 WARRANTY Snowmobile Engine Emissions Limited Warranty 340cc and 600cc Engines Only This snowmobile engine emissions limited warranty is in addition to the Polaris stan dard limited warranty for snowmobiles Polaris Industries Inc warrants that at the time it is first purchased this emissions certified snowmobile engine meets current U S Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051 1065 and 1068 Polaris warrants that the engine is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified snowmobile engine starts on the date when the engine is first
103. rks heaters trouble lights cigarettes etc Review the gasoline warnings found on page 68 Plug Cleaning Procedure 1 Turn the fuel tank supply valve off 2 Position a container or shop towels to 1 catch the contaminated gasoline 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube 4 Wipe residue from the plug and reinstall 2 it Reposition and tighten the clamps Continue until all traps have been emp tied 97 MAINTENANCE General Maintenance Carburetor The number stamped in the end of the main jet indicates the jet size The jet installed at the time of manufacture is not necessarily correct for your elevation It s your dealer s responsibility to make sure the correct main jet is installed CAUTION Operating the snowmobile with incorrect jetting can result in serious engine damage Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the carburetor may need adjustment e Hard starting e Poor idle e Overheated pistons and cylinder walls e Plug fouling e Poor engine response to various throttle valve openings 98 MAINTENANCE
104. rranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARIS ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion 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 141 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris snowmobiles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer The cos
105. rt supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law and may result in civil penalties 149 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km 150 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 151 INDEX A Accessories 00200 53 Air Pollution 5 Airbox Warning 21 Avalanches 005 13 B Battery joel aid 129 131 Battery Connections 130 Battery Fluid 129 Battery Installation 131 Battery Storage 128 131 BearingS 0005 126 Brake Components 103 Brake Fluid 104 Brake Inspection 103 Brake Lever Travel 59 103 Brake System Bleeding 105 Brakelight Replacement 108 Brakes i risu imio eat gd 59 Cc Carbide Skags 55 Carburetion 72 73 Carburetor
106. rts always use genuine Polaris parts available from your Polaris dealer Item See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 110 Drive Belt Condition 111 Clutches disassemble 109 Belt Tension l c l Clutch Sheaves 109 0 ENGINE COOLING Engine Mounts Recoil Rope Engine Mounting Plate Engine Torque Stop Cylinder Head Bolts Cylinder Base Nuts Ignition Timing BTDC VES System Coolant Level Water Pump Drive Belt Coolant Hose Heat Exchangers Coolant Circulation Coolant Leaks Spark Plug Condition l l l l l l c l l l l l l l o Exhaust Pipe Exhaust Retaining Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 85 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 750 mi 500mi 1000mi 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 103 l l l l Brake Disc l l l l Parking Brakes 60 l l l l Brake System 59
107. s dealer for inspec tion and adjustment Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16 1 5 mm wh AL N i T ULU RO Int CO TIT ee ee 103 MAINTENANCE General Maintenance Brake Fluid On some models the brake fluid level can be seen through a plastic sight glass in the brake reservoir If the fluid is sufficient the sight glass will be black If the sight glass is any color other than black add brake fluid On all other models frequently check the reservoir to be sure it contains the correct amount of fluid To add fluid remove the master cylinder reservoir cover Add the recommended brake fluid to bring the level up to the top of the fluid level mark on the inside of the reservoir Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid See page 132 for the part numbers of Polaris products A WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rap idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury A WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphra
108. se oil after the first 500 miles 800 km then every 1000 miles 1600 km or season ally Maintain the oil level between the safe marks on the dipstick Clean the magnetic plug on the dipstick whenever checking or changing oil Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 132 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the dipstick 1 and view the oil level on the dipstick 3 Add the recommended oil as needed Do not overfill 4 Clean the magnetic plug 2 5 Reinstall the dipstick 92 MAINTENANCE General Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization Refer to your Owner s Manual Supplement for the specific spark plug to be used in your machine CAUTION Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See your Owner s Manual Supplement e Use recommended spark plugs with the proper gap e Torque spark plugs to 18 22 ft lbs 24 30 Nm e Always carry spare spark plugs Spark plug condition is indicative of eng
