Polaris Offroad Vehicle 600 RMK 144 155 User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.

WARNING

Read, understand, and follow all of the instructions and safety precautions in

this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

Download from Www.Somanuals.com. All Manuals Search And Download.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

Download from Www.Somanuals.com. All Manuals Search And Download.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-

wide family of Polaris owners. We proudly produce an exciting line of

utility and recreational 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!

Download from Www.Somanuals.com. All Manuals Search And Download.

POLARIS, THE WAY OUT, PERC, DRAGON, IQ, RMK and ASSAULT are regis-

tered trademarks of Polaris Industries Inc.

based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor discrep-

ancies may result between the actual vehicle and the information presented in this publi-

cation. Depictions and/or procedures in this publication are intended for reference use

only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse

of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

Printed in U.S.A.

2010 Owner’s Manual P/N 9922332

600/800 RMK 144/155, 700 RMK 155,

800 DRAGON RMK 155/163, 800 ASSAULT RMK

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

This section contains helpful information for owners and drivers and

illustrates the location of important identification numbers that should

be recorded in the owner’s manual.

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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 . . . . . . . . . . . . . . . . . . . . . . . . . 39

This section explains how to tailor the suspension and other features for

an optimum riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 49

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

This section explains proper engine break-in, operation of features and

general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

This section defines your role, and your dealer’s role, in your snowmo-

bile’s regular maintenance.

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 110

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 111

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 125

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient ref-

erence. It should remain with the snowmobile when the snowmobile is

sold.

Some of the illustrations and photos used in this manual are general rep-

resentations. Your model may differ.

Follow the maintenance program outlined in this manual. Preventive

maintenance ensures that critical components of the snowmobile are

inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with

your snowmobile and forward it to us. This completed form is necessary

to ensure warranty coverage.

Protect and preserve your right to ride by joining your local trail riding

clubs.

When teaching inexperienced operators to ride, set up a predetermined

course for practice. Make sure they know how to drive and control the

snowmobile before allowing them to make longer trips. Teach them

proper snowmobile courtesy, and enroll them in driver’s training and

safety courses sponsored by local or state organizations.

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education cam-

paign. We encourage state and provincial governments across the snow-

belt to adopt rigorous safety training programs that encourage protection

of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to pro-

tect our environment. Please support their efforts and operate your

snowmobile with consideration for the protection and preservation of

our environment.

Noise Level

One of the most 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile’s identification numbers and key number in

the spaces provided below. The key number is stamped on the spare key.

The number on the rubber-coated key is in the form of raised dots.

Remove the spare key and store it in a safe place. An ignition key can be

duplicated only by ordering a Polaris key blank (using your key num-

ber) and mating it with one of your existing keys. The ignition switch

must be replaced if all keys are lost.

VIN

Vehicle Model Number: ___________________________________________________

Tunnel VIN: _____________________________________________________________

(lower right side of the tunnel)

Engine Serial Number (on valve cover): _______________________________________

Key Number: ___________________________________________________________

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual

and on your vehicle. Your safety is involved when these words and sym-

bols are used. Become familiar with their meanings before reading the

manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in

death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in

minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Follow the recommended maintenance program outlined beginning on

page 71 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 opera-

tion with any modifications, especially those that increase speed or power. DO

NOT MODIFY YOUR MACHINE. The snowmobile may become aerodynami-

cally unstable at speeds higher than those for which it is designed. Loss of con-

trol may occur at higher speeds. Modifications may also create a safety hazard

and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has been

added, or any modifications have been made, to increase the speed or power of

the snowmobile.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially

exposed for proper operation.

WARNING! Serious injuries may result if hands,

feet, or clothing become entangled in the track.

Be alert when riding, and remain properly seated

to stay clear of the track. Never hold the

snowmobile up or stand behind it while warming

up the track. A loose track or flying debris could

cause serious injury or death. We recommend

having your dealer perform all track service and

alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. Turn off the igni-

tion, raise the hood, make the adjustment, secure shields and guards,

secure the hood, and then restart the engine to check its operation.

WARNING! Serious injury can occur if fingers or clothing contact the moving

parts of an engine. Always stop the engine before attempting adjustments.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Riding Position

Operating a snowmobile requires skill and balance for proper control.

Rider positions may vary with experience; but under many conditions,

the proper position is to be seated with both feet on the running boards

and both hands on the handlebar grips for proper throttle, brake and

steering control.

WARNING! Improper riding position may reduce control and could result in

serious injury or death. Always ride in a position that allows for control of your

vehicle.

Survival Preparation

For your safety, always ride in a group of other snowmobilers. Always

tell someone where you’re going and how long you expect to be gone. If

it isn’t possible to ride with others, and you must travel into remote

areas, always carry survival equipment that’s appropriate to the condi-

tions you may encounter. Such equipment may include, but is not lim-

ited to: extra clothing, a sleeping bag, a flashlight, food and water, a

signaling mirror, a means of building a fire, and a two-way radio or cel-

lular telephone.

Always carry the owner’s manual on your snowmobile. For added pro-

tection, purchase and carry the following items on your snowmobile as

well:

• Spare Drive Belt

• Extra Set of Spark Plugs

• Tow Rope

• Winter Survival Kit

• Trail Map

• First Aid Kit

• Tool Kit

• Extra Oil

• Fuel Deicer

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Riding Apparel

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

Polaris vehicle, always wear a helmet that meets or exceeds established

safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

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.

Clothing

Be prepared, be warm and be com-

fortable when riding. Be aware of

the weather forecast, 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. Always wear an

approved helmet and eye protection.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and

physical skills.

WARNING! Operators with cognitive or physical disabilities have an increased

risk of loss of control, which could result in serious injury or death. Do not allow

disabled persons to operate this vehicle.

Rider Capacity

Your Polaris snowmobile is designed for a single rider only. Do not

carry a passenger.

Excessive Speed

WARNING! High speed driving, especially at night, could result in serious injury

or death. Always reduce speed when driving at night or in inclement weather.

Always observe all state and local laws governing snowmobile opera-

tion and speed limits. Always be alert and pay attention to the trail

ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling

about 60 feet (18 m) per second. If you look back for only two seconds,

your snowmobile will travel about 120 feet (36 m). If your speed is 60

MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in

two seconds.

Traveling at night requires extra caution. Check headlight and taillight

to ensure proper operation, and don’t over-drive your headlight beam.

Always be able to bring your snowmobile to a stop in the distance illu-

minated by the headlight.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles,

posts, or other obstacles. Be especially

alert if you’re snowmobiling after dark.

Always be on the alert for wire fences.

Single strands are especially dangerous,

since there may be a great distance

between posts. Guy wires on utility poles

are also difficult to distinguish.

Make sure the way is clear before crossing

railroads and other roads and highways.

The noise of your snowmobile will drown

out the sound of approaching vehicles.

Look ahead, behind, and to both sides

before turning or crossing railroad tracks

or highways. Steep embankments 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Avalanches

Snowmobilers should always be properly

trained and equipped before traveling in

mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped

with a shovel, probe and avalanche

beacon.

You don’t have to be snowmobiling on a slope for an avalanche to occur.

Be aware that all of the snow is connected. You may be riding on a flat

slope or snow covered road, but if the snowpack above is unstable

enough you can trigger an avalanche on a steeper slope above you.

Always be aware of snow conditions above you as you travel in moun-

tainous terrain.

Before riding in mountainous terrain, call or log on to your local ava-

lanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche condi-

tions, contact local law enforcement in your area, or visit the American

and Canadian online avalanche centers at www.avalanche.org.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING! Ice and snow build-up may interfere with the steering of your

snowmobile, resulting in serious injury or death. Keep the underhood area free

of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice

and snow are not interfering with full left and right steering. If difficulty

is encountered, remove ice and snow build-up that may be obstructing

the steering linkage.

Driving Downhill

When riding downhill, shift your weight to the rear of the snowmobile

and reduce your speed to a minimum. Apply just enough throttle to keep

the clutch engaged, allowing the engine’s compression to help slow the

snowmobile and keep it from rolling freely downhill.

WARNING! When driving on long downhill stretches, pump the brakes. Riding

the brakes may cause the brake system to overheat, which may result in brake

failure. Excessive or repetitive use of the brakes for high speed stops will also

cause an overheated brake system. This condition may lead to a sudden loss of

brakes and/or fire and may result in serious injury or death.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Driving on Slippery Surfaces

WARNING! Never attempt an abrupt change of direction when operating on

slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-

packed snow reduces steering and braking control, which may result in loss of

control and serious injury or death. Slow down and use extra caution when

operating on slippery surfaces.

Driving in Hilly Terrain

WARNING! Climbing a hill or crossing the face of a slope may result in loss of

balance and snowmobile rollover, causing serious injury or death. Use caution

and good judgement when driving in hilly terrain.

Use extra caution when operating in hilly terrain. If climbing a hill is

unavoidable, keep your weight low and forward. If you must cross the

face of a slope, keep your weight on the uphill side of the snowmobile to

maintain proper balance and avoid possible rollover.

Slow down when reaching the crest of a hill. Be prepared to react to

obstacles, sharp drops or other people or vehicles that may be on the

other side of the hill.

If you’re unable to continue up a hill, turn the snowmobile downhill

before it loses momentum. If this isn’t possible, spin the track just

enough to dig in to prevent it from rolling back down the hill. Stop the

engine and set the parking brake (if equipped). Keeping away from the

downhill side of the snowmobile, pull the rear of the snowmobile

around and point the front end and skis downhill. Remount the snowmo-

bile, restart the engine, release the parking brake, and descend the hill

carefully.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt must be performed

by your dealer.

NOTICE: Operation of the engine with the belt removed may result in injury or

damage to the engine.

Intake Silencer

Do not operate the engine with the intake silencer or filter removed.

Damage to the engine may occur if the intake silencer or filter are

removed.

Clutches

Do not attempt to service the clutches.

All clutch service must be performed by your dealer. The clutch is a

complex mechanism that rotates at high speeds. Each clutch is dynami-

cally balanced before installation. Any tampering may disrupt this 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 snowmobile into motion, but always operate within

safety limits and, on 2-up machines, with respect for a passenger.

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

snowmobiles designed to carry a load or a passenger.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Inadequate Snow Conditions

Since snow provides the only lubrication for the power slide suspension

and, on liquid cooled models, cooling for the engine, adequate snow

cover is a requirement for operation of your snowmobile.

NOTICE: Driving in too little snow will result in excessive wear and damage to

the slide rail, track and/or engine.

WARNING! Inadequate cooling and lubrication will lead to overheating of the

slide rail and track, causing premature wear, damage and failure, which can

result in serious injury. Reduce speeds and frequently drive into fresh snow to

allow adequate cooling and polishing of the slide rail and track surfaces. Avoid

operating for prolonged periods on ice, hard-packed surfaces or roads.

Operating in Deep Snow

If the snowmobile becomes stuck in snow, clear the running board area

of snow, then step down the snow in front of the snowmobile so that

when the throttle is opened, the snowmobile will be able to climb up and

over the snow.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile condi-

tions may become dangerous if operators drive improperly. If you’re

new to snowmobiling, acquaint yourself with the machine and with

what it will and won’t do under various conditions. Even seasoned driv-

ers should spend some time getting the feel for a machine before

attempting ambitious maneuvers.

• A snowmobile depends on the rider’s body position for proper bal-

ance in executing turns, traversing hills, etc. Always start on a

smooth, level area to begin building your operating experience.

• Before allowing someone else 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Windchill/Temperature Charts

The following information is provided to help you determine when tem-

peratures become dangerous for riding.

WIND CHILL CHART (°F)

Wind

Speed

Actual Thermometer Reading (_F)

-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

40 35 30 25 20 15 10

MPH

Calm 40 35 30 25 20 15 10

36 31 25 19 13

34 27 21 15

32 25 19 13

30 24 17 11

-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

25 18 11

25 17 10

-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.

WIND CHILL CHART (°C)

Wind

Speed

Actual Thermometer Reading (_C)

-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46

Equivalent Temperature (_C)

KPH

Calm

-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

-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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the snowmobile for your protec-

tion. Read and follow the instructions of the decals and other warnings

on the snowmobile carefully. If any of the decals depicted in this manual

differ from the decals on your snowmobile, always read and follow the

instructions of the decals on the snowmobile.

If any decal becomes illegible or comes off, contact your Polaris dealer

to purchase a replacement. Replacement safety decals are provided by

Polaris at no charge. The part number is printed on the decal.

Clutch Cover Warning

The clutch cover warning decal is 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.

Pressure Cap Warning

The pressure cap warning decal is found under the hood on the pressure

cap of applicable liquid cooled models.

