Polaris Offroad Vehicle 500 IQ Shift User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
WARNING  
The engine exhaust from this product contains chemicals known to the State  
of California to cause cancer, birth defects or other reproductive harm.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WELCOME  
Thank you for purchasing a Polaris vehicle, and welcome to our world-  
wide family of Polaris enthusiasts. Be sure to visit us online at  
www.polarisindustries.com for the latest news, new product introduc-  
tions, upcoming events, career opportunities and more.  
Here at Polaris we proudly produce an exciting line of utility and recre-  
ational products.  
• Snowmobiles  
• All-terrain vehicles (ATVs)  
RANGER utility vehicles  
• Victory motorcycles  
We believe Polaris sets a standard of excellence for all utility and recre-  
ational vehicles manufactured in the world today. Many years of experi-  
ence have gone into the engineering, design, and development of your  
Polaris vehicle, making it the finest machine we've ever produced.  
For safe and enjoyable operation of your vehicle, be sure to follow the  
instructions and recommendations in this owner's manual. Your manual  
contains instructions for minor maintenance, but information about  
major repairs is outlined in the Polaris Service Manual and should be  
performed only by a Factory Certified Master Service Dealer (MSD)  
Technician.  
Your Polaris dealer knows your vehicle best and is interested in your  
total satisfaction. Be sure to return to your dealership for all of your ser-  
vice needs during, and after, the warranty period.  
We also take great pride in our complete line of apparel, parts and acces-  
sories, available through our online store at www.purepolaris.com. Have  
your accessories and clothing delivered right to your door!  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-  
tries Inc.  
Copyright 2009 Polaris Sales Inc. All information contained within this publication is  
based on the latest product information at the time of publication. Due to constant  
improvements in the design and quality of production components, some minor discrep-  
ancies may result between the actual vehicle and the information presented in this publi-  
cation. Depictions and/or procedures in this publication are intended for reference use  
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse  
of the depictions and/or procedures contained within, whether whole or in part, is  
expressly prohibited.  
Printed in U.S.A.  
2010 IQ Shift Owner's Manual P/N 9922316  
2
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
This section contains helpful information for owners and drivers and  
illustrates the location of important identification numbers that should  
be recorded in the owner's manual.  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
This section describes safe vehicle operation and identifies warning  
decals and their locations.  
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
This section identifies the locations of your snowmobile's controls and  
features.  
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 28  
This section explains how to tailor the suspension and other features for  
an optimum riding experience.  
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 40  
This section explains procedures that must be performed before riding.  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47  
This section explains proper engine break-in, operation of features and  
general operating procedures.  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61  
This section defines your role, and your dealer's role, in your snowmo-  
bile's regular maintenance.  
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 98  
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 99  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104  
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 113  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Vehicle Identification Numbers  
Record your snowmobile's identification numbers and key number in  
the spaces provided. Remove the spare key and store it in a safe place.  
Your key can be duplicated only by mating a Polaris key blank with one  
of your existing keys, so if both keys are lost, the ignition switch must  
be replaced.  
+
Vehicle Model Number: ___________________________________________________  
Tunnel VIN (H)(right side of the tunnel):_______________________________________  
Engine Serial Number (on recoil housing): ____________________________________  
Key Number: ___________________________________________________________  
Important Notes for Owners and Drivers  
After reading this manual, store it in the snowmobile for convenient ref-  
erence. It should remain with the snowmobile when the snowmobile is  
sold.  
Follow the maintenance program outlined in this manual. Preventive  
maintenance ensures that critical components of the snowmobile are  
inspected by your dealer at specific mileage intervals.  
You and your dealer must complete the registration form included with  
your snowmobile and forward it to us. This completed form is neces-  
sary to ensure warranty coverage.  
Protect and preserve your right to ride by joining your local trail riding  
clubs.  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Preservation of the Environment  
Polaris is committed to supporting an environmental education cam-  
paign. We encourage governments to adopt rigorous safety training pro-  
grams that encourage protection of our environment, including wildlife  
and vegetation.  
Snowmobile clubs and other organizations are working together to pro-  
tect our environment. Please support their efforts and operate your  
snowmobile with consideration for the protection and preservation of  
our environment.  
Noise Level  
One of the most publicized issues about snowmobiles is noise. The  
Society of Automotive Engineers (SAE), the standard-setting body for  
snowmobile development, recommends that snowmobiles conform to  
prescribed sound levels.  
Polaris snowmobiles are engineered to conform to these SAE standards.  
Our muffler systems are designed to reduce noise levels and must not be  
altered or removed. The sound of your snowmobile may not be wel-  
come to non-snowmobilers, so you have a responsibility to operate your  
snowmobile with concern for others. We do our part by manufacturing  
quieter machines; we ask your help to further reduce the impact of noise  
by operating your snowmobile safely and responsibly.  
Air Pollution  
Polaris engineers continuously investigate ways to reduce emission lev-  
els of two-stroke engines. We expect our efforts to lead to the reduction  
of potential air pollution.  
In addition to our technological research, we encourage government  
agencies, manufacturers, distributors, dealers, ecologists, and other  
interested parties to work together to develop data on environmental  
topics.  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
The following signal words and symbols appear throughout this manual  
and on your vehicle. Your safety is involved when these words and sym-  
bols are used. Become familiar with their meanings before reading the  
manual.  
The safety alert symbol indicates a potential personal injury hazard.  
WARNING  
A WARNING indicates a hazardous situation which, if not avoided, may result in  
death or serious injury.  
CAUTION  
A CAUTION indicates a hazardous situation which, if not avoided, may result in  
minor or moderate injury.  
NOTICE  
A NOTICE indicates a situation that may result in property damage.  
The Prohibition Safety Sign indicates an action NOT to take in order  
to avoid a hazard.  
The Mandatory Action Sign indicates an action that NEEDS to be  
taken to avoid a hazard.  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Follow the recommended maintenance program beginning on page 62  
of this manual to ensure that all critical components on the snowmobile  
are thoroughly inspected by your dealer at specific mileage intervals.  
WARNING  
Driving a snowmobile requires your full attention. DO NOT drink alcohol or use  
drugs or medications before or while driving or riding as a passenger. They will  
reduce your alertness and slow your reaction time.  
Snowmobiles are capable of traveling at high speeds. Use extra caution to  
ensure operator safety. Make sure your snowmobile is in excellent operating  
condition at all times. Always check major and vital safety components before  
every ride.  
All Polaris snowmobiles are designed and tested to provide safe operation when  
used as directed. Failure of critical machine components may result from  
operation with any modifications, especially those that increase speed or power.  
DO NOT MODIFY YOUR MACHINE. The snowmobile may become  
aerodynamically unstable at speeds higher than those for which it is designed.  
Loss of control may occur at higher speeds. Modifications may also create a  
safety hazard and lead to bodily injury.  
The warranty on your entire machine is terminated if any equipment has been  
added, or any modifications have been made, to increase the speed or power of  
the snowmobile.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Stay Clear of Track  
Your snowmobile is propelled by a revolving track that must be partially  
exposed for proper operation.  
WARNING! Serious injuries may result if  
hands, feet, or clothing become entangled in  
the track. Be alert when riding, and remain  
properly seated to stay clear of the track.  
Never hold the snowmobile up or stand behind  
it while warming up the track. A loose track or  
flying debris could cause serious injury or  
death. We recommend having your dealer  
perform all track service and alignment  
procedures.  
Stay Clear of Engine  
Never attempt adjustments with the engine running. Turn off the igni-  
tion, raise the hood, make the adjustment, secure shields and guards,  
secure the hood, and then restart the engine to check its operation.  
WARNING! Serious injury can occur if fingers or clothing contact the moving  
parts of an engine. Always stop the engine before attempting adjustments.  
Riding Position  
Operating a snowmobile requires skill and balance for proper control.  
Rider positions may vary with experience and the features available on  
some snowmobiles, but under many conditions, the proper position is to  
be seated with both feet on the running boards and both hands on the  
handlebar grips for proper throttle, brake and steering control.  
WARNING! Improper riding position may reduce control and could result in  
serious injury or death. Always ride in a position that allows for control of your  
vehicle.  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Riding Apparel  
Be prepared, be warm and be com-  
fortable when riding. Be aware of the  
weather forecast, especially the wind-  
chill, and dress accordingly. See the  
chart on page 20.  
WARNING! Avoid wearing loose clothing  
or long scarves, which can become  
entangled in moving parts and cause  
serious injury.  
Helmet  
Wearing a helmet can prevent a  
severe head injury. Whenever riding a  
Polaris vehicle, always wear a helmet that meets or exceeds established  
safety standards.  
Approved helmets in the USA and Canada bear a U.S. Department of  
Transportation (DOT) label.  
Approved helmets in Europe, Asia and Oceania  
bear the ECE 22.05 label. The ECE mark consists  
4
of a circle surrounding the letter E, followed by the  
E
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.  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Survival Preparation  
For your safety, always ride in a group of other snowmobilers. Always  
tell someone where you're going and how long you expect to be gone. If  
it isn't possible to ride with others, and you must travel into remote  
areas, always carry survival equipment that's appropriate to the condi-  
tions you may encounter. Such equipment may include, but is not lim-  
ited to: extra clothing, a sleeping bag, a flashlight, food and water, a  
signaling mirror, a means of building a fire, and a two-way radio or cel-  
lular telephone.  
For added protection, carry the following items on your snowmobile at  
all times:  
• Spare Drive Belt  
• Extra Set of Spark Plugs  
• Tow Rope  
• Winter Survival Kit  
• Trail Map  
• Owner's Manual  
• First Aid Kit  
• Tool Kit  
• Extra Oil  
• Fuel Deicer  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Disabled Operators  
Safe operation of this rider-active vehicle requires good judgement and  
physical skills. Operators with cognitive or physical disabilities have an  
increased risk of loss of control, which could result in serious injury or  
death.  
Rider Capacity  
Your Polaris snowmobile is designed for a single rider only. Do not  
carry a passenger.  
Excessive Speed  
WARNING! High speed driving, especially at night, could result in serious injury  
or death. Always reduce speed when driving at night or in inclement weather.  
Always observe all laws governing snowmobile operation and speed  
limits. Always be alert and pay attention to the trail ahead. Multiplying  
speed (MPH) by 1.5 will equal the approximate number of feet per sec-  
ond your machine travels. If your speed is 40 MPH, your machine is  
traveling about 60 feet per second. If you look back for only two sec-  
onds, your machine will travel about 120 feet. If your speed is 60 MPH,  
your machine will travel about 180 feet in two seconds.  
Traveling at night requires extra caution. Check headlight and taillight  
to ensure proper operation, and don't over-drive your headlight beam.  
Always be able to bring your machine to a stop in the distance illumi-  
nated by the headlight.  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driver Awareness  
Slow down when traveling near poles,  
posts, or other obstacles. Be especially  
alert if you're snowmobiling after dark.  
Always be on the alert for wire fences.  
Single strands are especially dangerous,  
since there may be a great distance  
between posts. Guy wires on utility poles  
are also difficult to distinguish.  
Make sure the way is clear before crossing  
railroads and other roads and highways.  
The noise of your machine will drown out  
the sound of approaching vehicles. Look  
ahead, behind, and to both sides before  
turning or crossing railroad tracks or high-  
ways. Steep embankments may also hide  
your view. Always leave yourself a way  
out.  
R R  
Variances in snow depth and/or water currents may result in uneven ice  
thickness. You may drown if you break through the ice. Avoid travel-  
ling on frozen bodies of water.  
When teaching inexperienced operators to ride, set up a predetermined  
course for practice. Make sure they know how to drive and control the  
snowmobile before allowing them to make longer trips. Teach them  
proper snowmobile courtesy, and enroll them in driver's training and  
safety courses.  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Avalanches  
Snowmobilers should always be properly  
trained and equipped before traveling in  
mountainous terrain:  
• Take an avalanche class  
• Travel with experienced people  
• Travel on designated trails  
• Make sure each person is equipped  
with a shovel, probe and avalanche  
beacon.  
You don't have to be snowmobiling on a slope for an avalanche to occur.  
Be aware that all of the snow is connected. You may be riding on a flat  
slope or snow covered road, but if the snowpack above is unstable  
enough you can trigger an avalanche on a steeper slope above you.  
Always be aware of snow conditions above you as you travel in moun-  
tainous terrain.  
Before riding in mountainous terrain, call or log on to your local ava-  
lanche advisory to get current weather and snow stability information.  
For more information about avalanche training and avalanche condi-  
tions, contact local law enforcement in your area, or visit either the  
American Avalanche Association online at www.americanavalancheas-  
sociation.org or the U.S. Forest Service National Avalanche Center at  
www.avalanche.org.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Ice and Snow Build-up  
WARNING! Ice and snow build-up may interfere with the steering of your  
machine, resulting in serious injury or death. Keep the underhood area free of  
snow and ice.  
Before driving, manually turn the skis to the left and right to be sure ice  
and snow are not interfering with full left and right steering. If difficulty  
is encountered, remove ice and snow build-up that may be obstructing  
the steering linkage.  
Driving on Slippery Surfaces  
WARNING! Never attempt an abrupt change of direction when operating on  
slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-  
packed snow reduces steering and braking control, which may result in loss of  
control and serious injury or death. Slow down and use extra caution when  
operating on slippery surfaces.  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driving Downhill  
When riding downhill, shift your weight to the rear of the machine and  
reduce your speed to a minimum. Apply just enough throttle to keep the  
clutch engaged, allowing the engine's compression to help slow the  
machine and keep it from rolling freely downhill.  
WARNING! When driving on long downhill stretches, pump the brakes. Riding  
the brakes may cause the brake system to overheat, which may result in brake  
failure. Excessive or repetitive use of the brakes for high speed stops will also  
cause an overheated brake system. This condition may lead to a sudden loss of  
brakes and/or fire and may result in serious injury or death.  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driving in Hilly Terrain  
WARNING! Climbing a hill or crossing the face of a slope may result in loss of  
balance and machine roll-over, causing serious injury or death. Use caution and  
good judgement when driving in hilly terrain.  
Use extra caution when operating in hilly terrain. If climbing a hill is  
unavoidable, keep your weight low and forward. If you must cross the  
face of a slope, keep your weight on the uphill side of the machine to  
maintain proper balance and avoid possible roll-over.  
Slow down when reaching the crest of a hill. Be prepared to react to  
obstacles, sharp drops or other people or vehicles that may be on the  
other side of the hill.  
If you're unable to continue up a hill, turn the machine downhill before  
it loses momentum. If this isn't possible, spin the track just enough to  
dig in to prevent it from rolling back down the hill. Stop the engine and  
set the parking brake (if equipped). Keeping away from the downhill  
side of the machine, pull the rear of the snowmobile around and point  
the front end and skis downhill. Remount the machine, restart the  
engine, release the parking brake, and descend the hill carefully.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Drive Belt  
Do not operate the engine with the drive belt removed.  
Any servicing that requires operation without a belt must be performed  
by your dealer. Operation of the engine with the belt removed may  
result in injury or damage to the engine.  
Intake Silencer  
Do not operate the engine with the intake silencer or filter removed.  
Damage to the engine may occur if the intake silencer or filter are  
removed.  
Clutches  
Do not attempt to service the clutches.  
All clutch service must be performed by your dealer. The clutch is a  
complex mechanism that rotates at high speeds. Each clutch is dynami-  
cally balanced before installation. Any tampering may disrupt this pre-  
cision balancing and create an unstable condition.  
