Polaris Offroad Vehicle 550 Transport User Manual

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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.  
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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
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-  
tries Inc.  
Copyright 2008 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.  
2009 550 Transport/Trail Touring Deluxe Owner's Manual  
P/N 9921592  
2
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
This section identifies the locations of your snowmobile's controls and  
features.  
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 29  
This section explains how to tailor the suspension and other features for  
an optimum riding experience.  
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 45  
This section explains procedures that must be performed before riding.  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52  
This section explains proper engine break-in, operation of features and  
general operating procedures.  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 70  
This section defines your role, and your dealer's role, in your snowmo-  
bile's regular maintenance.  
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 113  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 114  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119  
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 130  
Record maintenance and service in the log for your reference and for  
future owners of the vehicle.  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134  
3
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INTRODUCTION  
Vehicle Identification Numbers  
Record your snowmobile's identification numbers and key number in  
the spaces provided. Remove the spare key and store it in a safe place.  
Your key can be duplicated only by mating a Polaris key blank with one  
of your existing keys, so if both keys are lost, the ignition switch must  
be replaced.  
Vehicle Model Number: ___________________________________________________  
Tunnel VIN:_____________________________________________________________  
(lower right side of the tunnel)  
Engine Serial Number:____________________________________________________  
(right front side of engine crankcase)  
Key Number: ___________________________________________________________  
Important Notes for Owners and Drivers  
After reading this manual, store it in the snowmobile for convenient ref-  
erence. It should remain with the snowmobile when the snowmobile is  
sold.  
When teaching inexperienced operators to ride, set up a predetermined  
course for practice. Make sure they know how to drive and control the  
snowmobile before allowing them to make longer trips. Teach them  
proper snowmobile courtesy, and enroll them in driver’s training and  
safety courses sponsored by local or state organizations.  
Follow the maintenance program outlined in this manual. Preventive  
maintenance ensures that critical components of the snowmobile are  
inspected by your dealer at specific mileage intervals.  
You and your dealer must complete the registration form included with  
your snowmobile and forward it to us. This completed form is necessary  
to ensure warranty coverage.  
Protect and preserve your right to ride by joining your local trail riding  
clubs.  
4
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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 welcome  
to non-snowmobilers, so you have a responsibility to operate your  
snowmobile with concern for others. We do our part by manufacturing  
quieter machines; we ask your help to further reduce the impact of noise  
by operating your snowmobile safely and responsibly.  
Air Pollution  
Polaris engineers continuously investigate ways to reduce emission lev-  
els of two-stroke engines. We expect our efforts to lead to the reduction  
of potential air pollution.  
In addition to our technological research, we encourage government  
agencies, manufacturers, distributors, dealers, ecologists, and other  
interested parties to work together to develop data on environmental  
topics.  
5
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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, on your vehicle or in this manual, alerts you to the  
potential for injury.  
WARNING  
The safety alert warning indicates a potential hazard that may result in serious  
injury or death.  
CAUTION  
The safety alert caution indicates a potential hazard that may result in minor  
injury or damage to the vehicle.  
CAUTION  
A caution indicates a situation that may result in damage to the vehicle.  
NOTE  
A note will alert you to important information or instructions.  
6
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SAFETY  
Operator Safety  
Follow the recommended maintenance program beginning on page 72  
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
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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.  
8
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SAFETY  
Operator Safety  
Riding Apparel  
Be prepared, be warm and be comfortable  
when riding. Be aware of the weather fore-  
cast, especially the windchill, and dress  
accordingly. See the chart on page 21.  
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
E
of a circle surrounding the letter E, followed by the  
distinguishing number of the country which has  
granted approval. The approval number and serial  
number will also be displayed on the label.  
051039  
0006.31  
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
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SAFETY  
Operator Safety  
Riding Position  
Operating a snowmobile requires skill and balance for proper control.  
Rider positions may vary with experience and the features available on  
some snowmobiles, but under many conditions, the proper position is to  
be seated with both feet on the running boards and both hands on the  
handlebar grips for proper throttle, brake and steering control.  
NOTE: Use of a backrest may hinder your weight shifting ability. This  
could affect your ability to control this rider-active vehicle in cer-  
tain extreme driving situations.  
WARNING  
Improper riding position may reduce control and could result in serious injury  
or death. Always ride in a position that allows for control of your vehicle.  
Survival Preparation  
For your safety, always ride in a group of other snowmobilers. Always  
tell someone where you're going and how long you expect to be gone. If  
it isn't possible to ride with others, and you must travel into remote  
areas, always carry survival equipment that's appropriate to the condi-  
tions you may encounter. Such equipment may include, but is not lim-  
ited to: extra clothing, a sleeping bag, a flashlight, food and water, a  
signaling mirror, a means of building a fire, and a two-way radio or cel-  
lular telephone.  
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  
• Extra Oil  
• Fuel Deicer  
10  
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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.  
Cargo Overload  
Too much weight on the rear of the machine may reduce your ability to  
steer. Do not exceed carrier and rack weight limits, and do not allow a  
passenger to sit on the seat back or the cargo carrier.  
WARNING  
Control becomes more difficult with two people on board. More space is  
required to make turns, and longer distances are needed for stopping. Make  
sure the passenger remains seated behind the driver, facing forward, with  
both feet placed firmly on the running boards. Slow down and avoid “jump-  
ing" your snowmobile.  
Rider Capacity  
Driving 1-Up - Some Polaris snowmobiles are designed for a single  
rider only. A decal on the console of these models indicates single rider  
operation.  
Driving 2-Up - Some Polaris snowmobiles are designed for up to two  
riders. A decal on the hood of these models indicates that the vehicle is  
designed for one operator and one passenger only. See page 23 for decal  
location.  
Machines designed for two riders should never be operated with more  
than two people on board. When traveling with a passenger, it's the  
driver's responsibility to operate the machine safely.  
Slow down! Control becomes more difficult with two people on board.  
More space is required to make turns, and longer distances are necessary  
for stopping.  
11  
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SAFETY  
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.  
12  
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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 travelling  
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.  
13  
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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 the American  
and Canadian online avalanche centers at www.avalanche.org.  
14  
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SAFETY  
Operator Safety  
Ice and Snow Build-up  
WARNING  
Ice and snow build-up may interfere with the steering of your machine, result-  
ing in serious injury or death. Keep the underhood area free of snow and ice.  
Before driving, manually turn the skis to the left and right to be sure ice  
and snow are not interfering with full left and right steering. If difficulty  
is encountered, remove ice and snow build-up that may be obstructing  
the steering linkage.  
Driving on Slippery Surfaces  
WARNING  
Driving on ice or hard-packed snow reduces steering and braking control,  
which may result in loss of control and serious injury or death. Never attempt  
an abrupt change of direction when operating on slippery surfaces. Slow  
down and use extra caution when operating on slippery surfaces.  
15  
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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.  
16  
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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.  
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.  
17  
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SAFETY  
Operator Safety  
Clutch Guard  
Do not operate the engine with the clutch guard removed.  
The clutch guard is designed to protect the operator from metal parts if  
the clutch should fail. Although the chance of failure is extremely  
remote, don't defeat the purpose of the safety guard by removing it.  
Clutches  
Do not attempt to service the clutches.  
All clutch service must be performed by your dealer. The clutch is a  
complex mechanism that rotates at high speeds. Each clutch is dynami-  
cally balanced before installation. Any tampering may disrupt this preci-  
sion balancing and create an unstable condition.  
Cold Weather Drive-Away  
Whenever your snowmobile has been parked for a length of time, espe-  
cially overnight, always make sure the skis and track are loosened from  
ice and snow before attempting to drive. Apply the throttle with enough  
authority to put the 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 72  
of this manual to ensure that all critical components on the snowmobile  
are thoroughly inspected by your dealer at specific mileage intervals.  
18  
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SAFETY  
Operator Safety  
Inadequate Snow Conditions  
Moveable hood closures are included on some Polaris snowmobiles.  
They are normally left open and are located on the front upper and lower  
hood openings. If operating in deep snow or in extreme cold conditions  
(below -20_ F), Polaris recommends closing the upper hood closure.  
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.  
CAUTION  
When operating on icy surfaces or hard-packed snow, avoid overheating the  
slide rail and track. Lack of lubrication and cooling will cause overheating of  
the slide rail and track, resulting in premature wear and failure. If frequently  
operating in low cooling conditions, see your dealer for an optional wheel kit  
that will reduce the wear from overheating.  
19  
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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 to use your snowmobile, know the  
extent of their operating skills. Check to see if they've taken a snow-  
mobile safety course and have an operator's certificate. For their pro-  
tection, as well as yours, make sure they take a snowmobile safety  
course. Everyone can benefit from the course.  
• Don't "jump" your snowmobile over large drifts or similar terrain.  
Jumping may injure your back because of spinal compression that  
could occur when the snowmobile impacts the ground. The seat and  
suspension of your snowmobile have been designed to provide pro-  
tection under normal riding conditions. Your snowmobile is not  
intended for this kind of use.  
• Be courteous to oncoming traffic by dimming your headlights and  
reducing your speed.  
• When traveling in a group of snowmobiles, don't tailgate (follow too  
closely). Leave enough distance between snowmobiles to provide  
ample stopping room and to provide protection from flying snow and  
debris. Allow even more distance when driving on slippery surfaces  
or when driving in darkness or other low visibility conditions. Be  
aware of any snowmobile traffic around your vehicle. Drive defen-  
sively to avoid accidents.  
• Remove the key from the ignition when you leave the snowmobile  
unattended.  
20  
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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.  
21  
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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.  
Air Box Warning  
This warning decal is found under the hood on applicable models:  
CAUTION  
Do not operate above 40 mph with hood-to-air box foam removed  
or engine failure will result.  
22  
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SAFETY  
Safety Decals and Locations  
Track Warning  
The track warning decal is on the  
rear of the tunnel:  
+
WARNING  
Stay clear of track. Do not sit on  
seat back. Entanglement with the  
track or a fall from seat back can  
result in severe injury or death.  
Passenger Warning  
Polaris touring models are  
designed for the operator and  
one passenger. For more infor-  
mation on operating with a pas-  
senger, see page 11.  
The passenger warning decal is  
located at the right side of the  
steering post:  
+
WARNING  
This vehicle is designed for  
operator and ONE passenger  
only.  
23  
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SAFETY  
Safety Decals and Locations  
Electronic Reverse Warning  
Polaris snowmobiles equipped  
with electronic reverse have a  
reverse warning decal on the  
lower dash:  
WARNING  
Reverse operation, even at low  
speeds, can cause loss of con-  
trol resulting in serious injury  
or death. To avoid loss of con-  
trol, always:  
+
• Look behind before and  
while backing up.  
• Avoid sharp turns.  
• Shift to or from reverse only  
when stopped.  
• Apply throttle slowly.  
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.  
• Elevation setting (above 6000 feet): push and hold for longer than 5  
seconds to set. Let go of button at desired setting-fast flash for high  
elevation, slower flash for low. Setting will remain until changed.  
24  
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SAFETY  
Safety Decals and Locations  
Operation Warning  
The operation warning decal is located on the console:  
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 posi-  
tion to control the vehicle.  
Oil injection system: Use unmixed fuel only. Check oil level when  
refueling.  
25  
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FEATURES  
Some Polaris snowmobiles are equipped with special features. Operat-  
ing controls and special feature controls are illustrated on this page. Not  
all models come with all special features. See your Owner's Manual  
Supplement.  
5
4
General  
Representation  
6
3
7
8
2
9
1
10  
1. Fuel Filler Cap  
2. Ignition Switch  
3. Brake Lever  
4. Speedometer  
5. Tachometer  
13  
12  
11  
6. Engine Stop Switch  
7. Throttle Control  
8. Hood Hold-Down Straps  
9. Choke  
10. Recoil Starter Handle  
11. Parking Brake Lock  
12. Handlebar Grip Warmer Switch  
13. Thumbwarmer Switch  
14  
17  
15  
16  
18  
14. Electronic Reverse Button  
15. Headlight Dimmer Switch  
16. Low Oil Level Indicator (550)  
17. Reverse Indicator (550)  
18. High Beam Indicator (550)  
550 Transport  
26  
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FEATURES  
9
5
8
4
6
7
Trail Touring Shown  
2
3
1
10  
11  
12  
13  
14  
1. Front Bumper (do not use for pulling  
or dragging the snowmobile)  
2. Hood  
3. Headlight  
15  
4. Windshield  
5. Handlebar  
6. Operator Seat  
7. Passenger Grab Handle  
8. Passenger Seat  
9. Passenger Backrest  
10. Suspension  
11. Track  
16  
17  
12. Trailing Arm  
13. Nosepan  
14. Ski  
15. Taillights  
16. Rear Bumper  
17. Snow Flap  
27  
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FEATURES  
Backrest  
The backrest is adjustable for either  
operator or passenger use.  