WARNING

Do not open hot. Test or replace when changing coolant. Press

down and turn to release cap. 13 PSI

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

“No Passenger” Warning

Snowmobiles designed for only a

single rider have a warning decal

on the console below the steering

post.

WARNING

“No Passenger”

Warning

This vehicle is designed for

operator only.

“NO PASSENGER”

Track Warning

The track warning decal is on the

rear of the tunnel.

Track

Warning

Hot Surface

Warning

WARNING

Stay clear of track. Do not sit on

seat back. Entanglement with the

track or a fall from seat back may

result in severe injury or death.

Hot Surface Warning

The hot surface warning is on the

rear center of the tunnel.

WARNING

Hot Surface

Do Not Touch

Burns may result. Entire top of

tunnel may be hot. Install only

accessories specifically

approved for this model by

Polaris. Do not place clothing,

bags or cargo on tunnel. Do not

cover this label.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Reverse Warning

Polaris snowmobiles equipped with

electric reverse have a reverse warning

decal on the console.

Reverse Warning

WARNING

Reverse operation, even at low

speeds, can cause loss of control

resulting in serious injury or death.

To avoid loss of control, always:

• Look behind before and while

backing up.

• Avoid sharp turns.

• Shift to or from reverse only when

stopped.

• Apply throttle slowly.

Operation Warning

NOTE: For more information, see

Owner's Manual.

If electric reverse:

• Machine stopped and engine at idle, push yellow button on LH con-

trol to reverse. Flashing light on dash indicates reverse operation.

• Push button again to return to forward.

Operation Warning

The operation warning decal is located on the console of all Polaris

snowmobiles.

WARNING

• To avoid serious injury or death, read and understand all warnings

and the Owner’s Manual before operation. If manual is missing, con-

tact 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.

(continued on next page)

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Operation Warning

(continued from previous page)

• 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 the engine, check throttle, brake, and steering for

proper operation. Make sure hood is latched. Be seated and in posi-

tion to control the vehicle.

Oil injection system: Use unmixed fuel only. Check oil level when

refueling.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

1. Front Bumper (do not use for

pulling or dragging the snow-

mobile)

9. Rear Bumper

10. Snow Flap

11. Track

12. Suspension

13. Tunnel

14. Side Panel

15. Ski

16. Nosepan

2. Hood

3. Headlight

4. Windshield

5. Mountain Bar (if equipped)

6. Handlebar

7. Seat

8. Taillights

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

1. Fuel Filler Cap

2. Ignition Switch

3. MFD (Multi-Function Display)

4. Engine Stop Switch

5. Throttle Control

6. Recoil Starter Handle

7. Hood Hold-Down Straps

8. Brake Lever

9. Parking Brake

10. Handlebar Grip Warmer

Switch

11. Thumbwarmer Switch

12. Electronic Reverse Button

13. MFD Control

14. Headlight Dimmer Switch

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Headlight Dimmer Switch

Use the headlight dimmer switch to adjust the headlights between high

beam and low beam. Switch headlights to low beam when meeting

oncoming traffic.

Dimmer Switch

Dimmer Switch (Dragon)

Adjustable Headlights

Move the adjuster to the left to

lower the headlight beam.

Move the adjuster to the right to

raise the headlight beam.

Adjuster

Adjustable Steering

The adjustable steering system allows you to adjust the handlebar posi-

tion to fit your style of riding. See page 47.

Accessory Cargo System

The maximum weight capacity for the rear cargo area is 15 lbs. (7 kg).

Always secure cargo before operating. Do not exceed the cargo weight

limit. Do not allow a passenger to sit on the seat back or the cargo area.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Detonation Elimination Technology (DET)

A detonation sensor monitors the engine and responds to detonation by

automatically reducing the engine timing and adding fuel. This results in

decreased engine RPM and performance.

Effect of DET

The DET system prevents damage to the engine from detonation while

developing the maximum power of the engine safely. If the system

senses detonation beyond a preset limit, it retards ignition timing and

adds fuel to reduce the detonation and prevent engine damage.

When the detonation returns to a permissible level, the system will

return spark and fuel to normal, allowing the engine to run at rated

power levels.

Sensor Fail-Safe

The DET includes a sensor fail-safe system to prevent the engine from

damage if the sensor fails, becomes disconnected or is unable to detect

detonation. The rider will experience a loss in power. The sensor must

be reconnected or repaired to regain full power.

TIP:The check engine light will flash six times if the sensor fails or becomes

disconnected.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

MFD Component Identification

Item

Analog Gauge (if

equipped)

Digital Gauge

Check Engine Indicator

Low Oil Indicator

High Temp Indicator

Brake Indicator

Reverse Indicator

High Beam Indicator

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

Digital Display Identification

Item

RPM or Speed

Altitude (if equipped)

Service Interval

Electrical System

Voltage Level

MAX -Maximum MPH/

KPH or RPM

MPH -Miles per hour

KPH - Kilometers per hour

RPM -Engine crankshaft

revolutions per

minute

Air Temp (if equipped)

Engine Temp

Degrees Celsius

Degrees Fahrenheit

Miles

Kilometers

Hours

Trip 1/Trip 2/Trip F

Service Label

Altitude Label

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

MFD Settings

The MFD Control Switch allows you to set the MFD display to your

preferences. The rocker switch has a MODE button (top) and a SET but-

ton (bottom). Specific instructions are outlined on the following pages.

MODE

SET

MFD Control Switch (Dragon)

MFD Control Switch

Standard vs. Metric

The MFD will display either standard or metric units of measurement.

While viewing a screen that displays measurements (MPH, km/h or

temperatures), press and hold the MODE switch until the unit of mea-

surement changes (about 10 seconds).

Speedometer/Tachometer

To change viewing preferences, press and hold the MODE button for

three seconds. When the button is released, the new setting becomes

active and screen colors change.

Option

Digital Display

Screen Backlight

RPM

Blue

Red

Speed

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

MFD Digital Display Programs

Press and release the MODE button to cycle through the three MFD pro-

grams: Performance, Engine and History. Each program remains active

until you cycle to the next program. While any program is active, press

and release the SET button to cycle through the program’s screens.

Performance Program

Press and release the MODE button until the performance program

screen is active. The default display for this screen includes electrical

system voltage, fuel level (if equipped) and either speed or tachometer,

whichever is selected (see page 32).

Press and release the SET button to cycle through the following screens:

odometer, trip 1 odometer, trip 2 odometer, fuel trip odometer (if fuel is

low) and clock (if equipped). Use the following procedures to make

changes to these screens.

Odometer Setting

The odometer records the vehicle's total

distance traveled since manufacture. The

odometer cannot be reset.

Trip Settings

Trip 1 and Trip 2 are odometers used to

check fuel mileage or to keep track of

distance traveled. Both odometers can be

reset to zero.

1. Enter the Performance Program.

2. Press and release the SET button

until the desired trip screen is active.

3. Press and hold the SET button for two seconds to reset the trip

odometer to zero.

4. Press and release the SET button to view another trip screen if

desired.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Trip Settings

Trip F automatically displays when the

fuel level is low if the snowmobile is

equipped with an electronic fuel gauge.

The fuel symbol and the last fuel bar on

the MFD gauge (if equipped) will blink

when the fuel level reaches 1/8 of a tank.

The Trip F odometer records distance

traveled, and the fuel symbol continues

to blink, until enough fuel is added to

raise the level above 1/4 of a tank. The

Trip F odometer will automatically reset

to zero after refueling.

Engine Program

Press and release the MODE button until the engine program screen is

active. The default display for this screen includes engine hours, electri-

cal system voltage level, fuel level (if equipped) and either engine cool-

ant temperature, air temperature (accessory) or altimeter (accessory).

Press and release the SET button to cycle through the following screens:

hour meter, engine temperature, air temperature (available as an acces-

sory) and altimeter (available as an accessory).

Hour Meter

The hour meter records the total hours of

engine operation since manufacture. This

meter cannot be reset.

Engine Temperature

A thermometer measures water temperature,

giving an indication of engine temperature.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

MFD Digital Display Programs

Engine Program

Air Temperature (accessory)

The MFD displays actual air temperature.

Press and hold the MODE switch for ten sec-

onds to switch between standard and metric

units of measurement.

Altimeter (accessory)

The rider can calibrate the altimeter for cur-

rent atmospheric conditions. Altimeter accu-

racy will be +/-300 ft. (91 m) after adjustment.

TIP:When “ALt-FT” displays, the program is in the

standard mode. If only "ALt" displays, the

program is in the metric mode.

1. Enter the Engine Program.

2. Press and release the SET button until the

altimeter screen is active.

3. Press and hold the SET button for five seconds.

4. When the digits begin to flash, release the SET button.

5. Press and release the SET button to advance the reading in 50-foot

(15 m) increments, or press and hold the button to advance quickly.

Adjust the altitude display to within 50 ft. (15 m) of the current

altitude.

TIP:The gauge reads barometric pressure and allows the rider to compensate

for daily fluctuations in air pressure. The gauge can adjust the displayed

altitude to +/- 1300 ft. (396 m) from the preset value. It will adjust up to

+1300 ft. (396 m) above the calibrated altitude. Once the +1300 ft. (396 m)

offset has been reached, the next adjustment is -1300 ft. (396 m) from the

calibrated altitude, and 50 ft. (15 m) will be added to the altitude each time

the SET button is pressed.

6. Press the MODE button to hold the reading at the adjusted value. If

the MODE button is not pressed within five seconds, the gauge will

automatically save the new setting.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Press and release the MODE button until the history program screen is

active. This screen will always display electrical system voltage level

and fuel level (if equipped).

Press and release the SET button to cycle through the following screens:

maximum vehicle speed, maximum engine RPM and service interval

reminder.

Maximum Speed/Maximum RPM

The gauge automatically logs the maximum

speed and engine RPM even if the history

program is not active in the display.

1. Enter the History Program.

2. Press and release the SET button until

one of the two screens is active. The

MPH and RPM values are both reset at

the same time. Reset the values before

each run to obtain accurate readings.

3. Press and hold the SET button for three

seconds to reset the recorded maximum

values for both MPH and RPM.

TIP:Due to electrical noise, the MFD may

occasionally display MAX MPH/RPM values

that are not representative of actual values.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Service Interval Reminder

The gauge logs the number of engine hours

accumulated between service reminders.

When the logged hours reaches the desig-

nated service interval (set by the user), the

gauge provides a reminder that service is

due. "SErVCE" will flash in the odometer

area and "ENG" will flash in the icon area

for five seconds each time the engine is started (until the service

reminder is reset.) Use the following procedures to reset the reminder.

To reset the reminder at the existing interval:

1. Enter the History Program.

2. Press and release the SET button until the service interval screen is

active.

3. Press and hold the SET button for ten seconds, continuing to hold

even after the display begins to flash.

4. When the display stops flashing, release the button. The service

interval has been reset.

To reset the reminder at a new interval:

1. Enter the History Program.

2. Press and release the SET button until the service interval screen is

active.

3. Press and hold the SET button for five seconds, until the hours begin

to flash. Immediately release the button.

4. Press the button again, up to five times, to advance the reminder in

20-hour increments. The maximum interval is 200 hours.

To disable the service interval reminder, press the SET button once after

reaching 200 hours on the display. The gauge will display "OFF".

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES

Instrumentation

Gauge Cleaning

1. Wipe the gauge face as needed using a clean cloth and a mild soap

and water solution. Wipe dry with clean, soft cloth.

2. Clean the back side of the gauge using a clean cloth and a mild soap

and water solution. Do not remove the electrical connectors or

protective rubber boot. Do not spray the back side of the gauge or

the wire harness with a pressure washer or other water source.

NOTICE: To prevent damage to the lens, do not use alcohol for cleaning. Do not

allow chemicals or sprays to contact the lens. Immediately clean off

any gasoline that splashes on the gauge during refueling.

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

IQ Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for approximately 150 miles (240 km) before

making any fine-tuning adjustments.

Settings will vary from rider to rider, depending on rider weight, vehicle

speed, riding style, and trail conditions. We recommend starting with

factory settings and then customizing each adjustment individually to

suit rider preference. The snowmobile should be methodically tested,

one change at a time, under the same conditions (trail and snow condi-

tions, vehicle speed, riding position, etc.) after each adjustment until the

best ride is achieved.

IFS Components

1. Ski

2. Front shock and spring

3. Rod ends

4. Upper control arms

5. Lower control arms

IFS Adjustment Options

• Shock spring preload

• Shock valving

• Optional springs

• Toe (ski alignment) (see

page 104)

• Camber (see your dealer)

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

IQ Front Suspension Adjustments

WARNING! Always verify ski alignment before making adjustments to the IFS.

See page 104 to check alignment. If the skis are misaligned, see your dealer, as

the camber adjustment may also be affected.

