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WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product introduc-
tions, upcoming events, career opportunities and more.
Here at Polaris we proudly produce an exciting line of utility and recre-
ational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence have gone into the engineering, design, and development of your
Polaris vehicle, making it the finest machine we've ever produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner's manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the Polaris Service Manual and should be
performed only by a Factory Certified Master Service Dealer (MSD)
Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
1
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2009 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2010 Owner's Manual P/N 9922322
600 IQ Shift/600 IQ ES/600 LX/600 Switchback/600 Dragon Switchback
800 IQ/800 Dragon IQ/800 Switchback/800 Dragon Switchback
2
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
This section identifies the locations of your snowmobile's controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 41
This section explains how to tailor the suspension and other features for
an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 58
This section explains procedures that must be performed before riding.
Operation
65
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
This section defines your role, and your dealer's role, in your snowmo-
bile's regular maintenance.
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 118
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 119
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 133
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3
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4
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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.
5
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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.
Air Pollution
Polaris engineers continuously investigate ways to reduce emission lev-
els of two-stroke engines. We expect our efforts to lead to the reduction
of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.
6
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INTRODUCTION
Vehicle Identification Numbers
Record your snowmobile's identification numbers and key number in
the spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a Polaris key blank with one
of your existing keys, so if both keys are lost, the ignition switch must
be replaced.
+
Vehicle Model Number: ___________________________________________________
Tunnel VIN (+)(right side of tunnel): __________________________________________
Engine Serial Number (on recoil housing): _____________________________________
Key Number: ____________________________________________________________
7
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SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
8
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SAFETY
Operator Safety
Follow the recommended maintenance program beginning on page 79
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.
9
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SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be partially
exposed for proper operation.
WARNING! Serious injuries may result if
hands, feet, or clothing become entangled in
the track. Be alert when riding, and remain
properly seated to stay clear of the track.
Never hold the snowmobile up or stand behind
it while warming up the track. A loose track or
flying debris could cause serious injury or
death. We recommend having your dealer
perform all track service and alignment
procedures.
Stay Clear of Engine
Never attempt adjustments with the engine running. Turn off the igni-
tion, raise the hood, make the adjustment, secure shields and guards,
secure the hood, and then restart the engine to check its operation.
WARNING! Serious injury can occur if fingers or clothing contact the moving
parts of an engine. Always stop the engine before attempting adjustments.
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience and the features available on
some snowmobiles, but under many conditions, the proper position is to
be seated with both feet on the running boards and both hands on the
handlebar grips for proper throttle, brake and steering control.
WARNING! Improper riding position may reduce control and could result in
serious injury or death. Always ride in a position that allows for control of your
vehicle.
10
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SAFETY
Operator Safety
Riding Apparel
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 22.
WARNING! Avoid wearing loose
clothing or long scarves, which can
become entangled in moving parts and
cause serious injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
4
E
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
051039
0006.31
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. When-
ever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
11
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SAFETY
Operator Safety
Disabled Operators
Safe operation of this rider-active vehicle requires good judgement and
physical skills. Operators with cognitive or physical disabilities have an
increased risk of loss of control, which could result in serious injury or
death.
Survival Preparation
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you're going and how long you expect to be gone. If
it isn't possible to ride with others, and you must travel into remote
areas, always carry survival equipment that's appropriate to the condi-
tions you may encounter. Such equipment may include, but is not lim-
ited to: extra clothing, a sleeping bag, a flashlight, food and water, a
signaling mirror, a means of building a fire, and a two-way radio or cel-
lular telephone.
For added protection, carry the following items on your snowmobile at
all times:
• Spare Drive Belt
• Extra Set of Spark Plugs
• Tow Rope
• Winter Survival Kit
• Trail Map
• Owner's Manual
• First Aid Kit
• Tool Kit
• Extra Oil
• Fuel Deicer
12
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SAFETY
Operator Safety
Rider Capacity
Driving 1-Up - Some Polaris snowmobiles are designed for a single
rider only. A decal on the console of these models indicates single rider
operation.
Driving 2-Up - Some Polaris snowmobiles are designed for up to two
riders. A decal on the hood of these models indicates that the vehicle is
designed for one operator and one passenger only.
Machines designed for two riders should never be operated with more
than two people on board. When traveling with a passenger, it's the
driver's responsibility to operate the machine safely.
Slow down! Control becomes more difficult with two people on board.
More space is required to make turns, and longer distances are necessary
for stopping.
Excessive Speed
WARNING! High speed driving, especially at night, could result in serious injury
or death. Always reduce speed when driving at night or in inclement weather.
Always observe all laws governing snowmobile operation and speed
limits. Always be alert and pay attention to the trail ahead. Multiplying
speed (MPH) by 1.5 will equal the approximate number of feet per sec-
ond your machine travels. If your speed is 40 MPH, your machine is
traveling about 60 feet per second. If you look back for only two sec-
onds, your machine will travel about 120 feet. If your speed is 60 MPH,
your machine will travel about 180 feet in two seconds.
Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don't over-drive your headlight beam.
Always be able to bring your machine to a stop in the distance illumi-
nated by the headlight.
13
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SAFETY
Operator Safety
Driver Awareness
Slow down when traveling near poles,
posts, or other obstacles. Be especially
alert if you're snowmobiling after dark.
Always be on the alert for wire fences.
Single strands are especially dangerous,
since there may be a great distance
between posts. Guy wires on utility poles
are also difficult to distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your machine will drown out
the sound of approaching vehicles. Look
ahead, behind, and to both sides before
turning or crossing railroad tracks or high-
ways. Steep embankments may also hide
your view. Always leave yourself a way
out.
R R
Variances in snow depth and/or water currents may result in uneven ice
thickness. You may drown if you break through the ice. Avoid travelling
on frozen bodies of water.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver's training and
safety courses.
14
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SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
• Take an avalanche class
• Travel with experienced people
• Travel on designated trails
• Make sure each person is equipped
with a shovel, probe and avalanche
beacon.
You don't have to be snowmobiling on a slope for an avalanche to occur.
Be aware that all of the snow is connected. You may be riding on a flat
slope or snow covered road, but if the snowpack above is unstable
enough you can trigger an avalanche on a steeper slope above you.
Always be aware of snow conditions above you as you travel in moun-
tainous terrain.
Before riding in mountainous terrain, call or log on to your local ava-
lanche advisory to get current weather and snow stability information.
For more information about avalanche training and avalanche condi-
tions, contact local law enforcement in your area, or visit the American
and Canadian online avalanche centers at www.avalanche.org.
15
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SAFETY
Operator Safety
Ice and Snow Build-up
WARNING! Ice and snow build-up may interfere with the steering of your
machine, resulting in serious injury or death. Keep the underhood area free of
snow and ice.
Before driving, manually turn the skis to the left and right to be sure ice
and snow are not interfering with full left and right steering. If difficulty
is encountered, remove ice and snow build-up that may be obstructing
the steering linkage.
Driving on Slippery Surfaces
WARNING! Never attempt an abrupt change of direction when operating on
slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-
packed snow reduces steering and braking control, which may result in loss of
control and serious injury or death. Slow down and use extra caution when
operating on slippery surfaces.
16
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SAFETY
Operator Safety
Driving Downhill
When riding downhill, shift your weight to the rear of the machine and
reduce your speed to a minimum. Apply just enough throttle to keep the
clutch engaged, allowing the engine's compression to help slow the
machine and keep it from rolling freely downhill.
WARNING! When driving on long downhill stretches, pump the brakes. Riding
the brakes may cause the brake system to overheat, which may result in brake
failure. Excessive or repetitive use of the brakes for high speed stops will also
cause an overheated brake system. This condition may lead to a sudden loss of
brakes and/or fire and may result in serious injury or death.
17
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SAFETY
Operator Safety
Driving in Hilly Terrain
WARNING! Climbing a hill or crossing the face of a slope may result in loss of
balance and machine roll-over, causing serious injury or death. Use caution and
good judgement when driving in hilly terrain.
Use extra caution when operating in hilly terrain. If climbing a hill is
unavoidable, keep your weight low and forward. If you must cross the
face of a slope, keep your weight on the uphill side of the machine to
maintain proper balance and avoid possible roll-over.
Slow down when reaching the crest of a hill. Be prepared to react to
obstacles, sharp drops or other people or vehicles that may be on the
other side of the hill.
If you're unable to continue up a hill, turn the machine downhill before
it loses momentum. If this isn't possible, spin the track just enough to
dig in to prevent it from rolling back down the hill. Stop the engine and
set the parking brake (if equipped). Keeping away from the downhill
side of the machine, pull the rear of the snowmobile around and point
the front end and skis downhill. Remount the machine, restart the
engine, release the parking brake, and descend the hill carefully.
18
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SAFETY
Operator Safety
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may result
in injury or damage to the engine.
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is dynami-
cally balanced before installation. Any tampering may disrupt this preci-
sion balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time, espe-
cially overnight, always make sure the skis and track are loosened from
ice and snow before attempting to drive. Apply the throttle with enough
authority to put the machine into motion, but always operate within
safety limits.
Maneuverability
While much control and maneuverability is achieved through the steer-
ing system and skis, maximum control is achieved by the shifting of
your body weight. Maneuverability will change for lighter operators or
machines designed to carry a load.
19
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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 machine becomes stuck in snow, clear the running board area of
snow, then step down the snow in front of the machine so that when the
throttle is opened, the snowmobile will be able to climb up and over the
snow.
20
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SAFETY
Operator Safety
Driving Responsibly
Every snowmobile handles differently, and even the most docile condi-
tions may become dangerous if operators drive improperly. If you're
new to snowmobiling, acquaint yourself with the machine and with
what it will and won't do under various conditions. Even seasoned driv-
ers should spend some time getting the feel for a machine before
attempting ambitious maneuvers.
