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Pioneer CD-IB100 Network Card User Manual

1. Maintenance Periodic Maintenance Chart ITEM SEE DAILY WEEKLY OR 50 100 150 PAGE BEFORE HRS HRS HRS EXTENDED PERIOD OF OPERATION Check track alignment 65 x Check track condition 67 x Check drive chain 59 X tension Check and tighten any 72 X loose suspension mounting bolts Tighten ski saddle and X spindle bolts if loose Check front and rear X limiter strap condition tighten loose bolts Check slider thickness 68 X replace when worn see dealer Tighten rear idler wheel x bolts if loose Check spark plug 52 X condition Check for brake cable 56 X wear and adjustment Throttle cable pivot slug 58 X x x Lubricate steering post x x x support bracket and pivot aerosol Grease ski spindles 73 x x X Lubricate ski bushings to 73 X X X spindle area Grease lower steering X X X post pivot Grease rear suspension 72 X X X pivot shafts Lubricate throttle cable 58 X X x and pivot Lubricate choke slide and 58 x x x cable Inspect exhaust pipe for 54 x x x cracks or damage 51 ADULT SECTION 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 the specifications section beginning on page 80 for recom mended spark plug type and gap CAUTION Using non recommended spark
2. 81 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2874865 Performance Synthetic 4 Stroke PS 4 Oil qt 2874866 Performance Synthetic 4 Stroke PS 4 Oil gal 2876244 Performance Synthetic 4 Stroke PS 4 Plus Oil qt 2876245 Performance Synthetic 4 Stroke PS 4 Plus Oil gal Gearcase Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant qt 2871653 Premium Front Gearcase Fluid 8 oz 2871654 Premium Demand Drive Hub Fluid 8 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogel Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 12 oz 2872893 Engine Degreaser 12 oz 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner 82 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 service or warranty Your deale
3. 50 53 57 16 2 2 6 10 13 17 21 24 28 32 36 39 43 47 50 54 58 62 24 1 3 7 11 15 19 22 26 30 34 38 42 45 49 53 57 61 65 32 0 4 8 12 16 20 24 28 32 36 39 43 47 51 55 59 63 67 40 1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 48 1 5 9 13 18 22 26 30 34 38 42 46 50 54 58 62 66 70 56 2 6 10 14 18 22 26 31 35 39 43 47 51 55 59 64 68 72 64 2 6 10 15 19 23 27 31 35 40 44 48 52 56 61 65 69 73 72 2 7_ 11 15 19 23 28 32 36 40 45 49 53 57 61 66 70 74 80 3 7 11 15 20 24 28 33 37 41 45 50 54 58 62 67 71 75 88 3 7 12 16 20 24 29 33 37 42 46 50 55 59 63 67 72 76 96 3 8 12 16 21 25 29 34 38 42 47 51 55 60 64 68 73 77 Frostbite in gt gt 30 min 10 min 5 min 39 ADULT SECTION Component Identification Seat and Storage Handlebar Windshield Taillight Headlight Suspension Track Trailing Arm 40 ADULT SECTION Component Identification Engine Stop Switch Brake Lever
4. Air induction system Ignition system Fuel system Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings e Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 92 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANT
5. Pantone 426C for Maintenance and Safety POLARIS The Way Out Pantone 426C For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922313 Rev 01 Printed in USA A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm OD RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris enthusiasts Visit us online at www polarisindus tries com for the latest news new product introductions upcoming events career opportunities and more At Polaris we proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles Victory Motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and developme
6. 19 28 Pre Ride Warm Up 47 R Recoil Starter 15 Registration Warranty 85 Riding Rules 21 24 S Safety Decals 13 Safety Symbols 10 Signal Words 10 Skag Replacement 71 Ski Skags 000 71 Slider Replacement 68 Snow and Ice Build Up 36 Snow Conditions 37 Spark Plug Condition 52 Spark Plugs 52 53 Speed Performance Regulation 44 Starting the Engine 45 Steering Adjustment 69 Steering Inspection 69 Steering System 68 Stop Switch 0 02 14 Stopping 00 18 Stopping Procedures 46 Storage esee 46 75 71 Engine Fogging 75 Stabilize the Fuel 76 Storage Area 00 77 Track and Suspension 77 Suspension Components 72 Suspension Lubrication 72 T Tether Strap Switch 15 Throttle Cable Lubrication 58 Throttle Cable Pivot Slug 58 Throttle Lever 14 TOWING S 42 n Rien eint ente 78 Track Alignment 65 Track Inspection 67 Track Lubrication 36 68 Track Tension 63 Track Tension Adjustment 64 Transporting the Snowmobile 78 Trou
7. Make sure they are latched tightly Hood Hold Down Straps Check the hood hold down straps Always make sure both hood straps are securely latched before you start the engine Track and Skis Never check the track or skis when the engine is running You could A get hurt if the snowmobile moves unexpectedly Never stand behind or in front of any snowmobile when the engine is running Make sure the engine is off then stand behind the snowmobile and lift up the rear end This will free the track if it is frozen to the ground Turn the handlebars all the way to the left and to the right This will turn the skis to make sure they aren t frozen to the ground If any of this is hard to do have an adult help you 19 YOUTH SECTION Pre Ride Check Gas Level Always have an adult put gas in your snowmobile Never try to do it A yourself Have an adult check the gas level to see if your snowmobile needs more gas Children should never open the gas cap or add gas Always have an adult do this Before anyone adds gas to your snowmobile they must read the instructions and warnings on page 43 in this Owner s Manual Oil Level Have an adult check the engine oil level when the engine is cold The engine is very hot after it has been running It could burn your skin Children should never check the oil Always have an adult do this i 2 Ways to STOP Always check to make sure that BOTH WAYS TO STOP ar
8. Throttle Lever po en Choke Knob Gas Cap Recoil Starter Handle Hood Hold Down Strap 41 ADULT SECTION Break In Period Engine Break In The break in period for your new snowmobile is defined as the first ten hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine 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 during the first three hours of use 1 Fill the fuel tank with gasoline Check the oil level See page 61 3 Drive slowly at first Select an area that s open and will allow room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See pages 19 and 25 6 Change the oil after the first 20 hours of operation 42 ADULT SECTION Operation Fuel When refueling use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel A WARNING Gasoline is highly flammable and explosive under certain conditions Always e
9. 9 4 10 16 22 28 35 41 47 53 59 66 72 15 32 25 19 13 6 7 43 19 26 32 39 45 51 58 64 71 77 20 30 24 17 11 4 2 9 15 22 29 35 42 48 55 61 68 74 81 25 29 23 16 9 3 4 11 17 24 31 37 44 51 58 64 71 78 84 30 28 22 15 8 1 5 12 19 26 33 39 46 53 60 67 73 80 87 35 28 21 14 7 0 7 14 21 27 34 41 48 55 62 69 76 82 89 40 27 20 13 6 1 8 15 22 29 36 43 50 57 64 71 78 84 91 45 26 19 12 5 2 9 16 23 30 37 44 51 58 65 72 79 86 93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in gt gt 30 min 10 min 5 min WINDCHILL CHART C Wind Actual Thermometer Reading C ino 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature C Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 4 7 11 14 18 22 25 29 32 36 39 43 46
10. 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 imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defe
11. In colder weather the track will need a few more revolutions to fully warm it 3 Stop the engine Remove the rear support 4 Grasp the skis by their front loops and move them from side to side to loosen frozen snow 47 ADULT SECTION Emission Control Information Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Emission Control Label Your snowmobile is equipped at the time of sale with an emission con trol information ECI label and a factory installed emissions informa tion hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is avail able to your qualified service technician Reverse if equipped must not be engaged
12. additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline Observe all fire safety rules when draining the carburetor Review the fuel related warnings on page 43 To eliminate any fuel remaining in the carbure tor run the engine until it stops 75 ADULT SECTION Maintenance Storage Stabilize the Fuel Proper off season preparation of the engine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage See page 82 for the part numbers of Polaris products 1 Fill the fuel tank with fresh fuel 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems 3 Start the engine Allow it to idle for five minutes to disperse addi tives through the entire fuel system 4 Turn the fuel valve off 76 Maintenance Storage Track and Suspension Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support This will allow the track to hang freely Elevate the front end of the machine and place blocks securely under it to remove tension from the shocks and springs This will minimize fatigue on the front shocks and springs Storage Area ADULT SECTION Yo