Air Shocks

Walker Evans air shocks can be adjusted for preload and valving. Please

see your Polaris dealer for these adjustments.

Standard Shocks

The tension at which the shock coil spring is set is called spring preload.

For the best ride, the suspension should be adjusted to use the full travel

of the shocks with occasional light bottoming.

The front springs can be changed if spring preload alone isn't sufficient

and further adjustment is desired to control suspension stiffness. See

your Polaris dealer for more information.

Shock Absorber Components

1. Retainer

2. Jounce Bumper

3. Shock Rod

4. Body

5. Threaded Spring Preload Adjuster Nut

6. Spring (Standard only)

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

IQ Front Suspension Adjustments

Assault Shocks

The tension at which the shock coil

spring is set is called spring preload.

For the best ride, the suspension should

be adjusted to use the full travel of the

shocks with occasional light bottom-

ing.

Stiffer

Ride

Softer

Ride

After making spring adjustments,

adjust shock clickers to control bot-

toming. Turning a clicker clockwise

increases damping for a stiffer ride and

less bottoming. Turning a clicker

counter-clockwise decreases damping

for a softer ride.

Test ride the snowmobile and continue

making spring and clicker adjustments

until you achieve the perfect ride.

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

Rear Suspension Adjustments

Rider weight, riding style, trail conditions, and vehicle speed all affect

suspension action.

Each rear suspension can be adjusted to suit rider preference and deliver

excellent performance for a given set of conditions. However, all sus-

pension designs and adjustments involve a compromise, or trade-off.

For example, a suspension set up for snow-cross racing would provide a

very stiff ride on the trail. A suspension set up for trail riding would bot-

tom out harshly on a snow-cross course.

Make adjustments to one area at a time so you can evaluate the change.

For further assistance, see your dealer.

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 set-up. 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 a

worn slide. It can also improve top speed.

TIP:Keep the suspension pivot points lubricated. This will reduce moisture and

rust build-up and ensure proper function of the suspension components.

Grease rear suspension pivots before adjusting the rear suspension. Refer

to the suspension lubrication information beginning on page 76.

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the rear suspension torsion

spring preload, measure the distance

between the ground and rear bumper.

This is measurement X.

Take this measurement with no rider

and with the rear suspension at full

extension.

TIP:The rear bumper may need to be

lifted upward slightly to fully extend

the suspension.

Next, have the rider drop down hard

on the seat and bounce up and down

several times, collapsing the rear

suspension. With the rider seated,

measure the distance between the

ground and the rear bumper at the

exact location used for measure-

ment X. This is measurement Y.

To determine sag, commonly

referred to as ride-in, subtract measurement Y from X (Sag=X-Y).

Adjust sag by rotating the torsion spring preload cams located on the

rear torque arm. See illustration. The ideal amount of sag for this rear

suspension is five inches (12.7 cm) (X-Y=5 in./12.7 cm).

If the rear suspension rides in less than four inches or more than six

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 setup, and final spring preload may

vary based on rider preference and riding conditions.

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

Rear Suspension Adjustments

Torsion Spring Preload

To adjust rear torsion spring preload, rotate the three-position cam using

the engine spark plug tool. Different rate torsion springs are available if

a firmer ride is desired. Contact your dealer for more information.

The following information is provided only as a guideline to be used for

initial suspension set-up. Your set-up may vary based on your desired

riding style.

Soft (long end of cam to front)

Medium (short end of cam up)

Firm (long end of cam up)

Soft

Medium

Firm

Limiter Strap Position

The following information is pro-

vided only as a guideline to be used

for initial suspension set-up. Your

set-up may vary based on your

High

Low

desired riding style.

High: Limiter strap in high position

increases ski pressure

Low: Limiter strap in low position

decreases ski pressure

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

Rear Suspension Adjustments

Shock Compression Valving

Standard Rear Track Shock

The standard RMK rear track shock is an

Arvin MPV Select shock that allows for

adjustments to the compression valving.

Adjustments are made by turning the

adjustment screw located near the base of

the shock. In half-turn increments:

• Turn the screw clockwise for a stiffer

ride.

• Turn the screw counterclockwise for a

softer ride.

If bottoming continues after the screw has

been turned fully clockwise, the torsion

spring should be adjusted (see page 44).

Return the screw to its original starting

position after the torsion spring has been

adjusted.

Stiffer

Softer

ASSAULT Rear Track Shock

Turn the adjustment knob on the shock

reservoir to make adjustments to the com-

pression damping. When adjusting, we

recommend that you turn the adjuster

slightly, then test ride.

• Turn the knob clockwise for a stiffer

ride.

• Turn the knob counterclockwise for a

softer ride.

Stiffer

Softer

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

Handlebar Adjustments

WARNING! Some aftermarket accessories (including windshields and cargo

bags) may interfere with the handlebar. Such accessories could limit your ability

to steer the vehicle and/or may contact the brake lever. This could lead to loss of

control resulting in serious injury or death. Always be sure that accessories do

not contact the handlebar or brake lever at any handlebar position.

Handlebar position and handlebar angle can be adjusted to rider prefer-

ence. After making handlebar adjustments, check to make sure wires are

not pinched or kinked. Make sure the handlebars, brake lever and throt-

tle lever operate smoothly and do not hit the gas tank, windshield or any

other part of the vehicle when the handlebars are turned fully to the left

or right.

When adjustments are complete, torque the front adjuster block bolts

first, then torque the rear bolts. Torque the bolts to 11-13 ft. lbs. (15-18

Nm).

Download from Www.Somanuals.com. All Manuals Search And Download.

THE PERFECT FIT

Handlebar Adjustments

Handlebar Position

1. Loosen the four bolts on the

bottom of the adjuster block.

If necessary, pry the blocks

apart with a screwdriver.

Loosen top bolts to adjust

handlebar angle

2. Adjust the handlebar forward

or rearward to the desired

position.

3. Tighten the bolts.

Handlebar Angle

1. Loosen the four bolts on the

top of the adjuster block. If

necessary, pry the blocks

apart with a screwdriver.

2. Adjust the handlebar forward

or rearward to the desired

angle.

Loosen bottom bolts to

adjust handlebar position

3. Tighten the bolts.

Download from Www.Somanuals.com. All Manuals Search And Download.

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. Exhaust systems are critical safety

areas that must use approved Polaris parts. Please see your Polaris

dealer for service.

Tether Switch

The accessory tether switch is available for all models. Order part num-

ber 2870668.

Download from Www.Somanuals.com. All Manuals Search And Download.

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition

before each use of the snowmobile. Procedures are outlined on the 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

Parking Brake Lock/Brake Lever/Brake System

Throttle Lever

51, 52, 89

Throttle Safety Switch

Auxiliary Shut-Off Switch (Engine Stop Switch)

Ignition Switch

55, 65

Taillight/Brakelight/Headlight

Coolant Level

Gearcase Oil Level

N/A

Engine Oil Level

Suspension Mounting Bolts

Skags (Wear Bars)

105

Ski Saddle and Spindle Bolts

Hood Straps/Latches

Seat Latches (if equipped)

Rear Wheel Idler Bolts

Tether Switch/Strap

N/A

54, 101

Track Alignment/Condition

Rail Slide Condition

53, 102

106

Chaincase Oil Level

Oil Level

Download from Www.Somanuals.com. All Manuals Search And Download.

PRE-RIDE INSPECTIONS

Before Starting the Engine

Before starting the engine, always refer to all safety warnings pertaining

to snowmobile operation. Never start the engine without checking all

vehicle components to be sure of proper operation.

WARNING! Operating the vehicle with worn, damaged, or malfunctioning

components could result in serious injury or death. Never start the engine

without checking all vehicle components to be sure of proper operation.

Read and Understand Your Owner's Manual

Read the Owner's Manual 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 snowmobile is operated.

See page 63 for procedure.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

PRE-RIDE INSPECTIONS

Before Starting the Engine

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.

n Brakes

Always check the following items for proper operation before starting

the engine.

Brake Lever Travel

Squeeze the brake lever. It

should move no closer to the

handgrip than 1/2" (1.3 cm).

1/2" (1.3 cm)

A smaller distance indicates

low brake fluid level or air in

the hydraulic system. Refer

to the brake bleeding infor-

mation on page 92.

Brake Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid

level and condition. Add fluid as needed. See page 91.

Check for the presence of air in the fluid system. See page 92 for more

information, or see your dealer for service.

WARNING! Continued use of “spongy” brakes may cause a complete loss of

brakes, which could result in serious injury or death. Always have the brakes

serviced at the first sign of sponginess.

Download from Www.Somanuals.com. All Manuals Search And Download.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

Use the parking brake lever lock

only when you want the snow-

mobile to remain stationary; for

example, when parked on an

incline for a period of five min-

utes or less.

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/

Cover

4. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze the

brake lever tightly and push for-

ward on the lock. Hold the lock

forward while releasing the

brake lever.

NOTICE: If the brake lever is squeezed tightly enough, the lock will move freely

into place. Do not force the lock or it may break.

The parking brake light on the gauge will light up if the parking brake

lever lock is set while the engine is running. It will also be lit when the

service brake is in use. If the parking brake light does not come on when

the parking brake or service brake is in use, have it serviced by your

dealer.

Lock Release

To release the lock, squeeze the brake lever tightly. The lock will return

to the unlocked position.

WARNING! If the parking brake lever lock is partially or entirely engaged while

riding, the brakes may overheat, resulting in brake damage. In extreme cases it

could cause a fire, which could result in serious injury or death. Always ensure

that the lever lock is completely disengaged before operating the snowmobile.

Download from Www.Somanuals.com. All Manuals Search And Download.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

Manually turn the skis completely to the right and to the left. If any dif-

ficulty is encountered, remove any ice and snow build-up that may be

obstructing the steering linkage.

n Track Inspection

WARNING! Operating the snowmobile with a damaged track increases the

possibility of track failure, which could cause loss of control resulting in serious

injury or death. Always inspect the track for damage before using the vehicle.

Use of traction products such as studs increases the possibility of track

damage and/or failure. Driving at high speeds for extended periods of

time in marginal lubrication could severely damage track rods, break

track edges and cause other track damage. Examples of marginal lubri-

cation would include frozen bodies of water without snow cover, icy

trails, and no-snow conditions. Track damage or failure caused by oper-

ation on ice or poor lubrication conditions voids the track warranty.

Deep Lug Tracks (if equipped)

The 2.4" powder track is designed specifically for deep snow applica-

tions. Operation in low snow conditions at high speeds may cause track

lug separation. Track lug separation is not covered under the Polaris

limited warranty policy. Polaris does not recommend operation above

70 mph with this track.

NOTICE: High speed use on hard-packed surfaces is not recommended for

models equipped with a deep lug track. Track lug damage may occur.

Keep high speed use to a minimum, including frequent slow-speed

intervals for track cooling.

Download from Www.Somanuals.com. All Manuals Search And Download.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Suspension Inspection

Loose nuts and bolts can reduce your snowmobile's reliability and cause

needless repairs and down time. Before beginning any snowmobile trip,

a visual inspection will uncover potential problems. Check the follow-

ing items on a weekly basis or before any long trip.

Item

Check

Page

Suspension mounting bolts

Rear idler wheel bolts

Rear idler adjusting bolt locknuts

Torque arm bolts

Tightness

Condition

Tension

101

Carrier and bogie wheel bolts

Front torque arm limiter strap

Rail slide

106

100

Track

All rear suspension components

Ski runner/skag

Lubrication

Condition

Tightness

Ski spindle bolts

Tie rod end nuts

Download from Www.Somanuals.com. All Manuals Search And Download.

PRE-RIDE INSPECTIONS

Start the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining

to snowmobile operation. Never engage the starter when the engine is

running. Never start the engine without checking all vehicle components

to be sure of proper operation. See Before Starting the Engine beginning

on page 50.

n Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the

switch down to stop the engine. Pull it up to allow restarting.

n Ignition Switch

Make sure the engine stops when the ignition switch is turned to OFF.

n Tether Switch

If your machine has a tether switch, remove the tether from the switch to

make sure the engine stops immediately.

n Lighting

Check the headlight (high and low beam), taillight, and brake light.

Replace burned out lamps before operating.

n Mirror Adjustment

If equipped, adjust your mirrors so they can be used to their full advan-

tage.

n Operating Area

Before driving away, check your surroundings. Be aware of obstacles

and make sure bystanders are a safe distance from the snowmobile.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Starting the Engine

NOTICE: Engaging the starter when the engine is running WILL result in serious

engine damage, especially if the transmission is in reverse. Never

engage the starter when the engine is running.

1. Turn the key to the ON position. Pull the engine stop switch up to

the RUN position.