• A snowmobile depends on the rider's body position for proper bal-
ance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
• Before allowing someone else to use your snowmobile, know the
extent of their operating skills. Check to see if they've taken a snow-
mobile safety course and have an operator's certificate. For their pro-
tection, as well as yours, make sure they take a snowmobile safety
course. Everyone can benefit from the course.
• Don't "jump" your snowmobile over large drifts or similar terrain.
Jumping may injure your back because of spinal compression that
could occur when the snowmobile impacts the ground. The seat and
suspension of your snowmobile have been designed to provide pro-
tection under normal riding conditions. Your snowmobile is not
intended for this kind of use.
• Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
• When traveling in a group of snowmobiles, don't tailgate (follow too
closely). Leave enough distance between snowmobiles to provide
ample stopping room and to provide protection from flying snow and
debris. Allow even more distance when driving on slippery surfaces
or when driving in darkness or other low visibility conditions. Be
aware of any snowmobile traffic around your vehicle. Drive defen-
sively to avoid accidents.
• Remove the key from the ignition when you leave the snowmobile
unattended.
21
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SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when tem-
peratures become dangerous for riding.
WINDCHILL CHART (_F)
Wind
Speed
in
Actual Thermometer Reading (_F)
40 35 30 25 20 15 10 -5 -10 -15 -20 -25 -30 -35 -40 -45
Equivalent Temperature (_F)
-5 -10 -15 -20 -25 -30 -35 -40 -45
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63
5
0
MPH
Calm 40 35 30 25 20 15 10
5
0
5
36 31 25 19 13
7
3
0
1
10
15
20
25
30
35
40
45
50
55
60
34 27 21 15
32 25 19 13
30 24 17 11
9
6
4
3
1
0
-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77
-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81
-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84
-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87
-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89
29 23 16
28 22 15
28 21 14
27 20 13
26 19 12
26 19 12
25 18 11
25 17 10
9
8
7
6
5
4
4
3
-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91
-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93
-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95
-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97
-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98
Frostbite in >> 30 min. 10 min. 5 min.
WINDCHILL CHART (_C)
Wind
Speed
in
Actual Thermometer Reading (_C)
5
2
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
Equivalent Temperature (_C)
KPH
Calm
8
5
3
2
1
0
2
0
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
-4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57
16
24
32
40
48
56
64
72
80
88
96
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77
Frostbite in >> 30 min. 10 min. 5 min.
22
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SAFETY
Safety Decals and Locations
Warning decals have been placed on the snowmobile for your protec-
tion. Read and follow the instructions of the decals and other warnings
on the snowmobile carefully. If any of the decals depicted in this manual
differ from the decals on your snowmobile, always read and follow the
instructions of the decals on the snowmobile.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
Clutch Cover Warning
This warning decal is found under the hood on the clutch cover:
WARNING
Do not operate engine with hood open.
Do not attempt adjustment with engine running.
Do not operate engine with plenum/belt guard removed.
Never run engine with drive belt removed.
Never service clutches yourself -- see your dealer.
Pressure Cap Warning
This warning decal is found under the hood on the pressure cap of appli-
cable liquid cooled models:
Do not open hot. Test or replace when changing coolant. Press
down and turn to release cap. 13 PSI
23
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SAFETY
Safety Decals and Locations
Hot Surface Warning
The hot surface warning is located
near the rear of the tunnel:
Hot Surface Warning
WARNING
HOT SURFACE - DO NOT TOUCH
Burn may result. Entire top of
tunnel may be hot.
Install only accessories specifi-
cally approved for this model by
Polaris.
Track Warning
The track warning decal is at the
rear of the tunnel:
Track 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.
“No Passenger” Warning
Snowmobiles designed for a single rider only have a NO PASSENGER
warning decal:
WARNING
This vehicle is designed for operator only. NO PASSENGER
“One Passenger” Warning
Snowmobiles designed for an operator and one passenger have a ONE
PASSENGER warning decal:
WARNING
This vehicle is designed for operator and ONE passenger only.
For more information about operating with a passenger, see page 13.
24
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SAFETY
Safety Decals and Locations
Reverse
Warning
“No Passenger”
Warning
Operation
Warning
or
“One Passenger”
Warning
Reverse Warning
The reverse warning decal is located on the console beside the steering
post:
WARNING
Reverse operation, even at low speeds, can cause loss of control
resulting in serious injury or death. To avoid loss of control,
always:
• Look behind before and while backing up.
• Avoid sharp turns.
• Shift to or from reverse only when stopped.
• Apply throttle slowly.
NOTE: For more information, see Owner's Manual.
If electric reverse:
• Machine stopped and engine at idle, push yellow button on LH con-
trol to reverse. Flashing light on dash indicates reverse operation.
• Push button again to return to forward.
Operation Warning
The operation warning decal is also located on the console. See page 26
for the text.
25
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SAFETY
Safety Decals and Locations
Operation Warning
• To avoid serious injury or death, read and understand all warnings
and the Owner's Manual before operation. If manual is missing, con-
tact a Polaris dealer for a replacement.
• This vehicle is capable of high speeds. Buried objects or uneven
terrain can cause loss of control. Reduce speed and use extreme
caution when operating in unfamiliar terrain.
• Excessive speed, especially at night or with limited visibility, can
result in insufficient time for you to react to terrain changes, to
avoid unexpected obstacles, or to stop safely.
• Never consume alcohol or drugs before or while operating this vehi-
cle.
• In an emergency, push down the Auxiliary Shut-Off Switch, located
on the top of the throttle control assembly, to stop the engine. Then
pull the brake lever to stop.
• Always wear an approved helmet, eye protection, and adequate
clothing while operating this vehicle.
• This vehicle is designed for adult use only. Check local laws for age
requirements.
• When operating with a passenger (on approved models only)
reduce speed and allow extra space for steering and stopping. A
passenger reduces your ability to control the vehicle.
• When operating on hard-packed snow, ice, or when crossing roads,
steering and braking ability are greatly reduced. Reduce speed and
allow extra space to turn or stop.
• To maintain vehicle control on ice or hard-packed surfaces, you
should have a proper balance of ski carbides to track studs. See
Owner's Manual for proper use of traction products.
• Repeated stops from high speed may cause fading or sudden loss
of braking ability.
• Parking brake may relax when used for long periods. Do not leave
brake engaged for more than five minutes.
• Before starting engine, check throttle, brake, and steering for
proper operation. Make sure hood is latched. Be seated and in posi-
tion to control the vehicle.
Oil injection system: Use unmixed fuel only. Check oil level when
refueling.
26
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FEATURES
7
6
8
5
9
4
10
3
11
12
1
2
13
Not all models are equipped with all features shown.
1. Nosepan
2. Skis
3. Front Bumper (do not use for
pulling or dragging the snow-
mobile)
4. Hood
5. Headlight
6. Windshield
7. Handlebar
8. Operator Seat
9. Taillight
10. Rear Bumper
11. Snow Flap
12. Suspension
13. Track
27
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FEATURES
3
4
5
6
2
7
1
Not all models are equipped with all features shown.
1. Fuel Filler Cap
2. Ignition Switch
8
9
10 11
3. MFD Gauge
4. Engine Stop Switch
5. Throttle Control
6. Recoil Starter Handle
7. Hood Hold Down Straps
8. Parking Brake Lock
9. Handlebar Grip Warmer Switch
10. Thumbwarmer Switch
11. Electronic Reverse Button
12. Multi-Function Display (MFD)
12
14
13
Control
13. Headlight Dimmer Switch
14. Brake Lever
28
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FEATURES
Cargo Area
+
The maximum weight capacity for the
cargo area is 15 lbs. (7 kg). Install only
accessories specifically approved for this
model by Polaris. Always secure cargo
before operating. Do not exceed the cargo
area weight limit.
Adjustable Headlights
Adjust the headlight beam by moving the
adjuster to the left or right.
Detonation Elimination
Technology (DET)
The DET system prevents damage to the engine from detonation by
automatically reducing the engine timing and adding fuel whenever the
sensors detect detonation.
You may notice decreased engine RPM and performance when DET is
activated, but in most cases DET activation is temporary, and the timing
will return to normal automatically. In extreme conditions the DET sys-
tem retards timing and holds it in a retarded state. If this occurs, replace
the fuel with recommended fuel or see your Polaris dealer for service.
Cause of DET Activation
Solution
Poor quality fuel
Improper engine modifications
Replace with higher quality fuel
Do not modify the engine
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 of power. The sensor must
be reconnected or repaired to regain full power. See your Polaris dealer
for service if this occurs.
TIP:The check engine light will flash six times if the sensor fails or becomes dis-
connected.
29
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FEATURES
Instrumentation
MFD Component Identification
Item
2
1
1
2
3
Analog (if equipped)
Digital Gauge
CHECK ENGINE
Indicator (carb models)
4
5
6
7
8
Low Oil Indicator
High Temp Indicator
Brake Indicator
3
8
4
7
5
6
Reverse Indicator
High Beam Indicator
Digital Display Identification
Item
1
RPM or Speed
Altitude (if equipped)
Service Interval
1
2
2
3
Electrical System
Voltage Level
MAX -Maximum MPH/
KPH or RPM
MPH -Miles per hour
KPH - Kilometers per hour
RPM -Engine crankshaft
revolutions per
minute
4
Air Temp (if equipped)
Engine Temp
Degrees Celsius
Degrees Fahrenheit
7
5
5
6
Miles
6
4
Kilometers
3
Hours
Trip 1/Trip 2/Trip F
Service Label
Altitude Label
7
Fuel Level (if equipped)
30
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FEATURES
Instrumentation
MFD Settings
With the engine running, use the
MFD Control Switch to set the MFD
display to your preference. The
rocker switch (+) has a MODE but-
ton (top) and a SET button (bottom).
+
Standard vs. Metric
The MFD will display either stan-
dard or metric units of measurement.