13. driver of the snowmobile you must learn how to keep yourself and those around you safe while you re riding Pay attention when you see this symbol snowmobile or in this manual it means PAY ATTENTION because you A This is the safety alert symbol When you see this symbol on your could die or be seriously hurt if you don t follow the instructions INTRODUCTION Preservation of the Environment Teach your child to drive their snowmobile with consideration for the protection and preservation of the environment Noise One of the most publicized subjects with regard to snowmobiles is noise The Society of Automotive Engineers SAE which is the stan dard setting body for snowmobiles has recommended that snowmobiles conform to prescribed sound levels This Polaris snowmobile has been engineered to conform to these SAE standards In order to be meaningful all regulations require the cooperation of the snowmobile owner Muffling systems designed to reduce noise levels should not be altered or removed Snowmobile drivers must be aware that they have a public responsibility to operate their snowmobiles with concern for others As a snowmobile operator you may not realize the sound of your snowmobile may annoy non snowmobilers We are attempting to do our part through the manufacture of quieter machines and we also ask your help in the effort to further reduce the impact of noise Air Pollution As a part of Polaris pla
14. factory for adequate fuel supply Higher altitude operation may require different adjustment and settings The number stamped in the end of the main jet indicates the jet size that was installed at the time of manufacture For questions about optional jetting for conditions in your area see your Polaris dealer Correct setup provides engine RPM within its given power band at full throttle settings and also provides maximum efficiency and operation at all other throttle openings See your dealer for carburetor adjustments which may include the following Carburetor component changes for specific altitude and ambient tem peratures Choke adjustment Air screw settings 1f applicable Idle RPM adjustments Throttle safety switch inspections and service Throttle block to throttle flipper clearance adjustment CAUTION Improper carburetor adjustments can result in safety hazards as well as seri ous engine damage We recommend that all carburetor adjustments be per formed by your Polaris dealer 55 ADULT SECTION Maintenance Brake Lever Travel 3 4 19 mm Firmly depress the brake lever Measure the clearance between the lever and brake block If clearance is more than 3 4 19 mm adjust the brake cable as outlined below Brake Cable Adjustment If proper adjustment cannot be achieved using the following methods check the brake band If the brake band has excessive wear see your Polaris de
15. is recommended that this service be performed by your dealer Know limitations of machine and skills of driver The operator should be aware that most areas have laws governing snowmobile operation and that these laws should be followed They have been established for the protection of all snowmobile riders Many local organizations offer a snowmobile safety course for children Check with local authorities to locate providers of this service This vehicle is intended for daylight use only Check both the headlight and taillight to ensure proper operation IMPORTANT The headlight and taillight are intended only to increase the visibility of the snowmobile during daylight operation Do not oper ate this snowmobile in the dark 34 ADULT SECTION Operation Warnings instruct all operators Teach all young drivers to always be alert and to pay attention to the driving area ahead When teaching inexperienced operators to ride set up a predetermined course Establish boundaries and make sure all oper ators know and understand them Make sure they know how to drive and control the snowmobile before you allow them to drive longer super vised distances Teach them proper snowmobile courtesy It s a good idea to predetermine some hand signals as a way to commu nicate with a child while giving instruction It may be difficult for a child to hear your voice over the sound of the snowmobile and through a helmet Teach the opera
16. non recommended oil improper use of the choke or incorrect carbu retion adjustments 53 ADULT SECTION Maintenance Fuel Valve Fuel Lines Inspect the fuel valve and the fuel lines regularly Carefully check the system s fuel line condition after periods of storage Normal deteriora tion from weather and fuel compounds can occur Replace any worn or damaged components Exhaust System At approximately 50 hours check the exhaust system for wear or dam age 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 grom mets 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 run ning 54 ADULT SECTION Maintenance Carburetor Proper carburetor adjustment is critical since a mixture too lean too much air too little fuel will result in overheating of the combustion chamber causing pre ignition of the fuel This results in piston burning bearing failure or complete engine failure A lean mixture can be the result of fuel line restrictions foreign matter in the carburetor etc A mixture too rich too much fuel too little air is also unfavorable because it can foul plugs and cause generally poor engine performance All carburetors have been pre set at the
17. only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the Polaris Warranty Department at 1 888 704 5290 93 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 HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 50 100 150 94 MAINTENANCE LOG DATE HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 95 INDEX A Air Pollution 7 B Bearings 0 2004 73 Brake Cable Adjustment 56 57 Brake Lever 14 Brake Lever Travel 56 Break In Period 42 C Carb fetor 22 tos cca ens 55 Carburetor Jetting 81 Chain Tensioner 59 Choke Knob 15 Choke Cable Lubrication 58 Component Identification 40 41 Controls and Linkage 73 Customer Service 83 D Daily Storage 46 Drive A
18. 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 49 ADULT SECTION Maintenance Periodic Maintenance Chart The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement parts always use genuine Polaris parts available from your Polaris dealer ITEM SEE DAILY WEEKLY OR 50 100 150 PAGE BEFORE HRS HRS HRS EXTENDED PERIOD OF OPERATION Test engine stop switch 20 25 X Test throttle safety switch 27 x Test tether switch 20 X Test throttle lever 19 26 X operation Test brake lever 19 X operation Check brake operation 56 x and adjustment Check steering system 26 x operation Check operation of 31 x headlight and taillight Clean dust and debris X from engine Check ski skags replace 71 X when worn to 1 2 original diameter Inspect fuel lines replace 54 X as needed Check engine oil level 20 61 X Oil the drive chain 60 Every 10 Hrs Check track tension 63 Every 10 Hrs tighten if necessary Grease the clutch 73 Every 15 Hrs Change oil 62 At 20 Hrs X X X 50 ADULT SECTION
19. plugs can result in serious engine damage Always use the spark plugs recommended for your snowmobile Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven 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 Spark Plug Removal and Replacement 1 Stop the engine 2 Remove the spark plug cap 3 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 4 Reverse the procedure for spark plug installation Torque to 12 14 ft Ibs 16 19 Nm 52 ADULT SECTION Maintenance Spark Plugs Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of
20. serious burns to skin Do not touch engine and exhaust parts after the engine has been running Disabled operators A WARNING Safe operation of this rider active vehicle requires good judgement and physi cal skills Persons with cognitive or physical disabilities who operate this vehi cle have an increased risk of overturns and loss of control which could result in serious injury or death 30 Operation Warnings Check brake lever travel Depress the brake lever fully Measure the clearance between the lever and brake block Clear ance should be no more than 3 4 1 9 cm Excessive travel indicates a need to adjust the brake cable Refer to the mechanical brake adjustment information on page 56 Secure the hood ADULT SECTION 3 4 19 mm The hood of the snowmobile protects the operator from moving and hot parts as well as aiding in sound emission control and other functions Never operate a snowmobile with the hood open or removed Check lights Start the engine and ensure that both the headlight and taillight operate 31 ADULT SECTION Operation Warnings Check surroundings Make sure the operation area is clear of obstacles and bystanders Some sideways movement is possible when the snowmobile first begins to move and debris may be thrown by the track Teach the operator to check the operating area before riding Sit properly on the snowmobile Operating a snowmobile requir
21. the snowmobile are thoroughly inspected by your dealer at various mileage intervals 12 SAFETY Safety Decals Safety and warning decals have been placed on the vehicle for the oper ator s protection Make sure the operator understands the information on all decals If any decal becomes illegible or comes off contact your Polaris dealer for a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal General Warning Decal WARNING Read and understand warnings and the Owner s Manual before operation Severe injury or death can result from not heeding the warnings This vehicle is intended for daylight use in restricted off road areas clear of obstacles primarily on snow and not on frozen bodies of water by a child of not less than 6 years of age who is in the presence of and in active supervi sion of an adult Use of this vehicle on public trails streets roads and high ways can be hazardous and is prohib ited by law in most cases Do not start or operate this vehicle without guards and shields in position or with hood not latched in place This vehicle is intended for one operator only no passenger Passengers cargo or towed objects can cause loss of control Verify proper operation of all controls before starting the engine When operating this vehicle the operator shall wear suitable protective cloth ing including an approved safety helmet and