CAUTION! To avoid injury and/or engine damage, do not operate the electric

starter or pull-rope starter while the engine is running.

2. 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.

3. If not equipped with electric start, grasp the starter handle and pull

slowly until the recoil engages; then pull abruptly to crank the

engine.

TIP:Don't pull the starter rope to the fully extended position and don't allow it to

snap back into the housing. Damage may result.

4. Repeat the cranking procedure as needed until the engine starts.

TIP:It may require as many as eight to ten pulls to prime the fuel system and

start the engine if the fuel tank has been completely emptied.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 gasoline with one pint of Polaris injection oil for each five

gallons of fuel. This, in addition to the lubrication supplied by the injec-

tion system, will assure proper engine break-in.

NOTICE: Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts. Do not operate at full throttle or high

speeds for extended periods during the first three hours of use. Vary

the throttle openings and machine speeds to reduce friction on all

close-fitting machined parts, allowing them to break in slowly without

damage.

Use of any lubricants other than those recommended by Polaris may

cause serious engine damage. We recommend the use of Polaris

lubricants for your vehicle.

Drive with extra caution during the break-in period. Perform regular

checks on fluid levels, lines, and all other important areas of the

machine.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Engine Break-In

Oil Injection System

Always fill the oil reservoir when refueling.

NOTICE: Serious engine damage can occur without the proper lubrication.

Check the oil tank level often during the first tank of fuel. If the oil level

doesn't go down, contact your dealer immediately.

Oil Recommendations

This snowmobile is equipped with a variable exhaust system (VES).

Engine lubrication comes from oil added to the fuel and oil injection

systems. Polaris recommends the use of VES Gold Plus Synthetic 2-

cycle oil for this engine. See page 110 for the part numbers of Polaris

products.

Never mix brands of oil. Serious chemical reactions can cause injection

system blockage, resulting in serious engine damage. Oils may also be

incompatible and the result could be sludge formation, filter blockage,

and reduced cold weather flow rates. All Polaris oils are compatible

with each other.

Slide Rail and Track Cooling

NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide

rail and track, resulting in premature wear and failure. Reduce speeds

and frequently drive into fresh snow to allow adequate cooling and

polishing of the slide rail and track surfaces. Avoid operating on ice,

hard-packed surfaces or roads.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Track Warm-Up

WARNING! A loose track or flying debris could cause serious injury or death.

Stand clear of the front of the machine and the moving track. Never hold the

snowmobile up or stand behind it while warming up the track. Do not use

excessive throttle during warm-up or when the track is free-hanging. Be sure the

rear support is stable.

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

approximately 4" (10 cm) off the

ground.

2. Start the engine and allow it to warm up

two to three minutes.

3. Depress the throttle abruptly and allow

the track to rotate several revolutions.

TIP:It will take longer to warm up the track sufficiently during colder outdoor

temperatures.

4. Release the throttle, apply the brakes, shut off the engine and lower

the snowmobile to the ground.

5. Grasp the skis by their front loops and move them from side to side

to loosen snow and ice.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel outdoors or in a well-ventilated area.

• Always turn off the engine before refueling.

• Do not overfill the tank. Do not fill the tank neck.

• Do not smoke or allow open flames or sparks in or near the area where refu-

eling is performed or where gasoline is stored.

• If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes

are poisonous and can cause loss of consciousness or death in a short time.

WARNING

The engine exhaust from this product contains chemicals known to cause can-

cer, birth defects or other reproductive harm. Operate this vehicle only outdoors

or in well-ventilated areas.

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 110 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Fuel

For peak performance, Polaris recommends the use of 91 octane or

higher fuel. Although 87 octane fuel is usable, some engine perfor-

mance will be lost and fuel economy will decrease. Do not use lower

than 87 octane fuel. Do not use fuel containing more than 10% ethanol

(including E85).

NOTICE: Operating with obstructed fuel systems will result in serious engine

damage. Perform maintenance as recommended.

Damage to the fuel pump will occur if the snowmobile is operated with

an empty fuel tank. Do not allow the snowmobile to run out of fuel.

Always refuel when the level is low.

Prolonged exposure to petroleum based products may damage paint.

Always protect painted surfaces when handling fuel.

Fuel Mode Change Wires

This snowmobile is equipped with a feature that allows you to select the

proper calibration map for the fuel available in your region. The fuel

mode change wires are located in the wiring harness secured to the rear

underside of the clutch guard behind the console. The disconnected

mode change wires must be connected when non-ethanol fuel is used.

NOTICE: Engine damage may occur if ethanol fuel is used after setting up the

vehicle for non-ethanol fuel use. Depending on your model, always

disconnect the mode change wires before operating with ethanol fuel.

When in doubt about fuel quality, always unplug the wires.

Ethanol fuel: Leave the wires

UNPLUGGED when using oxygen-

ated fuel containing up to 10% etha-

nol. Never use E85 blended fuel.

Non-ethanol fuel: CONNECT the

Connected for

Non-Ethanol

black/blue wires to the pink wire

when using non-ethanol blended

fuel.

Unplugged

for Ethanol

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Oil

n Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low.

Visually check for oil in the bottle. Add oil before further operation of

the snowmobile. See page 58 for oil recommendations.

NOTICE: Operating the snowmobile without adequate engine lubrication can

result in serious engine damage. Always check the oil level when

refueling. Add oil as needed.

n 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.

Maintain the oil level at the bottom of the filler neck. Always check and

fill the oil tank when refueling. Never operate the engine if oil is not vis-

ible in the tank.

TIP:The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See

your Polaris dealer for recommended replacement parts.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 RUN position

Stop

Switch

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 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. Lock the parking brake.

3. Start the engine and allow it to idle.

4. Hold the throttle lever pin stationary by

exerting pressure on the pivot pin in

the direction shown in the illustration.

5. Apply a slight amount of throttle. A

properly functioning switch must shut

down the engine.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

n 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 throttle body to determine

what caused the safety switch to activate.

3. Test the throttle lever by compressing and releasing it several times.

The lever and 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.

TIP:Excessive freeplay in the throttle cable may cause the safety switch to

activate, preventing the engine from starting. If this occurs, return the

snowmobile 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

snowmobile with the throttle safety switch disconnected. Return the

snowmobile to an authorized Polaris dealer for service as soon as possi-

ble.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

n Emergency Stopping

The following chart lists methods for stopping the snowmobile in the

event of an emergency. See page 63 for more information about the

engine stop switch.

THROTTLE

CONDITION

SYSTEM

Ignition Switch

WHAT IT DOES

Interrupts ignition circuit

Slows jackshaft

All

Brake

All

Engine Stop Switch

Choke (if equipped)

Throttle Safety Switch

Interrupts ignition circuit

Floods engine

All

Half throttle or less

Interrupts ignition circuit

All

Tether Switch (if equipped) Interrupts ignition circuit

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Electronic Reverse (PERC)

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 trans-

mission 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.

Electronic reverse will activate only if the engine RPM is below 4000.

The maximum engine RPM will be 6000 when in reverse.

NOTICE: Engaging the starter when the engine is running WILL result in serious

engine damage, especially if the transmission is in reverse. Never

engage the starter when the engine is running.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Electronic Reverse (PERC)

Engaging Reverse

1. Stop the snowmobile and leave the

engine idling.

2. Make sure the area behind your

snowmobile is clear.

3. Push the reverse button on the left-

hand control for one second, then

release. The engine will automatically

reduce RPM and start a reverse

rotation.

Reverse Button

TIP:A 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.

TIP:If the engine stops running, the

snowmobile will be in forward gear when

it's restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

NOTICE: Engaging the starter when the engine is running WILL result in serious

engine damage, especially if the transmission is in reverse. Never

engage the starter when the engine is running.

2. Push the 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

forward.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Daily Storage

At the end of each ride, park the snowmobile

on a level surface and support it at the rear

with an appropriate track stand. The track

should be suspended approximately 4" (10 cm)

off the ground.

Remove the key and cover the snowmobile.

Towing

Do not use the front bumper to pull or drag the

snowmobile. The front bumper is not designed for this type of use and

may detach from the vehicle if force is applied.

For your safety, do not attempt to use a tow hitch until you've read the

following warnings and understand the proper hitch functions.

WARNING! Objects towed with a rope have no braking power and can easily

collide with the rear of the snowmobile or other objects, resulting in serious

injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle

with a rope. Only a stiff metal pole connecting the towed object and the tow hitch

on the snowmobile should be used. If passengers are to be towed on a

toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to

prevent any possibility of contact between the snowmobile's track and a person

riding in the towed object.

WARNING! Braking distances increase when towing loads. Slow down to

maintain control of the snowmobile.

If the snowmobile becomes inoperable and must be towed, and if it isn't

possible to use a rigid tow bar, attach the tow rope to the ski spindles

(not to the ski loops) to prevent damage to the steering components.

Remove the drive belt before towing, and have someone ride on the

towed snowmobile to operate the brake and steering when necessary.

NOTICE: Towing a disabled snowmobile with the drive belt in place can result in

serious damage to the engine and drive system. Always remove the

drive belt from a disabled snowmobile before towing.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Emission Control Information

Any qualified repair shop or qualified person may maintain, replace, or

repair the emission control devices or systems on your snowmobile.

Emission Control Label

Your snowmobile is equipped at the time of sale with an emission con-

trol information (ECI) label and a factory-installed emissions informa-

tion hangtag. These items are required by U.S. Environmental

Protection Agency regulations. The ECI label is permanently affixed to

either the right side of the tunnel or the engine recoil cover. The ECI

label should not be removed, even after you purchase the snowmobile.

You may remove the factory-installed emissions information hangtag,

which is intended solely for your use in making a purchasing decision.

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum

octane level of 87 (R+M)/2. If your snowmobile is equipped with a

check engine light and it comes on, you must take your snowmobile to a

qualified dealer for diagnostic service. Specifications and adjustments

for engine tune-ups are located in the Service Manual, which is avail-

able to your qualified service technician. Reverse (if equipped) must not

be engaged during engine tune-ups.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow

recommended regular maintenance and perform service checks as out-

lined in this manual. Record maintenance and service in the Mainte-

nance Log beginning on page 125.

The recommended maintenance schedule on your snowmobile calls for

service and maintenance inspections at 150 miles (240 km), 500 miles

(800 km) and 1000 miles (1600 km). These inspections should be per-

formed by a qualified service technician. For continued optimum perfor-

mance and component life, continue maintenance checks at 1000 mile

(1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception

of authorized warranty repairs, become the responsibility of the regis-

tered owner. If, during the course of the warranty period, part failures

occur as a result of owner neglect in performing recommended regular

maintenance, the cost of repairs are the responsibility of the owner.

Personal safety is critical when attempting to service or make adjust-

ments to your snowmobile. If you're not familiar with safe service or

adjustment procedures and the use of tools, or if you don't feel comfort-

able performing these tasks yourself, contact an authorized Polaris

dealer for service.

NOTICE: Hot components can cause damage to plastic. Always make sure the

exhaust system and engine have cooled before tipping the snowmo-

bile on its side for service or inspection.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Interval Table

The following chart is a guide based on average riding conditions. You

may need to increase frequency based on riding conditions. When

inspection reveals the need for replacement parts, always use genuine

Polaris parts, available from your Polaris dealer.

Item

See

Page

Frequency

1000 mi.

150 mi.

500 mi.

2000 mi.

Pre-

Season

(240 km) (800 km) (1600 km) (3200 km)

CLUTCH

Clutch Alignment Offset

(without belt)

Drive Belt Condition

Clutches (disassemble)

Belt Tension

Clutch Sheaves

ENGINE/COOLING

Engine Mounts

Recoil Rope

Engine Torque Stop

Cylinder Head Bolts

Cylinder Base Nuts

Ignition Timing BTDC

VES System

Coolant Level

Coolant Hose

Heat Exchangers

Coolant Circulation

Coolant Leaks

Spark Plug Condition

Exhaust Pipe

Exhaust Retaining

Springs

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)

C - Clean

R - Replace

L - Lubricate

Download from Www.Somanuals.com. All Manuals Search And Download.

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

Brake Pads

Brake Disc

Parking Brake

Brake System

Brake Fluid

51, 89

FUEL MANAGEMENT

Idle RPM

Throttle Lever

50, 64

Oil Pump Lever

(synchronize)

Throttle Cable

Vent Lines

Throttle Position Sensor

Fuel Lines

Fuel Filter

Oil Filter

Oil Lines

Air Box/Plenum

Fuel Injectors

ELECTRICAL

Engine Stop Switch

Throttle Safety Switch

Ignition Switch

Taillight

Brakelight

Headlight

Download from Www.Somanuals.com. All Manuals Search And Download.