While viewing a screen that displays
measurements (MPH, KPH or tem-
peratures), press and hold the MODE switch until the unit of measure-
ment changes (about 10 seconds).
Speedometer/Tachometer
The speedometer and tachometer can be viewed in either the analog or
the digital display. If the analog display is set to show speedometer read-
ings, the digital screen will automatically display the tachometer (option
1). If the analog is set to show the tachometer, the digital screen will
show the speedometer (option 2).
To change preferences, press and hold the MODE button for three sec-
onds. When the button is released, the new setting becomes active and
screen colors change. See table below.
Analog
Display
Digital
Display
Analog
Screen
Digital
Screen
Option
1
Speed
RPM
Blue “mph”
Blue
Backlight
2
RPM
Speed
Red
“X100rpm”
Red
Backlight
31
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FEATURES
Instrumentation
MFD Digital Display Programs
Press the MODE button to cycle through the three MFD programs: Per-
formance, Engine and History. Each program will remain in the display
until another is selected.
TIP:The analog will always display either MPH or engine RPM (whichever set-
ting is selected) regardless of the display program being viewed.
Performance Program
The Performance Program automatically displays either speed or
tachometer, whichever is opposite the analog display. See page 31. It
also displays electrical system voltage and fuel level (if equipped).
While in the Performance mode, press the SET button to cycle through
the odometer, Trip 1, Trip 2, Trip F (if equipped with electronic fuel
gauge) and Clock settings.
32
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FEATURES
Instrumentation
MFD Digital Display Programs
Trip Settings
Trip 1 and Trip 2 are odometers used to
check fuel mileage or to keep track of
distance traveled.
1. To reset a trip odometer to zero,
enter the Trip 1 or Trip 2 display.
2. Press and hold the SET button for
two seconds.
If the snowmobile is equipped with an
electronic fuel gauge, Trip F automati-
cally displays when the fuel level is low.
The fuel symbol and the last fuel bar on
the MFD gauge will blink when the fuel
level reaches 1/8th tank. The Trip F
odometer records distance traveled until
enough fuel is added to raise the level
above 1/4 tank. The fuel symbol and the
fuel bar will continue to blink until the
fuel level is above 1/4 tank. The Trip F
odometer will automatically reset to zero
after refueling.
Odometer Setting
The odometer records the vehicle's total
distance traveled since manufacture. The
odometer cannot be reset.
33
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FEATURES
Instrumentation
MFD Digital Display Programs
Performance Program
Clock Setting
1. While in the CLOCK display, press
and hold the SET button for five
seconds.
2. When the hour starts flashing press
the SET switch once to advance
one hour, or press and hold the
SET button to advance the hour
once every 0.2 seconds.
3. Press the MODE button to save the hour and flash the minutes.
4. Set the minutes in the same manner.
5. When finished, press the MODE button to save the new setting. If
the MODE button is not pressed within ten seconds, the clock will
automatically save the new entry.
34
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FEATURES
Instrumentation
MFD Digital Display Programs
Engine Program
The Engine Program automatically displays the engine coolant tempera-
ture, engine hours, electrical system voltage level and fuel level (if
equipped). On machines equipped with altimeter sensor and ambient air
temperature sensors, altitude and ambient air temperature will display as
additional screens in the engine program. Press the SET button to dis-
play the ambient air temperature and altitude screens.
Air Temperature (if equipped)
The MFD displays actual air temperature.
Press and hold the MODE switch for ten
seconds to switch between standard and
metric units of measurement.
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.
35
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FEATURES
Instrumentation
MFD Digital Display Programs
Engine Program
Altitude (if equipped)
The rider can calibrate the altimeter for current
atmospheric conditions. Altimeter accuracy
will be +/-300 ft. (91 m) after adjustment.
TIP:Press and hold the MODE switch for ten sec-
onds to switch between standard and metric
units of measurement. When "ALt" displays,
the program is in the metric mode.
1. Enter the Engine Program and select the altimeter display.
2. Press and hold the SET button for five seconds.
3. When the digits begin to flash, press the SET button once to
advance 50 feet (15 m), or press and hold the button to advance 100
ft. (30 m) every 0.1 seconds. Adjust the altitude display to within 50
ft. (15 m) of 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.
4. Press the MODE button to hold the reading at the adjusted value. If
it's not pressed within five seconds, the gauge will automatically
save the new setting.
36
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FEATURES
Instrumentation
MFD Digital Display Programs
History Program
The History Program automatically displays electrical system voltage
level and fuel level (if equipped).
While in the History mode, press the SET button to view maximum
vehicle speed, maximum engine rpm or the current service interval set-
ting. The gauge automatically logs the maximum speed and engine rpm
even if the History Program is not currently displayed.
The History Program will display the history of the Maximum Speed,
Maximum RPM and Service Interval settings.
Maximum Speed/RPM Reset
While in either the MAX MPH or the MAX
RPM mode, press and hold the SET button
for three seconds to reset the recorded maxi-
mum values for both MPH and RPM. Both
of these values are reset at the same time.
Reset the MAX MPH/RPM values before
each run to obtain accurate readings.
TIP:Due to electrical noise, the MFD may occa-
sionally display MAX MPH/RPM values that
are not representative of actual values.
37
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FEATURES
Instrumentation
MFD Digital Display Programs
Service Interval Reminder
The gauge logs the number of engine
hours between service reminders.
When the logged hours reaches the
designated 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 sec-
onds each time the vehicle is started until the service reminder is reset.
To reset the reminder at the existing interval:
1. Enter the service interval screen.
2. Press and hold the SET button for ten seconds, continuing to hold
even after the display begins to flash.
3. 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 service interval screen.
2. Press and hold the SET button for five seconds, until the hours
begin to flash.
3. Immediately release the button.
4. Press the button again up to five times to advance the reminder in
50-hour increments. The maximum interval is 250 hours.
To disable the service interval reminder, press the SET button once after
reaching 250 hours on the display. The gauge will display "OFF".
38
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FEATURES
Instrumentation
MFD Battery Replacement (models with clocks)
If the clock function of the MFD isn't
working properly, replace the battery.
Replacement batteries are available from
your dealer.
1. Remove the plenum from the under-
side of the hood.
2. Locate the black battery compart-
ment. It has a red wire and a brown
wire with a white stripe. It's located
about three inches down the main
harness from the point where the
harness connects to the MFD.
3. Cut the plastic cable tie from the out-
side of the compartment.
4. Carefully cut the bottom of the com-
partment (opposite the wires) to separate the heat-sealed seams.
Squeeze the corners of the compartment inward so the battery is
visible.
TIP:Note the orientation of the battery before removing it. An incorrectly
installed battery will not maintain the clock.
5. Using needle-nose pliers, grasp the battery and rotate it so the lead-
ing edge of the battery is raised slightly away from the battery
holder. Pull the battery out gently.
TIP:The battery will not come out of the holder unless the leading edge of the
battery is raised. Hold the battery compartment, not the wires, while remov-
ing the battery. Pulling on the wires will separate them from the battery
holder.
39
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FEATURES
Instrumentation
MFD Battery Replacement (models with clocks)
6. Install a new battery with fingers only.
7. Seal the end of the battery compartment using high strength double-
sided tape between the two compartment halves or high strength
single-sided tape around the outside of the compartment.
8. Make sure the taped seam of the compartment faces the downward
side of the wire harness.
9. Install a cable tie to secure the compartment to the wire harness in
the same location where the previous cable tie was located. Make
sure the battery wires are not stretched tight.
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 pro-
tective 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 come into contact with the lens. Immedi-
ately clean off any gasoline that splashes on the gauge during refuel-
ing.
40
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THE PERFECT FIT
Front Suspension Adjustments
Independent Front Suspension (IFS)
Break in the suspension for about 150 miles (240 km) before making
any fine-tuning adjustments.
Settings will vary from rider to rider, depending on rider weight, vehicle
speed, riding style, and trail conditions. We recommend starting with
factory settings and then customizing each adjustment individually to
suit rider preference. The machine should be methodically tested, one
change at a time, under the same conditions (trail and snow conditions,
vehicle speed, riding position, etc.) after each adjustment until the best
ride is achieved.
IFS Components
1. Skis
1
2
2. Front shocks and springs
3. Rod ends
4. A-arms
3
IFS Adjustment Options
• Front shock spring preload
• Optional springs
• Optional shock valving
• Compression damping (Pre-
mium shocks)
4
41
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THE PERFECT FIT
Front Suspension Adjustments
Shock Spring Preload
Increasing spring preload will increase
ski-to-ground pressure. Decreasing spring
preload will decrease ski-to-ground pres-
sure. When adjusting, be sure the springs
on both the left and right sides of the
machine are at the same adjustment.
To change front shock spring preload,
grasp the spring and rotate it.
Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
suspension. Never exceed one inch of pre-
load beyond the factory settings, and
ensure that both sides are adjusted the
same. When decreasing preload, make
sure at least two turns of preload are hold-
ing the spring between the retainer on the
top of the shock and the threaded spring
High
Preload
Low
Preload
preload adjuster nut on the shock body. Failure to do so could cause the
retainer to fall off when the suspension is fully extended.
TIP:Not all models have shocks with thread-adjustable spring preload. See your
dealer for more information.
NOTICE: On some models equipped with a plastic adjuster nut, the nut will
break if it is unscrewed from the threaded body. Do not force the nut if
resistance suddenly increases while you’re turning it.
42
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THE PERFECT FIT
Front Suspension Adjustments
Shock Compression Damping (Premium Shocks)
Turn the adjuster to make adjustments
to the compression damping. When
adjusting, we recommend that you turn
the adjuster only one click, then test
ride. Always adjust both shocks
equally.
Softer
Stiffer
The standard setting is 4 clicks from
the softest position.
• Turn the adjuster to the left for a
stiffer ride.