109. sion 102 l l l l l Hood Latches 62 l l l l l Battery Fluid Level 129 l l l l l Rear Wheel Idler Bolts 119 l l l l l Idler Bolt Jam Nut 119 l l l l l Rear Suspension Pivot 88 L L L Shafts Camber Alignment l l l Radius Rod Bushings l Handlebar Centering l Tether Switch and Strap 63 l l l l l Track Alignment 120 l l l l l Track Tension 118 l l l l l Front Limiter Strap l l l l l Rail Slide Condition 124 l Chaincase Oil 92 l l l R l Gearcase Oil l l l R l Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 87 MAINTENANCE Lubrication Suspension and Steering Lubricate the suspension and steering components with Polaris Pre mium All Season Grease at 500 miles 800 km and annually or every 1000 miles 1600 km thereafter A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmo biles See page 132 for the part numbers of Polaris products The illustration shows the lubrication points of suspension and steering components Grease the left and right spindles Raise the front end of the machine to permit better grease entry into the spindle area Lubricate both of the front ski pivots at the fittings as shown e Grease the jackshaft and driveshaft clutch side bearings e Use an aerosol lubricant on the steering post support bracket e Grease the steering post lower pivot e Grease the rear suspensio
110. soned driv ers should spend some time getting the feel for a machine before attempting ambitious maneuvers e A snowmobile depends on the rider s body position for proper bal ance in executing turns traversing hills etc Always start on a smooth level area to begin building your operating experience Before allowing someone else use your snowmobile know the extent of their operating skills Check to see if they ve taken a snowmobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile Jumping may injure your back because of spinal compression The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions Your snowmobile is not intended for this kind of use e Be courteous to oncoming traffic by dimming your headlights and reducing your speed e When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic around your vehicle Drive defen sively to avoid accidents e Remove the key from the ignition when you leave the snowmob
111. sp the spring and turn it to the right Turn it to the left to decrease preload C Increasing the spring preload too much P may adversely affect the handling of the snowmobile and the performance of the Low High suspension Never exceed one inch of Preload Preload preload beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make sure at least two turns of preload are holding the spring between the retainer on top of the shock and the threaded spring preload adjuster nut on the shock body NOTE Not all models have shocks with thread adjustable spring pre load See your dealer for more information CAUTION Always leave one thread showing above the adjuster nut On models equipped with a plastic adjuster nut if the nut is unscrewed from the threaded body the nut will break 33 THE PERFECT FIT Front Suspension Adjustments Shock Valving RydeFX or RydeFX SOLO shocks can be revalved if spring preload alone isn t sufficient and further adjustment is desired to control suspen sion stiffness A WARNING Changing shock valving on RydeFX and RydeFX SOLO shocks requires special tools and a sound knowledge of mechanical theory tool use and shop procedures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme caution when handling high pres sure service equipment We recommend that this work be performed by a Polaris deale
112. system or remove the pressure cap when the engine is warm or hot Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part CAUTION 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 Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark 2 Elevate the front end of the machine slightly to aid in bleeding of the heat exchangers 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 Add coolant to the coolant bottle to the maximum mark Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air Stop the engine and check the coolant bottle level Fill as required Feel the heat exchangers under the running boards If the system is bled properly they ll be warm to the touch If they re not repeat step 5 Lift the front of the machine slightly to assist in the bleed ing 8 Replace the pressure cap and carefully lower the front end o
113. t Transfer 43 WELCOME 0055 1 Windchill 0 20
114. t of transpor tation 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 per form 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 142 WARRANTY Conditions and Exclusions In order to qualify for warranty the product must have been properly set up and tested by a Polaris Dealer if applicable Failure of any dealer to perform the required vehicle Pre Delivery Inspection perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage Use of the recommended Polaris products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occu