Raise/Lower  
1. Loosen the upper adjustment  
knobs to raise or lower the  
backrest.  
2. Loosen the lower adjustment  
knobs to move the backrest  
forward for operator use or  
rearward for passenger use.  
Operator/Passenger  
3. Always tighten the knobs  
securely after adjusting.  
28  
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THE PERFECT FIT  
Front Suspension Adjustments  
Independent Front Suspension (IFS)  
Break in the suspension for about 150 miles (240 km) before making  
any fine-tuning adjustments.  
Settings will vary from rider to rider, depending on rider weight, vehicle  
speed, riding style, and trail conditions. We recommend starting with  
factory settings and then customizing each adjustment individually to  
suit rider preference. The machine should be methodically tested, one  
change at a time, under the same conditions (trail and snow conditions,  
vehicle speed, riding position, etc.) after each adjustment until the best  
ride is achieved.  
IFS Components  
1. Skis  
2. Front shocks and springs  
3. Rod ends  
4. Trailing arms  
4
2
IFS Adjustment Options  
• Front shock spring preload  
• Optional springs  
• Toe (ski alignment) (see  
page 102)  
1
3
• Camber (see your dealer)  
29  
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THE PERFECT FIT  
Front Suspension Adjustments  
WARNING  
Always verify ski alignment before making adjustments to the IFS. See page  
102 to check alignment. If the skis are misaligned, see your dealer, as the  
camber adjustment may also be affected.  
For the best ride, the suspension should be adjusted to use the full travel  
of the shocks with occasional light bottoming. To determine if your  
machine is using full travel, push the jounce bumper down on the shock  
rod until it contacts the body and test ride the machine. The bumper will  
move up on the rod in relation to the amount of travel that was used dur-  
ing the ride. If the travel is full, the bumper will be seated at the top of  
the rod.  
Shock Components  
The front springs can be  
changed if spring preload  
alone isn't sufficient and  
further adjustment is  
desired to control suspen-  
sion stiffness. See your  
Polaris dealer for more  
information.  
1
2
3
4
1. Retainer  
5
2. Shock Rod  
3. Jounce Bumper  
4. Body  
5. Threaded Spring Pre-  
load Adjuster Nut  
30  
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THE PERFECT FIT  
Front Suspension Adjustments  
Spring Preload  
Increasing spring preload will increase  
ski-to-ground pressure. Decreasing  
spring preload will decrease ski-to-  
ground pressure. When adjusting, be  
sure the springs on both the left and right  
sides of the machine are at the same  
adjustment.  
To increase front shock spring preload,  
grasp the spring and turn it to the right.  
Turn it to the left to decrease preload.  
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  
preload beyond the factory settings, and  
ensure that both sides are adjusted the  
Low  
Preload  
High  
Preload  
same. When decreasing preload, make sure at least two turns of preload  
are holding the spring between the retainer on top of the shock and the  
threaded spring preload adjuster nut on the shock body.  
NOTE: Not all models have shocks with thread adjustable spring pre-  
load. See your dealer for more information.  
CAUTION  
Always leave one thread showing above the adjuster nut. On models  
equipped with a plastic adjuster nut, if the nut is unscrewed from the  
threaded body, the nut will break.  
Front Springs  
For models without externally adjustable or revalvable shocks, the front  
springs can be changed if spring preload alone isn't sufficient and fur-  
ther adjustment is desired to control suspension stiffness. See your  
Polaris dealer for more information.  
31  
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THE PERFECT FIT  
Rear Suspension Adjustments  
Rider weight, riding style, trail conditions, and vehicle speed all affect  
suspension action.  
Each rear suspension can be adjusted to suit rider preference and deliver  
excellent performance for a given set of conditions. However, all sus-  
pension designs and adjustments involve a compromise, or trade-off.  
For example, a suspension set up for snowcross racing would provide a  
very stiff ride on the trail. A suspension set up for trail riding would bot-  
tom out harshly on a snowcross course.  
See your Polaris dealer for initial suspension setup information. Addi-  
tional 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.  
32  
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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.  
NOTE: Keep the suspension pivot points lubricated. This will reduce  
moisture and rust build-up and ensure proper function of the  
suspension components. Grease rear suspension pivots before  
adjusting the rear suspension. See page 76.  
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 98.  
33  
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THE PERFECT FIT  
EDGE 136 Rear Suspension Adjustments  
Initial Spring Preload Setting (Sag Method)  
To set up the EDGE rear suspension  
torsion spring preload, measure the  
distance between the ground and  
rear bumper. This is measurement  
X.  
Take the first measurement with no  
rider and with the rear suspension at  
full extension.  
X
NOTE: The rear bumper may need  
to be lifted upward slightly  
to fully extend the rear sus-  
pension.  
Next, have the rider drop down  
hard on the seat and bounce up and  
down several times, collapsing the  
rear suspension. With the rider  
seated, measure the distance  
between the ground and the rear  
bumper at the exact location used  
for measurement X. This is mea-  
surement Y.  
Y
To determine sag, commonly referred to as ride-in, subtract measure-  
ment Y from X (sag=X-Y). Adjust sag by rotating the torsion spring  
preload cams located on the rear torque arm. Use the illustration for ref-  
erence. The ideal amount of Sag for the EDGE rear suspension is four  
inches (X-Y=4).  
If the rear suspension rides in less than three inches or more than five  
inches with the torsion spring preload cams at their maximum range of  
adjustment, optional torsion springs (softer or stiffer, respectively) may  
be required. This is only an initial set-up, and final spring preload may  
vary based on rider preference and riding conditions.  
34  
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THE PERFECT FIT  
EDGE 136 Rear Suspension Adjustments  
Rear Spring Tension  
To adjust rear torsion spring tension, rotate the three-position cam using  
the engine spark plug tool. Different rate torsion springs are available if  
a firmer ride is desired. See your dealer for more information.  
The following information is provided only as a guideline to be used for  
initial suspension set-up. Your set-up may vary based on your desired  
riding style.  
Low Tension  
Medium Tension  
High Tension  
35  
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THE PERFECT FIT  
EDGE 136 Rear Suspension Adjustments  
Indy Select Rear Shock  
Some snowmobiles are equipped with the Indy Select rear shock, which  
allows for adjustments to the compression valving. Locate the adjust-  
ment screw near the base of the shock. In half-turn increments, turn the  
screw clockwise to increase compression valving and stiffen the ride, or  
counterclockwise to reduce compression and soften the ride. There are  
approximately three full turns of adjustment available.  
If bottoming continues after the screw has been turned fully clockwise,  
the torsion spring should be adjusted (see page 35). Return the screw to  
its original starting position after the torsion spring has been tightened.  
Adjustment Screw  
36  
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THE PERFECT FIT  
EDGE 136 Rear Suspension Adjustments  
Optional Torsion Springs  
Different rate torsion springs are available for some shocks if a firmer  
ride is desired. Contact your dealer for more information.  
Suspension Coupling  
On all Polaris snowmobile rear suspensions, there are two torque arms  
that control the movement of the rail beam. Prior to the advent of sus-  
pension coupling, these torque arms could move independently of each  
other. Rear suspension coupling links the movement of the front and  
rear torque arms to each other. There are two types of rear suspension  
coupling.  
Front To Rear Coupling and the Front Rear Scissor Stop  
(FRSS)  
The front rear scissor stop (FRSS) couples the movement of the front  
torque arm with the rear torque arm and limits the amount of indepen-  
dence between the movement of the front torque arm and the rear torque  
arm.  
When hitting a bump, the front torque arm starts to compress. The FRSS  
links that movement to the rear torque arm, causing it to compress and  
raise the rear suspension up as one, allowing the suspension to hit the  
bump only once and reducing kickback.  
The factory setting is usually adequate for all riders and conditions.  
37  
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THE PERFECT FIT  
EDGE 136 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.  
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.  
38  
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THE PERFECT FIT  
EDGE 136 Rear Suspension Adjustments  
Weight Transfer During Acceleration  
The preferred method for controlling  
weight transfer during acceleration  
is by adjusting the rear rear scissor  
stop (RRSS). The factory setting is  
the best for most trail riding condi-  
tions.  
To decrease weight transfer under  
acceleration (for improved corner-  
ing), rotate the RRSS to a higher  
position.  
Stock  
To increase weight transfer or ski lift  
during acceleration, move the RRSS  
to the rearward hole on high posi-  
tion. The RRSS may also be rotated  
to a lower position for even more  
weight transfer if desired.  
Stock Position - This setting is most  
desirable for trail riding.  
Medium/High  
Medium or High Position (standard  
hole location) - This setting will  
decrease weight transfer.  
Rearward Upper Position  
(optional hole location - This setting  
will increase weight transfer.  
Rearward Upper  
NOTE: Your dealer can help you with initial setup and additional setup  
instructions to help you achieve your optimum ride. A scissor  
stop tool is also available from your dealer.  
39  
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THE PERFECT FIT  
Handlebar Adjustment  
Follow these steps to adjust handlebar angle at the handlebar block.  
1. Remove the handlebar cover  
to expose the handlebar and  
Cover  
the four adjuster block bolts.  
2. Using a 7/16-inch wrench,  
loosen the four nuts on the  
Bolts  
bottom of the adjuster block  
(turn the handlebar either left  
or right for access to the rear  
nuts).  
NOTE: If necessary, pry the  
blocks apart with a  
screwdriver.  
3. Adjust the handlebar to the  
desired angle. Be sure the  
handlebar, brake lever and  
throttle lever operate  
Nuts  
smoothly and do not hit the  
gas tank, windshield or any  
other part of the machine when the handlebar is turned fully to the  
left or right.  
4. Torque the front bolts first, then torque the rear bolts. Torque the  
bolts to 11-13 ft. lbs. (15-18 Nm).  
5. Reinstall the handlebar cover.  
40  
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THE PERFECT FIT  
Traction Products  
Studs  
Before equipping your machine with traction products, be aware of the  
laws in your area pertaining to the use of traction products. See your  
dealer about installing studs and/or carbides. Many tracks with deep lug  
designs cannot be studded, but your dealer will be able to offer advice  
and assistance.  
Use only Polaris traction products on your snowmobile. Track warran-  
ties are void if track damage or failure results from improper or exces-  
sive stud installation or the use of non-Polaris traction products.  
See your dealer about installing studs and/or carbides.  
CAUTION  
Always install wear strips before installing studs. Failure to install wear strips  
may result in cooler or tunnel damage. See page 43.  
Never add shims to the wear strip. Track damage will result because of lack  
of clearance between upper carrier wheels and track.  
Use of studs longer than the recommended length on machines equipped  
with center coolers will result in center cooler damage or damage to the tun-  
nel.  
Track studding will enhance braking control on hard-packed snow or  
ice, but extreme caution is still required on such surfaces. Steering abil-  
ity may be reduced on hard-packed snow or ice.  
When studded tracks are used, increased wear to the brake pads will  
result from increased braking. Extended-wear brake pad kits are avail-  
able. See your dealer.  
CAUTION  
Aggressive studding patterns may require grinding protruding stud bolts flush  
to prevent idler wheel damage. Maintain track tension on studded tracks on  
the tight side of the spec to prevent heat exchanger damage. The center of  
the stud must be at least 1 1/8I (2.86 cm) from the outside edge of the track.  
41  
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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. Use carbide skags with studded tracks  
to help maintain proper vehicle steering and control. See page 103.  
If your machine has carbide skags, it may be necessary to add track  
studs to maintain proper vehicle control. Maintain a proper balance  
between the number of studs and the length of carbide on the skags (the  
more studs you use, the longer the carbide on the skags should be). See  
your dealer's track studding chart.  
Inspect skags and studs frequently. Worn studs or skags may reduce  
steering and braking control on hard-packed snow and ice. Replace  
worn studs and 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.  
42  
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THE PERFECT FIT  
Traction Products  
Wear Strips  
To avoid excessive tunnel wear, tunnel wear strips must be installed  
whenever track studding is used. See your dealer for more information.  
Wear strips are designed for a specific stud length. See your dealer's  
studding chart for recommended traction accessories.  