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

Suspension Mounting

Bolts

Steering Fasteners

Rear Suspension

Fasteners

Walker Evans Air

Shocks

See your dealer for service

at 1500 mi. (2000 km)

Suspension Shock Oil

Cooling Fins/Shroud

Drive Shaft Bearings

Jackshaft Bearings

Skags (Wear Bars)

108

105

Ski Saddle/Spindle

Bolts

Drive Chain Tension

Hood Latches

Rear Wheel Idler Bolts

Idler Bolt Jam Nut

101

Rear Suspension Pivot

Shafts

Camber Alignment

Handlebar Centering

Tether Switch and Strap

Track Alignment

102

101

Track Tension

Front Limiter Strap

Rail Slide Condition

Chaincase Oil

106

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)

C - Clean

R - Replace

L - Lubricate

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lubrication

Front Suspension

The front suspension does not require lubrication.

Rear Suspension

Lubricate the suspension pivot shafts with Polaris Premium All Season

Grease at the intervals outlined in the Periodic Maintenance Table

beginning on page 72 and before seasonal storage. When operating in

heavy, wet snow conditions, lubricate every 500 miles (800 km).

Lack of lubrication will adversely affect your ride and the life of the sus-

pension. For more information about suspension lubrication and adjust-

ments, see your Polaris dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lubrication

Driveshaft Bearing

Fitting

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lubrication

n Chaincase Oil

Check the chaincase oil level at the

intervals outlined in the maintenance

charts beginning on page 71. The sight

glass is located on the lower rear of the

chaincase. Maintain the oil level at or

slightly below the center of the sight

glass. Change the chaincase oil after the

first 500 miles (800 km), then every

1000 miles (1600 km) or seasonally.

Fill

Plug

Polaris recommends the use of Polaris

Synthetic Chaincase Lube. See page 110

for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level sur-

face.

Sight Glass

2. View the oil level at the sight glass.

3. Remove the fill plug and add the

recommended oil as needed. Do not

overfill.

4. Reinstall the fill plug, making sure it

is seated properly.

Maintain Level Here

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lubrication

Chaincase Oil

Oil Change

1. Position the vehicle on a level surface.

2. Remove the drain plug and drain the

oil into a drain pan. Allow the oil to

drain completely.

3. Clean off all metal shavings from the

plug.

4. Install a new sealing washer on the

drain plug. The sealing surfaces on the

drain plug and the oil tank should be

clean and free of burrs, nicks or scratches.

Drain Plug

5. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).

6. Remove the fill plug. Clean off all metal shavings from the plug.

7. Add 11 oz. (325 ml) of the recommended oil. Do not overfill.

8. Reinstall the fill plug, making sure it is seated properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Spark Plugs

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine has been warmed up

and the vehicle has been driven at higher speeds. Immediately check the

spark plug for correct color.

CAUTION! A hot exhaust system and engine can cause burns. Wear

protective gloves when removing a spark plug for inspection.

Normal Spark Plug

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This indi-

cates the proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating,

caused by use of an improper spark plug or incorrect carburetor/throttle

body adjustments.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

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 carburetor/throttle body adjustments.

Download from Www.Somanuals.com. All Manuals Search And Download.

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. Change the spark plugs

every 2000-2500 miles (3200-4000 km).

NOTICE: Using non-recommended spark plugs can result in serious engine

damage. A spark plug with a heat range too high will always cause

engine damage if the engine is operated in conditions more severe

than intended for that plug. Always use the spark plugs recommended

for your snowmobile. See your Owner’s Manual Supplement.

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).

• Always carry spare spark plugs.

Spark Plug 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 to specification.

5. Reinstall the spark plug cap.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Intake Filters

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

Intake Foam Filters/Pre-filter

accumulation of snow.

NOTICE: Operating the snowmobile

with the intake filters

removed may cause intake

icing. The result will be poor

fuel economy or intake mal-

function. Always reinstall

the intake filters before

operating the snowmobile.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Fuel Injectors

All fuel injector service must be performed by an authorized Polaris

dealer. Do not attempt to clean or service the fuel injectors.

Fuel Pump

All fuel pump service must be performed by an authorized Polaris

dealer. Do not attempt to service the fuel pump.

Fuel Filter

See your Polaris dealer for replacement of the fuel filter at the intervals

outlined in the Periodic Maintenance Table beginning on page 72.

Fuel Lines

Inspect the fuel lines regularly for signs of deterioration or damage.

Always check fuel line condition after periods of storage. Normal dete-

rioration from weather and fuel compounds may occur. Replace worn or

damaged fuel lines promptly.

NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel

lines may cause damage to the lines. If a fuel line has been damaged

or kinked, replace it promptly.

Oil Lines

Inspect oil line condition at the intervals outlined in the Periodic Main-

tenance Table beginning on page 72.

Oil Filter

Have your dealer change the oil filter

and bleed the system at the intervals

outlined in the Periodic Maintenance

Table beginning on page 72.

TIP:The direction of the arrows indicates

the direction of flow through the

filter.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at the intervals outlined in

the Periodic Maintenance Table beginning on page 71.

CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for

the exhaust system to cool. Never perform this procedure with the engine

running.

Always allow the engine and exhaust system to cool completely before

inspecting.

1. Open the hood and inspect the muffler and pipes for cracks or dam-

age.

2. Check for weak or missing retaining springs or damper/support

grommets.

3. Check for loose clamps on the pipe covers.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cooling System

Coolant

The coolant supplied in the system is a 60/40 mixture of ethylene-glycol

and distilled water. This mixture provides protection against freezing.

Contact your dealer if greater protection is required.

Use Premium 60/40 anti-freeze coolant, which is already premixed and

ready to use. Do not dilute with water. Never exceed a 60% antifreeze/

40% water mixture. See page 110 for the part numbers of Polaris prod-

ucts.

TIP:Never add tap water to the cooling system. Minerals cause deposits and

may react adversely with the metals in the engine and cooling system.

n Coolant Level

The engine coolant level is controlled by the recovery system. The

recovery system components are:

• Coolant bottle or overflow tank

• Filler neck

• Pressure cap

• Connecting hoses

Always maintain the coolant level between the minimum and maximum

marks on the coolant bottle (when engine is cold) to prevent overheating

and serious engine damage.

NOTICE: Operating the snowmobile with insufficient coolant will result in over-

heating and serious engine damage. Always maintain the coolant

level as recommended.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cooling System

Coolant High Temperature Indicator Light

The high temperature indicator light will illuminate when engine cool-

ant temperature becomes too hot for safe continued operation of the

engine. If you must drive your snowmobile after the high temperature

indicator light has come on, drive slowly and stop frequently to allow

the engine to cool down. Driving in deep snow will also help cool the

engine. See your dealer for service. Add coolant if the level is low.

TIP:Engine performance will be reduced if you continue operating when the

high temperature light is on.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine,

drain the system completely every two years and add a fresh mixture of

antifreeze and distilled water. This service must be performed when the

engine is cold. Ask your Polaris dealer to check the coolant when he

performs the fall tune-up on your snowmobile.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cooling System

Bleeding the Cooling System

CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed

the cooling system or remove the pressure cap when the engine is warm or hot.

Use of a non-standard pressure cap will not allow the recovery system to

function properly. If the pressure cap needs replacement, contact your

dealer for the correct part.

NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or

engine damage may result. Most cooling systems are equipped with

a filter that should be periodically inspected or replaced.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cooling System

Bleeding the Cooling System

Bleed the cooling system at the intervals outlined in the Periodic Main-

tenance Table beginning on page 72. Perform the bleeding procedure

when the engine is cold.

1. Remove the pressure cap and fill the coolant bottle with properly

mixed coolant to the maximum mark.

2. Elevate the front end of the machine slightly to aid in bleeding of

the heat exchangers.

3. Remove the bleed screw from the water outlet manifold and/or the

thermostat housing. Allow the coolant to bleed through the system

until it runs out the bleed holes. Reinstall the bleed screw into the

manifold.

4. Add coolant to the coolant bottle to the maximum mark.

5. Start the engine and run at a fast idle for two to three minutes.

Loosen the bleed screw occasionally to purge any trapped air.

6. Stop the engine and check the coolant bottle level. Fill as required.

7. Feel the heat exchangers under the running boards. If the system is

bled properly, they'll be warm to the touch. If they're not, repeat step

5. Lift the front of the machine slightly to assist in the bleeding.

8. Replace the pressure cap and carefully lower the front end of the

machine.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Drive Chain Tension

Check drive chain tension weekly

and before each long trip. To

obtain correct chain tension:

1. Rotate the driven clutch

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

2. Loosen the adjuster bolt jam

nut.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Brakes

n Hydraulic Brake Inspection

Inspect the brake lever travel before each use of the snowmobile. See

page 51.

Brake pads must be replaced when the brake pad material becomes thin-

ner than the backing plate, approximately 1/16" (1.5mm). A kit is avail-

able 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 1/16" (1.5mm).

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Brakes

Brake Components

• Brake Disc

Bleed Screw

Brake Disc

• Bleed Screw

Brake Line

• Brake Line

Brake

• Brake Caliper

Caliper

• Brake Pad Material -

Replace when thickness is

less than 1/16" (1.5mm).

Brake Pad

Material

Excessive Lever Travel

Hydraulic brakes are self-

adjusting, but if excessive

brake pad clearance develops

(see page 89) bring the snow-

mobile to an authorized

Polaris dealer for inspection

and adjustment.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Brakes

n Brake Fluid

Replace brake fluid at least every two years with Polaris DOT 4 high

temperature brake fluid. See page 110 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

rapidly absorbs moisture from the air. The moisture causes the boiling

temperature of the brake fluid to drop, which can lead to early brake fade and

the possibility of accident or serious injury.

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.

The brake fluid level can be seen

through a plastic sight glass in the

brake reservoir. If the fluid is suf-

ficient, the sight glass will be

black. If the sight glass is any

color other than black, add brake

fluid.

Sight

Glass

NOTICE: Brake fluid will damage

decals, paint and some

plastics. Always wipe up

spills immediately.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action.

Bleed the system before operating the snowmobile.

WARNING! Operating the vehicle with a spongy brake lever can result in loss of

brakes, which could cause an accident and lead to serious injury or death.

Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as possi-

ble. The reservoir must be in this position to minimize the possibility of

air entering the system through the reservoir vent.

1. Remove brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX

marks or 1/4"-5/16" (.6-.8 cm) below the lip of the reservoir

opening. 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 91.

8. Reinstall the gasket and cover.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lights

Removing Halogen Bulbs

Do not touch a halogen bulb with bare fingers. Oil from skin leaves a

residue, causing a hot spot that will shorten the life of the lamp. If fin-

gers do touch the bulb, clean it with an alcohol-moistened towel.

1. Remove the plenum cov-

ering from the headlight

assembly.

Bulb

Spring

2. Lift the rubber boot to

expose the bulb.

Harness

3. Push down on the spring

to release it from the

housing.

4. With the wire harness

attached to the bulb,

withdraw the bulb from the housing.

5. Grasp the bulb by its metal base and carefully separate the bulb

from the harness.

Installing Halogen Bulbs

1. Hold the bulb by its metal base and install it into the wire harness.

2. Insert the bulb into the housing.

3. Connect the spring to the housing.

4. Carefully flip the spring back into the housing, placing it around the

wire harness.

5. Reinstall the plenum covering on the headlight assembly.

6. Adjust headlight aim. See page 28.

Replacing Taillight Bulbs

1. Remove the screws securing

the taillight lens.

Screws

2. Remove the bulb and install a

new bulb.

3. Reinstall the lens.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To

maintain optimum performance, clean with non-oil based cleaners such

as isopropyl alcohol.

WARNING! If you become aware of higher than normal clutch engagement or

an unusual vibration or shift pattern, see your dealer immediately. Do not

operate the snowmobile until repairs have been made.

All clutch maintenance and repairs must be performed by an authorized

Polaris dealer. Any unauthorized modifications to clutches, such as add-

ing or removing weights, will void the warranty.

NOTICE: The bushings in the weights and rollers of Polaris clutches are made

of a material that may be damaged if lubricated. Do not lubricate

clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor-

mance. Please see your Polaris dealer if you experience a decrease in

performance.

Clutch Center Distance

See your Owner's Manual Supplement for recommended center distance

for your machine. If adjustment is necessary, see your dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Clutch System

n Drive Belt Condition

Belt width and length must match the center distance of the clutches and

sheave width of the drive clutch. For this reason, Polaris recommends

that only O.E.M. belts be used. Other belts may match the dimensions,

but can drastically change the shift pattern, resulting in poor perfor-

mance. See Drive Belt Troubleshooting on page 115.

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.

TIP:A worn belt will continue to function, but will not deliver maximum

performance. Always carry a spare belt in case of an emergency.