115. tch Interrupts ignition circuit All Tether Switch Option Interrupts ignition circuit All 76 OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use Snowmobiles equipped with electric start have a recoil for emergency starting On non electric start models if the recoil starter system fails an emergency start strap is provided in the kit Open the hood Open the clutch guard Push on the inner sheave of the clutch and rotate clock wise slightly to relieve belt tension 4 Starting at one of the tower struts wind the strap counter clockwise around the clutch as shown A WARNING Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure DO NOT wrap the start strap around your hand Keep all bystanders and loose clothing away from the snowmobile when using the emergency starting procedure 5 Pull the strap abruptly so the strap comes free of the clutch while starting the engine Repeat until the engine starts Close the clutch guard Close and secure the hood 77 OPERATION Reverse Operation A WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed e Shift to or from reverse only wh
116. th styles of shock but there are some differences Indy Select Shock The factory setting for this shock is the softest position with the adjust ing screw all the way out counterclockwise If bottoming occurs the Indy Select feature should be used to achieve the desired ride The shocks have a wide range of adjustment capability By turning the screw clockwise the compression of the shock increases stiffening the ride When adjusting these shocks we recommend that you turn the screw only 1 4 turn at a time then test ride Always adjust both shocks equally RydeFX SOLO Shock The factory setting for this shock is at medium stiffness with the clicker knob set at position 4 The clicker can be actuated with the thumb and forefinger If bottoming occurs rotate the clicker clockwise to the next higher number If full shock travel isn t being used rotate the clicker counterclockwise to the next lower number When adjusting these shocks we recommend that you turn the clicker only one click at a time then test ride Always adjust both shocks equally 32 THE PERFECT FIT Front Suspension Adjustments Spring Preload Increasing spring preload will increase ski to ground pressure Decreasing spring preload will decrease ski to ground pressure When adjusting be sure the springs on both the left and right sides of the machine are at the same adjustment To increase front shock spring preload gra
117. thout damage Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the machine 65 OPERATION Engine Break In Oil Injection System Always check and fill the oil tank when refueling See page 71 CAUTION Serious engine damage can occur without the proper lubrication Check the oil tank level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately Oil Recommendations Engine lubrication comes from oil added to the fuel and oil injection systems On Polaris snowmobiles equipped with a variable exhaust sys tem VES Polaris highly recommends the use of only VES II 2 Cycle Oil See the table below for additional oil recommendations See page 132 for the part numbers of Polaris products Engine Premium Premium Gold VES Il Style 2 Cycle 2 Cycle 2 Cycle Fan Cooled Good Better N A Liquid Cooled Good Better N A Liquid Cooled w VES Good Better Best 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
118. tion 111 114 Steering System 61 Recoil Rope 62 Coolant Level 100 Park Brake Lock Brake Lever Brake System 59 60 103 Auxiliary Shut Off Switch Engine Stop Switch 63 Ignition Switch 63 Taillight Brakelight Headlight 63 Suspension Mounting Bolts 124 Skags Wear Bars 123 Ski Saddle and Spindle Bolts 124 Hood Straps Latches 62 Seat Latches if equipped N A Throttle Lever Safety Switch 74 75 Rear Wheel Idler Bolts 119 Tether Switch Strap 63 Track Alignment Condition 61 120 Rail Slide Condition 124 Chaincase Oil Level 92 Injection Oil Level 71 57 PRE RIDE INSPECTIONS Before Starting the Engine A WARNING Worn damaged or malfunctioning components may cause serious injury or death Before starting the engine check all components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often 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
119. to trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch engage ment Use fast aggressive throttle to engage clutch 138 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information con tained in this manual Contact your Polaris dealer for replacement parts ser vice 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 fol lowing information Serial number Model number Dealer name Date of purchase Details of trouble experienced DUAYEN Length of time and conditions of operation 7 Previous correspondence Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 763 417 8650 Canada 1 204 925 7100 139 WARRANTY Service and Warranty Information Polaris Anti Theft System The Polaris