Components (viewed from rear of track)  
1. Top of tunnel  
2. Wear strip  
3. Track  
4. Wear strip mounting holes  
2
1
4
3
CAUTION  
Whenever wear strips are relocated, be sure there's adequate stud clearance  
to the heat exchangers. Lack of clearance may result in damage to heat  
exchangers.  
43  
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THE PERFECT FIT  
Accessories  
Polaris offers a wide range of accessories for your snowmobile to help  
make each ride more enjoyable.  
Use only Polaris parts and accessories on your Polaris snowmobile. Use  
of unapproved parts and accessories may result in:  
• 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.  
NOTE: Exhaust systems are critical safety areas that must use  
approved Polaris parts. Please see your Polaris dealer for ser-  
vice.  
44  
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PRE-RIDE INSPECTIONS  
Pre-Ride Checklist  
Inspect all items on the checklist for proper operation or condition  
before each use of the snowmobile. Procedures are outlined on the refer-  
enced pages. Look for a checkmark (n) on the referenced pages to  
locate the pre-ride inspection items.  
Item  
See Page  
Drive Belt Condition  
Steering System  
Recoil Rope  
91, 94  
49  
50  
Parking Brake Lock/Brake Lever/Brake System  
Auxiliary Shut-Off Switch (Engine Stop Switch)  
Ignition Switch  
47, 48, 86  
51  
51  
Taillight/Brakelight/Headlight  
Suspension Mounting Bolts  
Skags (Wear Bars)  
51  
108  
103  
108  
50  
Ski Saddle and Spindle Bolts  
Hood Straps/Latches  
Seat Latches (if equipped)  
Throttle Lever/Safety Switch  
Rear Wheel Idler Bolts  
50  
62, 63  
99  
Tether Switch/Strap  
N/A  
49, 100  
101  
78  
Track Alignment/Condition  
Rail Slide Condition  
Chaincase Oil Level  
Injection Oil Level  
59  
45  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
Before starting the engine, always refer to all safety warnings pertaining  
to snowmobile operation. Never start the engine without checking all  
vehicle components to be sure of proper operation.  
WARNING  
Operating the vehicle with worn, damaged, or malfunctioning components  
coule result in serious injury or death. Never start the engine without check-  
ing all vehicle components to be sure of proper operation.  
Read and Understand Your Owner's Manual  
Read the Owner's Manual completely and refer to it often. The manual  
is your guide to safe and enjoyable snowmobiling experience.  
n Throttle Lever  
The throttle and brake are the primary controls of your snowmobile.  
Always make sure both are functioning properly.  
Squeeze the throttle lever to make sure it compresses evenly and  
smoothly. When released, the lever should immediately return to the  
idle position without binding or hesitation. If the throttle does not func-  
tion smoothly, or if you discover excessive lever freeplay, DO NOT start  
the engine. Have the throttle serviced immediately.  
n Throttle Safety Switch  
Test the throttle safety switch system before the machine is operated.  
See page 62.  
46  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Hydraulic Brakes  
Always check the following items for proper operation before starting  
the engine.  
Brake Lever Travel  
Squeeze the brake lever. It  
should move no closer to the  
handgrip than 1/2I (1.3 cm).  
A smaller distance indicates  
1/2I (1.3 cm)  
low brake fluid level or air in  
the hydraulic system. Refer to  
the brake bleeding information  
on page 88 or see your dealer for service.  
NOTE: If the brake lever feels “spongy” when squeezed, check the  
brake fluid level and condition. Add fluid as needed. See page  
87.  
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.  
47  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Parking Brake Lever Lock  
Your snowmobile may have a  
parking brake lever lock located  
over the brake lever. Use the  
brake lever lock only when you  
want the machine to remain sta-  
tionary; for example, when  
parked on an incline for a period  
of five minutes or less.  
4
3
2
1
1. Brake Lever  
2. Parking Brake Lever Lock  
(if equipped)  
3. Master Cylinder Reservoir/ Cover  
4. Fluid Level Indicator  
Lock Engagement  
To engage the lock, squeeze the brake lever tightly and push forward on  
the lock. Hold the lock forward while releasing the brake lever.  
NOTE: 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 on the console will light up if the parking brake lever  
lock is set while the engine is running. It will also be lit when the service  
brake is in use. If the parking brake light does not come on when the  
parking brake or service brake is in use, have it serviced by your dealer.  
Lock Release  
To release the lock, squeeze the brake lever tightly and release it. The  
lock will return to the unlocked position.  
WARNING  
If the parking brake lever lock is partially or entirely engaged while riding, the  
brakes may overheat, resulting in brake damage. In extreme cases it could  
cause a fire, which could result in serious injury or death. Always ensure that  
the lever lock is completely disengaged before operating the snowmobile.  
48  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Steering System  
WARNING  
Ice and snow build-up may interfere with the steering of your machine, result-  
ing in serious injury or death. Keep the underhood area free of snow and ice.  
Before driving, manually turn the skis to the left and right to be sure ice  
and snow are not interfering with full left and right steering. If difficulty  
is encountered, remove ice and snow build-up that may be obstructing  
the steering linkage.  
n Track  
WARNING  
Always inspect the track for damage before using the vehicle. 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.  
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 with inadequate lubrication could severely damage track rods,  
break track edges, and cause other track damage. Examples of inade-  
quate lubrication would include frozen bodies of water without snow  
cover, icy trails, and no-snow conditions.  
NOTE: Track damage or failure caused by operation on ice or under  
poor lubrication conditions voids the track warranty.  
49  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Hood Latches  
The hood of the snowmobile protects the operator from moving parts as  
well as aiding in sound emission control and other functions. Under no  
circumstances should your snowmobile be operated with the hood open  
or removed. Always ensure that the hood straps are in good condition  
and that the latches are securely in place before operating the snowmo-  
bile.  
n Seat Latches  
If your snowmobile is equipped with a removable seat, ensure that the  
seat latches are securely in place before every use of the snowmobile.  
n Recoil Rope  
Inspect the recoil rope and handle for excessive wear, and make sure the  
knot securing the rope inside the handle is secure. If excessive wear is  
found, see your Polaris dealer for replacement.  
50  
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PRE-RIDE INSPECTIONS  
Start the Engine and Check  
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 Lighting  
Check the headlight (high and low beam), taillight, and brake light.  
Replace burned out lamps before operating.  
n Mirror Adjustment (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.  
51  
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OPERATION  
Starting the Engine  
CAUTION  
Engaging the starter when the engine is running WILL result in serious  
engine damage, especially if the transmission is in reverse. Never engage  
the starter when the engine is running.  
1. Turn the fuel valve on. See  
page 57.  
CHOKE POSITIONS  
2. Turn the key to the ON  
position.  
OFF  
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.  
FULL CHOKE  
NOTE: Do not depress the throttle until the engine starts.  
WARNING  
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.  
To avoid injury and/or engine damage, do not operate the electric starter or  
pull-rope starter while the engine is running.  
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 recoil rope 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.  
52  
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OPERATION  
Engine Break-In  
No single action on your part is as important to long, trouble-free  
machine life as proper break-in of a new or rebuilt engine. Premix the  
first tank of fuel with one pint of Polaris injection oil for each five gal-  
lons of fuel. This, in addition to the lubrication supplied by the injection  
system, will assure proper engine break-in.  
CAUTION  
Excessive heat build-up during the first three hours of operation will damage  
close-fitted engine parts. Do not operate at full throttle or high speeds for  
extended periods during the first three hours of use. Vary the throttle open-  
ings and machine speeds to reduce friction on all close-fitting machined  
parts, allowing them to break in slowly 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.  
53  
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OPERATION  
Engine Break-In  
Oil Injection System  
Always check and fill the oil tank when refueling. See page 59.  
CAUTION  
Serious engine damage can occur without the proper lubrication. Check the  
oil tank level often during the first tank of fuel. If the oil level doesn't go down,  
contact your dealer immediately.  
Oil Recommendations  
This snowmobile is equipped with a variable exhaust system (VES).  
Engine lubrication comes from oil added to the fuel and oil injection  
systems. Polaris recommends the use of VES II 2 Cycle Oil for this  
engine. See page 113 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.  
54  
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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 throt-  
tle during warm-up or when the track is free-hanging. Use a stable rear sup-  
port.  
WARNING  
Use of traction products such as studs, ice growsers, etc. will increase the  
possibility of track damage and/or failure. This could cause loss of control,  
resulting in serious injury or death. Always inspect for track damage before  
operating the snowmobile.  
Follow these steps to ensure proper warm-up of the engine, drive train  
and track.  
1. Use an appropriate stand to securely  
support the rear of the snowmobile at  
the rear bumper. The track should be  
about 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 revo-  
lutions.  
NOTE: It will take longer to warm up the  
track sufficiently during colder outdoor temperatures.  
4. Release the throttle, apply the brakes, shut off the engine and lower  
the machine to the ground.  
5. Grasp the skis by their front loops and move them from side to side  
to loosen snow and ice.  
55  
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OPERATION  
Slide Rail and Track Cooling  
CAUTION  
Inadequate cooling and lubrication will lead to overheating of the slide rail  
and track, resulting in premature wear and failure. Reduce speeds and fre-  
quently drive into fresh snow to allow adequate cooling and polishing of the  
slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or  
roads.  
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  
refueling is performed or where gasoline is stored.  
• If gasoline spills on your skin or clothing, immediately wash it off with soap  
and water and change clothing.  
• Never start the engine or let it run in an enclosed area. Engine exhaust  
fumes are poisonous and can cause loss of consciousness or death in a  
short time.  
Turn the fuel valve off whenever the snowmobile is stored or parked.  
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.  
56  
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OPERATION  
Fuel  
Fuel Valve  
Turn the fuel valve clockwise to  
OFF to shut off the fuel supply.  
Turn the valve counter-clockwise  
to ON to turn the fuel supply on.  
OFF  
ON  
Fuel Recommendations  
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).  
CAUTION  
Using fuels with a lower than recommended octane or operating with  
obstructed fuel systems will result in serious and costly engine damage.  
Always use the recommended fuels for your machine.  
57  
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OPERATION  
Fuel  
Fuel Reserve Capacity (Mechanical Gauge)  
There are approximately two gallons of fuel left in the tank when the  
mechanical fuel gauge reads RES.  
Fuel System Deicers  
If you use non-oxygenated fuel, Polaris recommends the regular use of  
isopropyl-based fuel system deicer. Add one to two ounces per gallon  
(8-16 ml per liter) of gasoline to prevent engine damage resulting from  
fuel system icing and lean fuel mixtures. Never use deicers or additives  
containing methanol. Polaris also recommends the use of Carbon Clean  
Plus. See page 113 for the part numbers of Polaris products.  
If you use oxygenated fuel containing ethanol, additional alcohol deic-  
ers or water absorbing additives should not be used.  
CAUTION  
Prolonged exposure to petroleum based products may damage paint. Always  
protect painted surfaces when handling fuel.  
58  
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OPERATION  
n Oil  
Low Oil Indicator Light  
The low oil indicator light will alert the operator if the oil level is low.  
Visually check for oil in the bottle. Add oil before further operation of  
the snowmobile.  
CAUTION  
Operating the snowmobile without adequate engine lubrication can result in  
serious engine damage. Always check the oil level when refueling. Add oil as  
needed.  
Low Oil Level  
Maintaining the proper oil level will prevent system aeration and possi-  
ble loss of pumping action, which could result in engine damage. This is  
especially important when the machine is operated in mountainous ter-  
rain.  
Always check the oil level when refueling. Maintain the oil level above  
the tank's low level line. When the oil reaches the low level mark, add  
one U.S. quart of recommended oil. See page 54 for oil recommenda-  
tions.  
NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil  
flow. See your Polaris dealer for recommended replacement  
parts.  
59  
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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.  
60  
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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 from +5 to +25 degrees F. (-15 to -4 degrees 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 83 for more information.  
CAUTION  
A main jet that's too small will cause a lean operating condition and may  
cause serious engine damage. Jet the carburetors carefully for elevation and  
temperature according to the jetting charts in your Owner's Manual Supple-  
ment.  
NOTE: It's the owner's responsibility to ensure that the correct jets are  
installed in the machine for a geographical area. Be very care-  
ful when jetting down in warm weather. As the weather turns  
colder it will be necessary to re-jet upward to prevent engine  
damage. When selecting the proper main jet always use the  
lowest elevation and temperature that is likely to be encoun-  
tered.  