• Turn the adjuster to the right for a
softer ride.
Shock Valving
Some shocks can be revalved if spring preload alone isn't sufficient and
further adjustment is desired to control suspension stiffness. Please see
your Polaris dealer.
WARNING! Changing shock valving requires special tools and a sound
knowledge of mechanical theory, tool use, and shop procedures to perform the
work safely and correctly. Shocks contain high-pressure nitrogen gas. Use
extreme caution when handling high-pressure service equipment. We
recommend that this work be performed by a Polaris dealer.
43
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THE PERFECT FIT
Rear Suspension Adjustments
Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action.
Each rear suspension can be adjusted to suit rider preference and deliver
excellent performance for a given set of conditions. However, all sus-
pension designs and adjustments involve a compromise, or trade-off.
For example, a suspension set up for snowcross racing would provide a
very stiff ride on the trail. A suspension set up for trail riding would bot-
tom out harshly on a snowcross course.
Refer to the suspension setup label on your snowmobile, or see your
Polaris dealer for initial suspension setup information. Additional
adjustments can be made after initial setup. Make adjustments to one
area at a time so you can evaluate the change. For further assistance, see
your dealer.
44
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THE PERFECT FIT
Rear Suspension Adjustments
Suspension Performance Tips
• Rider weight usually determines the position at which the spring pre-
load should be set. However, this may vary with riding style. With a
little experimentation, each rider can find a preferred setup. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.
• In deep snow, a new rail slide will offer improved performance over
worn rail slide. It can also improve top speed.
• When riding on ice or hard-packed snow, adding a set of bogie wheels
to the rail may enhance the machine's performance. Bogie wheel kits
are available from your dealer.
• Polaris offers track kits for improved flotation in deep snow. See your
dealer for assistance.
• Keep the suspension pivot points lubricated. This will reduce mois-
ture and rust build-up and ensure proper function of the suspension
components. Grease rear suspension pivots before adjusting the rear
suspension. Refer to Suspension Maintenance beginning on page 114.
Track Tension
Track adjustment is critical for proper handling. Always maintain cor-
rect tension and alignment. Refer to the track tension maintenance sec-
tion beginning on page 108.
45
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THE PERFECT FIT
Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method)
To set up the rear suspension tor-
sion spring preload, measure the
distance between the ground and
rear bumper. This is measurement
X.
Take the first measurement with no
rider and with the rear suspension at
full extension. The rear bumper
may need to be lifted upward
slightly to fully extend the rear sus-
pension.
X
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.
Y
46
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THE PERFECT FIT
Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method)
To determine sag, commonly referred to as ride-in, subtract measure-
ment Y from X (sag=X-Y). If the measured sag is incorrect, adjust the
FRA position and/or rear torsion spring preload.
See
Page
Suspension Recommended Sag
Adjustment
IQ (121)
4-5 inches (10-13 cm)
Torsion Spring
Preload
48
SwitchBack & 4-5 inches (10-13 cm)
LX (136)
Torsion Spring
Preload
48
TIP:This is only an initial setup, and final spring preload may vary based on rider
preference and riding conditions.
47
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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. Adjustment is easiest when the cam is
rotated from low to medium, and then to high. Rotating directly from
low to high will require significantly more effort.
Different rate torsion springs are available if a firmer ride is desired. See
your dealer for more information.
Soft
Medium
Firm
48
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THE PERFECT FIT
Rear Suspension Adjustments
Limiter Strap Position (Ski Pressure)
Ski pressure is set at the factory to
deliver the optimum balance
between ride and handling. If a
rider prefers more ski pressure for
improved steering performance,
Upper
adjustments can be made to the
Nuts
front limiter straps. Tighten the
straps to increase ski pressure.
Loosen the straps to reduce ski
pressure.
Some models have only one lim-
iter strap.
1. Remove the nuts and flat washers from the upper limiter straps.
2. Relocate the straps to the desired position.
3. Reinstall the nuts and washers. Tighten securely.
49
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THE PERFECT FIT
Rear Suspension Adjustments
Rear Shock Compression Damping (Premium Shock)
Turn the adjuster on the shock
reservoir to make adjustments to the
compression damping. Positions are
labeled on the shock. When
adjusting, we recommend that you
turn the adjuster one click, then test
ride.
• Turn the adjuster clockwise for a
stiffer ride.
• Turn the adjuster counterclockwise
for a softer ride.
Stiffer
Softer
50
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THE PERFECT FIT
Rear Suspension Adjustments
Suspension Coupling
On all Polaris snowmobile rear suspensions, there are two torque arms
that control the movement of the rail beam. Prior to the advent of sus-
pension coupling, these torque arms could move independently of each
other. Rear suspension coupling links the movement of the front and
rear torque arms to each other. There are two types of rear suspension
coupling.
Front To Rear Coupling and the Front Rear Scissor Stop
(FRSS)
The front rear scissor stop (FRSS) couples the movement of the front
torque arm with the rear torque arm and limits the amount of indepen-
dence between the movement of the front torque arm and the rear torque
arm.
When hitting a bump, the front torque arm starts to compress. The FRSS
links that movement to the rear torque arm, causing it to compress and
raise the rear suspension up as one, allowing the suspension to hit the
bump only once and reducing kickback.
The factory setting is usually adequate for all riders and conditions.
51
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THE PERFECT FIT
Rear Suspension Adjustments
Rear To Front Coupling and the Rear Rear Scissor Stop
(RRSS)
The rear rear scissor stop (RRSS) couples the movement of the rear
torque arm with the front torque arm and limits the amount of indepen-
dent movement between the rear torque and the front torque arm.
Adjusting the RRSS either allows more weight to transfer to the rear for
more traction, or allows less weight to transfer to the rear, resulting in
improved cornering performance. An adjustment dot is located on the
RRSS. This dot is on the longest end of the scissor stop.
Rear Rear Scissor Stop (RRSS) - Attributes
Moving the RRSS to a higher position will have the following effects on
the suspension:
• Reduced weight transfer.
• Improved chatter bump ride.
• Improved cornering performance.
52
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THE PERFECT FIT
Rear Suspension Adjustments
Weight Transfer During Acceleration
The preferred method for control-
ling weight transfer during accel-
eration is by adjusting the rear rear
scissor stop (RRSS). The factory
setting is the best for most trail
riding conditions.
HIGH
LOW
LOW
MEDIUM
To decrease weight transfer under
acceleration (for improved corner-
ing), rotate the RRSS to a higher
position.
RRSS
FRSS
To increase weight transfer or ski
lift during acceleration, rotate the
RRSS to a lower position.
TIP:Your dealer can help you with ini-
tial setup and additional setup
instructions to help you achieve
your optimum ride. A scissor stop
tool is also available from your
dealer.
53
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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.
54
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THE PERFECT FIT
Accessories
Polaris offers a wide range of accessories for your snowmobile to help
make each ride more enjoyable.
Use only Polaris parts and accessories on your Polaris snowmobile. Use
of unapproved parts and accessories may result in:
• Non-compliance with government/industry requirements
• Voiding of warranty
• Injury to self or others
This applies, but is not limited to the following areas: brakes, clutches,
fuel systems, and exhaust systems. Exhaust systems are critical safety
areas that must use approved Polaris parts. Please see your Polaris
dealer for service.
55
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THE PERFECT FIT
Traction Products
Studs
Before equipping your machine with traction products, be aware of the
laws in your area pertaining to the use of traction products.
Use only Polaris traction products on your snowmobile. Track warran-
ties are void if track damage or failure results from improper or exces-
sive stud installation or the use of non-Polaris traction products.
See your dealer about installing studs and/or carbides.
NOTICE: Always install wear strips before installing studs. Failure to install wear
strips may result in cooler or tunnel damage. See page 57.
Never add shims to the wear strip. Track damage will result because
of lack of clearance between upper carrier wheels and track.
Use of studs longer than the recommended length on machines
equipped with center coolers will result in center cooler damage or
damage to the tunnel.
Track studding will enhance braking control on hard-packed snow or
ice, but extreme caution is still required on such surfaces. Steering abil-
ity may be reduced on hard-packed snow or ice.
When studded tracks are used, increased wear to the brake pads will
result from increased braking. Extended-wear brake pad kits are avail-
able. See your dealer.
NOTICE: Aggressive studding patterns may require grinding protruding stud
bolts flush to prevent idler wheel damage. Maintain track tension on
studded tracks on the tight side of the spec to prevent heat exchanger
damage. The center of the stud must be at least 1 1/8I (2.86 cm) from
the outside edge of the track.
56
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THE PERFECT FIT
Traction Products
nCarbide Skags
A skag is a replaceable bar attached to the underside of the ski to assist
in turning the snowmobile and to prevent ski wear caused by contact
with roads and other bare terrain. Use carbide skags with studded tracks
to help maintain proper vehicle steering and control. See page 113.
If your machine has carbide skags, it may be necessary to add track
studs to maintain proper vehicle control. Maintain a proper balance
between the number of studs and the length of carbide on the skags (the
more studs you use, the longer the carbide on the skags should be). See
your dealer's track studding chart.
Wear Strips
To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used. Wear strips are designed for a specific
stud length.
See your dealer's studding chart for recommended traction accesso-
ries.
NOTICE: Whenever wear strips are relocated, be sure there's adequate stud
clearance to the heat exchangers. Lack of clearance may result in
damage to heat exchangers.
57
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PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the refer-
enced pages. Look for a checkmark (n) on the referenced pages to
locate the pre-ride inspection items.