22. throttle in this situation but make sure they understand that too much throttle could cause the snowmobile to lurch forward Track Lubrication Do not operate the snowmobile for more than a few minutes on ground surfaces that contain little or no snow The track needs snow for lubrica tion so driving in too little snow will result in excessive wear and dam age to the slide rail and track Snow and Ice Build Up Snow and ice buildup in the underhood area can interfere with the steer ing Manually turn the skis completely to the right and to the left If dif ficulty is encountered remove any ice and snow buildup that may be obstructing the steering linkage 36 ADULT SECTION Operation Warnings Snow Conditions This snowmobile is designed to operate best on snow Maneuverability is attained by the steering skis and the shifting of the driver s body weight Maximum control will be attained by shifting body weight Maneuverability will change for lighter operators If the snowmobile becomes stuck in snow stop the engine Clear the snow away from the running board area and clear away or step down the snow in front of the snowmobile Restart the engine and drive out of the deep snow Encourage the operator to stay on established riding areas to avoid getting stuck Ice and Hard Packed Surfaces Steering and braking control are substantially reduced when operating on hard surfaces hard packed snow or icy surfaces Teach your child
23. IES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle Polaris recommends that you contact an autho rized Polaris dealer to perform any service that may be necessary for your vehicle Polaris also recommends that you use
24. PM 200 1650 NOTE These carburetor Main Jet 70 settings are to be used in Pilot Jet 50 P A ee Cutaway 170 Throttle which is based on the Valve recommended fuel octane Fuel Screw 1 75 Turns Pilot Air Jet 1 3 mm Cooling Air Cylinders 1 Ignition Timing 23 BTDC 3600 RPM Ignition Type Flywheel Magneto solid state Spark Plug Gap NGK BR6ES 028 70 mm Recommended Engine Oil PS 4 or PS 4 Plus Recommended Fuel Octane Minimum 87 octane non oxygenated or 89 octane oxygenated 80 SPECIFICATIONS Carburetor Jetti AMBIENT TEMPERATURE ALTITUDE Below 30 to 10 F 15 to 5 F 0 to 20 F 15 to 35 F 30 to 50 F 45 to 65 F Above Meters Feet 25 F 34 to 23 C 26 C to 15 C 18 to 7 C 9 to 2 C 1 to 10 C 7 to 18 C 60 F 31 C 16 C NOTE Main jet is the first number in each cell Pilot jet is the second number in italics 0 600 72 5 72 5 70 70 70 67 5 67 5 67 5 0 2000 55 55 50 50 50 50 45 45 600 1200 70 70 70 67 5 67 5 67 5 65 65 2000 4000 50 50 50 50 50 50 45 45 1200 1800 67 5 67 5 67 5 65 65 65 62 5 62 5 4000 6000 50 50 50 50 50 45 45 45 1800 2400 65 65 65 65 65 62 5 62 5 60 6000 8000 50 50 50 50 45 45 45 45 2400 3000 65 65 62 5 62 5 60 60 60 60 8000 10000 50 50 50 45 45 45 45 45 3000 3700 62 5 62 5 60 60 60 57 5 57 5 57 5 10000 12000 50 50 45 45 45 45 45 45
25. T SECTION Maintenance Engine Oil Oil Recommendations Polaris recommends the use of Performance Synthetic 4 Stroke oil PS 4 or PS 4 Plus for this engine PS 4 has been specially formulated for use in Polaris 4 cycle snowmobile engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50 Perform the break in oil change after 20 hours of operation Always change the oil any time it s contaminated with water fuel or debris CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Level Maintain the oil level between the upper and lower marks on the dip stick 1 Position the vehicle on a level surface Stop the engine 3 Remove the dipstick and wipe it dry with a clean shop towel 4 Insert the dipstick into the oil fill hole completely but do not thread it 5 Remove the dipstick and view the oil level 6 Ifthe oil level is below the lower mark on the dipstick add the recommended oil to the upper mark Dipstick 61 ADULT SECTION Maintenance Engine Oil Change 2 NOTE The drain plug is located Support the rear of the snowmobile slightly off the ground with an appropriate snowmo
26. age or failure caused by operation on ice or poor lubrication conditions may void the track warranty Steering System The steering systems on Polaris snowmobiles can be adjusted with ski toe alignment Improper toe alignment can cause erratic steering See your dealer for adjustments A WARNING Improper alignment or adjustment may cause loss of steering control result ing in serious injury or death Do not attempt to change the ski alignment See your Polaris dealer 68 ADULT SECTION Maintenance Steering Inspection Each week or before a long ride check all steering system fasteners Tighten any loose fasteners The stars in the illustration below indicate fastener locations Steering Adjustment 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 3 mm greater than the mea surement at point Y NOTE Ifthe skis are misaligned we recommend that your dealer make the necessary adjustments 69 ADULT SECTION Maintenance Handlebar Adjustment 1 Slide the handlebar pad upward to access the adjuster bolts If additional room is required unzip one Lower of the handlebar pad zippers Nut and roll the pad to the side 2 Remove the upper flange nut and carriage bolt 3 Loosen the lower flange
27. aler for installation of a new band A WARNING Improper brake adjustment can result in brake failure which could result in severe injury or death Perform the adjustment procedures exactly as outlined or see your Polaris dealer for service 1 Slide the two rubber protector covers back to expose the cable adjuster 2 Using an 8mm wrench to hold the barrel nut loosen the jam nut with a 10mm wrench 3 With your left hand grasp the cables as close to the adjuster as pos sible Use your right hand to rotate the barrel nut until you have reached the proper brake lever adjustment Jam Nut Barrel Nut Rubber Covers 56 ADULT SECTION Maintenance Brake Cable Adjustment 4 5 Check the actuator linkage to ensure there is adequate freedom of movement for positive brake operation and that all floating parts move freely and that all parts are mounted securely Tighten hardware as required Tighten the adjuster jam nut and slide the rubber protectors onto the adjuster The brake band is adjusted correctly when brake lever freeplay is 1 4 3 8 6 10 mm and clearance between the brake lever and block with the lever fully depressed is no more than 3 4 19 mm Torque the band bolt nut to 6 ft Ibs 8 Nm 57 ADULT SECTION Maintenance Throttle Cable Lubrication With the engine off lubricate the throttle cable occasionally Turn the handlebars to the left and lubricate liberally wi
28. bile outside overnight warm up the track before driving the snow mobile This reduces drive clutch wear 1 Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support A WARNING Never hold the snowmobile up or stand behind it while rotating the track A loose track or flying debris could cause serious personal injury or death Start the engine 3 Abruptly engage the clutch allowing the track to turn for several revolutions 4 Release the throttle and apply the brakes 5 Stop the engine 6 Lower the rear of the snowmobile to the ground while the engine is off 66 ADULT SECTION Maintenance Track Inspection Check track condition at the intervals outlined in the periodic mainte nance chart beginning on page 50 A WARNING Inspecting the track while the engine is running can result in serious per sonal injury if the track should being to move Never inspect the track with the engine running Never hold the snowmobile up or stand behind it while rotating the track A loose track or flying debris could cause serious personal injury or death 1 Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support 2 Rotate the track by hand to check for wear or damage 3 Carefully examine the track along the entire length of each track rod bending the track and inspect
29. bile support Place a drain pan under the drain plug under the bulkhead and in front of the engine Remove the drain plug Drain Plug Dipstick Remove the dipstick and wipe it dry with a clean shop towel NOTE The oil will drain faster with the dipstick removed 5 6 7 10 62 Allow the oil to drain completely Reinstall the drain plug and sealing washer Torque to 10 ft Ibs 13 5 Nm Using a long funnel pour 20 oz 6 1 of the recommended oil into the oil fill hole Insert the dipstick into the oil fill hole completely but do not thread it Remove the dipstick and view the oil level If the oil level is below the lower mark on the dipstick add the rec ommended oil to the upper mark Maintenance Track Tension ADULT SECTION Track adjustment is critical for proper handling Always maintain cor rect tension and alignment 1 Operate the snow mobile to warm up the track 2 Stop the engine 3 Support the rear of the snowmobile slightly off the ground with an appropriate snow mobile support 4 Hang a 10 pound 4 5 kg weight 8 inches 20 cm from the center of the rear idler wheel Adjusting Screw 10 Ibs 8 20 cm 4 5 kg 5 Measure the distance between wear surface of the track clip and the plastic slider at the point where the weight is hanging Deflection at this point should be 3 4 19 mm 6 Ifthe track tension needs adjustment fol
30. bleshooting 79 V Vehicle Identification Numbers 9 Ww Washing the Vehicle 74 Waxing the Vehicle 74 Windchill 0000 39 97
31. body 15 YOUTH SECTION Know Your Snowmobile Let s learn more about the parts of your snowmobile before we learn about riding Seat and Storage Handlebar Windshield Headlight Taillight 16 YOUTH SECTION Know Your Snowmobile Hood The hood covers the moving and hot parts of the engine Always make sure both hood straps are securely latched before you start the engine Headlight The headlight is always on when the engine is running It helps others see you when you re riding during daylight but it s not meant to be strong enough to help you see in the dark Drive your snowmobile only in the daylight Windshield Always keep your windshield clean so you can see through it Handlebar The handlebar is connected to the skis When you turn the handlebar the skis turn in the same direction Seat and Storage When the engine is stopped you can take the seat cushion off and put things under the seat in the special compartment Taillight The taillight is always on when the engine is running It will help others see you when you re riding Snow Flap The snow flap keeps snow ice or other things from flying out behind your snowmobile Track When you squeeze the throttle lever the track turns and makes the snowmobile move forward Never get close to a moving track Never wear clothing that could get A caught in a moving track like a long scarf or baggy clothing Tie up long hair Sk