Cold Weather Drive-Away  
Whenever your snowmobile has been parked for a length of time, espe-  
cially overnight, always make sure the skis and track are loosened from  
ice and snow before attempting to drive. Apply the throttle with enough  
authority to put the machine into motion, but always operate within  
safety limits.  
Maneuverability  
While much control and maneuverability is achieved through the steer-  
ing system and skis, maximum control is achieved by the shifting of  
your body weight. Maneuverability will change for lighter operators or  
machines designed to carry a load.  
Maintenance  
Follow the recommended maintenance program beginning on page 62  
of this manual to ensure that all critical components on the snowmobile  
are thoroughly inspected by your dealer at specific mileage intervals.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Inadequate Snow Conditions  
WARNING! Do not drive for prolonged periods on blacktop, gravel, or ice.  
Doing so could cause irreversible track damage and lead to serious injury.  
Since snow provides the only lubrication for the power slide suspension  
and, on liquid cooled models, cooling for the engine, adequate snow  
cover is a requirement for operation of your machine. Driving in too lit-  
tle snow will result in excessive wear and damage to the slide rail, track  
and/or engine.  
If the machine becomes stuck in snow, clear the running board area of  
snow, then step down the snow in front of the machine so that when the  
throttle is opened, the snowmobile will be able to climb up and over the  
snow.  
NOTICE: When operating on icy surfaces or hard-packed snow, avoid overheat-  
ing the slide rail and track. Lack of lubrication and cooling will cause  
overheating of the slide rail and track, resulting in premature wear and  
failure. If frequently operating in low cooling conditions, see your  
dealer for an optional wheel kit that will reduce the wear from over-  
heating.  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driving Responsibly  
Every snowmobile handles differently, and even the most docile condi-  
tions may become dangerous if operators drive improperly. If you're  
new to snowmobiling, acquaint yourself with the machine and with  
what it will and won't do under various conditions. Even seasoned driv-  
ers should spend some time getting the feel for a machine before  
attempting ambitious maneuvers.  
• A snowmobile depends on the rider's body position for proper bal-  
ance in executing turns, traversing hills, etc. Always start on a  
smooth, level area to begin building your operating experience.  
• Before allowing someone else use your snowmobile, know the extent  
of their operating skills. Check to see if they've taken a snowmobile  
safety course and have an operator's certificate. For their protection,  
as well as yours, make sure they take a snowmobile safety course.  
Everyone can benefit from the course.  
• Don't "jump" your snowmobile over large drifts or similar terrain.  
Jumping may injure your back because of spinal compression that  
could occur when the snowmobile impacts the ground. The seat and  
suspension of your snowmobile have been designed to provide pro-  
tection under normal riding conditions. Your snowmobile is not  
intended for this kind of use.  
• Be courteous to oncoming traffic by dimming your headlights and  
reducing your speed.  
• When traveling in a group of snowmobiles, don't tailgate (follow too  
closely). Leave enough distance between snowmobiles to provide  
ample stopping room and to provide protection from flying snow and  
debris. Allow even more distance when driving on slippery surfaces  
or when driving in darkness or other low visibility conditions. Be  
aware of any snowmobile traffic around your vehicle. Drive defen-  
sively to avoid accidents.  
• Remove the key from the ignition when you leave the snowmobile  
unattended.  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Windchill/Temperature Charts  
The following information is provided to help you determine when tem-  
peratures become dangerous for riding.  
WINDCHILL CHART (_F)  
Wind  
Speed  
in  
Actual Thermometer Reading (_F)  
40 35 30 25 20 15 10 -5 -10 -15 -20 -25 -30 -35 -40 -45  
Equivalent Temperature (_F)  
-5 -10 -15 -20 -25 -30 -35 -40 -45  
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63  
5
0
MPH  
Calm 40 35 30 25 20 15 10  
5
0
5
36 31 25 19 13  
7
3
0
1
10  
15  
20  
25  
30  
35  
40  
45  
50  
55  
60  
34 27 21 15  
32 25 19 13  
30 24 17 11  
9
6
4
3
1
0
-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72  
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77  
-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81  
-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84  
-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87  
-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89  
29 23 16  
28 22 15  
28 21 14  
27 20 13  
26 19 12  
26 19 12  
25 18 11  
25 17 10  
9
8
7
6
5
4
4
3
-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91  
-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93  
-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95  
-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97  
-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98  
Frostbite in >> 30 min. 10 min. 5 min.  
WINDCHILL CHART (_C)  
Wind  
Speed  
in  
Actual Thermometer Reading (_C)  
5
2
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46  
Equivalent Temperature (_C)  
KPH  
Calm  
8
5
3
2
1
0
2
0
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46  
-4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57  
16  
24  
32  
40  
48  
56  
64  
72  
80  
88  
96  
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62  
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65  
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67  
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69  
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70  
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72  
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73  
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74  
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75  
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76  
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77  
Frostbite in >> 30 min. 10 min. 5 min.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Warning decals have been placed on the snowmobile for your protec-  
tion. Read and follow the instructions of the decals and other warnings  
on the snowmobile carefully. If any of the decals depicted in this manual  
differ from the decals on your snowmobile, always read and follow the  
instructions of the decals on the snowmobile.  
If any decal becomes illegible or comes off, contact your Polaris dealer  
to purchase a replacement. Replacement safety decals are provided by  
Polaris at no charge. The part number is printed on the decal.  
Clutch Cover Warning  
This warning decal is found under the hood on the clutch cover:  
WARNING  
Do not operate engine with hood open.  
Do not attempt adjustment with engine running.  
Do not operate engine with plenum/belt guard removed.  
Never run engine with drive belt removed.  
Never service clutches yourself -- see your dealer.  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Track Warning  
The track warning decal is on the  
rear of the tunnel:  
Stay clear of track. Do not sit  
on seat back. Entanglement  
with the track or a fall from seat  
back may result in severe  
injury or death.  
+
"No Passenger" Warning  
The "NO PASSENGER" warning  
decal is on the console below the  
steering post:  
WARNING  
This vehicle is designed for  
operator only.  
“NO PASSENGER”  
+
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Reverse Warning  
+
The reverse warning decal is located  
on the upper console:  
WARNING  
Reverse operation, even at low  
speeds, can cause loss of control  
resulting in serious injury or  
death. To avoid loss of control,  
always:  
• Look behind before and while  
backing up.  
• Avoid sharp turns.  
• Shift to or from reverse only  
when stopped.  
• Apply throttle slowly.  
NOTE: For more information, see Owner's Manual.  
If electric reverse:  
• Machine stopped and engine at idle, push yellow button on LH con-  
trol to reverse. Flashing light on dash indicates reverse operation.  
• Push button again to return to forward.  
Operation Warning  
The operation warning decal is  
located on the lower console. See  
page 24 for the text.  
+
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Operation Warning  
• To avoid serious injury or death, read and understand all warnings  
and the Owner's Manual before operation. If manual is missing, con-  
tact a Polaris dealer for a replacement.  
• This vehicle is capable of high speeds. Buried objects or uneven  
terrain can cause loss of control. Reduce speed and use extreme  
caution when operating in unfamiliar terrain.  
• Excessive speed, especially at night or with limited visibility, can  
result in insufficient time for you to react to terrain changes, to  
avoid unexpected obstacles, or to stop safely.  
• Never consume alcohol or drugs before or while operating this vehi-  
cle.  
• In an emergency, push down the Auxiliary Shut-Off Switch, located  
on the top of the throttle control assembly, to stop the engine. Then  
pull the brake lever to stop.  
• Always wear an approved helmet, eye protection, and adequate  
clothing while operating this vehicle.  
• This vehicle is designed for adult use only. Check local laws for age  
requirements.  
• When operating with a passenger (on approved models only)  
reduce speed and allow extra space for steering and stopping. A  
passenger reduces your ability to control the vehicle.  
• When operating on hard-packed snow, ice, or when crossing roads,  
steering and braking ability are greatly reduced. Reduce speed and  
allow extra space to turn or stop.  
• To maintain vehicle control on ice or hard-packed surfaces, you  
should have a proper balance of ski carbides to track studs. See  
Owner's Manual for proper use of traction products.  
• Repeated stops from high speed may cause fading or sudden loss  
of braking ability.  
• Parking brake may relax when used for long periods. Do not leave  
brake engaged for more than five minutes.  
• Before starting engine, check throttle, brake, and steering for proper  
operation. Make sure hood is latched. Be seated and in position to  
control the vehicle.  
Oil injection system: Use unmixed fuel only. Check oil level when  
refueling.  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
4
3
2
5
6
7
1
8
14  
9
10  
11  
13  
12  
1. Hood  
2. Headlight  
3. Windshield  
4. Handlebar  
5. Seat  
6. Taillights  
7. Rear Bumper  
8. Snow Flap  
9. Console Storage Compartment (if equipped)  
10. Suspension  
11. Track  
12. Skis  
13. Nosepan  
14. Front Bumper (do not use for pulling or dragging the snowmobile)  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
2
1
6
3
7
8
5
4
1. Fuel Filler Cap/Dipstick  
2. Recoil Starter Handle  
3. Reverse Indicator  
4. Headlight Adjuster  
5. Speedometer  
10  
11  
12  
9
6. Engine Stop Switch  
7. Choke Lever  
8. Ignition Switch  
9. Brake Lever  
10. Parking Brake  
13  
14  
11. Handlebar Grip Warmer Switch  
12. Thumbwarmer Switch  
13. Electronic Reverse Button  
14. Headlight Dimmer Switch  
15. Throttle Control  
15  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Fuel Valve  
The fuel valve is located under the  
hood. Turn the fuel valve off when-  
ever the snowmobile is stored or  
parked.  
OFF  
1. Turn the valve clockwise to  
turn off the fuel supply.  
ON  
2. Turn the valve counter-clock-  
wise to turn on the fuel supply.  
Adjustable Headlights  
Adjust the headlight beam by moving the  
adjuster to the left or right.  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Front Suspension Adjustments  
Independent Front Suspension (IFS)  
Break in the suspension for about 150 miles (240 km) before making  
any fine-tuning adjustments.  
Settings will vary from rider to rider, depending on rider weight, vehicle  
speed, riding style, and trail conditions. We recommend starting with  
factory settings and then customizing each adjustment individually to  
suit rider preference. The machine should be methodically tested, one  
change at a time, under the same conditions (trail and snow conditions,  
vehicle speed, riding position, etc.) after each adjustment until the best  
ride is achieved.  
IFS Components  
1
1. Skis  
2
2. Front shocks and springs  
3. Rod ends  
4. A-arms  
3
IFS Adjustment Options  
• Front shock spring preload  
• Optional springs  
• Optional shocks  
4
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Front Suspension Adjustments  
Shock Spring Preload  
Increasing spring preload will increase  
ski-to-ground pressure. Decreasing spring  
preload will decrease ski-to-ground pres-  
sure. When adjusting, be sure the springs  
on both the left and right sides of the  
machine are at the same adjustment.  
To change front shock spring preload,  
grasp the spring and rotate it.  
Increasing the spring preload too much  
may adversely affect the handling of the  
snowmobile and the performance of the  
suspension. Never exceed one inch of pre-  
load beyond the factory settings, and  
ensure that both sides are adjusted the  
same. When decreasing preload, make  
sure at least two turns of preload are hold-  
ing the spring between the retainer on the  
top of the shock and the threaded spring  
preload adjuster nut on the shock body.  
High  
Preload  
Low  
Preload  
Failure to do so could cause the retainer to fall off when the suspension  
is fully extended.  
Tip: Not all models have shocks with thread adjustable spring preload. See your  
dealer for more information.  
NOTICE: On some models equipped with a plastic adjuster nut, the nut will  
break if it is unscrewed from the threaded body. Do not force the nut if  
resistance suddenly increases while you’re turning it.  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Rear Suspension Adjustments  
Rider weight, riding style, trail conditions, and vehicle speed all affect  
suspension action.  
Each rear suspension can be adjusted to suit rider preference and deliver  
excellent performance for a given set of conditions. However, all sus-  
pension designs and adjustments involve a compromise, or trade-off.  
For example, a suspension set up for snowcross racing would provide a  
very stiff ride on the trail. A suspension set up for trail riding would  
bottom out harshly on a snowcross course.  
Refer to the suspension setup label on your snowmobile, or see your  
Polaris dealer for initial suspension setup information. Additional  
adjustments can be made after initial setup. Make adjustments to one  
area at a time so you can evaluate the change. For further assistance, see  
your dealer.  
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Rear Suspension Adjustments  
Suspension Performance Tips  
• Rider weight usually determines the position at which the spring pre-  
load should be set. However, this may vary with riding style. With a  
little experimentation, each rider can find a preferred setup. These  
adjustments are easy to make, involve very little time or effort, and  
greatly affect the ride.  
• In deep snow, a new rail slide will offer improved performance over  
worn rail slide. It can also improve top speed.  
• When riding on ice or hard-packed snow, adding a set of bogie wheels  
to the rail may enhance the machine's performance. Bogie wheel kits  
are available from your dealer.  
• Polaris offers track kits for improved flotation in deep snow. See  
your dealer for assistance.  
Tip: Keep the suspension pivot points lubricated. This will reduce moisture and  
rust build-up and ensure proper function of the suspension components.  
Grease rear suspension pivots before adjusting the rear suspension. Refer  
to Suspension Maintenance beginning on page 94.  
Track Tension  
Track adjustment is critical for proper handling. Always maintain cor-  
rect tension and alignment. Refer to the track tension maintenance sec-  
tion beginning on page 86.  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Rear Suspension Adjustments  
Initial Spring Preload Setting (Sag Method)  
To set up the rear suspension torsion  
spring preload, measure the distance  
between the ground and rear  
bumper. This is measurement X.  
Take the first measurement with no  
rider and with the rear suspension at  
full extension.  
X
Tip: The rear bumper may need to be  
lifted upward slightly to fully extend  
the rear suspension.  
Next, have the rider drop down hard  
on the seat and bounce up and down  
several times, collapsing the rear  
suspension. With the rider seated,  
measure the distance between the  
ground and the rear bumper at the  
exact location used for measurement  
X. This is measurement Y.  
Y
To determine sag, commonly  
referred to as ride-in, subtract mea-  
surement Y from X (sag=X-Y). If the measured sag is incorrect, adjust  
the FRA position and/or rear torsion spring preload.  
See  
Suspension Recommended Sag Adjustment  
Page  
IQ (121)  
4-5 inches (10-13 cm)  
Torsion Spring  
Preload  
33  
Tip: This is only an initial setup, and final spring preload may vary based on rider  
preference and riding conditions.  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Rear Suspension Adjustments  
Torsion Spring Preload  
To adjust rear torsion spring preload, rotate the three-position cam using  
the engine spark plug tool. Adjustment is easiest when the cam is  
rotated from low to medium, and then to high. Rotating directly from  
low to high will require significantly more effort.  
Different rate torsion springs are available if a firmer ride is desired. See  
your dealer for more information.  
Soft  
Medium  
Firm  
Limiter Strap Position (Ski Pressure)  
Ski pressure is set at the factory to  
deliver the optimum balance  
between ride and handling. If a  
rider prefers more ski pressure for  
improved steering performance,  
adjustments can be made to the  
Upper  
Nuts  
front limiter straps. Tighten the  
straps to increase ski pressure.  
Loosen the straps to reduce ski  
pressure.  