Item
See Page
Drive Belt Condition
Steering System
Recoil Rope
102
62
63
Coolant Level
91
Parking Brake Lock/Brake Lever/Brake System
Auxiliary Shut-Off Switch (Engine Stop Switch)
Ignition Switch
60, 61, 96
64
64
Taillight/Brakelight/Headlight
Suspension Mounting Bolts
Skags (Wear Bars)
64
114
113
114
63
Ski Saddle and Spindle Bolts
Hood Straps/Latches
Seat Latches (if equipped)
Throttle Lever/Safety Switch
Rear Wheel Idler Bolts
63
72, 73
109
64
Tether Switch/Strap (if equipped)
Track Alignment/Condition
Rail Slide Condition
62, 110
114
85
Chaincase Oil Level
Injection Oil Level
71
58
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PRE-RIDE INSPECTIONS
Before Starting the Engine
Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never start the engine without checking all
vehicle components to be sure of proper operation.
WARNING! Operating the vehicle with worn, damaged, or malfunctioning
components 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 machine is operated.
See page 72.
59
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PRE-RIDE INSPECTIONS
Before Starting the Engine
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
1/2I (1.3 cm)
handgrip than 1/2I (1.3 cm).
A smaller distance indicates
low brake fluid level or air in
the hydraulic system. Refer
to the brake bleeding infor-
mation on page 98 or see
your dealer for service.
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 97.
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.
60
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Parking Brake Lever Lock
Use the parking brake lever lock only when you want the machine to
remain stationary; for example, when parked on an incline for a period
of five minutes or less.
1. Brake Lever
3
4
2
2. Parking Brake Lever
Lock
3. Master Cylinder Reser-
voir/ Cover
1
4. Fluid Level Indicator
Lock Engagement
To engage the lock, squeeze
the brake lever tightly and
push forward on the lock.
Hold the lock forward while
releasing the brake lever.
TIP:If the brake lever is squeezed tightly enough, the lock will move freely into
place. Do not force the lock or it may break.
The brake light will illuminate if the parking brake lever lock is set
while the engine is running. It will also illuminate when the service
brake is in use. If the parking brake light does not come on when the
parking brake or service brake is in use, have it serviced by your dealer.
Lock Release
To release the lock, squeeze the brake lever tightly. The lock will return
to the 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.
61
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Steering System
WARNING! Ice and snow build-up may interfere with the steering of your
machine, 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.
n Track
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.
WARNING! 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 lubrication would include
frozen bodies of water without snow cover, icy trails, and no-snow conditions.
Track damage or failure caused by operation on ice or poor lubrication
conditions voids the track warranty.
62
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Hood Latches
The hood of the snowmobile protects the operator from moving parts as
well as aiding in sound emission control and other functions. Under no
circumstances should your snowmobile be operated with the hood open
or removed. Always ensure that the hood straps are in good condition
and that the latches are securely in place before operating the snowmo-
bile.
n Seat Latches
If your snowmobile is equipped with a removable seat, ensure that the
seat latches are securely in place before every use of the snowmobile.
n Recoil Rope
Inspect the recoil rope and handle for excessive wear, and make sure the
knot securing the rope inside the handle is secure. If excessive wear is
found, see your Polaris dealer for replacement.
63
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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 59.
n Engine Stop Switch
Check the auxiliary shut-off switch for proper operation. Push the
switch down to stop the engine. Pull it up to allow restarting.
n Ignition Switch
Make sure the engine stops when the ignition switch is turned to OFF.
n Tether Switch (if equipped)
If your machine has a tether switch, remove the tether from the switch to
make sure the engine stops immediately.
n Lighting
Check the headlight (high and low beam), taillight, and brake light.
Replace burned out lamps before operating.
n Mirrors (if equipped)
Adjust the mirrors so they can be used to their full advantage.
n Operating Area
Before driving away, check your surroundings. Be aware of obstacles
and make sure bystanders are a safe distance from the machine.
64
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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.
2. Pull the engine stop switch up to the RUN position.
3. 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.
4. 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.
5. If the engine does not start after several attempts, slightly depress
the throttle (no more than 1/4I open) while cranking the engine.
When the engine starts, immediately release the throttle.
CAUTION! To avoid injury and/or engine damage, do not operate the electric
starter or pull-rope starter while the engine is running.
Restarting an Engine
If the rider stops the engine by pushing the engine stop switch down,
restart the engine using the normal starting procedure. If the engine fails
to start using the normal procedure:
1. Push the engine stop switch down to the OFF position.
2. Turn the key to the OFF position.
3. With both switches OFF, squeeze and hold the throttle in the wide
open position.
4. Crank the engine several times to clear the engine.
5. Release the throttle.
6. Restart the engine using the normal starting procedure.
65
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OPERATION
Engine Break-In
No single action on your part is as important to long, trouble-free
machine life as proper break-in of a new or rebuilt engine. Premix the
first tank of fuel with one pint of Polaris injection oil for each five gal-
lons of fuel. This, in addition to the lubrication supplied by the injection
system, will assure proper engine break-in.
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.
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OPERATION
Engine Break-In
Oil Injection System
Always check and fill the oil tank when refueling. See page 71.
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 118 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.
67
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OPERATION
Track Warm-Up
WARNING! A loose track or flying debris could cause serious injury or death.
Stand clear of the front of the machine and the moving track. Never hold the
snowmobile up or stand behind it while warming up the track. Do not use
excessive throttle during warm-up or when the track is free-hanging. Use a
stable rear support.
WARNING! Use of traction products such as studs, ice growsers, etc. will
increase the possibility of track damage and/or failure. This could cause loss of
control, resulting in serious injury or death. Always inspect for track damage
before operating the snowmobile.
Follow these steps to ensure proper warm-up of the engine, drive train
and track.
1. Use an appropriate stand to securely sup-
port the rear of the snowmobile at the rear
bumper. The track should be about 4I (10
cm) off the ground.
2. Start the engine and allow it to warm up
two to three minutes.
3. Depress the throttle abruptly and allow the
track to rotate several revolutions.
TIP:It will take longer to warm up the track suffi-
ciently during colder outdoor temperatures.
4. Release the throttle, apply the brakes, shut
off the engine and lower the machine to the ground.
5. Grasp the skis by their front loops and move them from side to side
to loosen snow and ice.
68
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OPERATION
Fuel
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel outdoors or in a well-ventilated area.
• Always turn off the engine before refueling.
• Do not overfill the tank. Do not fill the tank neck.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling is performed or where gasoline is stored.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Never start the engine or let it run in an enclosed area. Engine exhaust fumes
are poisonous and can cause loss of consciousness or death in a short time.
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 118 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.
69
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OPERATION
Fuel
Polaris recommends the use of 91 octane or higher fuel. Although 87
octane fuel is usable, some engine performance 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. Prolonged expo-
sure to petroleum based products may damage paint. Always protect
painted surfaces when handling fuel.
This snowmobile is equipped with a feature that allows you to select the
proper calibration map for the fuel available in your region. Fuel resis-
tors must be changed (600 models) or the disconnected mode change
wires in the wiring harness must be connected (800 models) 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
reinstall the ethanol fuel resistor or disconnect the mode change wires
before operating with ethanol fuel. When in doubt about fuel quality,
always use the ethanol fuel resistor or unplug the wires.
Fuel Resistor (600 Models)
On 600 cc models, the factory-installed
ETHANOL
10%24 OHM
fuel resistor is for the use of ethanol fuel. If
operating with non-ethanol fuel becomes
necessary, always install the non-ethanol
NON-ETHANOL
fuel resistor. The non-ethanol fuel resistor
160 OHM
is provided in the tool kit.
Fuel Mode Change Wires (800 Models)
On 800 cc models, fuel mode change
wires are located in the wiring har-
ness secured to the rear underside of
the clutch guard behind the console.
Ethanol fuel: Leave the wires
Connected for
Non-Ethanol
UNPLUGGED when using oxygen-
ated fuel containing up to 10% etha-
nol. Never use E85 blended fuel.
Unplugged
for Ethanol
Non-ethanol fuel: CONNECT the
black/blue wires to the pink wire
when using non-ethanol blended fuel.
70
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OPERATION
n Oil
Low Oil Indicator Light
The low oil indicator light will alert the operator if the oil level is low.
Visually check for oil in the bottle. Add oil before further operation of
the snowmobile. See page 67 for oil recommendations.
Low Oil Level
Maintaining the proper oil level will prevent system aeration and possi-
ble loss of pumping action, which could result in engine damage. This is
especially important when the machine is operated in mountainous ter-
rain.
NOTICE: Operating the snowmobile without adequate engine lubrication can
result in serious engine damage. Always check the oil level when refu-
eling. Add oil as needed.
Always maintain a visible level of oil in the tank. If oil is not visible,
continued operation may cause serious engine damage. See page 67 for
oil recommendations.
The Polaris oil cap on the oil bottle is vented to allow proper oil flow.
See your Polaris dealer for recommended replacement parts.
71
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OPERATION
n Engine Stop Switch
Push down on the engine
stop switch (+) to
ground out the ignition
and stop the engine
+
quickly. Pull the switch
up to the ON position to
allow restarting.
n Throttle Safety Switch
The throttle safety switch is designed to stop the engine whenever all
pressure is removed from the throttle lever and the throttle cable or
valves do not return to the normal closed position.
WARNING! Operating the snowmobile with a faulty throttle safety switch can
result in serious injury or death in the event of an accident. If the throttle safety
switch does not shut off the engine during a carburetor/throttle system
malfunction, immediately push down the engine stop switch. Do not start the
engine again until the malfunction has been corrected by your dealer.
Test the throttle safety switch
system daily before operation.
1. Sit on the seat.
2. Start the engine and allow it
to idle.
3. Hold the throttle lever pin
stationary by exerting pres-
sure on the pivot pin in the direction shown in the illustration.
4. Apply a slight amount of throttle. A properly functioning switch
must shut down the engine.
72
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OPERATION
Throttle Lever
WARNING! An improperly functioning throttle lever may cause erratic machine
behavior and loss of control, which could result in serious injury or death. If the
throttle lever does not work properly, DO NOT start the engine.