61  
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OPERATION  
n Engine Stop Switch  
Push down on the engine  
stop switch (+) to  
+
ground out the ignition  
and stop the engine  
quickly. Pull the switch  
up to the ON position to  
allow restarting.  
n Throttle Safety Switch  
The throttle safety switch is designed to stop the engine whenever all  
pressure is removed from the throttle lever and the throttle cable or  
valves do not return to the normal closed position.  
WARNING  
Operating the snowmobile with a faulty throttle safety switch can result in  
serious injury or death in the event of an accident. If the throttle safety switch  
does not shut off the engine during a carburetor/throttle system malfunction,  
immediately push down the engine stop switch. Do not start the engine again  
until the malfunction has been corrected by your dealer.  
Test the throttle safety switch  
system daily before operation.  
1. Sit on the seat.  
2. Start the engine and allow it  
to idle.  
3. Hold the throttle lever pin  
stationary by exerting pres-  
sure on the pivot pin in the direction shown in the illustration.  
4. Apply a slight amount of throttle. A properly functioning switch  
must shut down the engine.  
62  
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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.  
63  
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OPERATION  
Emergency Stopping  
The following chart lists methods for stopping the snowmobile in the  
event of an emergency. See page 62 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 (if available) Interrupts ignition circuit  
64  
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OPERATION  
Reverse 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 67. Always make sure the vehicle is  
stopped and the engine is running at idle before shifting to reverse.  
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.  
CAUTION  
Engaging the starter when the engine is running WILL result in serious  
engine damage, especially if the transmission is in reverse. Never engage  
the starter when the engine is running.  
65  
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OPERATION  
Reverse 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 but-  
ton (+) on the left-hand con-  
trol for one second, then  
release. The engine will auto-  
matically reduce RPM and  
start a reverse rotation. A  
flashing reverse light on the  
instrument panel will indicate  
that the transmission is in  
reverse.  
+
4. Apply the throttle slowly to  
make sure the transmission is  
in reverse.  
NOTE: The maximum engine RPM will be 6000 when in reverse.  
NOTE: If the engine stops running, the snowmobile will be in forward  
gear when it's restarted.  
66  
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OPERATION  
Reverse Operation  
Electronic Reverse (PERCt)  
Disengaging Reverse  
1. Stop the snowmobile and leave the engine idling.  
CAUTION  
Engaging the starter when the engine is running WILL result in serious  
engine damage, especially if the transmission is in reverse. Never engage  
the starter when the engine is running.  
2. Push the yellow reverse button for one second and release. The  
engine will slow and begin to rotate forward. The light on the  
instrument panel will shut off.  
3. Apply the throttle slowly to make sure the transmission is in for-  
ward.  
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.  
67  
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OPERATION  
Daily Storage  
At the end of each ride, park the snow-  
mobile on a level surface and support it  
at the rear with an appropriate track  
stand. The track should be suspended  
approximately 4I (10 cm) off the  
ground. Remove the key and cover the  
machine.  
68  
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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 tobog-  
gan or sled, make sure the pole is at least four feet (1.2 meters) long to pre-  
vent any possibility of contact between the snowmobile's track and a person  
riding in the towed object.  
Braking distances increase when towing loads. Slow down to maintain con-  
trol of the snowmobile.  
If the snowmobile becomes inoperable and must be towed, and if it isn't  
possible to use a rigid tow bar, attach the tow rope to the ski spindles  
(not to the ski loops) to prevent damage to the steering components.  
Remove the drive belt before towing, and have someone ride on the  
towed snowmobile to operate the brake and steering when necessary.  
CAUTION  
Towing a disabled snowmobile with the drive belt in place can result in seri-  
ous damage to the engine and drive system. Always remove the drive belt  
from a disabled snowmobile before towing.  
69  
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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.  
70  
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MAINTENANCE  
Emission Control Information  
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.  
71  
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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 130.  
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.  
CAUTION  
Hot components can cause damage to plastic. Always make sure the  
exhaust system and engine have cooled before tipping the snowmobile on its  
side for service or inspection.  
72  
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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  
1000 mi.  
150 mi.  
500 mi.  
2000 mi.  
Pre-  
Season  
(240 km) (800 km) (1600 km) (3200 km)  
CLUTCH  
Clutch Alignment Offset  
(without belt)  
91  
I
I
I
Drive Belt Condition  
Clutches (disassemble)  
Belt Tension  
91  
91  
--  
I
I
C
I
I
C
I
I
C
I
I
I
Clutch Sheaves  
91  
I
I
I
ENGINE/COOLING  
Engine Mounts  
--  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Recoil Rope  
Engine Mounting Plate  
Engine Torque Stop  
Cylinder Head Bolts  
Cylinder Base Nuts  
Ignition Timing BTDC  
Spark Plug Condition  
Exhaust Pipe  
--  
I
95  
--  
I
I
I
--  
I
I
I
I
I
I
--  
I
79  
85  
85  
R
I
I
I
I
Exhaust Retaining  
Springs  
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean R - Replace L - Lubricate  
73  
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MAINTENANCE  
Periodic Maintenance Interval Table  
Item  
See  
Page  
Frequency  
1000 mi.  
150 mi.  
500 mi.  
2000 mi.  
Pre-  
Season  
(240 km) (800 km) (1600 km) (3200 km)  
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  
86  
Brake Disc  
--  
Parking Brakes  
Brake System  
Brake Fluid  
48  
47, 86  
87  
R
FUEL MANAGEMENT  
Pilot Air Screws  
--  
I
I
I
I
I
I
Carburetor  
83  
(synchronize)  
Idle RPM  
--  
63  
--  
I
I
I
I
I
I
I
Throttle Lever  
I
I
I
I
Oil Pump Lever  
(synchronize)  
Throttle Cable  
Choke Cable  
Choke  
77  
77  
77  
--  
L
L
I
L
L
I
L
L
I
Vent Lines  
I
I
I
I
I
I
I
Fuel Lines  
82  
--  
I
I
I
I
I
Oil Lines  
I
I
Air Box  
--  
I
I
I
I
Drain and Water Traps  
84  
I
I
ELECTRICAL  
Auxiliary Shut-Off  
Switch  
51  
I
I
I
I
I
Throttle Safety Switch  
Ignition Switch  
Taillight  
62  
--  
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
51  
51  
51  
Brakelight  
Headlight  
74  
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MAINTENANCE  
Periodic Maintenance Interval Table  
Item  
See  
Page  
Frequency  
1000 mi.  
150 mi.  
500 mi.  
2000 mi.  
Pre-  
Season  
(240 km) (800 km) (1600 km) (3200 km)  
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  
--  
--  
I
I
I
I
I
I
I
I
Cooling Fins and  
Shroud  
Drive Shaft Bearing  
Jackshaft Bearings  
Skags (Wear Bars)  
77  
110  
103  
--  
L
I
L
I
L
I
I
I
I
I
I
I
I
I
I
Ski Saddle/Spindle  
Bolts  
I
I
I
Ski Pivots  
76  
76  
--  
L
L
L
L
L
L
L
L
I
I
I
I
Ski Spindle  
Steering Arm(s)  
Upper / Lower Steering  
Post Support Bracket  
76  
L
L
L
L
Drive Chain Tension  
Hood Latches  
85  
50  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Battery Fluid Level  
Rear Wheel Idler Bolts  
Idler Bolt Jam Nut  
104  
99  
I
I
I
I
I
I
99  
I
I
I
Rear Suspension Pivot  
Shafts  
76  
L
L
L
Camber Alignment  
Radius Rod Bushings  
Handlebar Centering  
Track Alignment  
Track Tension  
--  
--  
I
I
I
I
I
I
I
I
I
I
I
--  
100  
98  
--  
I
I
I
I
I
I
I
I
I
I
I
I
Front Limiter Strap  
Rail Slide Condition  
Chaincase Oil  
101  
78  
N/A  
I
I
I
I
I
I
R
R
Gearcase Oil  
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean R - Replace L - Lubricate  
75  
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MAINTENANCE  
Lubrication  
Suspension and Steering  
Lubricate the suspension and steering components with Polaris Pre-  
mium All-Season Grease at 500 miles (800 km) and annually or every  
1000 miles (1600 km) thereafter. A grease gun kit, complete with grease  
and adaptors, is available to lubricate all fittings on Polaris snowmo-  
biles. See page 113 for the part numbers of Polaris products.  
The illustration shows the lubrication points of suspension and steering  
components. Grease the left and right spindles. Raise the front end of  
the machine to permit better grease entry into the spindle area.  
• Lubricate both of the front ski pivots at the fittings as shown.  
• Grease the driveshaft clutch side bearing.  
• Use an aerosol lubricant on the steering post support bracket.  
• Grease the steering post lower pivot.  
• Grease the rear suspension pivot shafts (raise the rear of unit).  
+
+
+
+
+
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MAINTENANCE  
Lubrication  
EDGE 136 Rear Suspension  
+
+
+
+
Driveshaft Bearing  
+
Inject grease into the fitting on the speed-  
ometer sensor housing until grease purges  
from the seal on the inside of the tunnel.  
This should take approximately two  
pumps. Do not use more than four pumps.  
Throttle Cable  
Lubricate the throttle cable 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.  
77  
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MAINTENANCE  
Lubrication  
n Chaincase Oil  
Check the chaincase oil level at the intervals outlined in the mainte-  
nance charts beginning on page 72. Change the chaincase oil after the  
first 500 miles (800 km), then every 1000 miles (1600 km) or season-  
ally.  
Maintain the oil level between the “safe” marks on the dipstick. Clean  
the magnetic plug on the dipstick whenever checking or changing oil.  
Polaris recommends the use of Polaris Synthetic Chaincase Lube. See  
page 113 for the part numbers of Polaris products.  
Oil Check  
2
1. Position the vehicle on  
a level surface.  
1
2. Remove the dipstick (1)  
and view the oil level  
on the dipstick.  
3. Add the recommended  
oil as needed. Do not  
overfill.  
4. Clean the magnetic  
plug (2).  
5. Reinstall the dipstick.  
78  
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MAINTENANCE  
Spark Plugs  
A new engine can cause temporary spark plug fouling due to the preser-  
vative added during the assembly process. Avoid prolonged idle speeds,  
which cause plug fouling and carbonization. Refer to your Owner's  
Manual Supplement for the specific spark plug to be used in your  
machine.  
CAUTION  
Using non-recommended spark plugs can result in serious engine damage. A  
spark plug with a heat range too high will always cause engine damage if the  
engine is operated in conditions more severe than intended for that plug.  
Always use the spark plugs recommended for your snowmobile. See your  
Owner’s Manual Supplement.  
• Use recommended spark plugs with the proper gap.  
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.  
WARNING  
A hot exhaust system and engine can cause serious burns. Wear protective  
gloves when removing a spark plug for inspection.  
NOTE: Incorrect fuel mixture can often cause a spark plug to appear  
too dark or too light in color. Before changing spark plug heat  
ranges, be sure the correct main jet is installed in the carbure-  
tor(s). Refer to the Owner's Manual Supplement or see your  
dealer.  
79  
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MAINTENANCE  
Spark Plugs  
Normal Plug  
The normal insulator tip is gray, tan or light brown. There will be few  
combustion deposits. The electrodes are not burned or eroded. This indi-  
cates the proper type and heat range for the engine and the service.  
NOTE: The tip should not be white. A white insulator tip indicates over-  
heating, 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. Using the special wrench provided in the tool pouch, rotate the  
spark plug counterclockwise to remove it.  
3. Reverse the procedure for spark plug installation.  
4. Torque the spark plug to specification. See page 79.  
5. Verify that gap is within specification. See your Owner’s Manual  
Supplement.  
6. Reinstall the spark plug cap.  
80  
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MAINTENANCE  
Intake Filters  
CAUTION  
Operating the snowmobile with the intake filters removed may cause carbu-  
retor icing. The result will be poor fuel economy or carburetor malfunction.  
Always reinstall the intake filters before operating the snowmobile.  
The intake foam filter (+) limits snow ingestion into the intake system.  
When operating in loose powder snow, check the top of the foam filter  
periodically to remove any accumulation of snow.  
NOTE: These illustrations are general representations. Your model  
may differ.  
+
+
81  
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MAINTENANCE  
Fuel Filter/Fuel Lines  
The fuel filter is located inside the fuel tank. This component requires  
no maintenance.  
Inspect the fuel lines regularly for signs of deterioration or damage.  
Always check fuel line condition after periods of storage. Normal dete-  
rioration from weather and fuel compounds may occur. Replace worn or  
damaged fuel lines promptly.  