32. ck is centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rail A WARNING When performing the following checks and adjustments stay clear of all mov ing parts to avoid serious personal injury Make sure the track contains no objects that could be thrown out while the track is rotating Keep clear of track This includes but is not limited to hands tools feet and clothing Make sure no one is standing close to the machine while the track is rotating 1 Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support 2 Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revo lutions Stop the engine 3 Inspect track alignment by looking through the track windows to make sure the rails are evenly spaced on each side If the track runs to the left loosen the left idler wheel mounting bolt and tighten the left track adjusting bolt If the track runs to the right loosen the right idler wheel mounting bolt and tighten the right track adjusting bolt 4 After adjustments are complete tighten the locknuts and idler shaft bolts Torque to 35 40 ft Ibs 47 54 Nm 5 Repeat step 2 to verify proper alignment 65 ADULT SECTION Maintenance Track Warm Up After storing your snowmo
33. ct of materials or workmanship 87 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow mobiles that were Snow Checked through an authorized Polaris dealer during the March April Snow Check promotion The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transfer able 120 days after the original purchase date free of charge through any Polaris snow mobile dealer Coverage on Snow Check units is automatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty reg istration form This form is your proof of warranty Consumer Exclusions Each repair visit after the first twelve months of standard warranty coverage is 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 Snowmobiles used for commercial purposes or for racing are excluded from cover age 88 WARRANTY Polaris Second Year Engine Service Contract Coverage Coverage for second year engine failures due to defects in materials and workman
34. d 84 WARRANTY Limited Warranty Polaris Sales Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIM ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty The warranty begins on the date of purchase This warranty is transferable to another consumer during the war ranty period through a Polaris dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and 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
35. de of a snowmobile Driving Uphill Driving uphill should be attempted only by experienced operators 1 Stand on the running boards keeping body weight low and forward 2 Accelerate before the start of the climb releasing the throttle as needed to prevent the track from slipping on the snow 3 Slow down at the crest of the hill Be prepared to avoid obstacles sharp drops or other people or vehicles that may be on the other side of the hill Driving Downhill Drive downhill slowly Apply just enough throttle to keep the clutch engaged This will allow engine compression to help slow the machine and prevent the snowmobile from rolling freely downhill 38 Operation Warnings Windchill Temperature Charts ADULT SECTION The following information is provided to help you determine when tem peratures become dangerous for riding WINDCHILL CHART F Wind Actual Thermometer Reading F Spoed 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 MPH Equivalent Temperature F Calm 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 5 36 31 25 19 13 1 5 11 16 22 28 34 40 46 52 57 63 10 34 27 21 15
36. 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 warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REM EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLI GENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclu sion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusio
37. during engine tune ups Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty and read the maintenance section of your owner s manual You are responsi ble for ensuring that the specified maintenance is performed Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 48 ADULT SECTION Maintenance Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beginning on page 94 The recommended maintenance schedule for your snowmobile calls for a service and maintenance inspection at 50 hours at 100 hours and at 150 hours These inspections should be performed by a qualified service technician 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
38. e working the way they should Do you remember what they are Follow these steps 1 Start the engine Push the stop switch down The engine should stop 2 Start the engine Pull the tether strap off the switch The engine should stop If the engine does not stop when you do these checks do not ride the snowmobile until an adult fixes it 20 YOUTH SECTION Riding Rules Now you re ready to learn about driving your Polaris snowmobile This snowmobile is not a toy There are some things you can do and there are some things you must never do Rules are very important when you re driving a snowmobile Adults have riding rules too The rules help keep us safe when we ride You must be at least six 6 years old before you can ride this snowmo bile The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always drive safely Let s learn how to ride Always follow the safe riding rules found on the next pages You or A others around you could be seriously hurt or killed if you don t follow the safe riding rules p Your snowmobile is made for only one rider Never carry a passenger A passenger will make the snowmobile harder to drive You may lose control and hurt yourself and your passenger p Never pull anything behind your snowmobile p Make sure you know where you re going to drive before you start the engine Make sure the area is safe all around your snowmob
39. es skill and balance for proper control An improper position can reduce the child s ability to control the snow mobile The riding position may vary as the operator becomes more skilled but under most conditions the proper position is to be seated with both feet on the running boards in a comfortable position for proper throttle brake and steering control A WARNING This snowmobile is propelled by a revolving track which must be partially exposed for proper operation Serious injuries may be caused by operator carelessness resulting in hands feet hair or clothing becoming entangled in the track Teach the child to respect this machine and all moving parts Teach the child that being properly seated is the safest way to stay clear of the track A WARNING Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious per sonal injury or death 32 ADULT SECTION Operation Warnings Always wear clothing designed for snowmobiling Always make sure the operator is wearing an approved helmet and eye protection Do not allow the child to wear loose clothing or long scarves because they can easily become entangled in moving parts If your child has long hair be sure it is always tied up securely and tucked into the helmet or jacket Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet
40. esult if the vehicle is not inspected properly before operation Teach all operators to perform the following Pre Ride Check before each use of the snowmobile Check the throttle for proper operation See page 26 Check the brake for proper operation See page 26 Check the steering system for proper operation See page 26 Check the throttle safety switch for proper operation See page 27 Start the engine and push the stop switch down to test for proper operation The engine should stop immediately Start the engine and disconnect the tether switch to test for proper operation The engine should stop immediately Inspect the track See page 28 Make sure the seat is securely attached Always make sure both hood straps are securely latched before you start the engine Make sure the track and skis are not frozen to the ground Check the gas and oil levels for the rider Add more if necessary NVNN NNN N NN NN AS Make sure the headlight and taillight are working properly These checks should become automatic for the child before each ride As the adult teacher you must instill in all riders the importance of per forming this Pre Ride Check before they operate the snowmobile 25 ADULT SECTION Pre Ride Check Read and Understand Your Owner s Manual Read and make sure the operators understand the Owner s Manual com pletely before allowing anyone to operate this snowmobile It s also a good idea to review it peri
41. ight and to the left If difficulty 1s encountered check for ice and snow buildup that may be obstructing the steering linkage Make sure all greaseable components are properly lubricated 26 ADULT SECTION Pre Ride Check Check the throttle safety switch Test the throttle safety switch system on a daily basis before the vehicle is used With the engine idling hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration Apply a slight amount of throttle opening A properly functioning switch must shut down the engine The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valve does not return to the normal closed position If excessive play develops in the throttle cable the safety switch may be activated and will prevent the engine from starting If the engine doesn t start and throttle safety switch malfunction is suspected return the machine to an authorized Polaris 03 in 8 mm dealer for service 27 ADULT SECTION Pre Ride Check Inspect the track Driving for extended periods of time with marginal lubrication could severely damage the track Driving on icy trails or driving when there is little or no snow are two examples of situations that would provide mar ginal lubrication and are not recommended Do not operate the snowmo bile wi