If the engine stops abruptly when the throttle lever is released:
1. Turn the ignition switch to OFF.
2. Visually inspect the throttle cable and carburetor/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.
Excessive freeplay in the throttle cable may cause the safety switch to
activate, preventing the engine from starting. If this occurs, return the
machine to an authorized Polaris dealer for service.
If an emergency exists and it's necessary to start the engine, the throttle
safety switch and engine stop switch may be disconnected from the wire
harness. When these switches are disconnected, the ignition key switch
must be used to shut off the engine. DO NOT continue to operate the
machine with the throttle safety switch disconnected. Return the
machine to an authorized Polaris dealer for service as soon as possible.
73
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OPERATION
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 72 for more information about the
engine stop switch and throttle safety switch.
SYSTEM
Ignition Switch
WHAT IT DOES
Interrupts ignition circuit
Brake
Slows jackshaft
Engine Stop Switch
Throttle Safety Switch
Tether Switch (Option)
Interrupts ignition circuit
Interrupts ignition circuit
Interrupts ignition circuit
74
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OPERATION
Electronic Reverse (PERCt)
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.
75
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OPERATION
Electronic Reverse (PERCt)
Engaging Reverse
1. Stop the snowmobile and leave the engine idling.
2. Make sure the area behind your vehicle is clear.
3. Push the yellow reverse button on the left-hand control for one sec-
ond, then release. The engine will automatically reduce RPM and
start a reverse rotation. A flashing reverse light on the instrument
panel will indicate that the transmission is in reverse.
4. Apply the throttle slowly to make sure the transmission is in
reverse.The maximum engine RPM will be 6000 when in reverse.
TIP:If the engine stops running, the snowmobile will be in forward gear when it's
restarted.
Disengaging Reverse
1. Stop the snowmobile and leave the engine idling.
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 yellow reverse button for one second and release. The
engine will slow and begin to rotate forward. The light on the
instrument panel will shut off.
3. Apply the throttle slowly to make sure the transmission is in for-
ward.
76
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OPERATION
Daily Storage
At the end of each ride, park the snowmo-
bile on a level surface and support it at the
rear with an appropriate track stand. The
track should be suspended approximately
4I (10 cm) off the ground.
Remove the key and cover the machine.
Towing
Do not use the front bumper to pull or drag the snowmobile. The front
bumper is not designed for this type of use and may detach from the
vehicle if force is applied.
For your safety, do not attempt to use a tow hitch until you've read the
following warnings and understand the proper hitch functions.
WARNING! Objects towed with a rope have no braking power and can easily
collide with the rear of the snowmobile or other objects, resulting in serious
injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle
with a rope.
Only a stiff metal pole connecting the towed object and the tow hitch on
the snowmobile should be used. If passengers are to be towed on a
toboggan or sled, make sure the pole is at least four feet (1.2 meters)
long to prevent any possibility of contact between the snowmobile's
track and a person riding in the towed object.
Braking distances increase when towing loads. Slow down to maintain
control of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it isn't
possible to use a rigid tow bar, attach the tow rope to the ski spindles
(not to the ski loops) to prevent damage to the steering components.
Remove the drive belt before towing, and have someone ride on the
towed snowmobile to operate the brake and steering when necessary.
NOTICE: Towing a disabled snowmobile with the drive belt in place can result in
serious damage to the engine and drive system. Always remove the
drive belt from a disabled snowmobile before towing.
77
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MAINTENANCE
Emission Control Information
Any qualified repair shop or qualified person may maintain, replace, or
repair the emission control devices or systems on your snowmobile.
Emission Control Label
Your snowmobile is equipped at the time of sale with an emission con-
trol information (ECI) label and a factory-installed emissions informa-
tion hangtag. These items are required by U.S. Environmental
Protection Agency regulations. The ECI label is permanently affixed to
either the right side of the tunnel or the engine recoil cover. The ECI
label should not be removed, even after you purchase the snowmobile.
You may remove the factory-installed emissions information hangtag,
which is intended solely for your use in making a purchasing decision.
Emission Control Maintenance Requirements
Your snowmobile is certified to operate on gasoline with a minimum
octane level of 87 (R+M)/2. If your snowmobile is equipped with a
check engine light and it comes on, you must take your snowmobile to a
qualified dealer for diagnostic service. Specifications and adjustments
for engine tune-ups are located in the Service Manual, which is avail-
able to your qualified service technician. Reverse (if equipped) must not
be engaged during engine tune-ups.
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.
78
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MAINTENANCE
Polaris Recommended Maintenance Program
To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as out-
lined in this manual. Record maintenance and service in the Mainte-
nance Log beginning on page 133.
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.
79
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MAINTENANCE
Periodic Maintenance Interval Table
The following chart is a guide based on average riding conditions. You
may need to increase frequency based on riding conditions. When
inspection reveals the need for replacement parts, always use genuine
Polaris parts, available from your Polaris dealer.
Item
See
Page
Frequency
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km)
Season
CLUTCH
Clutch Alignment Offset
(without belt)
101
I
I
I
Drive Belt Condition
Clutches
102
101
--
I
I
C
I
I
C
I
I
C
Belt Tension
I
I
I
Clutch Sheaves
101
I
I
I
ENGINE/COOLING
Engine Mounts
--
--
I
I
I
I
I
I
I
I
I
I
I
Recoil Rope
Engine Torque Stop
Cylinder Head Bolts
Cylinder Base Nuts
Ignition Timing BTDC
VES System
105
--
I
I
I
I
--
I
I
I
I
I
--
I
I
--
C
I
C
I
C
R
I
I
I
I
I
Coolant Level
91
--
Coolant Hose
I
I
Heat Exchangers
Coolant Circulation
Coolant Leaks
93
--
I
I
I
I
I
I
I
I
--
I
I
I
I
I
I
I
Spark Plug Condition
Exhaust Pipe
88
94
94
I
I
R
I
Exhaust Retaining
Springs
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
80
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MAINTENANCE
Periodic Maintenance Interval Table
Item
See
Page
Frequency
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km)
Season
BRAKES
Hose Routing
Hose Condition
Fluid Leaks
--
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
--
Brake Pads
96
Brake Disc
--
Parking Brakes
Brake System
Brake Fluid
61
60, 96
97
R
FUEL MANAGEMENT
I
Idle RPM
--
73
--
I
I
I
I
I
I
Throttle Lever
I
I
I
I
Oil Pump Lever
(synchronize)
Throttle Cable
84
--
L
I
L
I
L
I
Throttle Position
Sensor
Fuel Lines
Fuel Filter
Oil Filter
Oil Lines
Air Box
90
90
89
89
--
I
I
I
I
R
R
I
I
R
R
I
I
I
I
I
I
I
ELECTRICAL
Auxiliary Shut-Off
Switch
64
I
I
I
I
I
Throttle Safety Switch
Ignition Switch
Taillight
72
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
64
64
64
Brakelight
Headlight
81
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MAINTENANCE
Periodic Maintenance Interval Table
Item
See
Page
Frequency
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km)
Season
CHASSIS
Ski Toe Alignment
--
--
I
I
I
I
I
I
Suspension Mounting
Bolts
I
I
Steering Fasteners
--
--
I
I
I
I
I
I
I
I
C
I
Rear Suspension
Fasteners
Suspension Shock Oil
--
--
I
I
I
I
I
I
I
I
Cooling Fins and
Shroud
Drive Shaft Bearing
Jackshaft Bearings
Skags (Wear Bars)
84
116
113
--
L
L
I
L
L
I
L
L
I
I
I
I
I
I
I
Ski Saddle/Spindle
Bolts
I
I
I
Drive Chain Tension
Hood Latches
95
63
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Rear Wheel Idler Bolts
Idler Bolt Jam Nut
109
109
83
I
I
I
I
I
I
Rear Suspension Pivot
Shafts
L
L
L
Steering Post U-Joint
Camber Alignment
Handlebar Centering
Tether Switch and Strap
Track Alignment
83
--
L
I
L
I
L
I
--
I
I
I
I
I
I
I
64
110
108
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Track Tension
Front Limiter Strap
Rail Slide Condition
Chaincase Oil
114
85
I
I
I
R
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
82
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MAINTENANCE
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 79 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.
IQ 121/Switchback 136/LX 136 Rear Suspension
+
+
+
+
IQ 121 Shown
The Dragon Premium rear sus-
pension has no grease points, it
does not require lubrication.
83
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MAINTENANCE
Lubrication
Driveshaft Bearing
+
Inject grease into the fitting on the
speedometer sensor housing until
grease purges from the seal on the
inside of the tunnel. This should
take approximately two pumps. Do
not use more than four pumps.
Throttle Cable
Lubricate the throttle cable lightly
with grease or oil. With the engine
off, turn the handlebars to the left
and lubricate liberally as shown.
+
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MAINTENANCE
Lubrication
n Chaincase Oil
Check the chaincase oil level at the
intervals outlined in the maintenance
charts beginning on page 79. The sight
glass (1) is located on the lower rear of
the chaincase. Maintain the oil level at
or slightly below the center of the sight
glass (2). Change the chaincase oil after
the first 500 miles (800 km), then every
1000 miles (1600 km) or seasonally.
3
Polaris recommends the use of Polaris
Synthetic Chaincase Lube. See page 118
for the part numbers of Polaris products.
1
Oil Check
1. Position the vehicle on a level sur-
face.
2. View the oil level at the sight glass.
3. Remove the fill plug (3) and add the
recommended oil as needed. Do not
overfill.
2
4. Reinstall the fill plug, making sure it
is seated properly.
85
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MAINTENANCE
Lubrication
Chaincase Oil
Oil Change
1. Position the vehicle on a level surface.
2. Remove the drain plug (4) and drain
the oil into a drain pan. Allow the oil
to drain completely.
4
3. Clean off all metal shavings from the
plug.