CAUTION  
Kinking the fuel lines or using a pliers or similar tools to remove fuel lines  
may cause damage to the lines. If a fuel line has been damaged or kinked,  
replace it promptly.  
Oil Filter  
The oil filter on your model is assembled into the oil sending unit  
located in the bottom of the oil tank. This component requires no main-  
tenance.  
If service is performed to the oil injection system, trapped air must be  
bled from the system. See your dealer for instructions, or have your  
dealer perform this service.  
82  
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MAINTENANCE  
Carburetor  
The number stamped in the end of the main jet indicates the jet size. The  
jet installed at the time of manufacture is not necessarily correct for your  
elevation. It's your dealer's responsibility to make sure the correct main  
jet is installed.  
CAUTION  
Operating the snowmobile with incorrect jetting can result in serious engine  
damage. Have your Polaris dealer perform all carburetor adjustments to  
ensure all adjustments are done correctly.  
Carburetor Adjustments  
The frequency at which the carburetors are synchronized or balanced is  
important. Properly adjusted carburetors can greatly improve engine  
performance, fuel economy, engine life, and reliability.  
If you notice any of the following conditions, the carburetor may need  
adjustment:  
• Hard starting  
• Poor idle  
• Overheated pistons and cylinder walls  
• Plug fouling  
• Poor engine response to various throttle valve openings  
83  
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MAINTENANCE  
Carburetor  
Water/Sediment Trap Service  
Most Polaris snowmobiles contain patented carburetor bowl water/sedi-  
ment traps located at the bottom of each carburetor. The trap, consisting  
of a hose with a plug, should be drained at least every 2000 miles (3200  
km) and inspected for contamination.  
WARNING  
When draining the traps, fuel spillage will occur. Always work in a well venti-  
lated area away from anything that may cause the fuel to ignite, such as open  
flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline  
warnings found on page 56.  
1. Turn the fuel tank supply valve off.  
Clamp  
2. Position a container or shop towels to  
catch the contaminated gasoline.  
3. Slide the clamp away from the drain  
plug and remove the drain plug from  
the sediment tube.  
4. Wipe residue from the plug and reinstall  
it. Reposition and tighten the clamps.  
Continue until all traps have been emp-  
tied.  
Drain  
Plug  
84  
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MAINTENANCE  
Exhaust System  
Check the exhaust system for wear or damage at approximately 2000  
miles (3200 km). To inspect, allow the engine and exhaust system to  
cool completely. Open the hood and inspect the muffler and pipes for  
cracks or damage. Check for weak or missing retaining springs or  
damper/support grommets.  
WARNING  
Hot exhaust system parts can cause serious burns. Allow adequate time for  
the exhaust system to cool. Never perform this procedure with the engine  
running.  
Drive Chain Tension  
To obtain correct chain tension:  
1. Rotate the driven clutch  
counterclockwise to move all  
chain slack to the tensioner  
side. Lock the brake lever  
lock, or have an assistant  
hold the brake lever firmly.  
Adjuster  
Bolt  
Jam  
Nut  
2. Loosen the adjuster bolt jam  
nut.  
3. Finger tighten the adjuster  
bolt until it can no longer be  
adjusted by hand, then back  
off 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.  
85  
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MAINTENANCE  
Brakes  
n Hydraulic Brake Inspection  
Inspect the brake lever reserve before each use of the snowmobile. See  
page 47.  
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).  
Excessive Lever Travel  
Hydraulic brakes are self-adjusting, but if excessive brake pad clearance  
develops, bring the machine to an authorized Polaris dealer for inspec-  
tion and adjustment.  
Brake Components  
1. Brake Caliper  
1
2
2. Brake Disc  
3. Brake Pad Material  
(Replace when thickness is  
less than 1/16I/1.5 mm).  
3
86  
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MAINTENANCE  
Brakes  
Brake Fluid  
On some models, the brake fluid level can be seen through a plastic  
sight glass in the brake reservoir. If the fluid is sufficient, the sight glass  
will be black. If the sight glass is any color other than black, add brake  
fluid.  
On all other models, frequently check the reservoir to be sure it contains  
the correct amount of fluid. To add fluid, remove the master cylinder  
reservoir cover. Add the recommended brake fluid to bring the level up  
to the top of the fluid level mark on the inside of the reservoir.  
Replace brake fluid at least every two years with Polaris DOT 4 high  
temperature brake fluid. See page 113 for the part numbers of Polaris  
products.  
WARNING  
After opening a bottle of brake fluid, always discard any unused portion.  
Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rap-  
idly absorbs moisture from the air. The moisture causes the boiling tempera-  
ture of the brake fluid to drop, which can lead to early brake fade and the  
possibility of accident or serious injury.  
WARNING  
Keep the master cylinder cover free of dirt and debris. The vent slits allow for  
diaphragm movement, and if they become plugged, movement of brake fluid  
below the diaphragm may be restricted, altering brake function.  
CAUTION  
Brake fluid will damage decals, paint and some plastics. Always wipe up  
spills immediately.  
87  
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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 87.  
8. Reinstall the gasket and cover.  
88  
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MAINTENANCE  
Lights  
Headlight Adjustment  
The headlight may be adjusted for vertical aim using the following pro-  
cedure.  
1. Place the snowmobile on a level surface with the headlight approxi-  
mately 25 feet (7.6 m) from a wall.  
2. Measure the distance from the floor to the center of the headlight  
and make a mark on the wall.  
3. Start the engine and turn the headlight switch to high beam.  
4. Observe the headlight aim. The most intense part of the headlight  
beam should be aimed 2I (5.1 cm) below the mark placed on the  
wall.  
NOTE: Rider weight must be included on the seat.  
5. Turn the adjustment nut (+), located inside the hood, just below the  
headlamp opening. Turn the knob in or out as needed for proper  
aim.  
25 ft. (7.6 m)  
Lamp Center Height  
2I (5.1 cm)  
+
89  
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MAINTENANCE  
Lights  
NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin  
leaves a residue, causing a hot spot that will shorten the life of  
the lamp. If fingers do touch the bulb, clean it with an alcohol-  
moistened towel.  
Headlight Bulb Replacement  
1. Pinch the ends of the spring (1)  
together and lift until it releases  
from the spring retainer.  
3
2. Lift the spring carefully around  
the wire harness (2) and flip it to  
the outside of the housing.  
2
3. With the wire harness attached  
to the bulb (3), withdraw the  
bulb from the housing.  
1
4. Grasp the bulb by its metal base  
and carefully separate the bulb from the harness.  
5. Hold the new bulb by its metal base and install it into the wire har-  
ness.  
6. Insert the bulb into the housing. Carefully flip the spring back into  
the housing, placing it around the wire harness.  
7. Squeeze the spring together until it's over the spring retainer and  
release.  
8. Verify headlight aim. See page 89.  
Taillight/Brakelight Replacement  
2
1. Remove the screws (1) securing the  
taillight housing (2).  
3
2. Remove and replace the bulb (3).  
3. Reassemble all components.  
1
90  
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MAINTENANCE  
Clutch System  
Periodically inspect clutch sheaves for damage, wear or belt residue. To  
maintain optimum performance, clean with non-oil based cleaners such  
as isopropyl alcohol.  
WARNING  
If you become aware of higher than normal clutch engagement or an unusual  
vibration or shift pattern, see your dealer immediately. Do not operate the  
machine until repairs have been made.  
All clutch maintenance and repairs must be performed by an authorized  
Polaris dealer. Any unauthorized modifications to clutches, such as adding or  
removing weights, will void the warranty.  
CAUTION  
The bushings in the weights and rollers of Polaris clutches are made of a  
material that may be damaged if lubricated. Do not lubricate clutch bushings.  
Clutch Alignment Offset  
Clutch alignment offset is important for maintaining optimum perfor-  
mance. Please see your Polaris dealer if you experience a decrease in  
performance.  
Clutch Center Distance  
See your Owner's Manual Supplement for recommended center distance  
for your machine. If adjustment is necessary, see your dealer.  
n Drive Belt Condition  
Periodically check the condition and tension of the drive belt, and  
always carry a spare. Inspect the belt for signs of excessive wear: frayed  
edges, missing cogs, cracks and excessive looseness. Replace the belt if  
any of these conditions exist. See Belt Troubleshooting on page 118.  
For improved drive-away during extremely cold temperatures, remove  
the belt and warm it to room temperature. Reinstall it before starting the  
snowmobile.  
91  
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MAINTENANCE  
Clutch System  
Drive Belt Removal  
CAUTION  
Do not attempt to remove the drive belt after operating in reverse. The snow-  
mobile must be stopped after forward motion to prevent damage to compo-  
nents during belt removal.  
1. Stop the engine after operating in a forward motion.  
2. Turn the ignition key off. Wait for the engine to stop completely.  
3. Lock the parking brake (if equipped).  
4. Open the hood.  
5. Remove the clutch guard retain-  
ing pin and open the clutch  
guard.  
6. Locate the L-wrench in the tool  
kit and install it into the open  
threaded hole in the outer sheave  
of the clutch. Rotate the wrench  
until the sheaves open far enough  
to remove the belt.  
7. Firmly grasp the belt midway  
between the clutches and pull  
upward and rearward to remove.  
See illustration.  
92  
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MAINTENANCE  
Clutch System  
Drive Belt Installation  
1. Drop the drive belt over the  
drive clutch and pull back  
the slack.  
NOTE: To ensure satisfactory  
belt life, install belts so  
they operate in the  
same direction of rota-  
tion by positioning the  
identification numbers  
so that you can read  
them. If required, sepa-  
rate the sheaves as  
outlined in the belt removal procedures.  
2. Turn the driven clutch moveable sheave clockwise while pushing  
inward and forcing the belt down between the sheaves.  
3. Hold the belt down between  
the sheaves and roll the bot-  
tom portion over the outer  
clutch sheave. Work the belt  
to the outer edge of the  
sheave.  
4. Rotate the L-wrench to  
tighten the sheaves. Remove  
the wrench and store in the  
tool kit.  
5. Close the clutch guard and  
reinstall the retaining pin.  
6. Close and secure the hood and release the parking brake.  
93  
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MAINTENANCE  
Clutch System  
n Drive 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 1/4  
inches (3.2 cm).  
Drive Belt Adjustment  
Belt deflection can be adjusted without removing the clutch from the  
jackshaft.  
1. Loosen the 7/16-inch jam nut on the belt width adjuster.  
2. Using a 1/8-inch Allen wrench, adjust the threaded set screw as  
needed.  
NOTE: Turn the set screw in (clockwise) to increase the distance  
between the sheaves and out (counterclockwise) to decrease  
the distance.  
3. Tighten the jam nut.  
94  
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MAINTENANCE  
Clutch System  
Torque Stop  
If your snowmobile is equipped  
with an engine torque stop, periodi-  
cally check torque stop clearance.  
.010-.030I  
(.25-.75 mm)  
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.  
Reverse Maintenance  
If your snowmobile is equipped  
with reverse, or if you have a  
reverse kit installed, it's especially important to maintain track tension  
as specified on page 98.  
WARNING  
Improper track tension can cause serious damage to the snowmobile, which  
can result in loss of vehicle control and serious injury or death. Always main-  
tain the track tension as specified.  
Allow the engine to reach idle speed before attempting to shift into or  
out of reverse.  
CAUTION  
Damage will occur to chaincase or transmission if shifting is attempted before  
the machine has come to a complete stop. Make sure the snowmobile has  
completely stopped and the engine has returned to idle speed before shifting  
gears.  
95  
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MAINTENANCE  
Chain Tension  
Maintain the proper chain tension as outlined on page 85.  
Fall Tune-Up  
For maximum performance, arrange for a fall service tune-up with your  
Polaris dealer. His experienced and trained service technician will keep  
your machine in peak operating condition.  
Tool Kit  
A tool kit is included with each machine for emergency and routine  
maintenance. Always keep the tool kit with the snowmobile.  
96  
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MAINTENANCE  
Track  
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.  
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 peri-  
ods on ice and other surfaces that have little or no snow for lubrication.  
The slide rail needs snow for lubrication. Excessive wear indicates  
insufficient lubrication. A new rail slide can cause faster heat build-up  
in limited lubrication, resulting in excessive wear.  
NOTE: If excessive rail slide wear occurs due to poor snow conditions,  
additional wheel kits are available. See your dealer for more  
information.  
NOTE: Track damage or failure caused by operation on ice or under  
other poor lubrication conditions will void the track warranty.  