For improved drive-away during extremely cold temperatures, remove

the belt and warm it to room temperature. Reinstall it before starting the

snowmobile.

Drive Belt Installation

1. Drop the drive belt over the drive

clutch and pull back the slack.

TIP:To ensure satisfactory belt life, install

belts so they operate in the same

direction of rotation by positioning the

identification numbers so that you

can read them. If required, separate

the sheaves as outlined in the belt

removal procedures.

2. Rotate the L-wrench counter-

clockwise to tighten the sheaves while working the belt to the outer

edge of the sheaves.

3. Remove the wrench and store it in the tool kit.

4. Reinstall the side panel.

5. Close and secure the hood.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Clutch System

Drive Belt Removal

NOTICE: Do not attempt to remove the drive belt after operating in reverse. The

snowmobile must be stopped after forward motion to prevent damage

to components during belt removal.

1. Stop the engine after operating in a forward motion.

TIP:For easier accessibility, make sure the clutch tool access hole is visible

between the 11:00 and 2:00 positions of the clutch sheave.

2. Turn the ignition key off.

Access Hole

Wait for the engine to come

to a complete stop.

3. Lock the parking brake.

4. Open the hood.

11:00

2:00

5. Remove the left side panel.

6. Rotate the driven clutch

counterclockwise 1/4 turn by

hand to ensure forward

engagement before

attempting to remove the

belt.

7. Locate the L-wrench in the tool kit. Install the wrench into the open

threaded access hole in the outer sheave of the clutch.

8. Turn the wrench clockwise until the sheaves open far enough to

remove the belt.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Clutch System

nDrive Belt Deflection

Straight

Edge

Measure

Measure belt deflection with both

clutches at rest and in their full

neutral position.

Place a straight edge on the belt

and apply downward pressure

while measuring at point A. This

measurement should be 1 1/4"

(3.2 cm).

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave

of the clutch (see page 96). Turn the wrench clockwise slightly to

remove pressure from the sheaves.

2. Loosen the 7/16" jam nut.

3. Using a 1/8" Allen wrench, turn the set screw inward (clockwise) to

increase the distance between the sheaves or outward

(counterclockwise) to decrease the distance.

4. Tighten the jam nut. Store the L-wrench in the tool kit.

Torque Stop

.010"-.030"

(.25-.75 mm)

Periodically check torque stop clear-

ance. With clutches in proper align-

ment, measure rear torque stop

clearance from the engine case. Rear

torque stop clearance should be .010"-

.030" (.25-.75mm). Adjust if neces-

sary. Secure the nut.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Track Replacement

When replacing the track, always install a track having the lug size rec-

ommended for your model. See your Polaris dealer.

NOTICE: Installing tracks with larger lugs on machines equipped with coolers

will result in damage to the cooler or tunnel. Always install a track hav-

ing the lug size recommended for your model.

Track Inspection

WARNING! Broken track rods can cause a rotating track to come off the

machine, which could cause serious injury or death. Never operate with a

damaged track. Never rotate a damaged track under power.

1. Using a hoist, safely lift and sup-

port the rear of the snowmobile

off the ground.

2. Rotate the track by hand to check

for damage.

3. Carefully examine the track along

the entire length of each rod.

Bend the track to check for

breakage.

4. Replace the track if any rod

damage is found.

Rods

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Track 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.

WARNING! Operating with insufficient lubrication between the rail slide and

track guide clips can cause track failure, loss of vehicle control and loss of

braking ability, which can result in serious injury or death. Avoid operating for

extended periods on ice and other surfaces that have little or no snow for

lubrication.

Track damage or failure caused by operation on ice or under other poor

lubrication conditions will void the track warranty.

NOTICE: High speed use on hard-packed surfaces is not recommended for

models equipped with a deep lug track. Track lug damage may occur.

Keep high speed use to a minimum, including frequent slow-speed

intervals for track cooling.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Track Tension

WARNING! Moving parts can cut and crush body parts. When performing the

checks and adjustments recommended on the following pages, stay clear of all

moving parts. Never perform track measurement or adjustments with the engine

running.

Track tension is critical for maximum efficiency and performance.

Track tension controls the approach angle of the track to the rail beam in

powder snow conditions. Deep snow performance will be optimized at

the specified tension. Looser tensions will cause the track to “bunch” in

front of the rail tips, causing improper approach angle and poor perfor-

mance. New tracks will need to be retightened and aligned after the first

ride.

TRACK TENSION DATA CHART

Measurement

Location

Slack

Measurement

Suspension

Weight

IQ RMK

10 lbs. (4.54 kg)

16" (40 cm)

ahead of rear

idler shaft

3/8"-1/2"

(1-1.3 cm)

TIP:Tension adjustments should be made only after the track is warmed up and

limber.

1. Turn the engine off.

2. Lift the rear of the snowmobile and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track

at the specified distance (see chart) ahead of the center of the rear

idler wheel. Measure at the point where the weight is placed.

4. Check for specified slack between the wear surface of the track clip

and the plastic rail slide.

100

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Track Tension

Adjusting

Screw

Idler Shaft Bolt

Lock

Nut

10 lbs.

(4.54 kg)

16" (40 cm)

If the track needs adjustment:

5. Loosen the rear idler shaft bolt.

6. Loosen the lock nuts.

7. Tighten or loosen the track adjusting screws as necessary to provide

equal adjustment on both sides of the track.

8. Repeat the measurement on the other side of the track.

TIP:Check more frequently when the snowmobile is new.

9. Start the engine and slowly rotate the track at least five revolutions.

Let the track come to a stop (do not apply brakes).

10. Check track alignment (see page 102) and adjust as necessary.

11. Tighten the lock nuts.

12. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).

101

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

nTrack Alignment

Periodically check that the track is

centered and running evenly on the

slide rails. Misalignment will cause

excessive wear to the track and slide

rail.

1. Safely support the rear of the

snowmobile with the track off the

ground.

2. Start the engine and apply a small

amount of throttle until the track

turns slowly at least five

Window

complete revolutions. Stop the

engine and let the track come to a

stop (do not apply brakes).

Rail

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 left locknut and tighten the left adjusting bolt.

If the track runs to the right, loosen the right locknut and tighten the

right adjusting bolt.

4. After adjustments are complete, 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.

102

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Steering System

Steering Inspection and Adjustment

Check all steering system fasteners weekly and before a long ride.

Tighten any loose fasteners.

103

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Steering System

Ski Alignment

WARNING! Improper ski alignment or adjustment may cause loss of steering

control, resulting in serious injury or death. Do not attempt to change the ski

alignment or camber adjustment. See your Polaris dealer.

With the handlebars in a straight ahead position, and with vehicle

weight compressing the suspension, measure from the straight edge of

the skis at the center of the ski mounting bolt. The measurement

between the skis at point X should be 1/8" to 1/4" (3-6 mm) greater than

the measurement at point Y.

If the skis are misaligned, we recommend that your dealer correct the

alignment, since camber adjustment may also be affected.

10 in.

(25.4 cm)

10 in.

(25.4 cm)

104

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Steering System

nSki 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. Carbide skags must be replaced if any abnormal wear or

chipping is found.

Skag Replacement

Some models are equipped with single skags. Other models are

equipped with dual skags.

1. Raise and support the front of

the snowmobile so the skis

are approximately 6" (15 cm)

from the ground.

2. Remove the attaching nuts

and pry the skag downward.

3. Remove the front end of the

skag.

4. Remove the rear end of the

skag.

5. Reverse the steps to install a

skag.

Skag

105

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Steering System

nRail Slide Wear

For ease of inspection, all

Polaris rail slides have a

wear limit indicator groove

to indicate the minimum

permissible slide thick-

ness. Replace the rail

Minimum

Thickness

slides if they are worn to

the top of the groove at any

point along their length.

Failure to do so may result

in permanent damage to

the track or rails.

Replace when

worn to top of

groove

106

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Matte Clear Coat Cleaning (if equipped)

Matte finish products are prone to trapping dirt, oils and other contami-

nants. Polaris Industries recommends cleaning with warm water and a

mild dish detergent. Use a soft sponge to gently rub the surface and rinse

with clean warm water. For stubborn stains such as grease or oil use a

citrus based cleaner (3M Citrus Base Cleaner recommended). Spray

onto the area to be cleaned and rub with a soft sponge. Allow to sit for a

couple of minutes and wash away with clean warm water. Repeat as

necessary to clean the surface.

NOTICE: Never use a polishing/buffing wax or any sponge that has an abrasive

surface. These products will buff the matte surface of the finish result-

ing in a glossy finish. It is not recommended that you clean matte fin-

ishes with a pressure washer as this will further imbed contaminants

into the clear coat and possibly damage the decals.

Extended Storage

Off-season or extended storage of your snowmobile requires preventive

measures to aid against deterioration and to prolong the useful life of

many components. See page 110 for the part numbers of Polaris prod-

ucts.

Cleaning and Preservation

Proper storage starts with cleaning, washing, and waxing the hood,

chassis, and plastic parts. Wipe down remaining surfaces with a damp

cloth. Clean and touch up with paint any rusted or previously painted

surfaces. Be sure that corrosive salt and acids are removed from surfaces

before beginning preservation with waxes and rust inhibitors (grease, oil

or paint).

The snowmobile should be stored in a dry garage or shed, out of direct

sunlight, and covered with a fabric snowmobile cover. Plastic tarp may

cause condensation to form and damage snowmobile components.

107

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Extended Storage

Controls and Linkage

Lubricate all bushings, spindle shafts, tie rod ends and cables as outlined

in the Periodic Maintenance Table beginning on page 72.

Bearings

Grease the jackshaft and drive shaft clutch side bearings with Polaris

Premium All-Season Grease or a similar high quality grease to prevent

corrosion.

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Do not lubricate

clutch components, except the driven clutch shaft bushing as outlined in

the Master Repair Manual. See your dealer.

Engine 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.

TIP:Do not spray fogging oil into the plenum. Remove the plenum and spray the

fogging oil into the boost box. Continue spraying until the engine stops.

Always add Premium Carbon Clean or a fuel conditioner/stabilizer to

the fuel tank. Follow the instructions on the container, running the

engine for five minutes to get additives through the entire fuel system.

Top off with fresh fuel. Do not allow the snowmobile to run out of fuel.

See page 68.

108

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Extended Storage

Electrical Connections

Replace worn or frayed electrical wire and connectors. Be sure wiring

harness is properly secured away from sharp edges, steering linkage,

moving parts, and hot exhaust parts.

Track and Suspension

Moderate track tension should be maintained during summer storage.

The machine should be supported off the ground to allow the track to

hang freely.

Transporting the Snowmobile

Whenever the snowmobile is transported:

1. Be sure the fuel cap and oil cap are installed correctly.

2. Always tie the snowmobile to the transporting unit securely using

suitable straps.

3. Remove the ignition key to prevent loss.

109

Download from Www.Somanuals.com. All Manuals Search And Download.

POLARIS PRODUCTS

Part No.

Description

Engine Lubricants

Fogging Oil (12 oz. Aerosol)

2870791

2877882

2877953

2877883

2877884

2877887

2877888

VES Gold Plus Synthetic 2-Cycle Engine Oil (qt.)

VES Gold Plus Synthetic 2-Cycle Engine Oil (2 qt.)

VES Gold Plus Synthetic 2-Cycle Engine Oil (gal.)

VES Gold Plus Synthetic 2-Cycle Engine Oil (2.5 gal.)

VES Gold Plus Synthetic 2-Cycle Engine Oil (ltr)

VES Gold Plus Synthetic 2-Cycle Engine Oil (4 ltr)

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

Coolant

2871323

2871534

Anitfreeze, 60/40 Premix (gal.)

Anitfreeze, 60/40 Premix (qt.)

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

110

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Troubleshooting

Unless you have experience and training in two-cycle engine repair,

see your dealer if technical problems arise.

Problem

Probable Cause Solution

Erratic engine oper- Drive clutch binding • SEE YOUR DEALER.

ating RPM during

Driven clutch mal-

function

• SEE YOUR DEALER.

• Replace the drive belt.

• SEE YOUR DEALER.

acceleration or load

variations

Harsh drive clutch

engagement

Drive belt worn or

too narrow

Excessive belt/

sheave clearance

Drive belt turns over Wrong belt for appli- • Replace the drive belt.

cation

Clutch alignment out • SEE YOUR DEALER.

of spec

Engine mount bro-

ken or loose

• Inspect and replace. SEE YOUR

DEALER.

Machine fails to

move

Clutch jammed

• Check for twisted belt or broken

spring. 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.

111

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Noise in drive sys-

tem

Broken drive clutch • SEE YOUR DEALER.

components

Bearing failure/

chaincase, jackshaft,

or front drive shaft

• SEE YOUR DEALER.