42. ile p Never ride alone An adult should always be watching you in case you need help Always drive where an adult can see you p Never ride on public trails When you re a beginner always stay on level ground Don t ride your snowmobile on roads or over railroad tracks Your snowmobile makes noise that will keep you from hearing cars trucks or trains that may be coming toward you gt Stay away from fences Make sure you know where all the fences are before you ride If you drive into a fence you could get hurt Don t ride at night The headlight on your snowmobile is there only so others can see you driving during the day 21 YOUTH SECTION Riding Rules wy Jacket p Always wear the right kind of clothing when you ride your snowmo bile Always wear a helmet with a face shield or goggles Wear a warm jacket and snowpants Make sure your clothing fits properly Tight clothing could keep you from moving easily Baggy clothing could hang down and get caught in the track or another moving part Never wear a long scarf Wear warm snowmobile boots and gloves and make sure your boot laces are tied If you have long hair tie it up or put it inside your helmet or jacket Learn if there are lakes rivers ponds and ditches in your driving area Stay away from them Never ride on frozen water Your snowmobile could fall through the ice into the water and you could drown or freeze to death p Always be alert and pay at
43. ing for breakage NOTE The three most common places where breakage occurs are shown in the illustration Lug Track 4 Check the track clips and window tighten any loose clips If any rod damage is found install a new track NOTE This snowmobile track has molded in track clips It is common for a thin layer of rubber to detach from the clip area and peel off during ini tial use 67 ADULT SECTION Maintenance Slider Replacement Polaris rail slides have a wear limit eee indicator groove to indicate the minimum permissible slide thick ness Replace the rail slides if they are worn to the top of the groove at Replace when any point along their length Fail worn to top of ure to do so may result in perma groove nent damage to the track or rails Track Lubrication Track failure loss of vehicle control and braking ability can result from extended use of this vehicle on surfaces providing marginal lubrication between the slider and track guide clips Examples of marginal lubrica tion would include lakes without snow cover icy trails and no snow conditions The slide rail is designed to operate in conditions with adequate snow cover in order to provide sufficient lubrication Excessive wear indicates insufficient lubrication A new slider can cause faster heat build up in limited lubrication than a used slider resulting in excessive wear NOTE Track dam
44. is The skis help you steer your snowmobile When you turn the handlebar the skis turn in the same direction 17 YOUTH SECTION Know Your Snowmobile Let s review the 2 ways to stop your snowmobile Push the stop switch down Pull the strap off the tether switch 18 YOUTH SECTION Pre Ride Check You re almost ready to have an adult start your snowmobile But first you must do a PRE RIDE CHECK to make sure the snowmobile is safe to ride Every time you want to ride your snowmobile always have an adult help you check these things before you start the engine y Throttle Lever Squeeze the throttle lever toward the handlebar and then let it go The lever should go right back to where it was before you squeezed it If it goes back slowly or stays close to the handlebar you have a sticky throt tle This means that something is wrong or broken Don t start the snowmobile until an adult fixes the sticky lever You A could get hurt if you ride with a sticky throttle Brake Lever Squeeze the brake lever toward the handlebar and then let it go The lever should go right back to where it was before you squeezed it If it goes back slowly or stays close to the handlebar you have a sticky brake lever This means that something is wrong or broken A Don t start the snowmobile until an adult fixes the sticky lever You could get hurt if you ride with sticky brakes Seat Latches Check the seat latches
45. itch up to RUN position Throttle safety switch malfunction See your Polaris dealer Out of fuel Refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s No spark to spark plug Inspect plug s replace if necessary Inspect plug s verify stop switch is on Overuse of choke Inspect clean and or replace spark plugs Mechanical failure See your Polaris dealer 79 SPECIFICATION S Capacities and Dimensions Body Style Mini Indy Rider Weight Capacity 1 140 Ibs 63 5 kg maximum Dry Weight 147 5 Ibs 67 kg Fuel Tank Capacity 5 gal 1 9 I Engine Oil Capacity 20 oz 61 Height 31 in 78 7 cm Length 75 in 190 5 cm Width 34 in 86 4 cm Track Length 69 in 175 3 cm Track Width 10 in 25 4 cm Brake Type Mechanical Ski Center Distance 30 in 76 2 cm Clutch Type Centrifugal Drive Chain Length 40 Front Type IFS IFS Shock Type Mini Rear Type Mini Indy Engine and Cooling Engine Model Number EH122PM018 Alternator Output 50 watt 3600 rpm Bore x Stroke 60 x 43 mm Displacement 121 cc Carburetor Model Mikuni BV18 Idle R
46. lication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 120 Snowmobile Owner s Manual P N 9922313 TABLE OF CONTENTS Introduction succ LEIERTTELEG bee ees 6 Important Notes for Owners and Drivers 6 Preservation of the Environment 7 Vehicle Identification Numbers Ls 9 Safety crede Rei sL oun et E us 10 Youth Section leeren 14 Know Your Snowmobile sess 14 Pre Ride GChecKz us uite sc te qa Roe OR Ae a 19 Riding RUES secte ese Seg DE ROC RES ede ER Paese RC Re Rs 21 Adult Section zucca c EX ES 25 Pro Hide Check is s 235 ieee vas ER Dr Eas 25 Operation Warnings llle 29 Component Identification 05 40 Break In Period 0 0000 cee eee 42 Operation eta Sb cee tet ede od MIN 43 Emission Control Information 48 Maintenance s uS soda gestae YN ob os ER QUA n ae 49 Troubleshooting 79 Specifications llluss 80 Polaris Products sre 82 Warranty 4122 wore xk X 83 Maintenance Log eese 94 Index deu scccuiie Ee Bee bee ars ee ks 96 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in
47. low the procedure on page NOTE Ifthe rear idler wheel assembly washers are removed be sure they are reinstalled with the domed side of the washer facing outward as shown Rear Idler Wheel Washer Domed Side Outward 63 ADULT SECTION Maintenance Track Tension Adjustment 1 Loosen the rear idler shaft bolt 2 Tighten or loosen the track adjusting screws to provide equal adjust ment on both sides of the track 3 Repeat the measurement on the other side of the track NOTE Check tension more frequently when the machine is new A WARNING When performing the following checks and adjustments stay clear of all mov ing parts to avoid serious personal injury Make sure the track contains no objects that could be thrown out while the track is rotating Keep clear of track This includes but is not limited to hands tools feet and clothing Make sure no one is standing close to the machine while the track is rotating 4 Start the engine and slowly rotate the track at least five revolutions Allow the track to stop rotating by itself do not apply brakes 5 Check and adjust track alignment See page 65 6 Tighten the idler shaft bolt Torque to 35 40 ft lbs 47 54 Nm 7 Readjust the toe block to proper spacing and tighten 64 ADULT SECTION Maintenance Track Alignment Check track alignment at the intervals outlined in the periodic mainte nance chart beginning on page 50 Make sure the tra
48. mergency See pages 14 and 27 for more information about the engine stop switch and throttle safety switch THROTTLE SYSTEM WHAT IT DOES CONDITION Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All Tether Switch Interrupts ignition circuit All Brake Slows driveshaft All Choke Floods engine Half throttle or less Daily Storage At the end of each ride park the snow mobile on a level surface Support the rear with an appropriate track stand The track should be suspended approxi mately 4 10 cm off the ground Cover the snowmobile with an appro priate snowmobile cover 46 ADULT SECTION Operation Pre Ride Warm Up Always warm up the engine drive train and track before operating the snowmobile Support the rear with an appropriate track stand The track should be suspended approximately 4 10 cm off the ground A WARNING A loose track or flying debris could cause serious personal injury or death Be sure the rear support is stable Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while perform ing this procedure Do not use too much throttle during warm up or when the track is free hanging 1 Start the engine Allow it to idle for two to three minutes 2 Engage the drive system abruptly and allow it to rotate the track several revolutions NOTE
49. n for the snowmobile s compatibility within the environment our engineers are investigating ways to reduce emission levels of engines We expect our efforts to lead to the reduction of potential air pollution The four stroke engine used in this snowmobile produces less exhaust emissions and reduces noise as well In addition to technological research we also suggest that governmental agencies manufacturers distributors dealers ecologists and other interested parties work together to develop data on environmental top ics We will continue to participate in this type of study so that someday we may find the answers to these difficult issues INTRODUCTION Preservation of the Environment Environmental Protection As part of the continuing environmental education campaign we are encouraging state and provincial governments across the snowbelt to adopt rigorous safety training programs which also encourage protec tion of our environment wildlife and vegetation Snowmobile clubs and other organizations are working together to protect our environment It is very important that we encourage them as well as become actively involved ourselves Protect and preserve your right to ride by joining your local trail riding clubs Teach your child the following Respect your snowmobile respect your environment and you will earn the respect of everyone INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification
50. ngine is cool Move the governor spring to hole 3 for maximum performance highest available speed Move the governor spring to hole 1 for minimum performance lowest available speed Jj 44 ADULT SECTION Operation Starting the Engine Never start the engine before performing the Pre Ride Check See pages 19 and 25 1 Pull the engine stop switch up to the RUN position 2 Do not use the choke when starting a warm engine If the engine is cold pull the choke lever completely out to the FULL ON position NOTE Do not apply throttle while starting 3 Grasp the starter handle and pull slowly until the recoil engages then pull abruptly to start the engine CAUTION Extending the starter rope too far or allowing it to snap back into the housing will cause damage to the recoil assembly Do not extend the starter rope to its maximum length and do not drop the rope handle during starting 4 Ifthe engine slows or stops position the choke knob half way in 5 Apply the brakes and vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke knob all the way in NOTE To prevent excessive wear on the clutch components don t engage the clutch while performing the warm up 45 ADULT SECTION Operation Emergency Stopping Procedures The following chart lists methods for stopping the snowmobile in the event of an e
51. ns may not apply to you if inconsistent with controlling state law 85 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris snowmobiles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polaris if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing
52. nt of your Polaris vehicle making it the finest machine we ve ever produced 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 WELCOME Dear Parents We believe your children should have the opportunity to enjoy The Way Out experience along with you We ve provided this owner s manual to assist you and your children in learning about the safe operation and care of your new Polaris snowmobile Please review the information in this manual with any child who may operate the snowmobile Help your children learn to operate the snowmobile with safety as a top priority Help them also learn to show respect for our environment and for the rights of others while operating the snowmobile Since the operator will be a newcomer to the exciting winter sport of snowmobiling please be sure he she understands this information before riding the snowmobile Never allow a child to operate the snowmobile without adult supervi sion This Owner s Manual contains instructions for minor maintenance but major repairs are covered in the Polaris Service Manual and should be performed by a factory certified Master Service Dealer MSD techni cian Be sure to return to your dealership for all of your service needs during and after the warranty period The preventive maintenance p
53. nue to be covered by the basic warranty For questions call Polaris Customer Assistance see page 83 91 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle Polaris Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applica ble U S Environmental Protection Agency emission regulations Polaris warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 200 hours of engine operation 4000 kilo meters 2485 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems
54. numbers in the spaces pro vided POLARIS Tunnel VIN Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number right front side of engine crankcase 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 10 SAFETY A WARNING Failure to follow the warnings in this manual can result in severe injury or death Read and understand the owner s manual and all warning decals before operating a Polaris snowmobile Adults must thoroughly explain this information including all safe operating procedures to all operators of the snowmobile All operators must be at least six 6 years old and must under stand the consequences and risks if they choose to ignore or neglect this information Equipment Modifications All P
55. nut only enough so the bracket can move freely Upper Bolt 4 Position the handlebar to the desired height 5 Reinstall the upper carriage bolt and flange nut 6 Torque both flange nuts to 15 17 ft Ibs 20 23 Nm 7 Reinstall the handlebar pad 70 ADULT SECTION Maintenance Ski Skags The skag is a replaceable bar attached to the underside of the ski The purpose of the A skag is to assist in turning the LO snowmobile and to prevent xs the wearing away of the ski Ses eo caused by contact with roads Skag and other bare terrain Check skags weekly to maintain positive steering characteristics Replace skags when they are worn to half their original diameter NOTE See the dealer track studding and skag chart for recommended skags A WARNING Worn skis and or skags will adversely affect handling and can cause loss of vehicle control which can lead to serious injury or death Replace worn skis and or skags when inspection reveals wear Skag Replacement 1 Raise and support the front of the machine so the skis are approxi mately 6 15 cm off the ground Remove the attaching nuts and pry the skag downward 3 Remove the forward portion of the skag 4 Reverse this procedure for new skag installation 71 ADULT SECTION Maintenance Lubrication Recommendations Suspension To maintain rider comfort and to retard wear of the pivot shafts lubri cate the suspension pivot shafts wi
56. odically to reinforce the information It s very important to familiarize all operators with the cautions and warnings pertaining to the machine as well as safe operating procedures We ve attempted to provide you with as much information as possible to alert you to the safety requirements of snowmobiling A WARNING The throttle and brake are the primary controls of the snowmobile If either should malfunction the operator could lose control which could lead to seri ous injury or death Always check the throttle and brake levers for proper operation before operating the vehicle Check the throttle for proper operation When checking the throttle make sure the throttle lever compresses evenly and smoothly When the lever is released it should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly do not start the engine Have the throttle serviced before operating the snowmobile Check the brake for proper operation Squeeze the brake lever toward the handlebar When the lever is released it should return to it s original position smoothly If the lever hesitates or seems sticky do not start the engine Have the brakes ser viced before operating the snowmobile See page 31 for brake lever travel specifications Check for proper operation of the steering system Check for proper operation of the steering system Manually turn the skis completely to the r
57. 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 86 WARRANTY Conditions and Exclusions In order to qualify for warranty the product must have been properly set up and tested by a Polaris Dealer if applicable Failure of any dealer to perform the required vehicle Pre Delivery Inspection perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage Use of the recommended Polaris products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur during the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con sideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components
58. olaris snowmobiles have been designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modification especially those that increase speed or power There is a significant possibility of loss of con trol at higher speeds We are concerned for the safety of our customers and for the general public Any modifications to the original equipment of the vehicle cre ate a substantial safety hazard and increase the risk of bodily injury Therefore we strongly recommend that consumers do not install on a Polaris snowmobile any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your Polaris snowmobile is terminated if any equip ment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power 11 SAFETY Maintenance Program This snowmobile is not a toy The information in this manual is pro vided to aid you in its safe operation For the safety of the operator always make sure that the snowmobile is in excellent operating condition at all times We strongly recommend that the operator as well as an adult check major and vital safety com ponents before each use of the vehicle We also recommend that you strictly follow the maintenance schedule outlined in this manual to ensure that all critical components on
59. ottle body parts are covered The fuel pump is covered Clutches and related clutch parts including but not limited to the drive belt are excluded from coverage Electrical components are excluded from coverage e Gearcases and transmissions are excluded from coverage 89 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls 90 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 Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle wa
60. r receives frequent updates on changes modifications and tips on snowmobile maintenance which may supersede information con tained in this manual Your dealer is also familiar with Polaris policies and pro cedures 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 1 888 704 5290 Canada 1 204 925 7100 83 WARRANTY Service and Warranty Information Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines Administration 1 Polaris snowmobile owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifying the proper owner when a unit is recovere