97  
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MAINTENANCE  
Track  
WARNING  
Moving parts can cut and crush body parts. When performing the checks and  
adjustments recommended on the following pages, stay clear of all moving  
parts. Never perform track measurement or adjustments with the engine run-  
ning.  
Track 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  
EDGE 136  
10 lbs. (4.54 kg)  
16I ahead of  
rear idler shaft  
1 1/8I-1 3/8I  
(2.9-3.5 cm)  
NOTE: Tension adjustments should be made only after the track is  
warmed up and limber.  
1. Turn the engine off.  
2. Lift the rear of the machine and safely support it off the ground.  
3. Place the recommended weight or downward pressure on the track  
at the specified distance (see chart) ahead of the center of the rear  
idler wheel.  
NOTE: Measure at the point where the weight is hanging.  
98  
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MAINTENANCE  
Track  
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  
98.  
If the track needs adjustment:  
5. Loosen the rear idler  
Locknut  
shaft bolts.  
Adjusting  
Screw  
Slack  
Measurement  
Shaft Bolt  
6. Loosen the locknuts.  
7. Tighten or loosen the  
track adjusting  
screws to provide  
equal adjustment on  
both sides of the  
track.  
8. Repeat the measure-  
ment on the other  
16 (40 cm)  
I
Track  
S
side of the track.  
NOTE: Check more fre-  
quently when  
the machine is  
new.  
10 lbs. (4.54 kg)  
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 100) 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).  
99  
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MAINTENANCE  
Track  
n Track Alignment  
Periodically check that the track is centered and running evenly on the  
slide rails. Misalignment will cause excessive wear to the track and slide  
rail.  
1. Safely support the rear of the 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.  
100  
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MAINTENANCE  
Steering System  
n Rail Slide Wear  
For ease of inspection, all  
Polaris rail slides have a  
wear limit indicator groove  
to indicate the minimum  
permissible slide thickness.  
Replace the rail slides if  
they are worn to the top of  
the groove at any point  
along their length. Failure  
to do so may result in per-  
manent damage to the track  
or rails.  
Minimum  
Thickness  
Replace when  
worn to top of  
groove  
Steering Inspection and Adjustment  
Each week, or before a long ride, check all steering system fasteners and  
tighten if necessary.  
EDGE IFS  
+
+
+
+
+
+
101  
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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 align-  
ment or camber adjustment. See your Polaris dealer.  
With the handlebars in a straight ahead position, and with vehicle  
weight compressing the suspension, measure from the straight edge of  
the skis at the center of the ski mounting bolt. The measurement  
between the skis at point X should be 1/8I to 1/4I (3-6 mm) greater  
than the measurement at point Y.  
NOTE: If the skis are misaligned, we recommend that your dealer cor-  
rect the alignment, since camber adjustment may also be  
affected.  
EDGE IFS  
X
10I  
10I  
Y
102  
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MAINTENANCE  
Steering System  
n Ski Skags  
WARNING  
Worn skis and/or skags will adversely affect handling. Loss of vehicle control  
may result, causing serious injury or death.  
See your dealer's studding chart for recommended skags. If you install longer  
or more aggressive carbide skags than the original equipment, it may also be  
necessary to add track studs to maintain proper vehicle control while turning  
on hard-packed snow or ice.  
Check skags before each use of the snowmobile to ensure positive steer-  
ing characteristics. Skags must be replaced when worn to half their orig-  
inal diameter.  
NOTE: Carbide skags must be replaced if any abnormal wear or chip-  
ping is found.  
Skag Replacement  
1. Raise and support the front of the machine so the skis are approxi-  
mately 6I (15.2 cm) from the ground.  
2. Remove the attaching hardware 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.  
103  
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MAINTENANCE  
Battery  
Battery Fluid  
A poorly maintained battery will deteriorate rapidly. Check the battery  
fluid level often. Maintain the fluid level between the upper and lower  
level marks.  
WARNING  
Battery electrolyte is poisonous. It contains acid! Serious burns can result  
from contact with the skin, eyes, or clothing. If contact occurs, seek immedi-  
ate medical attention.  
KEEP OUT OF REACH OF CHILDREN.  
EXTERNAL: Flush with water.  
INTERNAL: Drink large quantities of water or milk. Call physician immedi-  
ately.  
EYES: Flush with water for 15 minutes and get prompt medical attention.  
Batteries produce explosive gases. Keep sparks, open flames, cigarettes,  
etc. away. Ventilate when charging or using in closed space. Always shield  
eyes when working near batteries.  
Battery Connections  
Keep battery terminals and connections free of corrosion. When clean-  
ing is necessary, remove the corrosion with a stiff wire brush. Wash ter-  
minals and connections with a solution of one tablespoon baking soda  
and one cup water. Rinse well with tap water and dry with clean shop  
towels. Coat the terminals with dielectric grease or petroleum jelly.  
CAUTION  
Tap water contains minerals that will damage a battery and shorten its life.  
Use only distilled water to refill your battery. Never allow cleaning solution or  
tap water to enter the battery.  
104  
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MAINTENANCE  
Battery  
Battery Removal  
WARNING  
Improperly connecting or disconnecting battery cables can result in an explo-  
sion and cause serious injury or death. When removing the battery, always  
disconnect the negative (black) cable first. When reinstalling the battery,  
always connect the negative (black) cable last.  
1. Disconnect battery hold down straps.  
2. Remove battery vent tube from battery.  
3. Disconnect black (negative) battery cable first.  
4. Disconnect red (positive) battery cable second.  
5. Carefully lift the battery out of the snowmobile. Do not tip it side-  
ways or spill electrolyte.  
CAUTION  
If electrolyte spills, immediately wash it off with a solution of one tablespoon  
baking soda and one cup water to prevent damage to the vehicle.  
105  
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MAINTENANCE  
Battery  
Battery Installation  
WARNING  
Batteries contain gases that can explode. If the battery vent tube is pinched  
or kinked, battery gases could accumulate. Whenever removing or installing  
the battery, disconnect the negative (black) cable first and reinstall the nega-  
tive cable last to avoid the possibility of explosion.  
Battery electrolyte contains acid. Avoid skin contact with electrolyte as  
severe burns may result.  
1. Place the battery in its holder. Attach the hold down strap.  
2. Install the battery vent line. It must be free from obstructions and  
securely installed. Route the vent line properly to prevent kinks and  
to allow for proper drainage.  
3. Connect and tighten the red (positive) cable first.  
4. Connect and tighten the black (negative) cable last.  
5. Verify that cables and vent hose are properly routed.  
106  
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MAINTENANCE  
Battery  
Battery Storage  
When your snowmobile is placed in storage for one month or more:  
• Remove the battery.  
• Charge it to the proper level.  
• Store it in a cool dry place.  
• Check and/or charge monthly.  
Before using the battery, take it to your dealer for testing and recharging.  
Batteries may freeze if not fully charged, resulting in cell damage.  
Charge condition  
Will freeze at:  
100%  
75%  
50%  
25%  
0%  
-75_ F(-59_ C)  
-24_ F(-31_ C)  
0_ F(-18_ C)  
+13_ F(-11_ C)  
+18_ F(-8_ C)  
107  
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MAINTENANCE  
n Pre-Ride Suspension Inspection  
Loose nuts and bolts can reduce your snowmobile's reliability and cause  
needless repairs and down time. Before beginning any snowmobile trip,  
a visual inspection will uncover potential problems. Check the follow-  
ing items on a weekly basis or before any long trip:  
n Check suspension mounting bolts for tightness.  
n Check rear idler wheel bolts for tightness. See page 99.  
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 98.  
n Lubricate all rear suspension components. See page 76.  
n Check ski runner/skag condition. See page 103.  
n Check ski spindle bolts for tightness.  
n Check tie rod end nuts for tightness.  
108  
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MAINTENANCE  
Extended Storage  
Off-season or extended storage of your snowmobile requires preventive  
measures to aid against deterioration and to prolong the useful life of  
many components. See page 113 for the part numbers of Polaris prod-  
ucts.  
Cleaning and Preservation  
Proper storage starts with cleaning, washing, and waxing the hood,  
chassis, and plastic parts. Wipe down remaining surfaces with a damp  
cloth. Clean and touch up with paint any rusted or previously painted  
surfaces. Be sure that corrosive salt and acids are removed from surfaces  
before beginning preservation with waxes and rust inhibitors (grease, oil  
or paint).  
The machine should be stored in a dry garage or shed, out of direct sun-  
light, and covered with a fabric snowmobile cover. Plastic tarp may  
cause condensation to form and damage snowmobile components.  
Controls and Linkage  
Lubricate bushings, spindle shafts, tie rod ends and cables as outlined in  
the Periodic Maintenance Table beginning on page 73.  
109  
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MAINTENANCE  
Extended Storage  
Bearings  
Grease the drive shaft clutch side bearing 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. To prevent oxida-  
tion on the clutch sheaves, lubricate the sheave faces of the drive and  
driven clutches with a light coat of oil or Polaris Cable Lubricant.  
NOTE: After storage, always use acetone or alcohol to remove the oil  
before reinstalling the drive belt.  
Do not lubricate other 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.  
If stabilizer is not used, drain the carburetors by removing the water trap  
drain plugs. See page 84.  
NOTE: Jet restriction caused by improper storage can cause lean con-  
ditions and very poor slow speed driving quality.  
110  
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MAINTENANCE  
Extended Storage  
Engine and Carburetor Protection  
Using a fuel stabilizer and topping off the fuel tank eliminates the need  
to drain the fuel system. If you prefer to drain the fuel tank, use the fol-  
lowing procedure  
1. Transfer unused fuel from the fuel tank to an approved fuel con-  
tainer using a siphon pump. Do not re-use fuel after storage.  
2. Securely support the front of the snowmobile with a jack stand so  
the machine is elevated and the engine is tilted rearward.  
3. Remove the spark plug(s).  
4. Rotate the engine slowly, watching the piston until it's at bottom  
dead center (BDC), the lowest position in the cylinder. On twin cyl-  
inder models, the opposite piston will be up.  
5. Pour approximately two ounces of Polaris injector oil into the spark  
plug hole.  
6. Wait one to two minutes and perform steps 3-5 on remaining cylin-  
ders.  
7. Replace the spark plugs and lower the machine to the floor.  
111  
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MAINTENANCE  
Extended Storage  
Electrical Connections  
Separate electrical connector blocks and clean corrosive build-up from  
connectors. Lubricate or pack connector blocks with dielectric grease  
and re-connect.  
Replace worn or frayed electrical wire and connectors. Be sure wiring  
harness is properly secured away from sharp edges, steering linkage,  
moving parts, and hot exhaust parts.  
Battery  
Always prepare and maintain the battery as outlined on page 107.  
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 57.  
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.  
112  
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POLARIS PRODUCTS  
Part No.  
Description  
Engine Lubricants  
2870791  
Fogging Oil (12 oz. Aerosol)  
2871098  
2871097  
2871240  
2871721  
2871722  
2872347  
2874438  
2874439  
2874443  
Premium 2-Cycle Engine Oil (qt.)  
Premium 2-Cycle Engine Oil (gal.)  
Premium 2-Cycle Engine Oil (2.5 gal.)  
Premium Gold Synthetic 2-Cycle Engine Oil (qt.)  
Premium Gold Synthetic 2-Cycle Engine Oil (gal.)  
Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)  
VES II Synthetic 2-Cycle Engine Oil (qt.)  
VES II Synthetic 2-Cycle Engine Oil (gal.)  
VES II Synthetic 2-Cycle Engine Oil (2.5 gal.)  
Chaincase Lubricants  
2873105  
2872951  
Synthetic Chaincase Lubricant (qt.)  
Synthetic Chaincase Lubricant (12 oz.)  
Grease/Specialized Lubricants  
Grease Gun Kit, Premium All Season (3 oz.)  
Premium All Season Grease (3 oz. cartridge)  
Premium All Season Grease (14 oz. cartridge)  
Dielectric Grease (Nyogelt)  
2871312  
2871322  
2871423  
2871329  
Additives/Miscellaneous  
2871326  
2870652  
2872189  
2872893  
2870505  
2872889  
2872890  
Carbon Clean Plus (12 oz.)  
Fuel Stabilizer (16 oz.)  
DOT 4 Brake Fluid (12 oz.)  
Engine Degreaser (12 oz.)  
Isopropyl  
Brake and Clutch Cleaner  
Carb and Throttle Body Cleaner  
113  
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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  
ating RPM during  
Disassemble drive clutch to inspect  
shift weights for wear and free  
operation. SEE YOUR DEALER.  