Drive belt surface

flat spots

• Inspect and replace as needed.

Drive chain loose

• Inspect and adjust (or replace).

• SEE YOUR DEALER.

Drive chain worn,

sprocket teeth bro-

ken

Poor low RPM per-

formance

Worn drive belt

• Inspect and replace as needed.

• SEE YOUR DEALER.

Excessive belt/

sheave clearance

Loose torque stop

Sticky clutch

• Inspect and adjust.

• SEE YOUR DEALER.

• Use 91 octane fuel (or higher).

Poor fuel quality

Seized engine

Engine doesn't turn

• SEE YOUR DEALER. Seizure is a

result of poor lubrication, inade-

quate fuel supply, broken parts or

improper cooling.

Hydrostatic lock

• Fuel may have entered the crankcase

while the vehicle was standing or

being transported. SEE YOUR

DEALER to correct the cause.

Drain plug(s) are located on the

lower crankcase for emergency

draining.

112

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Engine turns but fails Faulty ignition

to start

• Install new spark plug(s). If engine

still fails to start, check for spark. If

there's no spark, SEE YOUR

DEALER.

No fuel to engine

• Make sure the fuel tank contains

fuel.

• Ice may be in the fuel line, filter or

pump. Add isopropyl alcohol to the

fuel system.

Engine lacks power

Fouled or defective

spark plug(s)

• Replace the plug(s).

Fuel filter (loss of

high RPM power)

• SEE YOUR DEALER.

Incorrect clutching

Faulty plug(s)

Fuel System

• SEE YOUR DEALER.

• Change plug(s).

Engine continually

backfires

• Dirt or ice may be in the fuel system

(deicer should be added to non-etha-

nol fuel at all times for assurance

against fuel line icing).

Incorrect throttle

freeplay or faulty

switch

• SEE YOUR DEALER.

Engine requires

more than normal

pulls to start

Poor fuel

• Replace with fresh winter fuel.

Not enough fuel get- • SEE YOUR DEALER.

ting to engine

Engine backfires but Spark plug wires

• Reinstall spark plug wires to the cor-

responding cylinder.

fails to start

may be on wrong

cylinder

113

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Suspension Troubleshooting

Problem

Solution

Rear suspension bot-

toms too easily

• Set static sag (see page 43). Adjust torsion spring blocks or

install optional torsion springs to achieve correct sag

dimensions.

Rides too stiff in rear • Check for binding suspension components and grease all

pivot points.

• Set static sag (see page 43). Adjust torsion spring blocks or

install optional torsion springs to achieve correct sag

dimensions.

Too much weight

transfer when climb-

ing

• Set static sag (see page 43). Adjust torsion spring blocks or

install optional torsion springs to achieve correct sag.

• Move limiter strap to high position (see page 44).

Too little weight

transfer when climb-

ing

• Set static sag (see page 43). Adjust torsion spring blocks or

install optional torsion springs to achieve correct sag.

• Move limiter strap to low position (see page 44).

Front end pushes

• Check for worn skags.

• Check for binding front suspension shafts/steering compo-

nents, grease all pivot points (elevate front of machine).

• Set static sag (see page 43). Adjust torsion spring blocks or

install optional torsion springs to achieve correct sag.

• Increase IFS preload (if equipped).

• Move limiter strap to high position (see page 44).

Steering is heavy

• Make sure spindles and all steering components turn freely.

• Check ski alignment (see page 104).

• Check skags and skis for damage.

• Set static sag (see page 43).

Machine darts from

side to side

• Check ski alignment (see page 104).

• Check for binding front suspension shafts/steering compo-

nents, grease all pivot points (elevate front of machine).

• Check for excessive play in steering assembly (see dealer).

• Ensure skags are straight on skis.

• Set static sag (see page 43).

• Check rail slide/replace if worn (see page 106).

• Install Accu-Trak dual skags (see your dealer).

114

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Drive Belt Troubleshooting

Belt Wear/Burn Diagnosis

Solutions

Causes

Driving at low RPM

• Drive at higher RPM. Gear the machine down. Check

belt deflection.

Insufficient warm-up

Towing at low RPM

• Warm the engine at least five minutes. Take the drive

belt off the machine in extremely cold weather and

warm it up. Break machine loose from the snow.

• Do not tow in deep snow. Use fast, aggressive throttle

to engage clutch.

Riding with high RPM

and slow speed (8000

RPM/10 MPH)

• Lower the gear ratio. Reduce RPM. Avoid riding in

high ambient temperatures. Check for snow ingestion.

Ice and snow build-up

between track and tunnel

• Warm the engine at least five minutes. Take the drive

belt off the machine in extremely cold weather and

warm it up. Break machine loose from the snow.

Poor engine performance • Check for water, ice or dirt in the fuel tank or fuel line.

Loading machines onto

trailers

• Skis may gouge into trailers and prevent the drivetrain

from spinning properly. Use enough speed to drive the

machine completely onto the trailer. Push and pull it to

finish loading if necessary.

Clutch malfunction

• Inspect clutch components. See your dealer.

Slow, easy clutch engage- • Use fast, aggressive throttle to engage clutch.

ment

115

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Service And Warranty Information

Obtaining Service and Warranty Assistance

Read and understand the service data and the Polaris warranty informa-

tion contained in this manual. Contact your Polaris dealer for replace-

ment parts, service or warranty. Your dealer receives frequent updates

on changes, modifications and tips on snowmobile maintenance, which

may supersede information contained in this manual. Your dealer is also

familiar with Polaris policies and procedures and will be happy to assist

you.

When contacting us about parts, service, or warranty, always provide the

following information:

1. Serial number

2. Model number

3. Dealer name

4. Date of purchase

5. Details of trouble experienced

6. Length of time and conditions of operation

7. Previous correspondence

Use the page provided near the front of your Owner’s Manual to record

the identification numbers of your snowmobile and its engine.

Polaris Customer Service

United States: 1-888-704-5290

Canada: 1-204-925-7100

116

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Service And Warranty Information

Polaris Anti-Theft System

The Polaris anti-theft system (PATS) monitoring program is designed to

aid owners of registered snowmobiles in recovery of stolen machines.

Administration

1. Polaris snowmobile owner reports theft.

A. In addition to notifying the proper law enforcement officials, the

owner must call Polaris Customer Service.

B. Owners must provide their name, address, telephone number and

the model and serial number of stolen machines.

2. Polaris warranty will provide all dealerships with a monthly updated

list of all stolen units to further monitor thefts.

3. Polaris warranty will aid in notifying the proper owner when a unit

is recovered

117

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Limited Warranty

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-

ITED WARRANTY on all components of the Polaris snowmobile against defects in

material or workmanship. This warranty covers the parts and labor charges for repair or

replacement of defective parts that are covered by this warranty. The warranty begins on

the date of purchase. This warranty is transferable to another consumer, during the 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 set-up of your snowmobile is very important in ensuring

trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer

set-up will void your warranty coverage.

Warranty Coverage and Exclusions

Limitations of warranties and remedies

This warranty excludes any failures not caused by a defect in material or workmanship.

The warranty does not cover accidental damage, normal wear and tear, abuse or

improper handling. The warranty also does not cover any snowmobile that has been

structurally altered, neglected, improperly maintained, used for racing or used for pur-

poses other than for which it was manufactured. The warranty does not cover any dam-

ages that occur during trailer transit or as a result of unauthorized service or parts. In

addition, this warranty does not cover physical damage to paint or finish, stress cracks,

tearing or puncturing of upholstery material, corrosion or 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.

118

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Limitations of warranties and remedies

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR

WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-

RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations

on how long an implied warranty lasts, so the above limitation may not apply to you if

inconsistent with controlling state law.

How to Obtain Warranty Service

If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-

rized to repair Polaris snowmobiles. When requesting warranty service you must present

your copy of the Warranty Registration form to the dealer. (The cost of 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.

119

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Conditions and Exclusions

In order to qualify for warranty, the product must have been properly set up and tested

by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle

Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer

sign the PDI form prior to delivery may void the warranty. Failure to provide proof of

required periodic maintenance upon request may result in denial of warranty coverage.

Use of the recommended Polaris products for lubrication and maintenance as directed by

the Owner’s manual is highly recommended. Should a failure occur during the warranty

period resulting from the use of non-recommended products, warranty coverage may be

denied.

Warranty does not apply to parts exposed to friction surfaces, stresses, environmental

conditions and/or contamination. The following items are excluded from warranty con-

sideration if the failure was due to wear or not the direct result of a defect:

Skis

Ski wear rods

Tracks

Slide rails

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Drive belts

Hydraulic components

Circuit breakers/Fuses

Electronic components

Light bulbs/Sealed beam lamps

Idler wheels

Warranty applies to the product only and does not allow for coverage of personal loss.

Some items are considered “consumable,” meaning they are considered part of normal

maintenance or part of completing an effective repair. The following items are excluded

from warranty coverage in the event of a warranty claim:

Spark Plugs

Filters

Fuel

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage/repair

Coolants

Sealants

Hotel fees

Meals

Towing charges

Mileage

Rentals/Loss of product use

Shipping/ handling fees

Product pick-up/delivery

Loss of vacation/personal time

This warranty also excludes failures resulting from improper lubrication; improper

engine timing; improper fuel; surface imperfections caused by external stress, heat, cold

or contamination; operator error or abuse; improper component alignment, tension,

adjustment or altitude compensation; failure due to snow, water, dirt or other foreign

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket components resulting in failure; unauthorized repairs; repairs made after

the warranty period expires or by an unauthorized repair center; use of the product in

competition or for commercial purposes. Warranty will not apply to any product which

has been damaged by abuse, accident, fire or any other casualty not determined a defect

of materials or workmanship.

120

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Polaris Second Year Engine Service Contract

Second Year Engine Service Contract is standard on all eligible new and unused snow-

mobiles that were Snow Checked through an authorized Polaris dealer during the

March/April Snow Check promotion. The free Second Year Engine Service Contract is

honored by all authorized Polaris snowmobile dealers in North America and is transfer-

able 120 days after the original purchase date, free of charge, through any Polaris snow-

mobile dealer. Coverage on Snow Check units is automatic. Although you do not

receive a warranty card, your dealership should have printed a copy of the warranty reg-

istration form. This form is your proof of warranty.

Consumer Exclusions

• Each repair visit after the first twelve months of standard warranty coverage is subject

to a $50 deductible.

• The free Second Year Engine Service Contract applies to the first 5,000 miles or two

(2) calendar years from date of purchase, whichever comes first. Tampering with the

odometer shall void all warranties/service contracts. No extensions to coverage under

this engine service contract can be given. Used snowmobiles are not eligible under this

program.

• Snowmobiles used for commercial purposes or for racing are excluded from coverage.

Coverage

Coverage for second year engine failures due to defects in materials and workmanship

will be determined by Polaris in its sole discretion. Coverage is automatic with no addi-

tional paperwork required. The free Second Year Engine Service Contract is subject to a

$50 deductible per visit. Regular, documented service maintenance visits are required to

validate this warranty.

A partial list of items excluded from coverage includes:

• Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.

• Damage caused by the failure of other components of the snowmobile.

• Failures caused by improper fuel or oil.

• Piston seizures, unless caused by a defective engine component.

• Failures caused due to improper adjustments.

• Failure due to unauthorized service.

• Failures due to lack of service as required in the owner’s manual or Polaris updates.

This includes off-season storage as listed in the owner’s manual.

• Failure due to use of unauthorized parts or modifications.

• Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,

and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and

exhaust manifolds excluding paint coverage.

• Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring

and other electrical components are excluded from coverage.

• Cooling system coverage is limited to the water pump assembly and components, fan,

fan bearings, temperature sensor, gasket and seals.

• Non wear related throttle body parts are covered. The fuel pump is covered.

• Clutches and related clutch parts, including but not limited to, the drive belt, are

excluded from coverage.

• Electrical components are excluded from coverage.

• Gearcases and transmissions are excluded from coverage.

121

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

Polaris Industries. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you

have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you

move or are traveling within the country where your vehicle was purchased, 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 116).

122

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the Polaris standard limited warranty

for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this

emissions-certified vehicle is designed, built and equipped so it conforms with applica-

ble U.S. Environmental Protection Agency emission regulations. Polaris warrants that

the vehicle is free from defects in materials and workmanship that would cause it to fail

to meet these regulations.

The warranty period for this emissions-certified vehicle starts on the date the vehicle is

first purchased and continues for a period of 200 hours of engine operation, 4000 kilo-

meters (2485 miles) of vehicle travel, or 30 calendar months from the date of purchase,

whichever comes first.