1. Remove the nuts and flat  
washers from the upper limiter  
straps.  
2. Relocate the straps to the desired position.  
3. Reinstall the nuts and washers. Tighten securely.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Rear Suspension Adjustments  
Suspension Coupling  
On all Polaris snowmobile rear suspensions, there are two torque arms  
that control the movement of the rail beam. Prior to the advent of sus-  
pension coupling, these torque arms could move independently of each  
other. Rear suspension coupling links the movement of the front and  
rear torque arms to each other.  
There are two types of rear suspension coupling.  
Front To Rear Coupling and the Front Rear Scissor Stop  
(FRSS)  
This type of coupling is available as an accessory for your model.  
The front rear scissor stop (FRSS) couples the movement of the front  
torque arm with the rear torque arm and limits the amount of indepen-  
dence between the movement of the front torque arm and the rear torque  
arm.  
When hitting a bump, the front torque arm starts to compress. The FRSS  
links that movement to the rear torque arm, causing it to compress and  
raise the rear suspension up as one, allowing the suspension to hit the  
bump only once and reducing kickback.  
The factory setting is usually adequate for all riders and conditions.  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Rear Suspension Adjustments  
Suspension Coupling  
Rear To Front Coupling and the Rear Rear Scissor Stop  
(RRSS)  
The rear rear scissor stop (RRSS) couples the movement of the rear  
torque arm with the front torque arm and limits the amount of indepen-  
dent movement between the rear torque and the front torque arm.  
Adjusting the RRSS either allows more weight to transfer to the rear for  
more traction, or allows less weight to transfer to the rear, resulting in  
improved cornering performance. An adjustment dot is located on the  
RRSS. This dot is on the longest end of the scissor stop.  
Rear Rear Scissor Stop (RRSS) - Attributes  
Moving the RRSS to a higher position will have the following effects on  
the suspension:  
• Reduced weight transfer  
• Improved chatter bump ride  
• Improved cornering performance  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Rear Suspension Adjustments  
Weight Transfer During Acceleration  
The preferred method for controlling  
weight transfer during acceleration is  
by adjusting the rear rear scissor stop  
(RRSS). The factory setting is the  
best for most trail riding conditions.  
HIGH  
LOW  
LOW  
MEDIUM  
To decrease weight transfer under  
acceleration (for improved corner-  
ing), rotate the RRSS to a higher  
position.  
To increase weight transfer or ski lift  
during acceleration, rotate the RRSS  
to a lower position.  
Tip: Your dealer can help you with initial  
setup and additional setup instruc-  
tions to help you achieve your opti-  
mum ride. A scissor stop tool is also  
available from your dealer.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Traction Products  
nCarbide Skags  
A skag is a replaceable bar attached to the underside of the ski to assist  
in turning the snowmobile and to prevent ski wear caused by contact  
with roads and other bare terrain.  
Inspect skags frequently. Worn skags may reduce steering and braking  
control on hard-packed snow and ice. Replace worn skags to maintain  
proper balance and vehicle control.  
WARNING! Loss of control can result in serious personal injury or death.  
Proper balance of traction products on the skis and track must be maintained to  
obtain proper vehicle control on hard-packed snow or ice. See your dealer for  
assistance.  
Accessories  
Polaris offers a wide range of accessories for your snowmobile to help  
make each ride more enjoyable.  
Use only Polaris parts and accessories on your Polaris snowmobile. Use  
of unapproved parts and accessories may result in:  
• Non-compliance with government/industry requirements  
Voiding of warranty  
• Injury to self or others  
This applies, but is not limited to the following areas: brakes, clutches,  
fuel systems, and exhaust systems.  
Tip: Exhaust systems are critical safety areas that must use approved Polaris  
parts. Please see your Polaris dealer for service.  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Handlebar Adjustments  
When making handlebar adjustments, always be sure the handlebars,  
brake lever and throttle lever operate smoothly and do not contact the  
fuel tank, windshield or any other part of the vehicle when the handle-  
bars are turned fully to the left or right.  
Upper  
Bolts  
Lower  
Bolts  
Handlebar Position  
Follow these steps to adjust handlebar position.  
1. Remove the handlebar cover.  
2. Loosen the four upper and four lower adjuster block bolts.  
3. Adjust the handlebar to the desired position.  
4. Torque the front bolts first, then torque the rear bolts. Torque the  
bolts to 15-17 ft. lbs. (20-23 Nm).  
5. Reinstall the handlebar cover.  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Handlebar Adjustments  
Handlebar Angle  
Follow these steps to adjust handlebar angle at the handlebar block.  
1. Remove the handlebar cover.  
2. Loosen the four upper adjuster block bolts.  
3. Adjust the handlebar to the desired angle.  
4. Torque the bolts to 15-17 ft. lbs. (20-23 Nm).  
5. Reinstall the handlebar cover.  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Pre-Ride Checklist  
Inspect all items on the checklist for proper operation or condition  
before each use of the snowmobile. Procedures are outlined on the ref-  
erenced pages. Look for a checkmark (n) on the referenced pages to  
locate the pre-ride inspection items.  
Item  
See Page  
Drive Belt Condition  
Steering System  
Recoil Rope  
83, 85  
44  
45  
Cooling System Seal  
73  
Parking Brake Lock/Brake Lever/Brake System  
Auxiliary Shut-Off Switch (Engine Stop Switch)  
Ignition Switch  
42, 43, 77  
46  
46  
Taillight/Brakelight/Headlight  
Suspension Mounting Bolts  
Skags (Wear Bars)  
46  
94  
93  
Ski Spindle Bolts  
94  
Hood Straps/Latches  
45  
Seat Latches (if equipped)  
Throttle Lever/Safety Switch  
Rear Wheel Idler Bolts  
N/A  
56, 57  
89  
Tether Switch/Strap (accessory)  
Track Alignment/Condition  
Rail Slide Condition  
46  
44, 90  
94  
Chaincase Oil Level  
68  
Injection Oil Level  
53  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
WARNING! Worn, damaged, or malfunctioning components may cause serious  
injury or death. Before starting the engine, check all components to be sure of  
proper operation.  
Read and Understand Your Owner's Manual  
Read the Owner's Manual completely and refer to it often. The manual  
is your guide to safe and enjoyable snowmobiling experience.  
nThrottle Lever  
The throttle and brake are the primary controls of your snowmobile.  
Always make sure both are functioning properly.  
Squeeze the throttle lever to make sure it compresses evenly and  
smoothly. When released, the lever should immediately return to the  
idle position without binding or hesitation. If the throttle does not func-  
tion smoothly, or if you discover excessive lever freeplay, DO NOT start  
the engine. Have the throttle serviced immediately.  
nThrottle Safety Switch  
Test the throttle safety switch system before the machine is operated.  
See page 56.  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
nBrakes  
Always check the following items for proper operation before starting  
the engine.  
Brake Lever Travel  
Squeeze the brake lever. It  
should move no closer to the  
handgrip than 1/2I(1.3 cm).  
1/2I(1.3 cm)  
A smaller distance indicates  
low brake fluid level or air in  
the hydraulic system. Refer  
to the brake bleeding infor-  
mation on page 79 or see  
your dealer for service.  
Lever Feel  
If the brake lever feels “spongy” when squeezed, check the brake fluid  
level and condition. Add fluid as needed. See page 78.  
WARNING! Continued use of “spongy” brakes may cause a complete loss of  
brakes, which could result in serious injury or death. Always have the brakes  
serviced at the first sign of sponginess.  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
nParking Brake Lever Lock  
Use the parking brake lever lock only when you want the machine to  
remain stationary; for example, when parked on an incline for a period  
of five minutes or less.  
1. Brake Lever  
3
4
2. Parking Brake Lever  
Lock  
1
2
3. Master Cylinder Reser-  
voir/ Cover  
4. Fluid Level Indicator  
Lock Engagement  
To engage the lock, squeeze  
the brake lever tightly and  
push forward on the lock.  
Hold the lock forward while  
releasing the brake lever.  
Tip: If the brake lever is squeezed tightly enough, the lock will move freely into  
place. Do not force the lock or it may break.  
The brake light will illuminate if the parking brake lever lock is set  
while the engine is running. It will also illuminate when the service  
brake is in use. If the parking brake light does not come on when the  
parking brake or service brake is in use, have it serviced by your dealer.  
Lock Release  
To release the lock, squeeze the brake lever tightly. The lock will return  
to the unlock position.  
WARNING! If the parking brake lever lock is partially or entirely engaged while  
riding, the brakes may overheat, resulting in brake damage. In extreme cases it  
could cause a fire, which could result in serious injury or death. Always ensure  
that the lever lock is completely disengaged before operating the snowmobile.  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
nSteering System  
Before driving, manually turn the skis to the left and right to be sure ice  
and snow are not interfering with full left and right steering. If difficulty  
is encountered, remove ice and snow build-up that may be obstructing  
the steering linkage.  
nTrack  
WARNING! Operating the snowmobile with a damaged track increases the  
possibility of track failure, which could cause loss of control resulting in serious  
injury or death. Always inspect the track for damage before using the vehicle.  
Use of traction products such as studs increases the possibility of track  
damage and/or failure. Driving at high speeds for extended periods of  
time in marginal lubrication could severely damage track rods, break  
track edges, and cause other track damage. Examples of marginal lubri-  
cation would include frozen bodies of water without snow cover, icy  
trails, and no-snow conditions.  
Tip: Track damage or failure caused by operation on ice or poor lubrication con-  
ditions voids the track warranty.  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
nHood Latches  
The hood of the snowmobile protects the operator from moving parts as  
well as aiding in sound emission control and other functions. Under no  
circumstances should your snowmobile be operated with the hood open  
or removed. Always ensure that the hood straps are in good condition  
and that the latches are securely in place before operating the snowmo-  
bile.  
nRecoil Rope  
Inspect the recoil rope and handle for excessive wear, and make sure the  
knot securing the rope inside the handle is secure. If excessive wear is  
found, see your Polaris dealer for replacement.  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Start the Engine and Check  
Before starting the engine, always refer to all safety warnings pertaining  
to snowmobile operation. Never start your snowmobile without check-  
ing all components to be sure of proper operation. See Before Starting  
the Engine beginning on page 41.  
n Engine Stop Switch  
Check the auxiliary shut-off switch for proper operation. Push the  
switch down to stop the engine. Pull it up to allow restarting.  
n Ignition Switch  
Make sure the engine stops when the ignition switch is turned to OFF.  
n Tether Switch (if equipped)  
If your machine has a tether switch, remove the tether from the switch to  
make sure the engine stops immediately.  
n Lighting  
Check the headlight (high and low beam), taillight, and brake light.  
Replace burned out lamps before operating.  
n Mirrors (if equipped)  
Adjust the mirrors so they can be used to their full advantage.  
n Operating Area  
Before driving away, check your surroundings. Be aware of obstacles  
and make sure bystanders are a safe distance from the machine.  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Starting the Engine  
NOTICE: Engaging the starter when the engine is running WILL result in serious  
engine damage, especially if the transmission is in reverse. Never  
engage the starter when the engine is running.  
1. Turn the fuel valve on. See  
page 27.  
CHOKE POSITIONS  
OFF  
2. Turn the key to the ON  
position.  
3. Pull the engine stop switch  
up to the RUN position.  
1/2 CHOKE  
4. If starting a cold engine,  
flip the choke toggle to  
FULL CHOKE. Do not use  
the choke if starting a warm  
engine. Do not depress the  
throttle until the engine  
starts.  
FULL CHOKE  
CAUTION! To avoid injury and/or engine damage, do not operate the electric  
starter or pull-rope starter while the engine is running.  
NOTICE: Don't pull the starter rope to the fully extended position and don't allow  
it to snap back into the housing. Damage may result.  
5. If equipped with electric start, turn the key to START to crank the  
engine. Release the key to the ON position when the engine starts.  
6. If not equipped with electric start, grasp the starter handle and pull  
slowly until the recoil engages; then pull abruptly to crank the  
engine.  
7. Repeat the cranking procedure as needed until the engine starts.  
8. After the engine starts, flip the choke toggle to the OFF position. If  
the engine slows or wants to stop, use intermittent choking to the  
HALF CHOKE position.  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Emergency Stopping  
The following chart lists methods for stopping the snowmobile in the  
event of an emergency. See page 56 for more information about the  
engine stop switch and throttle safety switch.  
THROTTLE  
CONDITION  
SYSTEM  
Ignition Switch  
WHAT IT DOES  
Interrupts ignition circuit  
Slows jackshaft  
All  
Brake  
All  
Choke  
Floods engine  
Half throttle or less  
Engine Stop Switch  
Throttle Safety Switch  
Interrupts ignition circuit  
Interrupts ignition circuit  
All  
All  
All  
Tether Switch (accessory) Interrupts ignition circuit  
Engine Break-In  
No single action on your part is as important to long, trouble-free  
machine life as proper break-in of a new or rebuilt engine. Premix the  
first tank of fuel with one pint of Polaris injection oil for each five gal-  
lons of fuel. This, in addition to the lubrication supplied by the injection  
system, will assure proper engine break-in.  
NOTICE: Excessive heat build-up during the first three hours of operation will  
damage close-fitted engine parts. Do not operate at full throttle or high  
speeds for extended periods during the first three hours of use. Vary  
the throttle openings and machine speeds to reduce friction on all  
close-fitting machined parts, allowing them to break in slowly without  
damage.  
Use of any lubricants other than those recommended by Polaris may  
cause serious engine damage. We recommend the use of Polaris  
lubricants for your vehicle.  
Drive with extra caution during the break-in period. Perform regular  
checks on fluid levels, lines, and all other important areas of the  
machine.  
48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Engine Break-In  
Oil Injection System  
Always check and fill the oil tank when refueling. See page 53.  
NOTICE: Serious engine damage can occur without the proper lubrication.  
Check the oil tank level often during the first tank of fuel. If the oil level  
doesn't go down, contact your dealer immediately.  
Oil Recommendations  
Engine lubrication comes from oil added to the fuel and oil injection  
systems. Polaris recommends the use of Polaris Premium (Blue) or VES  
II 2-cycle oil for this engine. See page 98 for the part numbers of Polaris  
products.  
Never mix brands of oil. Serious chemical reactions can cause injection  
system blockage, resulting in serious engine damage. Oils may also be  
incompatible and the result could be sludge formation, filter blockage,  
and reduced cold weather flow rates. All Polaris oils are compatible  
with each other.  
Slide Rail and Track Cooling  
NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide  
rail and track, resulting in premature wear and failure. Reduce speeds  
and frequently drive into fresh snow to allow adequate cooling and  
polishing of the slide rail and track surfaces. Avoid operating on ice,  
hard-packed surfaces or roads.  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Track Warm-Up  
WARNING! A loose track or flying debris could cause serious injury or death.  
Stand clear of the front of the machine and the moving track. Never hold the  
snowmobile up or stand behind it while warming up the track. Do not use  
excessive throttle during warm-up or when the track is free-hanging. Use a  
stable rear support.  
WARNING! Use of traction products such as studs, ice growsers, etc. will  
increase the possibility of track damage and/or failure. This could cause loss of  
control, resulting in serious injury or death. Always inspect for track damage  
before operating the snowmobile.  
Follow these steps to ensure proper warm-up of the engine, drive train  
and track.  
1. Use an appropriate stand to securely sup-  
port the rear of the snowmobile at the rear  
bumper. The track should be about 4I(10  
cm) off the ground.  