Clean and polish stationary shaft  
hub.  
acceleration or load  
variations  
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.  
SEE YOUR DEALER.  
Replace the drive belt.  
Excessive belt/  
sheave clearance  
Drive belt turns over Wrong belt for appli-  
cation  
Clutch alignment out  
of spec  
Adjust alignment offset. SEE  
YOUR DEALER.  
Engine mount bro-  
ken or loose  
Inspect and adjust or replace. SEE  
YOUR DEALER.  
Machine fails to  
move  
Clutch jammed  
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.  
114  
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TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause Solution  
Noise in drive sys-  
tem  
Broken drive clutch  
components  
SEE YOUR DEALER.  
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 crank-  
case while the vehicle was standing  
or being transported. SEE YOUR  
DEALER to correct the cause.  
Drain plug(s) are located on the  
lower crankcase for emergency  
draining.  
Engine doesn't start  
(electric start mod-  
els)  
Wire connections  
Poor fuel  
SEE YOUR DEALER.  
Engine requires  
more than normal  
pulls to start  
Replace with fresh winter fuel.  
SEE YOUR DEALER.  
Not enough fuel get-  
ting to engine  
115  
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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. See page 52.  
Make sure fuel tank contains fuel.  
Ice may be in fuel line, filter or  
pump. Add isopropyl alcohol to  
fuel system. On the standard  
Polaris carburetor, the choke will  
not function with the throttle  
depressed. See second item under  
Probable Cause" of Engine Contin-  
ually Backfires".  
Flooded engine (too  
much choke used)  
Hold throttle open, crank engine  
several times (may be necessary to  
change plug(s).  
Poor engine com-  
pression  
Mixture is too lean. A main jet that  
is too small will cause seizure  
resulting in loss of power. This  
indicates a major engine problem  
that must be repaired before operat-  
ing. SEE YOUR DEALER.  
Engine lacks power  
Fouled or defective  
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 sys-  
tem (add deicer to non-ethanol fuel  
at all times to prevent icing).  
Incorrect throttle  
freeplay or faulty  
switch  
SEE YOUR DEALER.  
116  
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TROUBLESHOOTING  
EDGE 136 Suspension  
Problem  
Solution  
Rear suspension bottoms  
too easily  
Increase torsion spring preload  
Increase rear shock compression damping by turning  
screw clockwise  
Increase torsion spring wire diameter (see your dealer)  
Rotate RRSS to a higher position. See page 39.  
Rides too stiff in rear  
Check for binding suspension shafts and grease all  
pivot points  
Decrease torsion spring preload adjustments  
Decrease rear shock compression valving by turning  
screw counterclockwise)  
Check for proper track tension  
Rotate RRSS to a lower position. See page 39.  
Machine darts from side  
to side  
Make sure skis are aligned properly  
Make sure spindles and all steering components are  
free turning  
Make sure skags are straight on skis  
Check rail slide and replace if worn  
Reduce ski pressure:  
A) Increase front track spring preload  
B) Reduce IFS spring preload  
C) Reduce rear torsion spring preload  
Front end pushes  
Steering is heavy  
Check for worn skags  
Check for binding suspension shafts and grease all  
pivot points  
Increase IFS spring preload by adjusting cam or  
threaded adjuster  
Adjust RRSS to a higher position  
Check ski alignment  
Check skags and skis for damage  
Reduce ski pressure:  
A) Increase front track spring preload  
B) Reduce IFS spring preload by adjusting cam  
C) Reduce rear torsion spring preload  
Make sure spindles and all steering components are  
free turning (elevate machine to check)  
Too much weight transfer  
under acceleration  
Rotate RRSS to a higher position. See page 39.  
Not enough weight trans-  
fer under acceleration  
Move RRSS to the rearward upper hole on high posi-  
tion. See page 39.  
117  
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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  
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.  
between track and tunnel  
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.  
Use fast, aggressive throttle to engage clutch.  
Slow, easy clutch engage-  
ment  
118  
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WARRANTY  
Service and Warranty Information  
Obtaining Service and Warranty Assistance  
Read and understand the service data and the Polaris warranty information con-  
tained in this manual. Contact your Polaris dealer for replacement parts, service  
or warranty. Your dealer receives frequent updates on changes, modifications  
and tips on snowmobile maintenance, which may supersede information con-  
tained in this manual. Your dealer is also familiar with Polaris policies and pro-  
cedures and will be happy to assist you.  
When contacting us about parts, service, or warranty, always provide the fol-  
lowing information:  
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: 1-763-417-8650  
Canada: 1-204-925-7100  
119  
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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.  
120  
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WARRANTY  
Limited Warranty  
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-  
ITED WARRANTY on all components of the Polaris snowmobile against defects in  
material or workmanship. This warranty covers the parts and labor charges for repair or  
replacement of defective parts that are covered by this warranty. The warranty begins on  
the date of purchase. This warranty is transferable to another consumer, during the war-  
ranty period, through a Polaris dealer.  
Registration  
At the time of sale, the Warranty Registration Form must be completed by your dealer  
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will  
record the registration for warranty. No verification of registration will be sent to the  
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-  
ment. If you have not signed the original registration and received the customer copy,  
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE  
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.  
Initial dealer preparation and setup of your snowmobile is very important in ensuring  
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer  
setup will void your warranty coverage.  
Warranty Coverage and Exclusions  
Limitations of warranties and remedies  
This warranty excludes any failures not caused by a defect in material or workmanship.  
The warranty does not cover accidental damage, normal wear and tear, abuse or  
improper handling. The warranty also does not cover any snowmobile that has been  
structurally altered, neglected, improperly maintained, used for racing or used for pur-  
poses other than for which it was manufactured. The warranty does not cover any dam-  
ages that occur during trailer transit or as a result of unauthorized service or parts. In  
addition, this warranty does not cover physical damage to paint or finish, stress cracks,  
tearing or puncturing of upholstery material, corrosion or defects in parts, components  
or the snowmobile due to fire, explosions or any other cause beyond Polaris' control.  
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that  
are not compatible with the snowmobile.  
The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option,  
repair or replacement of any defective materials, or components or products. THE REM-  
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-  
ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL  
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL  
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF  
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-  
GENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-  
sion or limitation of incidental or consequential damages or implied warranties, so the  
above limitations or exclusions may not apply to you if inconsistent with controlling  
state law.  
121  
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WARRANTY  
Limitations of warranties and remedies  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE  
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-  
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR  
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-  
RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations  
on how long an implied warranty lasts, so the above limitation may not apply to you if  
inconsistent with controlling state law.  
How to Obtain Warranty Service  
If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-  
rized to repair Polaris snowmobiles. When requesting warranty service you must present  
your copy of the Warranty Registration form to the dealer. (The cost of transportation to  
and from the dealer is YOUR responsibility). Polaris recommends that you use your  
original selling dealer; however, you may use any Polaris Servicing Dealer to perform  
warranty service.  
Please work with your dealer to resolve any warranty issues. Your dealer will contact the  
appropriate personnel at Polaris if additional assistance is needed.  
This warranty gives you specific legal rights, and you may also have other rights which  
vary from state to state.  
If any of the above terms are void because of state or federal law, all other warranty  
terms will remain in effect.  
Engine Oil  
1. Mixing 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.  
122  
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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.  
123  
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WARRANTY  
Polaris Second Year Engine Service Contract  
Second Year Engine Service Contract is standard on all eligible new and unused snow-  
mobiles that were Snow Checked through an authorized Polaris dealer during the  
March/April Snow Check promotion. The free Second Year Engine Service Contract is  
honored by all authorized Polaris snowmobile dealers in North America and is transfer-  
able 120 days after the original purchase date, free of charge, through any Polaris snow-  
mobile dealer. Coverage on Snow Check units is automatic. Although you do not  
receive a warranty card, your dealership should have printed a copy of the warranty reg-  
istration form. This form is your proof of warranty.  
Consumer Exclusions  
Each repair visit after the first twelve months of standard warranty coverage is sub-  
ject to a $50 deductible.  
The free Second Year Engine Service Contract applies to the first 5,000 miles or two  
(2) calendar years from date of purchase, whichever comes first. Tampering with the  
odometer shall void all warranties/service contracts. No extensions to coverage under  
this engine service contract can be given. Used snowmobiles are not eligible under  
this program.  
Snowmobiles used for commercial purposes or for racing are excluded from cover-  
age.  
124  
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WARRANTY  
Polaris Second Year Engine Service Contract  
Coverage  
Coverage for second year engine failures due to defects in materials and workmanship  
will be determined by Polaris in its sole discretion. Coverage is automatic with no addi-  
tional paperwork required. The free Second Year Engine Service Contract is subject to a  
$50 deductible per visit. Regular, documented service maintenance visits are required to  
validate this warranty.  
A partial list of items excluded from coverage includes:  
Damage due to accident, fire, explosion, theft, or other causes beyond Polaris' con-  
trol.  
Damage caused by the failure of other components of the snowmobile.  
Failures caused by improper fuel or oil.  
Piston seizures, unless caused by a defective engine component.  
Failures caused due to improper adjustments.  
Failure due to unauthorized service.  
Failures due to lack of service as required in the owner's manual or Polaris updates.  
This includes off-season storage as listed in the owner's manual.  
Failure due to use of unauthorized parts or modifications.  
Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,  
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and  
exhaust manifolds excluding paint coverage.  
Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring  
and other electrical components are excluded from coverage.  
Cooling system coverage is limited to the water pump assembly and components,  
fan, fan bearings, temperature sensor, gasket and seals.  
Non wear related 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.  
125  
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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.  
126  
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WARRANTY  
Exported Vehicles  
How to Get Service  
In the Country where your vehicle was purchased:  
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you  
move or are traveling within the country where your vehicle was purchased, Warranty or  
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells  
the same line as your vehicle.  
Outside the Country where your vehicle 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 119).  
127  
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WARRANTY  
Snowmobile Engine Emissions Limited Warranty  
This snowmobile engine emissions limited warranty is in addition to the Polaris  
standard limited warranty for snowmobiles.  
Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-  
certified snowmobile engine is designed, built and equipped so it conforms with U.S.  
Environmental Protection Agency regulations applicable to snowmobile emissions.  
Polaris warrants that the engine is free from defects in materials and workmanship that  
would cause it to fail to meet these regulations. The warranty period for this emissions  
certified snowmobile engine starts on the date when the engine is first purchased and  
continues for a period of 200 hours of engine operation, 4000 kilometers (2485 miles) of  
vehicle travel, or 30 calendar months from the date of purchase, whichever comes first.  
This engine emissions limited warranty covers the parts and labor charges for repair or  
replacement of defective parts that are covered by this warranty. This includes all  
components whose failure increases the snowmobile engine's emissions. Replacing or  
repairing other components not covered by this warranty is the responsibility of the  
snowmobile owner.  
The exclusive remedy for breach of this limited warranty shall be, at the exclusive  
option of Polaris, repair or replacement of any defective materials, components or  
products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE  
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS  
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR  
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY  
DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED  
WARRANTY OR ANY OTHER 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 STATE 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 inconsistent  
with the controlling state law.  
128  
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WARRANTY  
Snowmobile Engine Emissions Limited Warranty  
This limited warranty excludes failures not caused by a defect in material or  
workmanship. 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 snowmobile has been used in  
racing competition. This limited warranty also does not cover physical damage,  
corrosion or defects caused by fire, explosions or other similar causes beyond the  
control of Polaris.  
Owners are responsible for performing the scheduled maintenance identified in the  
owner's manual. Polaris can deny an emissions warranty claim if any specified critical  
emissions-related maintenance is not performed. Performance of other scheduled  
maintenance is strongly recommended, but is not necessary to keep the emissions-  
related warranty valid.  
Any qualified repair shop or person may maintain, replace, or repair the emission con-  
trol devices or systems on your snowmobile. Polaris recommends that you contact an  
authorized Polaris dealer to perform any service that may be necessary for your snow-  
mobile. 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.  