120. tuds and skags to maintain proper balance and vehicle control A WARNING Loss of control can result in serious personal injury or death Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice See your dealer for assistance 55 THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used See your dealer for more information Some models are manufactured with tunnel wear strips or wear strip coolers installed Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories Components viewed from rear of track 1 Top of tunnel 2 Wear strip 3 Track 4 Wear strip mounting holes 1 2 w p ees Sep n CAUTION Whenever wear strips are relocated be sure there s adequate stud clearance to the heat exchangers Lack of clearance may result in damage to heat exchangers 56 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on the refer enced pages Look for a checkmark on the referenced pages to locate the pre ride inspection items Item See Page Drive Belt Condi
121. ubs INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam paign We encourage governments to adopt rigorous safety training pro grams 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 publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be wel come 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 gover
122. ve belt removed Any servicing that requires operation without a belt must be performed by your dealer Operation of the engine with the belt removed may result in injury or damage to the engine Intake Silencer Do not operate the engine with the intake silencer or filter removed Damage to the engine may occur if the intake silencer or filter are removed Clutch Guard Do not operate the engine with the clutch guard removed The clutch guard is designed to protect the operator from metal parts if the clutch should fail Although the chance of failure is extremely remote don t defeat the purpose of the safety guard by removing it 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 pre cision balancing and create an unstable condition Maneuverability While much control and maneuverability is achieved through the steer ing system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or machines designed to carry a load 17 SAFETY Operator Safety Inadequate Snow Conditions Moveable hood closures are included on some Polaris snowmobiles They are normally left open and are located on the front upper and lower hood openings If operating in deep snow or in extre
123. w the engine to reach idle speed before attempting to shift into or out of reverse CAUTION Damage will occur to chaincase or transmission if shifting is attempted before the machine has come to a complete stop Make sure the snowmobile has completely stopped and the engine has returned to idle speed before shifting gears 115 MAINTENANCE General Maintenance Chain Tension Maintain the proper chain tension as outlined on page 102 Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer His experienced and trained service technician will keep your machine in peak operating condition Tool Kit A tool kit is included with each machine for emergency and routine maintenance Your tool kit will contain only the tools applicable to your model Always keep the tool kit with the snowmobile Emergency Start Strap L Wrench Tubular Socket Tubular Socket Handle Screwdriver Phillips Screwdriver ON ee es Scissor Stop Wrench EDGE Box End Wrench Spanner Wrench M 10 116 MAINTENANCE Track Maintenance Track Inspection A 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 support the rear of the snow mobile off the ground 2 Rotate the track by hand to check fo
124. wer level marks A WARNING Battery electrolyte is poisonous It contains acid Serious burns can result from contact with the skin eyes or clothing If contact occurs seek immedi ate medical attention KEEP OUT OF REACH OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Call physician immedi ately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks open flames cigarettes etc away Ventilate when charging or using in closed space Always shield eyes when working near batteries 129 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion When clean ing is necessary remove the corrosion with a stiff wire brush Wash ter minals and connections with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry with clean shop towels Coat the terminals with dielectric grease or petroleum jelly CAUTION Tap water contains minerals that will damage a battery and shorten its life Use only distilled water to refill your battery Never allow cleaning solution or tap water to enter the battery Battery Removal A WARNING Improperly connecting or disconnecting battery cables can result in an explo sion and cause serious injury or death When removing the battery always disconnect the negative black cable first Wh
125. zed tightly enough the lock will move freely into place Do not force the lock or it may break The brake light on the console will light up if the park brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the park brake light does not come on when the park brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly and release it The lock will return to the unlock position A WARNING If the park 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 Engine 1 Steering System A WARNING Ice and snow build up may interfere with the steering of your machine result ing 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 YY Track A WARNING Operating the snowmobile with a damaged track increases the possibility of track failure wh

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