2. Start the engine and allow it to warm up  
two to three minutes.  
3. Depress the throttle abruptly and allow the  
track to rotate several revolutions.  
Tip: It will take longer to warm up the track suffi-  
ciently during colder outdoor temperatures.  
4. Release the throttle, apply the brakes, shut  
off the engine and lower the machine to the ground.  
5. Grasp the skis by their front loops and move them from side to side  
to loosen snow and ice.  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Fuel  
WARNING  
Gasoline is highly flammable and explosive under certain conditions.  
• Always exercise extreme caution whenever handling gasoline.  
• Always refuel outdoors or in a well-ventilated area.  
• Always turn off the engine before refueling.  
• Do not overfill the tank. Do not fill the tank neck.  
• Do not smoke or allow open flames or sparks in or near the area where refu-  
eling is performed or where gasoline is stored.  
• If gasoline spills on your skin or clothing, immediately wash it off with soap  
and water and change clothing.  
• Never start the engine or let it run in an enclosed area. Engine exhaust fumes  
are poisonous and can cause loss of consciousness or death in a short time.  
Turn the fuel valve off whenever the snowmobile is stored or parked.  
WARNING  
The engine exhaust from this product contains chemicals known to cause  
cancer, birth defects or other reproductive harm. Operate this vehicle only  
outdoors or in well-ventilated areas.  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Fuel  
Your Polaris engine is designed to run on 87 octane non-oxygenated or  
89 octane oxygenated pump gasoline. There's a great deal of variability  
in the quality of the 87 octane gasoline available across the country, so  
we encourage the use of premium fuel when possible. Do not use fuel  
containing more than 10% ethanol (including E85).  
NOTICE: Using fuels with a lower than recommended octane or operating with  
obstructed fuel systems will result in serious and costly engine dam-  
age. Always use the recommended fuels for your machine.  
Fuel System Deicers  
If you use non-oxygenated fuel, Polaris recommends the regular use of  
isopropyl-based fuel system deicer. Add one to two ounces per gallon  
(8-16 ml per liter) of gasoline to prevent engine damage resulting from  
fuel system icing and lean fuel mixtures. Never use deicers or additives  
containing methanol. Polaris also recommends the use of Carbon Clean  
Plus. See page 98 for the part numbers of Polaris products.  
If you use oxygenated fuel containing ethanol, additional alcohol deic-  
ers or water absorbing additives should not be used.  
Fuel Valve  
Turn the fuel valve clockwise to  
OFF to shut off the fuel supply.  
OFF  
Turn the valve counter-clockwise  
to ON to turn the fuel supply on.  
ON  
52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
nOil  
Low Oil Indicator Light  
The low oil indicator light will alert the operator if the oil level is low.  
Visually check for oil in the bottle. Add oil before further operation of  
the snowmobile. See page 49 for oil recommendations.  
Low Oil Level  
Maintaining the proper oil level will prevent system aeration and possi-  
ble loss of pumping action, which could result in engine damage. This is  
especially important when the machine is operated in mountainous ter-  
rain.  
NOTICE: Operating the snowmobile without adequate engine lubrication can  
result in serious engine damage. Always check the oil level when refu-  
eling. Add oil as needed.  
Always maintain a visible level of oil in the tank. If oil is not visible,  
continued operation may cause serious engine damage. See page 49 for  
oil recommendations.  
The Polaris oil cap on the oil bottle is vented to allow proper oil flow.  
See your Polaris dealer for recommended replacement parts.  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Carburetion  
Proper carburetor adjustment is critical. A lean mixture (too much air,  
too little fuel) may result in piston burning, bearing failure, or complete  
engine failure. A rich mixture (too much fuel, too little air) may foul  
plugs and cause generally poor engine performance.  
A lean mixture may be caused by things like fuel line restrictions, for-  
eign matter in the carburetor or clogged fuel filters. A rich mixture may  
be caused by snow build-up on the pre-filter in the air intake system.  
Either condition may be caused by improper carburetor adjustment.  
WARNING! Improper carburetor adjustments may result in operator safety  
hazards as well as serious engine damage. Always have your Polaris dealer  
perform any carburetor adjustments.  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Carburetion  
Jetting Guidelines  
Changes in altitude and temperature affect air density, which is the  
amount of oxygen available for combustion. In low elevations and cold  
temperatures, the air has more oxygen. In higher elevations and higher  
temperatures, the air is less dense.  
The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and  
ambient temperatures of 0_to +20_F. (-18_to -7_C). Carburetors must  
be re-calibrated if the snowmobile is operated outside this production  
temperature and/or altitude range. The main jet installed in production is  
not correct for all altitudes and/or temperatures. See page 74 for more  
information.  
NOTICE: A main jet that's too small will cause a lean operating condition and  
may cause serious engine damage. Jet the carburetors carefully for  
elevation and temperature according to the jetting charts in your  
Owner's Manual Supplement.  
Tip: It's the owner's responsibility to ensure that the correct jets are installed in  
the machine for a geographical area. Be very careful when jetting down in  
warm weather. As the weather turns colder it will be necessary to re-jet  
upward to prevent engine damage. When selecting the proper main jet  
always use the lowest elevation and temperature that is likely to be encoun-  
tered.  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
nEngine Stop Switch  
Push down on the engine  
stop switch (+) to ground  
+
out the ignition and stop  
the engine quickly. Pull  
the switch up to the ON  
position to allow restart-  
ing.  
nThrottle Safety Switch  
The throttle safety switch is designed to stop the engine whenever all  
pressure is removed from the throttle lever and the throttle cable or  
valves do not return to the normal closed position.  
WARNING! Operating the snowmobile with a faulty throttle safety switch can  
result in serious injury or death in the event of an accident. If the throttle safety  
switch does not shut off the engine during a carburetor/throttle system  
malfunction, immediately push down the engine stop switch. Do not start the  
engine again until the malfunction has been corrected by your dealer.  
Test the throttle safety  
switch system daily before  
operation.  
1. Sit on the seat.  
2. Start the engine and  
allow it to idle.  
3. Hold the throttle lever  
pin stationary by exert-  
ing pressure on the pivot pin in the direction shown in the illustra-  
tion.  
4. Apply a slight amount of throttle. A properly functioning switch  
must shut down the engine.  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Throttle Lever  
WARNING! An improperly functioning throttle lever may cause erratic machine  
behavior and loss of control, which could result in serious injury or death. If the  
throttle lever does not work properly, DO NOT start the engine.  
If the engine stops abruptly when the throttle lever is released:  
1. Turn the ignition switch to OFF.  
2. Visually inspect the throttle cable and carburetor to determine what  
caused the safety switch to activate.  
3. Test the throttle lever by compressing and releasing it several times.  
The lever and cable must return to the idle position quickly and  
completely.  
4. If the throttle lever operates properly, turn the ignition switch on and  
go through normal starting procedures.  
5. If the engine doesn't start, take the snowmobile to an authorized  
Polaris dealer for service.  
Excessive freeplay in the throttle cable may cause the safety switch to  
activate, preventing the engine from starting. If this occurs, return the  
machine to an authorized Polaris dealer for service.  
If an emergency exists and it's necessary to start the engine, the throttle  
safety switch and engine stop switch may be disconnected from the wire  
harness. When these switches are disconnected, the ignition key switch  
must be used to shut off the engine. DO NOT continue to operate the  
machine with the throttle safety switch disconnected. Return the  
machine to an authorized Polaris dealer for service as soon as possible.  
57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Electronic Reverse (PERCt)  
Electronic reverse will activate only if the engine RPM is below 4000. If  
your machine is running at an altitude of over 6000 feet, adjust the igni-  
tion setting as described on page 59. Always make sure the vehicle is  
stopped and the engine is running at idle before shifting to reverse  
Tip: The engine will activate a misfire mode and begin to stutter after 45 sec-  
onds in reverse. This feature protects the engine from overheating and will  
reset when it is shifted into forward or when the engine is stopped and  
restarted.  
WARNING! Improper reverse operation, even at low speeds, may cause loss of  
control, resulting in serious injury or death. Damage will occur to the chaincase  
or transmission if shifting is attempted when the engine is operating above idle  
speed.  
• Shift to or from reverse only when the snowmobile is stopped and when  
engine speed is at idle.  
• Look behind the vehicle before and while backing.  
• Avoid sharp turns.  
• Apply throttle slowly.  
58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Electronic Reverse (PERCt)  
Engaging Reverse  
1. Stop the snowmobile and leave the engine idling.  
2. Make sure the area behind your vehicle is clear.  
3. Push the yellow reverse button on the left-hand control for one sec-  
ond, then release. The engine will automatically reduce RPM and  
start a reverse rotation. A flashing reverse light on the instrument  
panel will indicate that the machine is in reverse.  
4. Apply the throttle slowly to make sure the machine is in reverse.  
Tip: The maximum engine RPM will be 6000 when in reverse.  
Tip: If the engine stops running, the snowmobile will be in forward gear when it's  
restarted.  
Disengaging Reverse  
1. Stop the snowmobile and leave the engine idling.  
2. Push the yellow reverse button for one second and release. The  
engine will slow and and begin to rotate forward. The light on the  
instrument panel will shut off.  
3. Apply the throttle slowly to make sure the machine is in forward.  
Altitude Setting  
At higher altitudes (above 6000 feet), the engine will require a different  
ignition setting to improve the success of the reverse system. To set for a  
higher altitude, start the engine and hold the button down until the light  
on the instrument panel flashes rapidly, then release the button.  
To set the reverse for lower elevations, continue holding the button  
down until the reverse indicator light blinks slowly. Once set, it's stored  
in memory until changed, whether the machine is running or not.  
59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Towing  
Do not use the front bumper to pull or drag the snowmobile. The front  
bumper is not designed for this type of use and may detach from the  
vehicle if force is applied.  
For your safety, do not attempt to use a tow hitch until you've read the  
following warnings and understand the proper hitch functions.  
WARNING! Objects towed with a rope have no braking power and can easily  
collide with the rear of the snowmobile or other objects, resulting in serious  
injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle  
with a rope.  
Only a stiff metal pole connecting the towed object and the tow hitch on  
the snowmobile should be used. If passengers are to be towed on a  
toboggan or sled, make sure the pole is at least four feet (1.2 meters)  
long to prevent any possibility of contact between the snowmobile's  
track and a person riding in the towed object.  
Braking distances increase when towing loads. Slow down to maintain  
control of the snowmobile.  
If the snowmobile becomes inoperable and must be towed, and if it isn't  
possible to use a rigid tow bar, attach the tow rope to the ski spindles  
(not to the ski loops) to prevent damage to the steering components.  
Remove the drive belt before towing, and have someone ride on the  
towed snowmobile to operate the brake and steering when necessary.  
NOTICE: Towing a disabled snowmobile with the drive belt in place can result in  
serious damage to the engine and drive system. Always remove the  
drive belt from a disabled snowmobile before towing.  
60  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Emission Control Information  
Any qualified repair shop or qualified person may maintain, replace, or  
repair the emission control devices or systems on your snowmobile.  
Emission Control Label  
Your snowmobile is equipped at the time of sale with an emission con-  
trol information (ECI) label and a factory-installed emissions informa-  
tion hangtag. These items are required by U.S. Environmental  
Protection Agency regulations. The ECI label is permanently affixed to  
either the right side of the tunnel or the engine recoil cover. The ECI  
label should not be removed, even after you purchase the snowmobile.  
You may remove the factory-installed emissions information hangtag,  
which is intended solely for your use in making a purchasing decision.  
Emission Control Maintenance Requirements  
Your snowmobile is certified to operate on gasoline with a minimum  
octane level of 87 (R+M)/2. If your snowmobile is equipped with a  
check engine light and it comes on, you must take your snowmobile to a  
qualified dealer for diagnostic service. Specifications and adjustments  
for engine tune-ups are located in the Service Manual, which is avail-  
able to your qualified service technician. Reverse (if equipped) must not  
be engaged during engine tune-ups.  
Owner's Responsibilities  
Please read the Snowmobile Engine Emissions Limited Warranty, and  
read the maintenance section of your owner's manual. You are responsi-  
ble for ensuring that the specified maintenance is performed. Polaris  
recommends that you contact an authorized Polaris dealer to perform  
any service that may be necessary.  
61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 113.  
The recommended maintenance schedule on your snowmobile calls for  
service and maintenance inspections at 150 miles (240 km), 500 miles  
(800 km) and 1000 miles (1600 km). These inspections should be per-  
formed by a qualified service technician. For continued optimum perfor-  
mance and component life, continue maintenance checks at 1000 mile  
(1600 km) intervals.  
All necessary replacement parts and labor incurred, with the exception  
of authorized warranty repairs, become the responsibility of the regis-  
tered owner. If, during the course of the warranty period, part failures  
occur as a result of owner neglect in performing recommended regular  
maintenance, the cost of repairs are the responsibility of the owner.  
Personal safety is critical when attempting to service or make adjust-  
ments to your snowmobile. If you're not familiar with safe service or  
adjustment procedures and the use of tools, or if you don't feel comfort-  
able performing these tasks yourself, contact an authorized Polaris  
dealer for service.  
NOTICE: Hot components can cause damage to plastic. Always make sure the  
exhaust system and engine have cooled before tipping the snowmo-  
bile on its side for service or inspection.  
62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Interval Table  
The following chart is a guide based on average riding conditions. You  
may need to increase frequency based on riding conditions. When  
inspection reveals the need for replacement parts, always use genuine  
Polaris parts, available from your Polaris dealer.  
Item  
See  
Page  
Frequency  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km)  
Season  
CLUTCH  
Clutch Alignment Offset  
(without belt)  
82  
I
I
I
Drive Belt Condition  
Clutches (disassemble)  
Belt Tension  
83  
82  
--  
I
C
I
I
C
I
I
C
I
I
I
I
Clutch Sheaves  
82  
I
I
I
ENGINE  
Engine Mounts  
--  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Engine Mounting Plate  
Engine Torque Stop  
Cylinder Head Bolts  
Cylinder Base Nuts  
Ignition Timing BTDC  
Recoil Rope  
85  
--  
I
I
--  
I
I
I
--  
I
--  
I
I
I
I
I
Spark Plug Condition  
Exhaust Pipe  
71  
73  
73  
R
I
Exhaust Retaining  
Springs  
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean R - Replace L - Lubricate  
63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Interval Table  
Item  
See  
Page  
Frequency  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km)  
Season  
BRAKES  
Hose Routing  
Hose Condition  
Fluid Leaks  
--  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
--  
Brake Pads  
77  
Brake Disc  
--  
Parking Brake  
Brake System  
Brake Fluid  
43  
42, 77  
78  
R
FUEL MANAGEMENT  
Pilot Air Screws  
--  
I
I
I
I
I
I
Carburetor  
74  
(synchronize)  
Idle RPM  
--  
57  
--  
I
I
I
I
I
I
I
Throttle Lever  
I
I
I
I
Oil Pump Lever  
(synchronize)  
Throttle Cable  
Choke Cable  
Choke  
67  
67  
67  
--  
L
L
I
L
L
I
L
L
I
Vent Lines  
Fuel Lines  
Fuel Filter  
I
I
I
I
I
73  
73  
72  
72  
--  
I
I
I
I
I
R
R
I
R
R
I
Oil Filter  
Oil Lines  
I
I
Air Box  
I
I
I
I
Drain and Water Traps  
75  
I
I
ELECTRICAL  
Auxiliary Shut-Off  
Switch  
56  
I
I
I
I
I
Throttle Safety Switch  
Ignition Switch  
Taillight  
56  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
46  
46  
46  
Brakelight  
Headlight  
64  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Interval Table  
Item  
See  
Page  
Frequency  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km)  
Season  
CHASSIS  
Ski Toe Alignment  
--  
--  
I
I
I
I
I
I
Suspension Mounting  
Bolts  
I
I
Steering Fasteners  
--  
--  
I
I
I
I
I
I
I
I
C
I
Rear Suspension Fas-  
teners  
Suspension Shock Oil  
Cooling System  
--  
I
I
I
I
I
I
I
I
I
I
I
I
73  
67  
96  
93  
--  
Drive Shaft Bearing  
Jackshaft Bearings  
Skags (Wear Bars)  
L
L
I
L
L
I
L
L
I
I
I
Ski Saddle/Spindle  
Bolts  
I
I
I
Steering Arm(s)  
--  
I
I
Drive Chain Tension  
Hood Latches  
76  
45  
89  
89  
66  
I
I
I
I
I
I
I
I
I
I
I
I
I
Rear Wheel Idler Bolts  
Idler Bolt Jam Nut  
I
I
I
I
I
I
Rear Suspension Pivot  
Shafts  
L
L
L
Camber Alignment  
Handlebar Centering  
Tether Switch and Strap  
Track Alignment  
--  
--  
I
I
I
I
I
I
I
I
I
I
46  
90  
88  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Track Tension  
Front Limiter Strap  
Rail Slide Condition  
Chaincase Oil  
94  
68  
I
I
I
R
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean R - Replace L - Lubricate  
65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
Front Suspension  
The front suspension does not require lubrication.  