4. Install a new sealing washer on the
drain plug. The sealing surfaces on the drain plug and the oil tank
should be clean and free of burrs, nicks or scratches.
5. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).
6. Remove the fill plug. Clean off all metal shavings from the plug.
7. Add 11 oz. (325 ml) of the recommended oil. Do not overfill.
8. Reinstall the fill plug, making sure it is seated properly.
86
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MAINTENANCE
Spark Plugs
A new engine can cause temporary spark plug fouling due to the preser-
vative added during the assembly process. Avoid prolonged idle speeds,
which cause plug fouling and carbonization.
Refer to your Owner's Manual Supplement for the specific spark plug to
be used in your machine.
Change the spark plugs every 2000-2500 miles (3200-4000 km).
• 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.
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.
87
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MAINTENANCE
Spark Plug Condition
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
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.
TIP: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
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 or
use of non-recommended injection oil.
88
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MAINTENANCE
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.
3. Reverse the procedure for spark plug
installation.
4. Torque to 18-22 ft. lbs. (24-30 Nm).
5. Reinstall the spark plug cap.
Oil Lines
Inspect oil line condition every 1000 miles (1600 km).
Oil Filter
The oil filter is located at the side of
the oil tank. Have your dealer change
the oil filter and bleed the system
annually or every 1000 miles (1600
km).
TIP:The direction of the arrows indicates
the direction of flow through the fil-
ter.
89
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MAINTENANCE
Intake Filters
The intake foam filters limit
snow ingestion into the intake
system. When operating in
loose powder snow, check the
foam filters periodically to
remove any accumulation of
snow.
+
NOTICE: Operating the snowmobile with the intake filters removed may cause
carburetor icing. The result will be poor fuel economy or carburetor
malfunction. Always reinstall the intake filters before operating the
snowmobile.
Fuel Pump
All fuel pump service must be performed by an authorized Polaris
dealer. Do not attempt to service the fuel pump.
Fuel Filter/Fuel Lines
See your Polaris dealer for replacement of the fuel filter every 1000
miles (or annually).
Inspect the fuel lines regularly for signs of deterioration or damage.
Always check fuel line condition after periods of storage. Normal dete-
rioration from weather and fuel compounds may occur. Replace worn or
damaged fuel lines promptly.
NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel
lines may cause damage to the lines. If a fuel line has been damaged
or kinked, replace it promptly.
90
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MAINTENANCE
Cooling System
Coolant
The coolant supplied in the system at the factory is a 50/50 mixture of
ethylene-glycol and distilled water, which will provide adequate freeze
protection under most conditions. If the vehicle will be stored or oper-
ated at extremely low temperatures, greater protection may be required.
Please see your Polaris dealer.
When adding or changing coolant, Polaris recommends using 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 118 for Polaris products.
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
• Engine 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.
91
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MAINTENANCE
Cooling System
Coolant High Temperature Indicator Light
CAUTION! Steam and hot liquids will cause burns to your skin. Never remove
the pressure cap when the engine is warm or hot.
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 machine after the high temperature indi-
cator 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. 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.
92
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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.
Perform the bleeding procedure when the engine is cold.
1. Position the vehicle so that the top of the tunnel is level. Elevate the
front of the vehicle slightly if necessary.
2. Remove the pressure cap and fill the coolant bottle with properly
mixed coolant to the maximum mark.
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. (On Switchback
models, feel the tunnel gripper coolers on both sides.) 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.
93
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MAINTENANCE
Exhaust System
Check the exhaust system for wear or damage at approximately 2000
miles (3200 km). Always allow the engine and exhaust system to cool
completely before inspecting.
CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for
the exhaust system to cool. Never perform this procedure with the engine
running.
1. Open the hood and inspect the muffler and pipes for cracks or dam-
age.
2. Check for weak or missing retaining springs or damper/support
grommets.
3. Check for loose clamps on the pipe covers.
94
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MAINTENANCE
Drive Chain Tension
Check drive chain tension weekly and
before each long trip. To obtain correct
chain tension:
1. Rotate the driven clutch counter-
clockwise to move all chain slack to
the tensioner side. Lock the brake
lever lock, or have an assistant hold
the brake lever firmly.
2
1
2. Loosen the adjuster bolt jam nut (1).
3. Finger tighten the adjuster bolt (2)
until it can no longer be adjusted by
hand, then back off 1/4 turn.
4. Tighten the jam nut while holding
the adjuster bolt. Torque to 21 ft.
lbs. (28 Nm).
5. Release the brake lever lock.
95
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MAINTENANCE
Brakes
Hydraulic Brake Inspection
Inspect the brake lever reserve before each use of the snowmobile. See
page 60.
Brake pads must be replaced when the brake pad material becomes thin-
ner than the backing plate (approximately 1/16I). A kit is available for
replacing brake pads. See your dealer.
WARNING! Brake failure during operation can result in serious injury or death.
Properly functioning brakes are vital to your safety. Be sure the brake pads do
not drag on the disc and that brake lever travel is not excessive. Always replace
brake pads when the brake pad material becomes thinner than the backing plate
(approximately 1/16I).
Brake Components
1. Brake Caliper
3
2. Brake Disc
1
3. Brake Pad Material
(Replace when thickness is
less than 1/16I/1.5 mm).
2
Excessive Lever Travel
Hydraulic brakes are self-
adjusting, but if excessive
brake pad clearance develops,
bring the machine to an autho-
rized Polaris dealer for inspec-
tion and adjustment.
96
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MAINTENANCE
Brakes
Brake Fluid
WARNING! After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and
the possibility of accident or serious injury.
The brake fluid level can be seen through a plastic sight glass in the
brake reservoir. If the fluid is sufficient, the sight glass will be black. If
the sight glass is any color other than black, add brake fluid.
Keep the master cylinder cover free of dirt and debris. The vent slits
allow for diaphragm movement, and if they become plugged, movement
of brake fluid below the diaphragm may be restricted, altering brake
function.
Replace brake fluid at least every two years with Polaris DOT 4 high
temperature brake fluid. See page 118 for the part numbers of Polaris
products.
NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe
up spills immediately.
97
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MAINTENANCE
Brakes
Bleeding the Hydraulic Brake System
Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.
WARNING! Operating the vehicle with a spongy brake lever can result in loss of
brakes, which could cause an accident and lead to serious injury or death.
Never operate the vehicle with a spongy-feeling brake lever.
During the bleeding procedure, keep the brake handle as level as possi-
ble. The reservoir must be in this position to minimize the possibility of
air entering the system through the reservoir vent.
1. Remove the brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4-5/16I (.6-.8 cm) below the lip of the reservoir open-
ing. Reinstall the gasket and cover.
3. Slip a rubber tube over the ball of the bleeder valve and direct the
flow of fluid into an approved container.
4. Squeeze the brake lever a full stroke. Then unscrew the bleeder
valve 3/4 of a turn to release air.
5. Close the bleeder valve and release the brake lever.
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a
solid stream free of air bubbles.
WARNING! Overfilling the master cylinder leaves no room for fluid expansion
and may cause the brakes to lock, resulting in serious injury or death. Always
add brake fluid to the fill line as recommended.
7. After bleeding is complete, refill the reservoir to the proper level.
See page 97.
8. Reinstall the gasket and cover.
98
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MAINTENANCE
Lights
Do not touch a halogen bulb with bare fingers. Oil from skin leaves a
residue, causing a hot spot that will shorten the life of the lamp. If fin-
gers do touch the bulb, clean it with an alcohol-moistened towel.
Headlight Bulb Removal
1. Remove the plenum covering
from the headlight assembly.
2. Lift the rubber boot to expose
2
the bulb.
3
3. Push down on the spring (1)
to release it from the housing.
4. With the wire harness (2)
1
attached to the bulb (3), with-
draw the bulb from the hous-
ing.
5. Grasp the bulb by its metal base and carefully separate the bulb
from the harness.
Headlight Bulb Installation
1. Hold the bulb by its metal base and install it into the wire harness.
TIP:Recommended replacement bulbs include H4, HB2 and 9003 bulbs.
2. Insert the bulb into the housing.
3. Connect the spring to the housing.
4. Carefully flip the spring back into the housing, placing it around the
wire harness.
5. Reinstall the plenum covering on the headlight assembly.
6. Verify headlight aim.
99
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MAINTENANCE
Lights
Taillight/Brakelight Replacement
1. Remove the screws securing the taillight lens. Remove the lens.
2. Push the bulb inward and turn it counterclockwise to remove it.
3. Install a new bulb. Push the bulb inward and turn it clockwise to
secure it.
4. Reinstall the taillight lens.
100
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MAINTENANCE
Clutch System
Periodically inspect clutch sheaves for damage, wear or belt residue. To
maintain optimum performance, clean with non-oil based cleaners such
as isopropyl alcohol.
WARNING! If you become aware of higher than normal clutch engagement or
an unusual vibration or shift pattern, see your dealer immediately. Do not
operate the machine until repairs have been made. All clutch maintenance and
repairs must be performed by an authorized Polaris dealer. Any unauthorized
modifications to clutches, such as adding or removing weights, will void the
warranty.
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. See your dealer for service and adjustments. A special tool is
required to check for proper alignment.
Clutch Center Distance
See your Owner's Manual Supplement for recommended center distance
for your machine. If adjustment is necessary, see your dealer.
101
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MAINTENANCE
Clutch System
n Drive Belt Condition
Periodically check the condition and tension of the drive belt, and
always carry a spare. Inspect the belt for signs of excessive wear: frayed
edges, missing cogs, cracks and excessive looseness. Replace the belt if
any of these conditions exist. See Drive Belt Troubleshooting on page
123.
Always carry a spare drive
belt for emergency use.
Store the spare belt on top
of the electrical box, which
is mounted to the clutch
cover.
For improved drive-away
during extremely cold tem-
peratures, remove the belt
and warm it to room tem-
perature. Reinstall it before
starting the snowmobile.