61. r that might have entered the engine or exhaust system Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Ifany decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are pro vided by Polaris at no charge Waxing the Vehicle Your snowmobile can be waxed with any high quality brand of automo tive paste wax Avoid the use of harsh cleaners since they can scratch the body finish 74 ADULT SECTION Maintenance 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 rod the Engine i ON Ne Oo o n Treat the fuel system with Polaris Carbon Clean See page 76 Support the front end of the machine so the engine is level or tilted slightly rearward Turn the fuel valve off Remove the spark plug Pour 5cc of Premium 4 Synthetic 0W40 engine oil into the cylinder Slowly pull the recoil starter to turn the engine over two or three times Reinstall the spark plug Rotate the piston to bottom dead center BDC and Slowly pull the recoil starter handle until resistance is felt Leave it in that position 10 Clean the engine thoroughly with an oiled cloth NOTE If Polaris fuel system
62. rogram outlined in this manual is designed to ensure that all critical components on your child s snowmo bile are thoroughly inspected at various intervals If you have any ques tions about the snowmobile contact a Polaris dealer for assistance See page 82 for the part numbers of Polaris products WELCOME Dear Children Before you ride your new Polaris snowmobile there are some important things that you need to know Your parents and Polaris want you to enjoy riding your new snowmobile and that s why you need to read and understand the information in your owner s manual Ask your parents to explain anything you don t understand and pay close attention to the warnings and instructions you read Your safety and the safety of others is the most important thing to think about at all times As the driver of the snowmobile you must learn how to keep yourself and those around you safe while you re riding So read your manual and then enjoy riding your new Polaris snowmobile POLARIS and THE WAY OUT are registered trademarks of Polaris Industries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this pub
63. s 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 Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will conti
64. shield or goggles Securely attach the safety lanyard to the child s body before starting the engine This vehicle can be operated between 0 and 8 mph 13 km h However it is recommended that the adult supervising the child regulate the maximum speed to match the experience and ability of the child Instructions for regulat ing maximum speed are provided in the Owner s Manual The Auxiliary Shut Off Switch is the primary means of stopping this vehicle in case of emergency and is located on the top of the throttle control assembly Depress the switch to stop the engine Routinely check this switch for proper function with the engine idling If Owner s Manual is missing contact a Polaris Dealer for a replacement General Warning Decal 13 YOUTH SECTION Know Your Snowmobile Before you have an adult start the engine for you for the first time let s learn about the controls on your new snowmobile Engine Stop Switch Brake Lever Throttle Lever Pone Hood Hold Down Strap Engine Stop Switch When the engine is running push this button down to stop the engine Pull the stop switch up before trying to start the engine again Throttle Lever The throttle lever makes your snowmobile go forward when you press it with your thumb Before you drive your snowmobile always make sure the throttle lever does not stick Read more about it on page 19 Brake Lever Squeeze the brake lever toward the handlebar to make yo
65. ship will be determined by Polaris in its sole discretion Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris con trol Damage caused by the failure of other components of the snowmobile Failures caused by improper fuel or oil Piston seizures unless caused by a defective engine component Failures caused due to improper adjustments Failure due to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of unauthorized parts or modifications Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related thr
66. tention to where you re driving Always watch out for objects or people in your driving area and stay a safe distance away from them 22 YOUTH SECTION Riding Rules p Always sit down when you drive Keep both hands on the handlebars Keep both feet on the running boards p Never follow another snowmobile too closely Always allow lots of space to stop your snowmobile p Ride your snowmobile only where you know it s safe to drive and where you have permission to drive p Always be a polite driver Don t drive through the flower garden or over small trees p Always attach the tether strap to your body and to the switch on your snowmobile every time you drive Keep both hands on the handlebars Sit down Keep both feet on the running boards Attach tether strap to loop or right wrist l Attach tether strap to the switch on your snowmobile 23 YOUTH SECTION Riding Rules Learn how to use your hands and arms as signals Use these signals to let others know when you are getting ready to turn or stop your snow mobile Read and understand your Owner s Manual Left Turn Right Turn 24 ADULT SECTION Pre Ride Check As the adult you must teach the child the proper and safe way to ride a snowmobile Set boundaries and adhere to them keeping the child s safety foremost in your mind Never allow the child to operate this vehi cle without adult supervision A WARNING Serious injury or death could r
67. th Polaris All Season Grease Choke Cable Lubrication Lubricate the choke slide and cables occasionally as shown Operate the choke intermittently before turning the engine off This draws moisture out of the choke plunger area and reduces the possi bility of the choke becoming fro zen Throttle Cable Pivot Slug Lubricate the throttle cable pivot slug every 50 hours or twice a year using an aerosol lubricant 58 ADULT SECTION Maintenance Chain Tensioner Inspect the chain Proper deflection is one inch 25 mm Adjust the chain if deflection is incorrect 1 Loosen the nut on the chain tensioner 2 Raise the tensioner until the correct deflection is attained 3 Tighten the nut to 15 18 ft lbs 20 24 Nm NOTE When the chain has stretched to within 1 8 3 mm of the muffler mount bracket on the chassis replace the chain Inspect the sprockets as they also wear and often need replacement when the chain is replaced Muffler Mount Bracket Chain Tensioner 59 ADULT SECTION Maintenance Driveline Lubrication NOTE Driveline noise is normal for this vehicle To ensure long life of the snowmobile s driveline lubricate as follows Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease Lubricate Point B every 10 hours of operation with aerosol chain lube or SAE 30 oil Torque Converter Centrifugal Clutch 60 ADUL
68. th Polaris Premium All Season Grease several times during the season and again before summer storage each year Lack of lubrication will result in reduced performance and a less comfortable riding experience NOTE The stars in the following illustration indicate lubrication points A grease gun kit complete with grease and adaptors is available to lubri cate all fittings on Polaris snowmobiles See page 82 for the part num bers of Polaris products IMPORTANT Make it a weekly practice to check for loose bolts and nuts on the suspension system If any loose bolts are found on the rail be sure to clean the threads and apply LOCTITE 262 before tightening Suspension Components Carrier Wheel Torsion ii Springs Rear Limiter Strap Torsion Spring Sleeve Front Limiter Strap Adjuster Rail Bumper Bolts Torque Arm 72 ADULT SECTION Maintenance Lubrication Recommendations Inspect and lubricate all greaseable components at the intervals outlined in the Periodic Maintenance Chart beginning on page 50 Controls and Linkage Lubricate all bushings and tie rod ends with a light coat of oil or grease Remove the spindle shafts and lubricate the bushings on the top and bot tom of the trailing arm Lubricate throttle and brake controls and cables with Polaris Premium All Season Grease Force a small amount of lubricant down the cable See page 58 Bearings Always grease drive shaft clutch side bearings with a high q
69. th a damaged track A WARNING Operating the snowmobile with a damaged track will increase the possibility of additional track damage and or failure This could cause loss of control result ing in severe injury or death Always inspect for damage before using the snowmobile NOTE Track damage or failure caused by operation under poor lubrication conditions will void the track warranty 28 ADULT SECTION Operation Warnings Do not carry passengers This snowmobile is designed for a single operator Do not operate with intake silencer removed CAUTION If the engine is operated with the intake silencer removed damage to the engine may occur Do not operate the engine with the intake silencer removed Stay clear of track A WARNING During warm up and operation stand clear of the rotating track Entanglement and serious injury or death may result Use just enough throttle to rotate the track and warm up the engine Do not operate with drive chain guard removed A WARNING The drive chain guard is designed to protect the operator from metal parts in the event of a drive chain failure Although the chance of failure is extremely remote do not defeat the purpose of the guard by removing it It is provided for the safety of the child 29 ADULT SECTION Operation Warnings Do not touch the engine after it s been running A WARNING Hot components can cause