Rear Suspension  
Lubricate the suspension pivot shafts with Polaris Premium All Season  
Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after  
that, and before off-season storage each year. Lack of lubrication will  
adversely affect your ride and the life of the suspension. For more infor-  
mation about suspension lubrication and adjustments, see your Polaris  
dealer.  
+
+
+
+
66  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
Driveshaft Bearing  
Inject grease into the fitting on the  
speedometer sensor housing until  
grease purges from the seal on the  
inside of the tunnel. This should  
take approximately two pumps. Do  
not use more than four pumps.  
+
Throttle Cable  
Lubricate the throttle cable lightly  
with grease or oil. With the engine  
off, turn the handlebars to the left  
and lubricate liberally as shown.  
+
Choke and Choke Cable  
+
Lubricate the choke slide and cables  
lightly with oil or grease. Before  
turning the engine off, operate the  
choke intermittently to draw mois-  
ture out of the choke plunger area  
and reduce the possibility of the  
choke becoming frozen.  
67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
nChaincase Oil  
Check the chaincase oil level at the  
intervals outlined in the maintenance  
charts beginning on page 62. The sight  
glass (1) is located on the lower rear of  
the chaincase. Maintain the oil level at  
or slightly below the center of the sight  
glass (2). Change the chaincase oil after  
the first 500 miles (800 km), then every  
1000 miles (1600 km) or seasonally.  
3
Polaris recommends the use of Polaris  
Synthetic Chaincase Lube. See page 98  
for the part numbers of Polaris products.  
Oil Check  
1
1. Position the vehicle on a level sur-  
face.  
2. View the oil level at the sight glass.  
3. Remove the fill plug (3) and add the  
recommended oil as needed. Do not  
overfill.  
2
4. Reinstall the fill plug, making sure it  
is seated properly.  
68  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
Chaincase Oil  
Oil Change  
1. Position the vehicle on a level surface.  
2. Remove the drain plug (4) and drain  
the oil into a drain pan. Allow the oil  
to drain completely.  
4
3. Clean off all metal shavings from the  
plug.  
4. Install a new sealing washer on the  
drain plug.  
Tip: The sealing surfaces on the drain plug and the oil tank should be clean and  
free of burrs, nicks or scratches.  
5. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).  
6. Remove the fill plug. Clean off all metal shavings from the plug.  
7. Add 9 oz. (265 ml) of the recommended oil. Do not overfill.  
8. Reinstall the fill plug, making sure it is seated properly.  
69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
It’s very important to use the correct spark plug for your machine. A  
spark plug with a heat range too high will cause engine damage. A spark  
plug with a heat range too low will cause excessive fouling and engine  
malfunctioning. Change the spark plugs every 2000-2500 miles (3200-  
4000 km).  
NOTICE: A spark plug with a heat range too high will always cause engine dam-  
age if the engine is operated in conditions more severe than intended  
for that plug. Always use the spark plugs recommended for your  
snowmobile. See your Owner’s Manual Supplement.  
A new engine can cause temporary spark plug fouling due to the preser-  
vative added during the assembly process. Avoid prolonged idle speeds,  
which cause plug fouling and carbonization.  
• Use recommended spark plugs with the proper gap.  
• Use only resistor-type spark plugs.  
• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).  
• Always carry spare spark plugs.  
Spark plug condition is indicative of engine operation. The spark plug  
firing end condition should be read after the engine has been warmed up  
and the vehicle has been driven at higher speeds. Immediately check the  
spark plug for correct color.  
CAUTION! A hot exhaust system and engine can cause burns. Wear  
protective gloves when removing a spark plug for inspection.  
Tip: Incorrect fuel mixture can often cause a spark plug to appear too dark or too  
light in color. Before changing spark plug heat ranges, be sure the correct  
main jet is installed in the carburetor(s). Refer to the Owner's Manual Sup-  
plement or see your dealer.  
70  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
Spark Plug Condition  
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  
indicates the proper type and heat range for the engine and the service.  
The tip should not be white. A white insulator tip indicates overheating,  
caused by use of an improper spark plug or incorrect carburetor/throttle  
body 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 non-recommended injection oil, improper use of the choke, or incor-  
rect carburetion adjustments.  
Spark Plug Removal and Replacement  
1. Remove the spark plug cap.  
2. Rotate the spark plug counterclockwise to remove it.  
3. Reverse the procedure for spark plug installation.  
4. Torque to 18-22 ft. lbs. (24-30 Nm).  
5. Reinstall the spark plug cap.  
71  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Intake Filters  
The intake foam filters limit snow  
ingestion into the intake system.  
When operating in loose powder  
snow, check the foam filters period-  
ically to remove any accumulation  
of snow.  
+
NOTICE: Operating the snowmobile  
with the intake filters removed  
may cause carburetor icing.  
The result will be poor fuel  
economy or carburetor mal-  
function. Always reinstall the  
intake filters before operating  
the snowmobile.  
Oil Lines  
Inspect oil line condition every 1000 miles (1600 km).  
Oil Filter  
The oil filter is located at the side of  
the oil tank. Have your dealer change  
the oil filter and bleed the system  
annually or every 1000 miles (1600  
km).  
Tip: The direction of the arrows indicates  
the direction of flow through the fil-  
ter.  
Fuel Pump  
All fuel pump service must be performed by an authorized Polaris  
dealer. Do not attempt to service the fuel pump.  
72  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Fuel Filter/Fuel Lines  
See your Polaris dealer for replacement of the under-tank fuel filter  
every 1000 miles (or annually).  
Inspect the fuel lines regularly for signs of deterioration or damage.  
Always check fuel line condition after periods of storage. Normal dete-  
rioration from weather and fuel compounds may occur. Replace worn or  
damaged fuel lines promptly.  
NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel  
lines may cause damage to the lines. If a fuel line has been damaged  
or kinked, replace it promptly.  
nCooling System  
Inspect the fan intake and outlet edge seal at the input and output for  
cracks, loosening of duct and blockage or obstructions. Make any neces-  
sary repairs promptly.  
Exhaust System  
Check the exhaust system for wear or damage at approximately 2000  
miles (3200 km). Always allow the engine and exhaust system to cool  
completely before inspecting.  
CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for  
the exhaust system to cool. Never perform this procedure with the engine  
running.  
1. Open the hood and inspect the muffler and pipes for cracks or dam-  
age.  
2. Check for weak or missing retaining springs or damper/support  
grommets.  
3. Check for loose clamps on the pipe covers.  
73  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Carburetor  
The number stamped in the end of the main jet indicates the jet size. The  
jet installed at the time of manufacture is not necessarily correct for your  
elevation. It's your dealer's responsibility to make sure the correct main  
jet is installed.  
NOTICE: Operating the snowmobile with incorrect jetting can result in serious  
engine damage. Have your Polaris dealer perform all carburetor  
adjustments to ensure all adjustments are done correctly.  
Carburetor Adjustments  
The frequency at which the carburetors are synchronized or balanced is  
important. Properly adjusted carburetors can greatly improve engine  
performance, fuel economy, engine life, and reliability.  
If you notice any of the following conditions, the carburetor may need  
adjustment:  
• Hard starting  
• Poor idle  
• Overheated pistons and cylinder walls  
• Plug fouling  
• Poor engine response to various throttle valve openings  
74  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Carburetor Water/Sediment Trap  
Most Polaris snowmobiles contain patented carburetor bowl water/sedi-  
ment traps located at the bottom of each carburetor. The trap, consisting  
of a hose with a plug, should be drained about every 1000 miles (1600  
km) and inspected for contamination.  
WARNING! When draining the traps, fuel spillage will occur. Always work in a  
well ventilated area away from anything that may cause the fuel to ignite, such  
as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the fuel  
warnings on page 51.  
Cleaning Procedure  
1. Turn the fuel valve off.  
2. Place a container or shop  
1
towels below the plug to  
catch drained fuel.  
2
3. Slide the clamp (1) away  
from the drain plug (2) and  
remove the drain plug from  
the sediment tube.  
4. Wipe residue from the plug and reinstall it. Reposition and tighten  
the clamp.  
5. Repeat the draining procedure for any remaining traps.  
75  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain Tension  
Check drive chain tension weekly and  
before each long trip. To obtain correct  
chain tension:  
1. Rotate the driven clutch counter-  
clockwise to move all chain slack to  
the tensioner side. Lock the brake  
lever lock, or have an assistant hold  
the brake lever firmly.  
2
2. Loosen the adjuster bolt jam nut (1).  
1
3. Finger tighten the adjuster bolt (2)  
until it can no longer be adjusted by  
hand, then back off 1/4 turn.  
4. Tighten the jam nut while holding  
the adjuster bolt. Torque to 21 ft.  
lbs. (28 Nm).  
5. Release the brake lever lock.  
76  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
nHydraulic Brake Inspection  
Inspect brake lever travel before each use of the snowmobile. See page  
42.  
Brake pads must be replaced when the brake pad material becomes thin-  
ner than the backing plate (approximately 1/16I). A kit is available for  
replacing brake pads. See your dealer.  
WARNING! Brake failure during operation can result in serious injury or death.  
Properly functioning brakes are vital to your safety. Be sure the brake pads do  
not drag on the disc and that brake lever travel is not excessive. Always replace  
brake pads when the brake pad material becomes thinner than the backing plate  
(approximately 1/16I)  
Brake Components  
1. Brake Caliper  
3
2. Brake Disc  
1
3. Brake Pad Material  
(Replace when thickness is  
less than 1/16I/1.5 mm).  
2
Excessive Lever Travel  
Hydraulic brakes are self-  
adjusting, but if excessive  
brake pad clearance develops,  
bring the machine to an autho-  
rized Polaris dealer for inspec-  
tion and adjustment.  
77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
Brake Fluid  
WARNING! After opening a bottle of brake fluid, always discard any unused  
portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it  
rapidly absorbs moisture from the air. The moisture causes the boiling  
temperature of the brake fluid to drop, which can lead to early brake fade and  
the possibility of accident or serious injury.  
The brake fluid level can be seen through a plastic sight glass in the  
brake reservoir. If the fluid is sufficient, the sight glass will be black. If  
the sight glass is any color other than black, add brake fluid.  
Keep the master cylinder cover free of dirt and debris. The vent slits  
allow for diaphragm movement, and if they become plugged, movement  
of brake fluid below the diaphragm may be restricted, altering brake  
function.  
Replace brake fluid at least every two years with Polaris DOT 4 high  
temperature brake fluid. See page 98 for the part numbers of Polaris  
products.  
NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe  
up spills immediately.  
78  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
Bleeding the Hydraulic Brake System  
Air in the hydraulic brake system will cause spongy brake lever action.  
Bleed the system before operating the snowmobile.  
WARNING! Operating the vehicle with a spongy brake lever can result in loss of  
brakes, which could cause an accident and lead to serious injury or death.  
Never operate the vehicle with a spongy-feeling brake lever.  
During the bleeding procedure, keep the brake handle as level as possi-  
ble. The reservoir must be in this position to minimize the possibility of  
air entering the system through the reservoir vent.  
1. Remove the brake master cylinder reservoir cover and gasket.  
2. Fill the master cylinder reservoir to between the MIN and MAX  
marks or 1/4-5/16I(.6-.8 cm) below the lip of the reservoir open-  
ing. Reinstall the gasket and cover.  
3. Slip a rubber tube over the ball of the bleeder valve and direct the  
flow of fluid into an approved container.  
4. Squeeze the brake lever a full stroke. Then unscrew the bleeder  
valve 3/4 of a turn to release air.  
5. Close the bleeder valve and release the brake lever.  
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a  
solid stream free of air bubbles.  
WARNING! Overfilling the master cylinder leaves no room for fluid expansion  
and may cause the brakes to lock, resulting in serious injury or death. Always  
add brake fluid to the fill line as recommended.  
7. After bleeding is complete, refill the reservoir to the proper level.  
See page 78.  
8. Reinstall the gasket and cover.  
79  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lights  
Do not touch a halogen bulb with bare fingers. Oil from skin leaves a  
residue, causing a hot spot that will shorten the life of the lamp. If fin-  
gers do touch the bulb, clean it with an alcohol-moistened towel.  
Headlight Bulb Removal  
1. Remove the plenum covering  
from the headlight assembly.  
2. Lift the rubber boot to expose  
the bulb.  
2
3. Push down on the spring (1) to  
release it from the housing.  
3
4. With the wire harness (2)  
attached to the bulb (3), with-  
draw the bulb from the housing.  
1
5. Grasp the bulb by its metal base  
and carefully separate the bulb from the harness.  
Headlight Bulb Installation  
1. Hold the bulb by its metal base and install it into the wire harness.  
NOTE: Recommended replacement bulbs include H4, HB2 and 9003 bulbs.  
2. Insert the bulb into the housing.  
3. Connect the spring to the housing.  
4. Carefully flip the spring back into the housing, placing it around the  
wire harness.  
5. Reinstall the plenum covering on the headlight assembly.  
6. Verify headlight aim.  
80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lights  
Taillight/Brakelight Replacement  
1. Remove the screws securing the taillight lens. Remove the lens.  
2. Push the bulb inward and turn it counterclockwise to remove it.  
3. Install a new bulb. Push the bulb inward and turn it clockwise to  
secure it.  
4. Reinstall the taillight lens.  
81  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
Periodically inspect clutch sheaves for damage, wear or belt residue. To  
maintain optimum performance, clean with non-oil based cleaners such  
as isopropyl alcohol.  
NOTICE: If you become aware of higher than normal clutch engagement or an  
unusual vibration or shift pattern, see your dealer immediately. Do not  
operate the machine until repairs have been made.  
All clutch maintenance and repairs must be performed by an autho-  
rized Polaris dealer. Any unauthorized modifications to clutches, such  
as adding or removing weights, will void the warranty.  