This emissions limited warranty covers components whose failure increases the vehi-

cle’s regulated emissions, and it covers components of systems whose only purpose is to

control emissions. Repairing or replacing other components not covered by this war-

ranty is the responsibility of the vehicle owner. This emissions limited warranty does not

cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to

the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emis-

sions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

The following parts are considered emission-related components for evaporative emis-

sions:

•

Fuel Tank

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

•

Vacuum Control Diaphragms*

Control Cables*

Control Linkages*

Purge Valves

Vapor Hoses

Liquid/Vapor Separator

Carbon Canister

Canister Mounting Brackets

Carburetor Purge Port Connector

*As related to the evaporative emission control system.

123

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

U.S.A. EPA Emissions Limited Warranty

The exclusive remedy for breach of this limited warranty shall be, at the exclusive

option of Polaris, repair or replacement of any defective materials, components or prod-

ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on

how long an implied warranty lasts, so the above limitation may not apply if it is incon-

sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship.This limited warranty does not cover damage due to accidents, abuse or improper

handling, maintenance or use. This limited warranty also does not cover any engine that

has been structurally altered, or when the vehicle has been used in racing competition.

This limited warranty also does not cover physical damage, corrosion or defects caused

by fire, explosions or other similar causes beyond the control of Polaris.

Owners are responsible for performing the scheduled maintenance identified in the

owner's manual. Polaris may deny warranty claims for failures that have been caused by

the owner’s or operator’s improper maintenance or use, by accidents for which Polaris

has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission con-

trol devices or systems on your vehicle. Polaris recommends that you contact an autho-

rized Polaris dealer to perform any service that may be necessary for your vehicle.

Polaris also recommends that you use only Pure Polaris parts. It is a potential violation

of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the

effectiveness of the vehicle's emission controls. Tampering with emission controls is

prohibited by federal law.

If you have any questions regarding your warranty rights and responsibilities, please

contact the Polaris Warranty Department at 1-888-704-5290.

124

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE LOG

Present this section of your manual to your dealer each time your snow-

mobile is serviced. This will provide you and future owners with an

accurate log of maintenance and services performed on the snowmobile.

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

125

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

126

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

127

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Accessories . . . . . . . . . . . . . . . . . . . 48

Apparel for Riding. . . . . . . . . . . . . . 12

Avalanches. . . . . . . . . . . . . . . . . . . . 15

Drive Chain Tension . . . . . . . . . . . . . 88

Driver Awareness . . . . . . . . . . . . . . . 14

Driving Downhill. . . . . . . . . . . . . . . . 16

Driving in Hilly Terrain. . . . . . . . . . . 17

Driving on Slippery Surfaces . . . . . . 17

Driving Responsibly . . . . . . . . . . . . . 20

Brake Components. . . . . . . . . . . . . . 90

Brake Fluid . . . . . . . . . . . . . . . . . . . 91

Brake Inspection . . . . . . . . . . . . . . . 89

Brake Lever Feel . . . . . . . . . . . . . . . 51

Brake Lever Travel . . . . . . . . . . 51, 90

Brake System, Bleeding. . . . . . . . . . 92

Brakes . . . . . . . . . . . . . . . . . . 51, 89-92

Break-In, Engine . . . . . . . . . . . . . 57-58

Bulbs, Replacing . . . . . . . . . . . . . . . 93

Electrical Connections. . . . . . . . . . . 109

Emission Control Information. . . 69-70

Emission Control Label. . . . . . . . . . . 69

Emission Control Maintenance . . . . . 69

Engine Break-In. . . . . . . . . . . . . . 57-58

Engine Protection . . . . . . . . . . . . . . 108

Engine Stop Switch . . . . . . . . . . . . . . 63

Engine, Starting . . . . . . . . . . . . . . . . . 56

Environment Preservation . . . . . . . . . . 6

Exhaust System . . . . . . . . . . . . . . . . . 83

Eye Protection . . . . . . . . . . . . . . . . . . 12

Cargo System. . . . . . . . . . . . . . . . . . 28

Chaincase Oil. . . . . . . . . . . . . . . . 77-78

Clutch Alignment Offset . . . . . . . . . 94

Clutch Center Distance . . . . . . . . . . 94

Clutch Cover Warning. . . . . . . . . . . 22

Clutch System . . . . . . . . . . . . . . . 94-97

Clutches . . . . . . . . . . . . . . . . . . . . . . 18

Coolant. . . . . . . . . . . . . . . . . . . . . . . 84

Coolant High Temperature Light. . . 85

Coolant Level. . . . . . . . . . . . . . . . . . 84

Cooling System . . . . . . . . . . . . . . 84-87

Cooling System Bleeding . . . . . . 86-87

Cooling System Flushing. . . . . . . . . 85

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 82

Fuel Injectors. . . . . . . . . . . . . . . . . . . 82

Fuel Lines . . . . . . . . . . . . . . . . . . . . . 82

Fuel Mode Change Wires . . . . . . . . . 61

Fuel Pump . . . . . . . . . . . . . . . . . . . . . 82

Fuel Recommendations . . . . . . . . . . . 61

Fuel Safety. . . . . . . . . . . . . . . . . . . . . 60

Fuel System Deicers . . . . . . . . . . . . . 61

Fuel, Non-Ethanol vs. Ethanol . . . . . 61

DET . . . . . . . . . . . . . . . . . . . . . . . . . 29

Detonation Elimination Technology 29

Digital Display. . . . . . . . . . . . . . . . . 31

Digital Display Programs . . . . . . 33-37

Disabled Operators . . . . . . . . . . . . . 13

Drive Belt. . . . . . . . . . . . . . . . . . . . . 18

Drive Belt Adjustment. . . . . . . . . . . 97

Drive Belt Condition . . . . . . . . . . . . 95

Drive Belt Deflection. . . . . . . . . . . . 97

Drive Belt Installation . . . . . . . . . . . 95

Drive Belt Removal. . . . . . . . . . . . . 96

Drive Belt Troubleshooting. . . . . . 115

Gauge Cleaning . . . . . . . . . . . . . . . . . 38

Handlebar Adjustments . . . . . . . . 46-47

Handlebar Angle . . . . . . . . . . . . . . . . 47

Handlebar Position . . . . . . . . . . . . . . 47

Headlight Adjustments . . . . . . . . . . . 28

Helmet Recommendations. . . . . . . . . 12

Hood Latches. . . . . . . . . . . . . . . . . . . 50

Hot Surface Warning. . . . . . . . . . . . . 23

128

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Ice and Snow Build-up . . . . . . . . . . . 16

IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Instrumentation . . . . . . . . . . . . . . 30-38

Intake Filters . . . . . . . . . . . . . . . . . . . 81

Intake Silencer . . . . . . . . . . . . . . . . . 18

Parking Brake Lever Lock . . . . . . . . 52

Passenger Warning . . . . . . . . . . . . . . 23

Polaris Products . . . . . . . . . . . . . . . 110

Pre-Ride Checklist . . . . . . . . . . . 49-55

Pressure Cap Warning . . . . . . . . . . . 22

Lights . . . . . . . . . . . . . . . . . . . . . . . . 93

Limiter Strap Position. . . . . . . . . . . . 44

Low Oil Indicator Light . . . . . . . . . . 62

Lubrication . . . . . . . . . . . . . . . . 75-78

Chaincase . . . . . . . . . . . . . . .77-78

Driveshaft Bearing . . . . . . . . . . 76

Front Suspension. . . . . . . . . . . . 75

Rear Suspension . . . . . . . . . . . . 75

Throttle Cable . . . . . . . . . . . . . . 76

Rail Slide Wear. . . . . . . . . . . . . . . . 106

Recoil Rope . . . . . . . . . . . . . . . . . . . 51

Reverse Operation . . . . . . . . . . . 66-67

Reverse Warning . . . . . . . . . . . . . . . 24

Rider Capacity . . . . . . . . . . . . . . . . . 13

Safety . . . . . . . . . . . . . . . . . . . . . . 8-21

Safety Decals . . . . . . . . . . . . . . . 22-25

Sag Settings . . . . . . . . . . . . . . . . . . . 43

Shock Components . . . . . . . . . . . . . . 40

Shock Compression Valving . . . . . . 45

Shocks, Air . . . . . . . . . . . . . . . . . . . . 40

Shocks, Assault. . . . . . . . . . . . . . . . . 41

Shocks, Standard. . . . . . . . . . . . . . . . 40

Skags. . . . . . . . . . . . . . . . . . . . . . . . 105

Ski Alignment. . . . . . . . . . . . . . . . . 104

Slide Rail and Track Cooling . . . . . . 58

Snow Build-up . . . . . . . . . . . . . . . . . 16

Snow Conditions. . . . . . . . . . . . . . . . 19

Spark Plugs . . . . . . . . . . . . . . . . . 79-80

Speed. . . . . . . . . . . . . . . . . . . . . . . . . 13

Spring Preload . . . . . . . . . . . . . . . . . 43

Starting the Engine . . . . . . . . . . . . . . 56

Steering Adjustments . . . . . . . . . . . . 28

Steering Inspection . . . . . . . . . . 53, 103

Steering System . . . . . . . . . . . 103-106

Stop Switch. . . . . . . . . . . . . . . . . . . . 63

Stopping . . . . . . . . . . . . . . . . . . . . . . 65

Storage, Daily . . . . . . . . . . . . . . . . . . 68

Storage, Extended. . . . . . . . . . 107-109

Maintenance Interval Table . . . . 72-74

Maintenance Program. . . . . . . . . . . . 71

Maneuverability . . . . . . . . . . . . . . . . 18

MFD Components. . . . . . . . . . . . . . . 30

MFD Digital Display . . . . . . . . . . . . 33

MFD Digital Display Programs . 34-37

MFD Settings . . . . . . . . . . . . . . . . . . 32

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Oil Filter . . . . . . . . . . . . . . . . . . . . . . 82

Oil Injection System . . . . . . . . . . . . . 58

Oil Level . . . . . . . . . . . . . . . . . . . . . . 62

Oil Lines . . . . . . . . . . . . . . . . . . . . . . 82

Oil Recommendations. . . . . . . . . . . . 58

Oil, Chaincase. . . . . . . . . . . . . . . . . . 77

Oil, Engine . . . . . . . . . . . . . . . . . . . . 62

Operating in Deep Snow. . . . . . . . . . 19

Operation Warning . . . . . . . . . . . 24-25

129

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Survival Preparation . . . . . . . . . . . . 11

Suspension Adjustments, Front . . 39-41

Suspension Adjustments, Rear . . 42-45

Suspension Inspection . . . . . . . . . . . 54

Suspension Lubrication, Front. . . . . 75

Suspension Lubrication, Rear . . . . . 75

Suspension Performance Tips . . . . . 42

Suspension, Front . . . . . . . . . . . . . . 39

Switches. . . . . . . . . . . . . . . . . . . . . . 63

Vehicle Identification Numbers. . . . . . 7

Warning Labels/Decals . . . . . . . . 22-25

Warranty, Engine Emissions . . . . . . 123

Windchill/Temperature Charts . . . . . 21

Tether Switch. . . . . . . . . . . . . . . . . . 48

Throttle Lever . . . . . . . . . . . . . . 50, 64

Throttle Safety Switch. . . . . . . . 50, 63

Torque Stop . . . . . . . . . . . . . . . . . . . 97

Torsion Spring Preload . . . . . . . . . . 44

Towing. . . . . . . . . . . . . . . . . . . . . . . 68

Track Alignment . . . . . . . . . . . . . . 102

Track Care for Storage. . . . . . . . . . 109

Track Inspection . . . . . . . . . . . . 53, 98

Track Lubrication . . . . . . . . . . . . . . 99

Track Replacement . . . . . . . . . . . . . 98

Track Tension . . . . . . . . . . . . . 100-101

Track Warm-Up. . . . . . . . . . . . . . . . 59

Track Warning. . . . . . . . . . . . . . . . . 23

Track, Deep Lug . . . . . . . . . . . . . . . 53

Transporting the Snowmobile . . . . 109

Troubleshooting, Drive Belt . . . . . 115

Troubleshooting, Engine . . . . . 111-113

Troubleshooting, Rear Suspension 114

130

Download from Www.Somanuals.com. All Manuals Search And Download.

Philips Air Cleaner AC4083 00 User Manual
Philips Cordless Telephone DECT7272S User Manual
Philips Indoor Furnishings T10VHO User Manual
Philips Portable DVD Player PET712 05 User Manual
Pico Communications Computer Hardware E 15 User Manual
Pioneer CD Player FM AM DEH 1800 User Manual
Plasmon Pet Fence LF 8600 User Manual
Porter Cable Laser Level LR1100 User Manual
ProForm Elliptical Trainer PFEVEL27860 User Manual
Promise Technology Computer Hardware SATA 300 User Manual