70. that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean 33 ADULT SECTION Operation Warnings Stop engine before attempting adjustments A WARNING The snowmobile engine compartment contains moving parts Shields and guards have been provided for safety but it is still possible to carelessly get your hands or fingers into a moving chain or a rotating shaft For this reason never attempt adjustments with the engine running Serious personal injuries can result Instead stop the engine raise the hood make the adjustment secure shields and guards secure the hood and then re start the engine to check its operation The same is true of track alignment If the track must be re aligned it
71. the snowmobile for convenient ref erence It should remain with the snowmobile when the snowmobile is sold You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage NOTE The illustrations and photos used in this manual are general represen tations Your model may differ IMPORTANT Parents should sit down with their children and read the Youth Section with them before allowing them to use this snowmobile Parents must also read the Adult Section before allowing their children to ride this snowmobile PARENTS Do not allow anyone under the age of six 6 to operate this machine Review the information in this manual with any child who may be operating the snowmobile It is up to you to teach any operator the proper and safe way to ride a snowmobile You must set boundaries and adhere to them keeping the operator s safety foremost in your mind Never allow a child to operate this machine without adult supervision These units are not designed for adult use Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded Never exceed the maximum rider weight capacity See page 80 CHILDREN Before you ride your new Polaris snowmobile there are some important things that you need to know Your safety and the safety of others is the most important thing to think about at all times As the
72. to reduce speed to maintain control in all driving conditions If necessary limit the maximum speed of the snowmobile as outlined on page 44 If ice or slippery conditions are unavoidable use extreme caution and operate at speeds no faster than a walk The skis need snow to help the snowmobile make turns On hard surfaces the snowmobile will not make turns easily It may be best to stop the engine dismount and man ually move the front or rear of the snowmobile to change direction Never make a sharp turn on a slippery surface The snowmobile may skid out of control Teach all operators to drive only in approved areas within the vision of the supervising adult A WARNING Children must never ride on a frozen body of water Make sure all operators understand that severe injury or death can result if the snowmobile and its rider fall through the ice 37 ADULT SECTION Operation Warnings Driving on Hills Traveling on hills is not recommended A child may not be capable of maneuvering body weight as needed for operating on hills If traveling on hills is unavoidable teach your child to use extreme caution and obey the following proper operating procedures A WARNING Serious injury or death can result if the snowmobile rolls or slides downhill If the snowmobile stops while the operator is driving on a hill the operator should dismount on the uphill side of the vehicle Never dismount or stand on the downhill si
73. tor that the sound of the engine will make it difficult to hear the sound of approaching vehicles Do not allow a child to operate the snowmobile on or near roads and railroad tracks Teach operators what it means to drive defensively Never tailgate and always allow ample stopping distances Bealert for obstacles Wire fences are a serious hazard Teach operators to always be on the alert for fences Single strands are especially dan gerous since there can be a great distance between posts Ground wires on utility poles are also difficult to see Teach opera tors to reduce speed when traveling near poles posts or other obstacles Check the weather Extremely cold weather can cause frost bite and or hypothermia Always be aware of weather conditions especially the windchill See the table on page 39 35 ADULT SECTION Operation Warnings Driving Responsibly As the adult you must teach the child the proper and safe way to ride a snowmobile Set boundaries and adhere to them keeping the child s safety foremost in your mind Never allow the child to operate this vehi cle without adult supervision Drive Away from Parked When the snowmobile has been parked for more than a few hours espe cially overnight the skis and track may freeze to the ground Loosen the skis and track for the operator You may have to apply extra throttle ini tially to move the snowmobile Teach operators not to be afraid of applying extra
74. uality bear ing grease to prevent corrosion which will destroy the bearings Electrical Connections Separate the electrical connector blocks and clean corrosive build up from the connectors Lubricate the blocks with dielectric grease and re connect Replace worn or frayed electrical wire and connectors Be sure wiring harnesses are properly secured away from sharp edges steering linkage moving parts and hot exhaust components 73 ADULT SECTION Maintenance Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle NOTE fa high pressure car wash is used not recommended grease all zerk fittings immediately after washing Remove the spindle shafts and lubricate the bushings on the top and bottom of the trailing arm Also run the vehicle to evaporate any wate
75. ur snowmobile slow down or stop Always take your thumb off the throttle lever when you squeeze the A brake lever 14 YOUTH SECTION Know Your Snowmobile Gas Cap An adult will take the gas cap off to put gas in your snowmobile Never take the gas cap off Always make sure it s tightly closed Always have an adult put gas in your snowmobile Never try to do it A yourself Recoil Starter Handle Pull the recoil starter handle to start your snowmobile An adult will help you start it the first time Choke Knob You may need to use the choke to help start your snowmobile if the engine is cold Read more about it on page 45 Hood Hold Down Strap Two straps hold down the hood of your snowmobile Always make sure both hood straps are securely latched before you start the engine Tether Strap Switch Always attach the tether strap to your body and to the switch on your snow mobile every time you drive If you fall off your snowmobile the tether strap will pull away from the switch and the engine will stop Attach to Loop or Wrist When you attach the strap to your body you can clip it to a loop on your cloth ing or you can wrap the Attach to strap around your right Switch wrist and attach the clip to the strap Never ride without the tether strap attached to your body and to your A snowmobile Be careful not to let the cord get tangled around the han dlebars or any part of your
76. ur snowmobile should be stored in a dry garage or shed out of direct sunlight It should be covered with a fabric snowmobile cover Plastic covers can cause condensation to form and may damage some snowmo bile components 77 ADULT SECTION Maintenance Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken 1 Turn the fuel valve off 2 Be sure the fuel cap is installed correctly 3 Always tie the snowmobile to the transporting unit securely using suitable straps Fall Tune Up To obtain maximum performance from your snowmobile we encourage you to arrange for a fall service tune up with your Polaris dealer Towing Do not pull or tow any person or object behind this snowmobile Ifa disabled snowmobile must be towed by another snowmobile attach the tow rope to the spindles of the disabled snowmobile not to the ski toe loops Emergency Preparation For your added protection carry the following items in your snowmo bile when traveling farther than a five minute walk from home Extra Spark Plugs First Aid Kit Winter Survival Kit Extra Gloves Owner s Manual 78 TROUBLESHOOTING Engine Turns Over Fails to Start Contact your Polaris dealer for service if you re unable to identify solu tions using the following chart Possible Cause Solution Tether switch not engaged Install tether switch strap Engine stop switch not on Pull stop sw
77. way from Parked 36 Driveline Lubrication 60 Driving on Hills 38 Driving Responsibly 36 E Electrical Connections 73 Emergency Preparation 78 Emission Control Information 48 Engine Break In 42 Engine Emissions Warranty 92 93 Engine Oil 61 62 Engine Starting 45 Engine Stop Switch 14 Environment uses 7 8 Exhaust System 54 F Fall Tune Up 0 78 puel i nie Rem WEN 43 Fuel Lines 12 5 RIRs 54 Fuel Valve 00 54 G Gas Cap oe eec e CEU es 15 96 H Handlebar Adjustment 70 Hood Hold Down Strap 15 l Ice and Hard Packed Surfaces 37 K Know Your Snowmobile 14 18 L Lubrication Bearings 0 73 Controls and Linkage 73 Electrical Connections 73 Lubrication Recommendations 72 73 M Maintenance 49 78 Maintenance Chart 50 51 Maintenance Log 94 95 Maintenance Program 12 49 Modifications 11 N NOlS zai ue Sew ee eee eee 7 0 Oil Change 2 en Sanne eke 62 Oil E amp yel i 2223 o fa Sites 61 Oil Recommendations 61 Oil Engine 0 61 62 Operation 005 43 47 Operation Wamings 29 39 P Polaris Products 82 Pre Ride Check
78. xercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing f you get gasoline in your eyes or if you swallow gasoline see your doctor immediately 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 vehicle 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 out doors or in well ventilated areas 43 ADULT SECTION Operation Speed Performance Regulation As the adult you must teach the child the proper and safe way to ride a snowmobile Set boundaries and adhere to them keeping the child s safety foremost in your mind Never allow the child to operate this vehi cle without adult supervision You can regulate the speed and acceleration of the snowmobile A CAUTION Hot engine components can cause serious burns to skin Always perform the following procedures when the e

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