The bushings in the weights and rollers of Polaris clutches are made  
of a material that may be damaged if lubricated. Do not lubricate  
clutch bushings.  
Clutch Alignment Offset  
Clutch alignment offset is important for maintaining optimum perfor-  
mance. See your dealer for service and adjustments. A special tool is  
required to check for proper alignment.  
Clutch Center Distance  
See your Owner's Manual Supplement for recommended center distance  
for your machine. If adjustment is necessary, see your dealer.  
82  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
nDrive Belt Condition  
Periodically check the condition and tension of the drive belt, and  
always carry a spare. Inspect the belt for signs of excessive wear: frayed  
edges, missing cogs, cracks and excessive looseness. Replace the belt if  
any of these conditions exist. See Drive Belt Troubleshooting on page  
103.  
For improved drive-away during extremely cold temperatures, remove  
the belt and warm it to room temperature. Reinstall it before starting the  
snowmobile.  
Drive Belt Removal  
NOTICE: Do not attempt to remove the drive belt after operating in reverse. The  
snowmobile must be stopped after forward motion to prevent damage  
to components during belt removal.  
1. Stop the engine after operating in a forward motion.  
2. Turn the ignition key off. Wait for the engine to come to a complete  
stop.  
3. Lock the parking brake.  
4. Open the hood.  
5. Remove the left side panel.  
6. Locate the L-wrench in the tool kit. Install the wrench into the open  
threaded hole in the outer sheave of the clutch.  
7. Turn the wrench clockwise until the sheaves open far enough to  
remove the belt.  
83  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
Drive Belt Installation  
1. Drop the drive belt over the  
drive clutch and pull back the  
slack.  
Tip: To ensure satisfactory belt life,  
install belts so they operate in  
the same direction of rotation by  
positioning the identification  
numbers so that you can read  
them. If required, separate the  
sheaves as outlined in the belt  
removal procedures.  
2. Rotate the L-wrench counter-  
clockwise to tighten the  
sheaves while working the belt to the outer edge of the sheaves.  
3. Remove the L-wrench and store it in the tool kit.  
4. Reinstall the side panel.  
5. Close and secure the hood.  
Drive Belt  
Belt width and length must match the center distance of the clutches and  
sheave width of the drive clutch. Polaris recommends the use of O.E.M.  
belts. Other belts may match the dimensions, but can drastically change  
the shift pattern, resulting in poor performance.  
Tip: A worn belt will continue to function, but will not deliver maximum perfor-  
mance. Always carry a spare belt in case of an emergency.  
84  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
nDrive Belt Deflection  
1
Measure belt deflection with both  
clutches at rest and in their full  
neutral position.  
2
Place a straight edge (1) on the  
belt and apply downward pressure  
while measuring at point 2. This  
measurement should be 1 1/4I  
(3.2 cm).  
Drive Belt Adjustment  
1. Install the L-wrench into the open threaded hole in the outer sheave  
of the clutch (see page 83). Turn the wrench clockwise slightly to  
remove pressure from the sheaves.  
2. Loosen the 7/16Ijam nut.  
3. Using a 1/8IAllen wrench, turn the set screw inward (clockwise) to  
increase the distance between the sheaves or outward (counterclock-  
wise) to decrease the distance.  
4. Tighten the jam nut. Store the L-wrench in the tool kit.  
Torque Stop  
Periodically check torque stop  
.010I-.030I  
(.25-.75 mm)  
clearance. With clutches in  
proper alignment, the torque  
stop clearance should be  
.010I-.030I(.25-.75 mm)  
from the engine case.  
Adjust if necessary, and lock  
the jam nut.  
85  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Maintenance  
Track Inspection  
WARNING! Broken track rods can cause a rotating track to come off the  
machine, which could cause serious injury or death. Never operate with a  
damaged track. Never rotate a damaged track under power.  
1. Using a hoist, safely lift and  
support the rear of the snow-  
mobile off the ground.  
+
2. Rotate the track by hand to  
check for damage.  
3. Carefully examine the track  
along the entire length of  
each rod (+). Bend the track  
to check for breakage.  
4. Replace the track if any rod  
damage is found.  
86  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Maintenance  
Track Lubrication  
WARNING! Operating with insufficient lubrication between the rail slide and  
track guide clips can cause track failure, loss of vehicle control and loss of  
braking ability, which can result in serious injury or death. Avoid operating for  
extended periods on ice and other surfaces that have little or no snow for  
lubrication.  
The slide rail needs snow for lubrication. Excessive wear indicates  
insufficient lubrication. A new rail slide can cause faster heat build-up  
in limited lubrication, resulting in excessive wear.  
Tip: If excessive rail slide wear occurs due to poor snow conditions, additional  
wheel kits are available. See your dealer for more information.  
Tip: Track damage or failure caused by operation on ice or under other poor  
lubrication conditions will void the track warranty.  
87  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Maintenance  
WARNING! Moving parts can cut and crush body parts. When performing the  
checks and adjustments recommended on the following pages, stay clear of all  
moving parts. Never perform track measurement or adjustments with the engine  
running.  
Track Tension  
Track adjustment is critical for proper handling. Always maintain cor-  
rect tension and alignment.  
TRACK TENSION DATA CHART  
Measurement  
Location  
Slack  
Measurement  
Suspension  
Weight  
IQ  
10 lbs. (4.54 kg)  
16 in. (40 cm)  
ahead of rear  
idler shaft  
7/8-1 1/8 in.  
(2.2-2.9 cm)  
Tip: Tension adjustments should be made only after the track is warmed up and  
limber.  
1. Turn the engine off.  
2. Lift the rear of the machine and safely support it off the ground.  
3. Place the recommended weight or downward pressure on the track  
at the specified distance (see chart) ahead of the center of the rear  
idler wheel. Measure at the point where the weight is hanging.  
88  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Maintenance  
Track Tension  
4. Check for specified slack between the wear surface of the track clip  
and the plastic slider. Refer to the Track Tension Data Chart on page  
88.  
If the track needs adjustment:  
5. Loosen the rear idler shaft bolt.  
6. Loosen the locknuts.  
Adjusting Screw  
Lock Nut  
Slack Measurement  
Shaft  
Bolt  
S
Track  
10 lbs.  
(4.54 kg)  
16I(40 cm)  
7. Tighten or loosen the track adjusting screws to provide equal adjust-  
ment on both sides of the track.  
8. Repeat the measurement on the other side of the track.  
Tip: Check more frequently when the machine is new.  
9. Start the machine and slowly rotate the track at least five revolu-  
tions. Let the track come to a stop (do not apply brakes).  
10. Check track alignment (see page 90) and adjust as necessary.  
11. Tighten the locknuts.  
12. Tighten the idler shaft bolts.  
13. (n) Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).  
89  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Maintenance  
nTrack Alignment  
Periodically check that the track is centered and running evenly on the  
slide rails. Misalignment will cause excessive wear to the track and  
slide rail.  
1. Safely support the rear of the machine with the track off the ground.  
2. Start the engine and apply a small amount of throttle until the track  
turns slowly at least five complete revolutions. Stop the engine and  
let the track come to a stop (do not apply brakes).  
3. Inspect track alignment by  
looking through the track  
window to make sure the  
rails (+) are evenly spaced  
on each side. If the track  
runs to the left, loosen the  
idler shaft bolts, then  
loosen the left locknut and  
tighten the left adjusting  
bolt. If the track runs to the  
right, loosen the idler shaft  
bolts, then loosen the right  
locknut and tighten the  
right adjusting bolt.  
4. After adjustments are com-  
plete, tighten the locknuts  
and torque idler shaft bolts  
to 35 ft. lbs. (47.5 Nm).  
+
5. Repeat steps 2 and 3 to verify proper alignment.  
90  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
Steering Inspection and Adjustment  
Each week, or before a long ride, check all steering system fasteners and  
tighten if necessary.  
+
+
+
+
+
91  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
Ski Alignment  
WARNING! Improper ski alignment or adjustment may cause loss of steering  
control, resulting in serious injury or death. Do not attempt to change the ski  
alignment or camber adjustment. See your Polaris dealer.  
With the handlebars in a straight ahead position, and with vehicle  
weight compressing the suspension, measure from the straight edge of  
the skis at the center of the ski mounting bolt. The measurement  
between the skis at point X should be 1/8Ito 1/4I(3-6 mm) greater  
than the measurement at point Y.  
Tip: If the skis are misaligned, we recommend that your dealer correct the align-  
ment, since camber adjustment may also be affected.  
X
10I  
10I  
Y
92  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
nSki Skags  
See your dealer's studding chart for recommended skags. If you install  
longer or more aggressive carbide skags than the original equipment, it  
may also be necessary to add track studs to maintain proper vehicle con-  
trol while turning on hard-packed snow or ice.  
WARNING! Worn skis and/or skags will adversely affect handling. Loss of  
vehicle control may result, causing serious injury or death.  
Check skags before each use of the snowmobile to ensure positive steer-  
ing characteristics. Skags must be replaced when worn to half their orig-  
inal diameter.  
Tip: Carbide skags must be replaced if any abnormal wear or chipping is found.  
Skag Replacement  
1. Raise and support the front of  
the machine so the skis are  
approximately 6I(15.2 cm)  
from the ground.  
2. Remove the attaching nuts  
and pry the skag downward.  
3. Remove the rear end of the  
skag.  
4. Remove the front end of the  
skag.  
5. Reverse the steps to install a  
skag.  
93  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
nRail Slide Wear  
Measure slide thickness at  
several points along the rail.  
Have your dealer replace the  
slide when it's worn down to  
the top of the wear limit  
7/16I  
(1.1 cm)  
+
indicator groove (+). Do not  
operate the snowmobile if  
slide thickness measures less  
than 7/16I(1.1 cm).  
Suspension Maintenance  
nPre-Ride Suspension Inspection  
Loose nuts and bolts can reduce your snowmobile's reliability and cause  
needless repairs and down time. Before beginning any snowmobile trip,  
a visual inspection will uncover potential problems. Check the follow-  
ing items on a weekly basis or before any long trip:  
n Check suspension mounting bolts for tightness.  
n Check rear idler wheel bolts for tightness. See page 89.  
n Check rear idler adjusting bolt locknuts for tightness.  
n Check front torque arm limiter strap condition.  
n Check rail slide condition.  
n Check track tension. See page 88.  
n Lubricate all rear suspension components. See page 66.  
n Check ski runner/skag condition. See page 93.  
n Check ski spindle bolts for tightness.  
n Check tie rod end nuts for tightness.  
94  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Daily Storage  
At the end of each ride, park the snowmo-  
bile on a level surface and support it at the  
rear with an appropriate track stand. The  
track should be suspended approximately  
4I(10 cm) off the ground.  
Remove the key and cover the machine.  
Fall Tune-Up  
For maximum performance, arrange for a fall service tune-up with your  
Polaris dealer. His experienced and trained service technician will keep  
your machine in peak operating condition  
Extended Storage  
Off-season or extended storage of your snowmobile requires preventive  
measures to aid against deterioration and to prolong the useful life of  
many components. See page 98 for the part numbers of Polaris products.  
Cleaning and Preservation  
Proper storage starts with cleaning, washing, and waxing the hood,  
chassis, and plastic parts. Wipe down remaining surfaces with a damp  
cloth. Clean and touch up with paint any rusted or previously painted  
surfaces. Be sure that corrosive salt and acids are removed from sur-  
faces before beginning preservation with waxes and rust inhibitors  
(grease, oil or paint).  
The machine should be stored in a dry garage or shed, out of direct sun-  
light, and covered with a fabric snowmobile cover. Plastic tarp may  
cause condensation to form and damage snowmobile components.  
Controls and Linkage  
Lubricate all bushings and cables as outlined in the Periodic Mainte-  
nance Table beginning on page 63.  
95  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Extended Storage  
Bearings  
Grease the jackshaft and drive shaft clutch side bearings with Polaris  
Premium All-Season Grease or a similar high quality grease to prevent  
corrosion.  
Clutch and Drive System  
Remove the drive belt and store in a cool dry location. Do not lubricate  
clutch components, except the driven clutch shaft bushing as outlined in  
the Master Repair Manual. See your dealer.  
Engine and Carburetor Protection  
Proper preparation of the engine and fuel system is vital to the preven-  
tion of rust and corrosion on precision engine parts during storage.  
Whenever the machine is stored for a period of more than 60 days, the  
engine must be fogged with fogging oil. Follow the engine fogging  
instructions provided on the container.  
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to  
the fuel tank. Follow the instructions on the container, running the  
engine for five minutes to get additives through the entire fuel system.  
Top off with fresh fuel. Do not allow the snowmobile to run out of fuel.  
If stabilizer is not used, drain the carburetors by removing the water trap  
drain plugs. See page 75.  
Tip: Jet restriction caused by improper storage can cause lean conditions and  
very poor slow speed driving quality.  
96  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Extended Storage  
Electrical Connections  
Replace worn or frayed electrical wire and connectors. Be sure wiring  
harness is properly secured away from sharp edges, steering linkage,  
moving parts, and hot exhaust parts.  
Track and Suspension  
Moderate track tension should be maintained  
during summer storage. The machine should be  
supported off the ground to allow the track to  
hang freely.  
Transporting the Snowmobile  
Whenever the snowmobile is transported:  
1. Turn the fuel valve off. See page 27.  
2. Be sure the fuel cap and oil cap are installed  
correctly.  
3. Always tie the snowmobile to the transporting unit securely using  
suitable straps.  
4. Remove the ignition key to prevent loss.  
97  
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS PRODUCTS  
Part No.  
Description  
Engine Lubricants  
2870791  
2875035  
2875036  
2875037  
2874438  
2874439  
2874443  
Fogging Oil (12 oz./355 ml Aerosol)  
Premium Synthetic Blend (Blue) 2-Cycle Oil (qt./.95 l)  
Premium Synthetic Blend (Blue) 2-Cycle Oil (gal./3.8 l)  
Premium Synthetic Blend (Blue) 2-Cycle Oil (2.5 gal./9.5 l)  
VES II Synthetic 2-Cycle Oil (qt./.95 l)  
VES II Synthetic 2-Cycle Oil (gal./3.8 l)  
VES II Synthetic 2-Cycle Oil (2.5 gal./9.5 l)  
Chaincase Lubricants  
2873105  
2872951  
Synthetic Chaincase Lubricant (qt./.95 l)  
Synthetic Chaincase Lubricant (12 oz./355 ml)  
Grease/Specialized Lubricants  
2871312  
2871322  
2871423  
2871329  
Grease Gun Kit, Premium All Season (3 oz./89 ml)  
Premium All Season Grease (3 oz./89 ml cartridge)  
Premium All Season Grease (14 oz./414 ml cartridge)  
Dielectric Grease (Nyogelt)  
Additives/Miscellaneous  
2871326  
2870652  
2872189  
2872893  
2870505  
2872889  
2872890  
Carbon Clean Plus (12 oz./355 ml)  
Fuel Stabilizer (16 oz./473 ml)  
DOT 4 Brake Fluid (12 oz./355 ml)  
Engine Degreaser (12 oz./355 ml)  
Isopropyl  
Brake and Clutch Cleaner  
Carb and Throttle Body Cleaner  
98  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
Unless you have experience and training in two-cycle engine repair,  
see your dealer if technical problems arise.  