129  
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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)  
130  
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MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
131  
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MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
132  
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MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
133  
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INDEX  
A
C
Accessories . . . . . . . . . . . . . . . . . . . 44  
Air Box Warning . . . . . . . . . . . . . . . 22  
Air Pollution . . . . . . . . . . . . . . . . . . . 5  
Altitude Setting, Reverse. . . . . . . . . 67  
Avalanches. . . . . . . . . . . . . . . . . . . . 14  
Coupling, Suspension . . . . . . . . . 37-38  
Customer Service. . . . . . . . . . . . . . . 119  
D
Deicers. . . . . . . . . . . . . . . . . . . . . . . . 58  
Disabled Operators . . . . . . . . . . . . . . 11  
Drive Belt . . . . . . . . . . . . . . . . . . . . . 17  
Drive Belt Adjustment. . . . . . . . . . . . 94  
Drive Belt Condition . . . . . . . . . . . . . 91  
Drive Belt Deflection. . . . . . . . . . . . . 94  
Drive Belt Installation . . . . . . . . . . . . 93  
Drive Belt Removal. . . . . . . . . . . . . . 92  
Drive Chain Tension . . . . . . . . . . . . . 85  
Driver Awareness . . . . . . . . . . . . . . . 13  
Driveshaft Bearing Lubrication. . . . . 77  
Driving Downhill. . . . . . . . . . . . . . . . 16  
Driving in Hilly Terrain. . . . . . . . . . . 17  
Driving on Slippery Surfaces . . . . . . 15  
Driving Responsibly . . . . . . . . . . . . . 20  
B
Backrest . . . . . . . . . . . . . . . . . . . . . . 28  
Battery . . . . . . . . . . . . . . . . . . . 104-107  
Battery Connections. . . . . . . . . . . . 104  
Battery Fluid . . . . . . . . . . . . . . . . . 104  
Battery Installation. . . . . . . . . . . . . 106  
Battery Storage . . . . . . . . . . . 107, 112  
Bearings. . . . . . . . . . . . . . . . . . . . . 110  
Bleeding the Brake System . . . . . . . 88  
Brake Components. . . . . . . . . . . . . . 86  
Brake Fluid . . . . . . . . . . . . . . . . . . . 87  
Brake Inspection . . . . . . . . . . . . . . . 86  
Brake Inspection, Hydraulic . . . . . . 86  
Brake Lever Travel, Hydraulic . . . . 47  
Brake System Bleeding . . . . . . . . . . 88  
Brakelight Replacement. . . . . . . . . . 90  
Brakes . . . . . . . . . . . . . . . . . . 47, 86-88  
E
Electrical Connections. . . . . . . . . . . 112  
Emission Control Information. . . 70-71  
Engine Break-In. . . . . . . . . . . . . . 53-54  
Engine Emissions Warranty . . 128-129  
Engine Protection . . . . . . . . . . 110-111  
Engine Safety. . . . . . . . . . . . . . . . . . . . 8  
Engine Stop Switch . . . . . . . . . . . . . . 62  
Environment . . . . . . . . . . . . . . . . . . . . 5  
Exhaust System . . . . . . . . . . . . . . . . . 85  
C
Carbide Skags . . . . . . . . . . . . . . . . . 42  
Carburetion . . . . . . . . . . . . . . . . . 60-61  
Carburetor . . . . . . . . . . . . . . . . . . 83-84  
Carburetor Adjustments. . . . . . . . . . 83  
Carburetor Protection. . . . . . . . 110-111  
Cargo Overload . . . . . . . . . . . . . . . . 11  
Chain Tension . . . . . . . . . . . . . . . . . 96  
Chaincase Oil. . . . . . . . . . . . . . . . . . 78  
Choke. . . . . . . . . . . . . . . . . . . . . . . . 52  
Choke Cable Lubrication. . . . . . . . . 77  
Choke Lubrication . . . . . . . . . . . . . . 77  
Cleaning and Preservation. . . . . . . 109  
Clutch Alignment Offset . . . . . . . . . 91  
Clutch and Drive System. . . . . . . . 110  
Clutch Center Distance . . . . . . . . . . 91  
Clutch Cover Warning. . . . . . . . . . . 22  
Clutch Guard . . . . . . . . . . . . . . . . . . 18  
Clutch Safety . . . . . . . . . . . . . . . . . . 18  
Clutch System . . . . . . . . . . . . . . . 91-95  
Cold Weather Drive-Away . . . . . . . 18  
Controls and Linkage. . . . . . . . . . . 109  
Coupling, Front To Rear . . . . . . . . . 37  
Coupling, Rear To Front . . . . . . . . . 38  
F
Filters, Intake. . . . . . . . . . . . . . . . . . . 81  
FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 37  
Fuel . . . . . . . . . . . . . . . . . . . . . . . 56-58  
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 82  
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 82  
Fuel Recommendations . . . . . . . . . . . 57  
Fuel Reserve . . . . . . . . . . . . . . . . . . . 58  
Fuel System Deicers . . . . . . . . . . . . . 58  
Fuel Valve . . . . . . . . . . . . . . . . . . . . . 57  
H
Handlebar Adjustment. . . . . . . . . . . . 40  
Headlight Adjustment . . . . . . . . . . . . 89  
Headlight Bulb Replacement. . . . . . . 90  
Hood Latches. . . . . . . . . . . . . . . . . . . 50  
134  
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INDEX  
I
P
Ice and Snow Build-up . . . . . . . . . . . 15  
IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
IFS Adjustments . . . . . . . . . . . . . . . . 29  
IFS Components . . . . . . . . . . . . . . . . 29  
Inadequate Snow Conditions . . . . . . 19  
Intake Filters . . . . . . . . . . . . . . . . . . . 81  
Intake Silencer . . . . . . . . . . . . . . . . . 17  
Parking Brake Lever Lock . . . . . . . . 48  
Passenger Warning . . . . . . . . . . . . . . 23  
Polaris Products . . . . . . . . . . . . . . . 113  
Preload, Front Shock Spring. . . . . . . 31  
Pre-Ride Checklist . . . . . . . . . . . . . . 45  
Pre-Ride Suspension Inspection . . . 108  
R
J
Rail Slide Wear. . . . . . . . . . . . . . . . 101  
Recoil Rope . . . . . . . . . . . . . . . . . . . 50  
Registration, Warranty . . . . . . . . . . 121  
Reverse Maintenance . . . . . . . . . . . . 95  
Reverse Operation . . . . . . . . . . . 65-67  
Reverse Warning, Electronic . . . . . . 24  
Reverse, Electronic. . . . . . . . . . . 65-67  
Rider Capacity . . . . . . . . . . . . . . . . . 11  
Riding Apparel . . . . . . . . . . . . . . . . . . 9  
Riding Position . . . . . . . . . . . . . . . . . 10  
RRSS. . . . . . . . . . . . . . . . . . . . . . . . . 38  
Jetting Guidelines . . . . . . . . . . . . . . . 61  
L
Lever  
Brake. . . . . . . . . . . . . . . . . . . . . 26  
Brake, Excessive Travel . . . . . . 86  
Brake, Hydraulic. . . . . . . . . . . . 47  
Brake, Spongy. . . . . . . . . . . . . . 88  
Throttle . . . . . . . . . . . . . . . . 46, 63  
Lever Travel, Brake . . . . . . . . . . . . . 86  
Lights . . . . . . . . . . . . . . . . . . . . . 89-90  
Low Oil Indicator Light . . . . . . . . . . 59  
Lubrication . . . . . . . . . . . . . . . . . 76-78  
S
Safety Decals . . . . . . . . . . . . . . . 22-25  
Safety Symbols . . . . . . . . . . . . . . . . . . 6  
Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 34  
Scissor Stop, Front Rear . . . . . . . . . . 37  
Scissor Stop, Rear Rear . . . . . . . . . . 38  
Shock Components . . . . . . . . . . . . . . 30  
Shock, Rear, Indy Select. . . . . . . . . . 36  
Signal Words . . . . . . . . . . . . . . . . . . . 6  
Ski Alignment. . . . . . . . . . . . . . . . . 102  
Ski Skags . . . . . . . . . . . . . . . . . . . . 103  
Slide Rail and Track Cooling . . . . . . 56  
Snow Conditions. . . . . . . . . . . . . . . . 19  
Spark Plug Condition . . . . . . . . . . . . 79  
Spark Plug Removal . . . . . . . . . . . . . 80  
Spark Plugs . . . . . . . . . . . . . . . . . 79-80  
Speed. . . . . . . . . . . . . . . . . . . . . . . . . 12  
Spring Preload, Front Shock. . . . . . . 31  
Spring Preload, Rear. . . . . . . . . . . . . 34  
Springs, Front . . . . . . . . . . . . . . . . . . 31  
Starting the Engine . . . . . . . . . . . 52-53  
M
Maintenance . . . . . . . . . . . . . . . . . . . 18  
Maintenance Interval Table . . . . 73-75  
Maintenance Log . . . . . . . . . . 130-133  
Maintenance Program. . . . . . . . . . . . 72  
Maneuverability . . . . . . . . . . . . . . . . 18  
N
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
O
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 82  
Oil Injection System . . . . . . . . . . . . . 54  
Oil Level . . . . . . . . . . . . . . . . . . . . . . 59  
Oil Recommendations. . . . . . . . . . . . 54  
Operation Warning . . . . . . . . . . . . . . 25  
Operator Safety. . . . . . . . . . . . . . . 6-21  
135  
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INDEX  
S
T
Steering Inspection/Adjustment. . . 101  
Steering Lubrication . . . . . . . . . . . . 76  
Steering System . . . . . . . . . 49, 101-103  
Stopping, Emergency. . . . . . . . . . . . 64  
Storage, Daily . . . . . . . . . . . . . . . . . 68  
Storage, Extended . . . . . . . . . . 109-112  
Studs . . . . . . . . . . . . . . . . . . . . . . . . 41  
Survival Preparation . . . . . . . . . . . . 10  
Suspension Adjustments  
Torsion Springs . . . . . . . . . . . . . . . . . 37  
Towing. . . . . . . . . . . . . . . . . . . . . . . . 69  
Track  
Alignment . . . . . . . . . . . . . . . . 100  
Care for Storage. . . . . . . . . . . . 112  
Cooling . . . . . . . . . . . . . . . . . . . 56  
Damage . . . . . . . . . . . . . . . . . . . 49  
Inspection. . . . . . . . . . . . . . . . . . 97  
Lubrication. . . . . . . . . . . . . . . . . 97  
Safety. . . . . . . . . . . . . . . . . . . . . . 8  
Tension . . . . . . . . . . . . . . . . 33, 98  
Warm-Up. . . . . . . . . . . . . . . . . . 55  
Warning . . . . . . . . . . . . . . . . . . . 23  
Traction Products. . . . . . . . . . . . . 41-43  
Transporting the Snowmobile . . . . . 112  
Trap, Carburetor . . . . . . . . . . . . . . . . 84  
Troubleshooting  
EDGE 136 . . . . . . . . . . . . . . 34-39  
Front. . . . . . . . . . . . . . . . . . . 29-31  
Rear . . . . . . . . . . . . . . . . . . . 32-33  
Suspension Coupling . . . . . . . . . . 37-38  
Suspension Inspection, Pre-Ride . . 108  
Suspension Lubrication . . . . . . . . 76-77  
Suspension Performance Tips . . . . . 33  
Switches  
Drive Belt . . . . . . . . . . . . . . . . 118  
Engine . . . . . . . . . . . . . . . 114-116  
Suspension, EDGE 136 . . . . . . 117  
Tune-Up. . . . . . . . . . . . . . . . . . . . . . . 96  
Engine Stop . . . . . . . . . 26, 51, 62  
Handwarmer . . . . . . . . . . . . . . 26  
Headlight Dimmer . . . . . . . . . . 26  
Ignition. . . . . . . . . . . . . . . . 26, 51  
Throttle Safety . . . . . . . . . . 46, 62  
Thumbwarmer . . . . . . . . . . . . . 26  
V
Vehicle Identification Numbers. . . . . . 4  
T
W
Taillight/Brakelight Replacement . . 90  
Tension, Rear Spring . . . . . . . . . . . . 35  
Throttle Cable Lubrication . . . . . . . 77  
Throttle Lever . . . . . . . . . . . . . . 46, 63  
Throttle Safety Switch. . . . . . . . 46, 62  
Tool Kit . . . . . . . . . . . . . . . . . . . . . . 96  
Torque Stop . . . . . . . . . . . . . . . . . . . 95  
Warranty, Engine Emissions . . 128-129  
Water Pump Belt . . . . . . . . . . . . . . . . 81  
Water/Sediment Trap Service . . . . . . 84  
Wear Strips . . . . . . . . . . . . . . . . . . . . 43  
Weight Transfer. . . . . . . . . . . . . . . . . 39  
Windchill . . . . . . . . . . . . . . . . . . . . . . 21  
136  
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