Problem  
Probable Cause Solution  
Erratic engine oper- Drive clutch binding • Disassemble drive clutch to inspect  
ating RPM during  
acceleration or load  
variations  
shift weights for wear and free oper-  
ation. SEE YOUR DEALER.  
• Clean and polish stationary shaft  
hub.  
Driven clutch mal-  
function  
• Replace ramp buttons and rollers.  
SEE YOUR DEALER.  
• Inspect movable sheaves for exces-  
sive bushing clearance and replace if  
necessary. SEE YOUR DEALER.  
Harsh drive clutch  
engagement  
Drive belt worn or  
too narrow  
• Replace the drive belt.  
Excessive belt/  
sheave clearance  
• SEE YOUR DEALER.  
Drive belt turns over Wrong belt for appli- • Replace the drive belt.  
cation  
Clutch alignment out • Adjust alignment offset. SEE YOUR  
of spec  
DEALER.  
Engine mount bro-  
ken or loose  
• Inspect and adjust or replace. SEE  
YOUR DEALER.  
Machine fails to  
move  
Clutch jammed  
• Check for twisted belt, broken  
spring, sticking weights, lubrica-  
tion. SEE YOUR DEALER.  
Track jammed  
• Foreign object may be caught or the  
rail slide melted to the track clips  
due to lack of lubrication.  
• Track may be iced up or frozen to  
the ground.  
Chaincase sprocket  
or chain jammed or  
broken  
• Chain is loose or broken or chain  
tightener is loose. SEE YOUR  
DEALER.  
Engine stutters in  
reverse  
Misfire mode has  
activated to prevent  
engine overheat  
• Shift to forward or restart the engine  
to clear the misfire mode.  
99  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause Solution  
Noise in drive sys-  
tem  
Broken drive clutch • SEE YOUR DEALER.  
components  
Bearing failure/  
chaincase, jackshaft,  
or front drive shaft  
• SEE YOUR DEALER.  
Drive belt surface  
flat spots  
• Inspect and replace as needed.  
Drive chain loose  
• Inspect and adjust (or replace).  
• SEE YOUR DEALER.  
Drive chain worn,  
sprocket teeth bro-  
ken  
Poor low RPM per-  
formance  
Worn drive belt  
• Inspect and replace as needed.  
• SEE YOUR DEALER.  
Excessive belt/  
sheave clearance  
Loose torque stop  
Sticky clutch  
• Inspect and adjust.  
• SEE YOUR DEALER.  
Engine doesn't turn  
Seized engine  
• SEE YOUR DEALER. Seizure is a  
result of poor lubrication, inade-  
quate fuel supply, broken parts or  
improper cooling.  
Hydrostatic lock  
• Fuel may have entered the crankcase  
while the vehicle was standing or  
being transported. SEE YOUR  
DEALER to correct the cause. Drain  
plug(s) are located on the lower  
crankcase for emergency draining.  
Engine doesn't start  
(electric start mod-  
els)  
Wire connections  
Poor fuel  
• SEE YOUR DEALER.  
Engine requires  
more than normal  
pulls to start  
• Replace with fresh winter fuel.  
Not enough fuel get- • SEE YOUR DEALER.  
ting to engine  
100  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause Solution  
Engine turns but fails Faulty ignition  
to start  
• Install new spark plug(s). If engine  
still fails to start, check for spark. If  
there's no spark, SEE YOUR  
DEALER.  
No fuel to engine  
• Make sure the fuel valve is on.  
• Use the choke.  
• Make sure fuel tank contains fuel.  
• Ice may be in fuel line, filter or  
pump. Add isopropyl alcohol to fuel  
system. On the standard Polaris car-  
buretor, the choke will not function  
with the throttle depressed. See sec-  
ond item under Probable Cause" of  
Engine Continually Backfires".  
Flooded engine (too • Hold throttle open, crank engine  
much choke used)  
several times (may be necessary to  
change plug(s).  
Poor engine com-  
pression  
• Mixture is too lean. A main jet that  
is too small will cause seizure result-  
ing in loss of power. This indicates a  
major engine problem that must be  
repaired before operating. SEE  
YOUR DEALER.  
Engine lacks power  
Fouled or defective  
spark plug(s)  
• Replace the plug(s).  
Fuel filter (loss of  
high RPM power)  
• Check fuel filter flow. Disconnect  
hose and drain 1/2 cup. Fuel flow  
should be steady and encompass the  
entire diameter of fuel line. If not,  
replace filter.  
Incorrect clutching  
• SEE YOUR DEALER.  
• SEE YOUR DEALER.  
Carburetor and fuel  
pump  
Engine continually  
backfires  
Faulty plug(s)  
• Change plug(s).  
Carburetor / Fuel  
System  
• Dirt or ice may be in the fuel system  
(add deicer to non-ethanol fuel at all  
times to prevent icing).  
Incorrect throttle  
freeplay or faulty  
switch  
• SEE YOUR DEALER.  
101  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
IQ Suspension Troubleshooting  
Problem  
Solution  
Rear suspension bot-  
toms too easily  
• Adjust torsion spring preload to achieve proper static sag  
(see page 32).  
• Change torsion spring to stiffer optional spring (see your  
dealer).  
• Revalve rear track shock (see your dealer).  
Rides too stiff in rear • Check for binding suspension shafts and grease all pivot  
points.  
• Adjust torsion spring preload to achieve proper static sag  
(see page 32).  
• Change torsion spring to softer optional spring (see your  
dealer).  
• Check track tension (see page 88).  
Machine darts from  
side to side  
• Check ski alignment (see page 92).  
• Make sure spindles and all steering components turn freely.  
• Check for excessive play in steering assembly (see your  
dealer).  
• Ensure skags are straight on skis.  
• Set static sag (see page 32).  
• Check rail slide/replace if worn (see page 94).  
• Install Accu-Trak dual skags (see your dealer).  
Front end pushes  
• Check for worn skags.  
• Check for binding front suspension shafts and steering  
components, grease all pivot points (elevate front of  
machine).  
• Set static sag (see page 32).  
• Install single skag (see your dealer).  
• Increase IFS preload (if equipped) (see page 28).  
• Rotate RRSS to high position (see page 36).  
Steering is heavy  
• Make sure spindles and all steering components turn freely.  
• Check ski alignment (see page 92).  
• Check skags and skis for damage.  
• Set static sag (see page 32).  
102  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Drive Belt Troubleshooting  
Belt Wear/Burn Diagnosis  
Solutions  
Causes  
Driving at low RPM  
• Drive at higher RPMs. Gear the machine down. Check  
belt deflection.  
Insufficient warm-up  
Towing at low RPM  
• Warm the engine at least five minutes. Take the drive  
belt off the machine in extremely cold weather and  
warm it up. Break machine loose from the snow.  
• Do not tow in deep snow. Use fast, aggressive throttle  
to engage clutch.  
Riding with high RPM  
and slow speed (8000  
RPM/10 MPH)  
• Lower the gear ratio. Reduce RPM. Avoid riding in  
high ambient temperatures. Check for snow ingestion.  
Ice and snow build-up  
between track and tunnel  
• Warm the engine at least five minutes. Take the drive  
belt off the machine in extremely cold weather and  
warm it up. Break machine loose from the snow.  
Poor engine performance • Check for carburetor and choke synchronization, fouled  
plugs, debris in the carburetor(s) and water, ice or dirt  
in the fuel tank or fuel line.  
Loading machines onto  
trailers  
• Skis may gouge into trailers and prevent the drivetrain  
from spinning properly. Use enough speed to drive the  
machine completely onto the trailer. Push and pull it to  
finish loading if necessary.  
Clutch malfunction  
• Inspect clutch components. See your dealer.  
Slow, easy clutch engage- • Use fast, aggressive throttle to engage clutch.  
ment  
103  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Service and Warranty Information  
Obtaining Service and Warranty Assistance  
Read and understand the service data and the Polaris warranty information con-  
tained in this manual. Contact your Polaris dealer for replacement parts, ser-  
vice or warranty. Your dealer receives frequent updates on changes,  
modifications and tips on snowmobile maintenance, which may supersede  
information contained in this manual. Your dealer is also familiar with Polaris  
policies and procedures and will be happy to assist you.  
When contacting us about parts, service, or warranty, always provide the fol-  
lowing information:  
1. Serial number  
2. Model number  
3. Dealer name  
4. Date of purchase  
5. Details of trouble experienced  
6. 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  
104  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Service and Warranty Information  
Polaris Anti-Theft System  
The Polaris anti-theft system (PATS) monitoring program is designed to aid  
owners of registered snowmobiles in recovery of stolen machines.  
Administration  
1. Polaris snowmobile owner reports theft.  
A. In addition to notifying the proper law enforcement officials, the  
owner must call Polaris Customer Service.  
B. Owners must provide their name, address, telephone number and  
the model and serial number of stolen machines.  
2. Polaris warranty will provide all dealerships with a monthly updated  
list of all stolen units to further monitor thefts.  
3. Polaris warranty will aid in notifying the proper owner when a unit  
is recovered.  
105  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Limited Warranty  
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-  
ITED WARRANTY on all components of the Polaris snowmobile against defects in  
material or workmanship. This warranty covers the parts and labor charges for repair or  
replacement of defective parts that are covered by this warranty. The warranty begins  
on the date of purchase. This warranty is transferable to another consumer, during the  
warranty period, through a Polaris dealer.  
Registration  
At the time of sale, the Warranty Registration Form must be completed by your dealer  
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will  
record the registration for warranty. No verification of registration will be sent to the  
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-  
ment. If you have not signed the original registration and received the customer copy,  
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE  
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.  
Initial dealer preparation and setup of your snowmobile is very important in ensuring  
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer  
setup will void your warranty coverage.  
Warranty Coverage and Exclusions  
Limitations of warranties and remedies  
This warranty excludes any failures not caused by a defect in material or workmanship.  
The warranty does not cover accidental damage, normal wear and tear, abuse or  
improper handling. The warranty also does not cover any snowmobile that has been  
structurally altered, neglected, improperly maintained, used for racing or used for pur-  
poses other than for which it was manufactured. The warranty does not cover any dam-  
ages that occur during trailer transit or as a result of unauthorized service or parts. In  
addition, this warranty does not cover physical damage to paint or finish, stress cracks,  
tearing or puncturing of upholstery material, corrosion or defects in parts, components  
or the snowmobile due to fire, explosions or any other cause beyond Polaris' control.  
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that  
are not compatible with the snowmobile.  
The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option,  
repair or replacement of any defective materials, or components or products. THE  
REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES  
AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS  
SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-  
QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARIS-  
ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,  
NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the  
exclusion or limitation of incidental or consequential damages or implied warranties, so  
the above limitations or exclusions may not apply to you if inconsistent with controlling  
state law.  
106  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 transpor-  
tation to and from the dealer is YOUR responsibility). Polaris recommends that you use  
your original selling dealer; however, you may use any Polaris Servicing Dealer to per-  
form warranty service.  
Please work with your dealer to resolve any warranty issues. Your dealer will contact  
the appropriate personnel at Polaris if additional assistance is needed.  
This warranty gives you specific legal rights, and you may also have other rights which  
vary from state to state.  
If any of the above terms are void because of state or federal law, all other warranty  
terms will remain in effect.  
Engine Oil  
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-  
ommend the use of Polaris engine oil.  
2. Damage resulting from the use of non-recommended lubricants may not be covered  
by warranty.  
107  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
Brake components  
Seat components  
Clutches and components  
Steering components  
Batteries  
Finished and unfinished surfaces  
Carburetor/Throttle body components  
Engine components  
Drive belts  
Hydraulic components  
Circuit breakers/Fuses  
Electronic components  
Light bulbs/Sealed beam lamps  
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  
Filters  
Fuel  
Lubricants such as oil, grease, etc.  
Batteries (unless defective)  
Cosmetic damage/repair  
Coolants  
Sealants  
Hotel fees  
Meals  
Towing charges  
Mileage  
Rentals/Loss of product use  
Shipping/ handling fees  
Product pick-up/delivery  
Loss of vacation/personal time  
This warranty also excludes failures resulting from improper lubrication; improper  
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold  
or contamination; operator error or abuse; improper component alignment, tension,  
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign  
substance ingestion/contamination; improper maintenance; modified components; use  
of aftermarket components resulting in failure; unauthorized repairs; repairs made after  
the warranty period expires or by an unauthorized repair center; use of the product in  
competition or for commercial purposes. Warranty will not apply to any product which  
has been damaged by abuse, accident, fire or any other casualty not determined a defect  
of materials or workmanship.  
108  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Polaris Second Year Engine Service Contract  
Second Year Engine Service Contract is standard on all eligible new and unused snow-  
mobiles that were Snow Checked through an authorized Polaris dealer during the  
March/April Snow Check promotion. The free Second Year Engine Service Contract is  
honored by all authorized Polaris snowmobile dealers in North America and is transfer-  
able 120 days after the original purchase date, free of charge, through any Polaris snow-  
mobile dealer. Coverage on Snow Check units is automatic. Although you do not  
receive a warranty card, your dealership should have printed a copy of the warranty reg-  
istration form. This form is your proof of warranty.  
Consumer Exclusions  
• Each repair visit after the first twelve months of standard warranty coverage is subject  
to a $50 deductible.  
• The free Second Year Engine Service Contract applies to the first 5,000 miles or two  
(2) calendar years from date of purchase, whichever comes first. Tampering with the  
odometer shall void all warranties/service contracts. No extensions to coverage under  
this engine service contract can be given. Used snowmobiles are not eligible under  
this program.  
• Snowmobiles used for commercial purposes or for racing are excluded from coverage.  
Coverage  
Coverage for second year engine failures due to defects in materials and workmanship  
will be determined by Polaris in its sole discretion. Coverage is automatic with no addi-  
tional paperwork required. The free Second Year Engine Service Contract is subject to a  
$50 deductible per visit. Regular, documented service maintenance visits are required to  
validate this warranty.  
A partial list of items excluded from coverage includes:  
• Damage due to accident, fire, explosion, theft, or other causes beyond Polaris' control.  
• Damage caused by the failure of other components of the snowmobile.  
• Failures caused by improper fuel or oil.  
• Piston seizures, unless caused by a defective engine component.  
• Failures caused due to improper adjustments.  
• Failure due to unauthorized service.  
• Failures due to lack of service as required in the owner's manual or Polaris updates.  
This includes off-season storage as listed in the owner's manual.  
• Failure due to use of unauthorized parts or modifications.  
• Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,  
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and  
exhaust manifolds excluding paint coverage.  
• Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring  
and other electrical components are excluded from coverage.  
• Cooling system coverage is limited to the water pump assembly and components, fan,  
fan bearings, temperature sensor, gasket and seals.  
• Non wear related throttle body parts are covered. The fuel pump is covered.  
• Clutches and related clutch parts, including but not limited to, the drive belt, are  
excluded from coverage.  
• Electrical components are excluded from coverage.  
• Gearcases and transmissions are excluded from coverage.  
109  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Exported Vehicles  
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-  
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD  
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-  
TION.  
This policy does not apply to vehicles that have received authorization for export from  
Polaris Industries. Dealers may not give authorization for export. You should consult an  
authorized dealer to determine this vehicle's warranty or service bulletin coverage if you  
have any questions.  
This policy does not apply to vehicles registered to government officials or military per-  
sonnel on assignment outside the country of the selling dealer's authorized location.  
This policy does not apply to Safety Recalls.  
How to Get Service  
In the Country where your vehicle was purchased:  
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If  
you move or are traveling within the country where your vehicle was purchased, War-  
ranty or Service Bulletin repairs may be requested from any authorized Polaris dealer  
who sells the same line as your vehicle.  
Outside the Country where your vehicle was purchased:  
If you are traveling temporarily outside the country where your vehicle was purchased,  
you should take your vehicle to an authorized Polaris dealer. You must show the dealer  
photo identification from the country of the selling dealer's authorized location as proof  
of residence. Upon residence verification, the servicing dealer will be authorized to per-  
form the warranty repair.  
If You Move:  
If you move to another country, be sure to contact Polaris Customer Assistance and the  
customs department of the destination country before you move. Vehicles importation  
rules vary considerably from country to country. You may be required to present docu-  
mentation of your move to Polaris Industries in order to continue your warranty cover-  
age. You may also be required to obtain documentation from Polaris Industries in order  
to register your vehicle in your new country.  
If Purchased From A Private Party:  
If you purchase a Polaris product from a private citizen outside of the country in which  
the vehicle was originally purchased, all warranty coverage will be denied.  
Notice  
If your vehicle is registered outside of the country where it was purchased, and you have  
not followed the procedure set out above, your vehicle will no longer be eligible for war-  
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-  
cials or military personnel on assignment outside of the country where the vehicle was  
purchased will continue to be covered by the basic warranty.)  
For questions call Polaris Customer Assistance (see page 104).  
110  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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:  
Air-induction system  
Fuel system  
Ignition system  
Exhaust gas recirculation systems  
The following parts are also considered emission-related components for exhaust emis-  
sions:  
Aftertreatment devices  
Crankcase ventilation valves  
Sensors  
Electronic control units  
The following parts are considered emission-related components for evaporative emis-  
sions:  
Fuel Tank  
Fuel Cap  
Fuel Line  
Fuel Line Fittings  
Clamps*  
Pressure Relief Valves*  
Control Valves*  
Control Solenoids*  
Electronic Controls*  
Vacuum Control Diaphragms*  
Control Cables*  
Control Linkages*  
Purge Valves  
Vapor Hoses  
Liquid/Vapor Separator  
Carbon Canister  
Canister Mounting Brackets  
Carburetor Purge Port Connector  
*As related to the evaporative emission control system.  
111  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
U.S.A. EPA Emissions Limited Warranty  
The exclusive remedy for breach of this limited warranty shall be, at the exclusive  
option of Polaris, repair or replacement of any defective materials, components or prod-  
ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE  
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-  
RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-  
DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY  
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-  
RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR  
OTHERWISE.  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY  
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-  
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY  
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-  
TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on  
how long an implied warranty lasts, so the above limitation may not apply if it is incon-  
sistent with the controlling state law.  
This limited warranty excludes failures not caused by a defect in material or workman-  
ship.This limited warranty does not cover damage due to accidents, abuse or improper  
handling, maintenance or use. This limited warranty also does not cover any engine that  
has been structurally altered, or when the vehicle has been used in racing competition.  
This limited warranty also does not cover physical damage, corrosion or defects caused  
by fire, explosions or other similar causes beyond the control of Polaris.  
Owners are responsible for performing the scheduled maintenance identified in the  
owner's manual. Polaris may deny warranty claims for failures that have been caused by  
the owner’s or operator’s improper maintenance or use, by accidents for which Polaris  
has no responsibility, or by acts of God.  
Any qualified repair shop or person may maintain, replace, or repair the emission con-  
trol devices or systems on your vehicle. Polaris recommends that you contact an autho-  
rized Polaris dealer to perform any service that may be necessary for your vehicle.  
Polaris also recommends that you use only Pure Polaris parts. It is a potential violation  
of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the  
effectiveness of 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.  
112  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
Present this section of your manual to your dealer each time your snow-  
mobile is serviced. This will provide you and future owners with an  
accurate log of maintenance and services performed on the snowmobile.  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
150 mi.  
(240 km)  
500 mi.  
(800 km)  
1000 mi.  
(1600 km)  
2000 mi.  
(3200 km)  
113  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
114  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
115  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
A
D
Accessories . . . . . . . . . . . . . . . . . . . 37  
Adjustable Headlights . . . . . . . . . . . 27  
Air Pollution . . . . . . . . . . . . . . . . . . . 5  
Altitude Setting . . . . . . . . . . . . . . . . 59  
Avalanches. . . . . . . . . . . . . . . . . . . . 13  
Disabled Operators . . . . . . . . . . . . . . 11  
Drive Belt . . . . . . . . . . . . . . . . . . 17, 84  
Drive Belt Adjustment. . . . . . . . . . . . 85  
Drive Belt Condition . . . . . . . . . . . . . 83  
Drive Belt Deflection. . . . . . . . . . . . . 85  
Drive Belt Installation . . . . . . . . . . . . 84  
Drive Belt Removal. . . . . . . . . . . . . . 83  
Drive Belt Troubleshooting. . . . . . . 103  
Drive Chain Tension . . . . . . . . . . . . . 76  
Driver Awareness . . . . . . . . . . . . . . . 12  
Driveshaft Bearing. . . . . . . . . . . . . . . 67  
Driving Downhill. . . . . . . . . . . . . . . . 15  
Driving in Hilly Terrain. . . . . . . . . . . 16  
Driving on Slippery Surfaces . . . . . . 14  
Driving Responsibly . . . . . . . . . . . . . 19  
B
Bearings. . . . . . . . . . . . . . . . . . . . . . 96  
Before Starting the Engine. . . . . . . . 41  
Bleeding the Brake System . . . . . . . 79  
Brake Components. . . . . . . . . . . . . . 77  
Brake Fluid . . . . . . . . . . . . . . . . . . . 78  
Brake Inspection . . . . . . . . . . . . . . . 77  
Brake Lever Travel . . . . . . . . . . 42, 77  
Brake System Bleeding . . . . . . . . . . 79  
Brakelight Replacement. . . . . . . . . . 81  
Brakes . . . . . . . . . . . . . . . . . . 42, 77-79  
E
Electrical Connections. . . . . . . . . . . . 97  
Engine Break-In. . . . . . . . . . . . . . 48-49  
Engine Protection . . . . . . . . . . . . . . . 96  
Engine Safety. . . . . . . . . . . . . . . . . . . . 8  
Engine Stop Switch . . . . . . . . . . . . . . 56  
Environment . . . . . . . . . . . . . . . . . . . . 5  
Exhaust System . . . . . . . . . . . . . . . . . 73  
C
Carbide Skags . . . . . . . . . . . . . . . . . 37  
Carburetion . . . . . . . . . . . . . . . . . 54-55  
Carburetor . . . . . . . . . . . . . . . . . . . . 74  
Carburetor Adjustments. . . . . . . . . . 74  
Carburetor Protection. . . . . . . . . . . . 96  
Carburetor Water/Sediment Trap . . 75  
Chaincase Oil. . . . . . . . . . . . . . . . 68-69  
Choke. . . . . . . . . . . . . . . . . . . . . . . . 67  
Choke Cable. . . . . . . . . . . . . . . . . . . 67  
Choke Operation . . . . . . . . . . . . . . . 47  
Cleaning and Preservation. . . . . . . . 95  
Clutch Alignment Offset . . . . . . . . . 82  
Clutch and Drive System. . . . . . . . . 96  
Clutch Center Distance . . . . . . . . . . 82  
Clutch Cover Warning. . . . . . . . . . . 21  
Clutch Safety . . . . . . . . . . . . . . . . . . 17  
Clutch System . . . . . . . . . . . . . . . 82-85  
Cold Weather Drive-Away . . . . . . . 17  
Controls and Linkage. . . . . . . . . . . . 95  
Coolant. . . . . . . . . . . . . . . . . . . . . . . 73  
Cooling System . . . . . . . . . . . . . . . . 73  
Customer Service. . . . . . . . . . . . . . 104  
F
Front Rear Scissor Stop. . . . . . . . . . . 34  
Front Suspension Adjustments . . 28-29  
Front To Rear Coupling. . . . . . . . . . . 34  
FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 34  
Fuel . . . . . . . . . . . . . . . . . . . . . . . 51-52  
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 73  
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 73  
Fuel Pump . . . . . . . . . . . . . . . . . . . . . 72  
Fuel System Deicers . . . . . . . . . . . . . 52  
Fuel Valve . . . . . . . . . . . . . . . . . . 27, 52  
H
Handlebar Adjustments . . . . . . . . . . . 38  
Headlight Adjustment . . . . . . . . . . . . 27  
Headlight Bulb Installation . . . . . . . . 80  
Headlight Bulb Removal . . . . . . . . . . 80  
Hood Latches. . . . . . . . . . . . . . . . . . . 45  
116  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
I
R
Ice and Snow Build-up . . . . . . . . . . . 14  
IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
IFS Adjustment Options . . . . . . . . . . 28  
IFS Components . . . . . . . . . . . . . . . . 28  
Inadequate Snow Conditions . . . . . . 18  
Intake Filters . . . . . . . . . . . . . . . . . . . 72  
Intake Silencer . . . . . . . . . . . . . . . . . 17  
Rail Slide Wear. . . . . . . . . . . . . . . . . 94  
Rear Rear Scissor Stop . . . . . . . . . . . 35  
Rear Suspension Adjustments . . 30-36  
Rear To Front Coupling . . . . . . . . . . 35  
Recoil Rope . . . . . . . . . . . . . . . . . . . 45  
Recommended Maintenance. . . . . . . . 7  
Registration, Warranty . . . . . . . . . . 106  
Reverse . . . . . . . . . . . . . . . . . . . . 58-59  
Reverse Warning . . . . . . . . . . . . . . . 23  
Rider Capacity . . . . . . . . . . . . . . . . . 11  
Riding Apparel . . . . . . . . . . . . . . . . . . 9  
Riding Position . . . . . . . . . . . . . . . . . . 8  
RRSS. . . . . . . . . . . . . . . . . . . . . . . . . 35  
J
Jetting Guidelines . . . . . . . . . . . . . . . 55  
L
Lights . . . . . . . . . . . . . . . . . . . . . 80-81  
Limiter Strap Position. . . . . . . . . . . . 33  
Low Oil Indicator Light . . . . . . . . . . 53  
Lubrication . . . . . . . . . . . . . . . . . 66-69  
S
Safety Decals . . . . . . . . . . . . . . . 21-24  
Safety Symbols . . . . . . . . . . . . . . . . . . 6  
Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
Sediment Trap. . . . . . . . . . . . . . . . . . 75  
Signal Words . . . . . . . . . . . . . . . . . . . 6  
Ski Alignment. . . . . . . . . . . . . . . . . . 92  
Ski Pressure . . . . . . . . . . . . . . . . . . . 33  
Ski Skags . . . . . . . . . . . . . . . . . . . . . 93  
Slide Rail and Track Cooling . . . . . . 49  
Snow Conditions. . . . . . . . . . . . . . . . 18  
Spark Plug. . . . . . . . . . . . . . . . . . . . . 71  
Spark Plug Condition . . . . . . . . . . . . 71  
Spark Plugs . . . . . . . . . . . . . . . . . 70-71  
Speed. . . . . . . . . . . . . . . . . . . . . . . . . 11  
Spring Preload . . . . . . . . . . . . . . . . . 32  
Spring Preload, IFS Shock . . . . . . . . 29  
Spring Preload, Rear, IQ. . . . . . . . . . 32  
Starting the Engine . . . . . . . . . . . . . . 47  
Steering Inspection/Adjustment . . . . 91  
Steering System . . . . . . . . . . 44, 91-94  
Stopping, Emergency . . . . . . . . . . . . 48  
Storage, Daily . . . . . . . . . . . . . . . . . . 95  
Storage, Extended. . . . . . . . . . . . 95-97  
Survival Preparation . . . . . . . . . . . . . 10  
Suspension Coupling, IQ . . . . . . 34-35  
Suspension Inspection, Pre-Ride . . . 94  
Suspension Maintenance . . . . . . . . . 94  
Suspension Performance Tips. . . . . . 31  
Suspension, Front, Lubrication. . . . . 66  
Suspension, Rear, Lubrication . . . . . 66  
M
Maintenance . . . . . . . . . . . . . . . . . . . 17  
Maintenance Interval Table . . . . 63-65  
Maintenance Log . . . . . . . . . . 113-115  
Maintenance Program. . . . . . . . . . . . 62  
Maneuverability . . . . . . . . . . . . . . . . 17  
N
No Passenger Warning . . . . . . . . . . . 22  
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
O
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 72  
Oil Injection System . . . . . . . . . . . . . 49  
Oil Level . . . . . . . . . . . . . . . . . . . . . . 53  
Oil Lines . . . . . . . . . . . . . . . . . . . . . . 72  
Oil Recommendations. . . . . . . . . . . . 49  
Operation Warning . . . . . . . . . . . 23-24  
Operator Safety. . . . . . . . . . . . . . . 6-20  
P
Park Brake Lever Lock. . . . . . . . . . . 43  
Polaris Products . . . . . . . . . . . . . . . . 98  
Preload, IFS Shock Spring . . . . . . . . 29  
Pre-Ride Checklist . . . . . . . . . . . . . . 40  
Pre-Ride Suspension Inspection . . . . 94  
117  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
T
V
Taillight/Brakelight Replacement . . 81  
Throttle Cable . . . . . . . . . . . . . . . . . 67  
Throttle Lever . . . . . . . . . . . . . . 41, 57  
Throttle Safety Switch. . . . . . . . 41, 56  
Torque Stop . . . . . . . . . . . . . . . . . . . 85  
Torsion Spring Preload, IQ . . . . . . . 33  
Towing. . . . . . . . . . . . . . . . . . . . . . . 60  
Track . . . . . . . . . . . . . . . . . . . . . . . . 44  
Track Alignment . . . . . . . . . . . . . . . 90  
Track Care for Storage. . . . . . . . . . . 97  
Track Inspection . . . . . . . . . . . . . . . 86  
Track Lubrication . . . . . . . . . . . . . . 87  
Track Maintenance . . . . . . . . . . . 86-90  
Track Safety. . . . . . . . . . . . . . . . . . . . 8  
Track Tension . . . . . . . . . . . . . . 31, 88  
Track Warm-Up. . . . . . . . . . . . . . . . 50  
Track Warning. . . . . . . . . . . . . . . . . 22  
Traction Products. . . . . . . . . . . . . . . 37  
Transporting the Snowmobile . . . . . 97  
Troubleshooting, Drive Belt . . . . . 103  
Troubleshooting, Engine . . . . . . 99-101  
Troubleshooting, Rear Suspension 102  
Tune-Up. . . . . . . . . . . . . . . . . . . . . . 95  
Vehicle Identification Numbers. . . . . . 4  
W
Weight Transfer. . . . . . . . . . . . . . . . . 36  
Windchill . . . . . . . . . . . . . . . . . . . . . . 20  
Windchill/Temperature Charts . . . . . 20  
118  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Philips Flat Panel Television 14AA3322 User Manual
Philips TV Cables SWA2104W 27 User Manual
Philips TV Receiver 29PT5631 User Manual
Philips Work Light P 5776 B User Manual
Pioneer Automobile Alarm DEH P5200 User Manual
Pioneer Car Stereo System DEH 4400HD User Manual
Plantronics Switch Electronic Hook Switch User Manual
Poulan Blower PPBP30 9096320642 User Manual
Pride Mobility Mobility Aid 614 User Manual
Pure Digital Radio 1XT User Manual