102
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MAINTENANCE
Clutch System
n Drive Belt Deflection
1
Measure belt deflection with both
clutches at rest and in their full
neutral position.
2
Place a straight edge (1) on the
belt and apply downward pressure
while measuring at point 2. This
measurement should be 1 1/4I
(3.2 cm).
Drive Belt Adjustment
1. Install the L-wrench into the open threaded hole in the outer sheave
of the clutch (see page 104). Turn the wrench clockwise slightly to
remove pressure from the sheaves.
2. Loosen the 7/16I jam nut.
3. Using a 1/8I Allen wrench, turn the set screw inward (clockwise) to
increase the distance between the sheaves or outward (counter-
clockwise) to decrease the distance.
4. Tighten the jam nut. Remove the L-wrench and store it in the tool
kit.
103
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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. Rotate the driven clutch counter-
clockwise 1/4 turn by hand to ensure forward engagement before
attempting to remove the belt.
1. Stop the engine after operat-
ing in a forward motion.
2. Turn the ignition key off.
+
Wait for the engine to come
to a complete stop.
3. Lock the parking brake.
4. Open the hood and remove
the left side panel.
5. Rotate the driven clutch
counterclockwise 1/4 turn
by hand to ensure forward
engagement.
6. Locate the L-wrench in the tool kit. Install the wrench into the open
threaded hole in the outer sheave of the clutch (+).
7. Turn the wrench clockwise until the sheaves open far enough to
remove the belt. If the wrench does not turn readily, rotate the
driven clutch counterclockwise an additional 1/4 turn by hand and
try again.
8. Grasp the belt at the lower edge and remove it.
104
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MAINTENANCE
Clutch System
Drive Belt Installation
1. Drop the drive belt over the
drive clutch and pull back the
slack.
2. To ensure satisfactory belt
life, install belts so they oper-
ate 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.
3. Rotate the L-wrench counterclockwise to tighten the sheaves while
working the belt to the outer edge of the sheaves.
4. Remove the L-wrench and store it in the tool kit.
5. Reinstall the side panel.
6. Close and secure the hood.
Torque Stop
Periodically check torque stop clearance.
.010I-.030I
(.25-.75 mm)
With clutches in proper alignment, the
torque stop clearance should be .010I-
.030I (.25-.75 mm) from the engine case.
Adjust if necessary. Lock the jam nut.
105
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MAINTENANCE
Fall Tune-Up
For maximum performance, arrange for a fall service tune-up with your
Polaris dealer. His experienced and trained service technician will keep
your machine in peak operating condition.
Matte Clear Coat Cleaning
Matte finish products are prone to trapping dirt, oils and other contami-
nants. Polaris Industries rec-ommends 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.
106
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MAINTENANCE
Track Maintenance
Track Inspection
WARNING! Broken track rods can cause a rotating track to come off the
machine, which could cause serious injury or death. Never operate with a
damaged track. Never rotate a damaged track under power.
1. Using a hoist, safely lift and
support the rear of the snow-
mobile off the ground.
2. Rotate the track by hand to
check for damage.
3. Carefully examine the track
along the entire length of each
rod (+). Bend the track to
check for breakage.
4. Replace the track if any rod
damage is found.
+
Track Lubrication
WARNING! Operating with insufficient lubrication between the rail slide and
track guide clips can cause track failure, loss of vehicle control and loss of
braking ability, which can result in serious injury or death. Avoid operating for
extended periods on ice and other surfaces that have little or no snow for
lubrication.
The slide rail needs snow for lubrication. Excessive wear indicates
insufficient lubrication. A new rail slide can cause faster heat build-up
in limited lubrication, resulting in excessive wear.
If excessive rail slide wear occurs due to poor snow conditions, addi-
tional wheel kits are available. See your dealer for more information.
Track damage or failure caused by operation on ice or under other poor
lubrication conditions will void the track warranty.
107
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MAINTENANCE
Track Maintenance
WARNING! Moving parts can cut and crush body parts. When performing the
checks and adjustments recommended on the following pages, stay clear of all
moving parts. Never perform track measurement or adjustments with the engine
running.
Track Tension
Track adjustment is critical for proper handling. Always maintain cor-
rect tension and alignment.
TRACK TENSION DATA CHART
Measurement
Suspension
Slack Measurement
Weight
Location
IQ 121
Switchback 136
LX 136
7/8"-1 1/8" (2.2-2.9 cm)
7/8"-1 1/8" (2.2-2.9 cm)
10 lbs.
(4.54 kg)
16" (40 cm)
ahead of rear
idler shaft
TIP:Tension adjustments should be made only after the track is warmed up and
limber.
1. Turn the engine off.
2. Lift the rear of the machine and safely support it off the ground.
3. Place the recommended weight or downward pressure on the track
at the specified distance (see chart) ahead of the center of the rear
idler wheel.
4. Measure at the point where the weight is hanging.
108
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MAINTENANCE
Track Maintenance
Track Tension
5. Check for specified slack between the wear surface of the track clip
and the plastic slider. Refer to the Track Tension Data Chart on page
108.
If the track needs adjustment:
6. Loosen the rear idler shaft bolt.
7. Loosen the locknuts.
Adjusting Screw
Lock Nut
Slack Measurement
Shaft
Bolt
S
Track
16I(40 cm)
10 lbs. (4.54 kg)
8. Tighten or loosen the track adjusting screws to provide equal adjust-
ment on both sides of the track.
9. Repeat the measurement on the other side of the track.
TIP:Check more frequently when the machine is new.
10. Start the machine and slowly rotate the track at least five revolu-
tions. Let the track come to a stop (do not apply brakes).
11. Check track alignment (see page 110) and adjust as necessary.
12. Tighten the locknuts.
13. Tighten the idler shaft bolts.
14. (n) Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).
109
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MAINTENANCE
Track Maintenance
n Track Alignment
Periodically check that the track is centered and running evenly on the
slide rails. Misalignment will cause excessive wear to the track and slide
rail.
1. Safely support the rear of the machine with the track off the ground.
2. Start the engine and apply a small amount of throttle until the track
turns slowly at least five complete revolutions. Stop the engine and
let the track come to a stop (do not apply brakes).
3. Inspect track alignment by
looking through the track
window to make sure the
rails (+) are evenly spaced
on each side. If the track
runs to the left, loosen the
idler shaft bolts, then
loosen the left locknut and
tighten the left adjusting
bolt. If the track runs to the
right, loosen the idler shaft
bolts, then loosen the right
locknut and tighten the
right adjusting bolt.
4. After adjustments are com-
plete, tighten the locknuts
and torque idler shaft bolts
to 35 ft. lbs. (47.5 Nm).
+
5. Repeat steps 2 and 3 to verify proper alignment.
110
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MAINTENANCE
Steering System
Steering Inspection and Adjustment
Each week, or before a long ride, check all steering system fasteners and
tighten if necessary.
+
+
+
+
+
111
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MAINTENANCE
Steering System
Ski Alignment
WARNING! Improper ski alignment or adjustment may cause loss of steering
control, resulting in serious injury or death. Do not attempt to change the ski
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 1/8I to 1/4I (3-6 mm) greater
than the measurement at point Y.
TIP:If the skis are misaligned, we recommend that your dealer correct the align-
ment, since camber adjustment may also be affected.
X
10I
10I
Y
112
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MAINTENANCE
Steering System
n Ski Skags
WARNING! Worn skis and/or skags will adversely affect handling. Loss of
vehicle control may result, causing serious injury or death. See your dealer's
studding chart for recommended skags. If you install longer or more aggressive
carbide skags than the original equipment, it may also be necessary to add track
studs to maintain proper vehicle control while turning on hard-packed snow or
ice.
Check skags before each use of the snowmobile to ensure positive steer-
ing characteristics. Skags must be replaced when worn to half their orig-
inal diameter.
TIP:Carbide skags must be replaced if any abnormal wear or chipping is found.
Skag Replacement
Some models are equipped with single skags. Some models are
equipped with dual skags.
1. Raise and support the front of
the machine so the skis are
approximately 6I (15.2 cm)
from the ground.
2. Remove the attaching nuts and
pry the skag downward.
3. Remove the front end of the
skag.
4. Remove the rear end of the
skag.
5. Reverse the steps to install a
skag.
Skag
113
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MAINTENANCE
Steering System
n Rail Slide Wear
Measure slide thickness at
several points along the rail.
Have your dealer replace the
slide when it's worn down to
the top of the wear limit
7/16I
(1.1 cm)
+
indicator groove (+). Do not
operate the snowmobile if
slide thickness measures less
than 7/16I (1.1 cm).
Suspension Maintenance
n Pre-Ride Suspension Inspection
Loose nuts and bolts can reduce your snowmobile's reliability and cause
needless repairs and down time. Before beginning any snowmobile trip,
a visual inspection will uncover potential problems. Check the follow-
ing items on a weekly basis or before any long trip:
n Check suspension mounting bolts for tightness.
n Check rear idler wheel bolts for tightness. See page 109.
n Check rear idler adjusting bolt locknuts for tightness.
n Check front torque arm limiter strap condition.
n Check rail slide condition. See page 114.
n Check track tension. See page 108.
n Lubricate all rear suspension components. See page 83.
n Check ski runner/skag condition. See page 113.
n Check ski spindle bolts for tightness.
n Check tie rod end nuts for tightness.
114
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MAINTENANCE
Extended Storage
Off-season or extended storage of your snowmobile requires preventive
measures to aid against deterioration and to prolong the useful life of
many components. See page 118 for the part numbers of Polaris prod-
ucts.
Cleaning and Preservation
Proper storage starts with cleaning, washing, and waxing the hood,
chassis, and plastic parts. Wipe down remaining surfaces with a damp
cloth. Clean and touch up with paint any rusted or previously painted
surfaces. Be sure that corrosive salt and acids are removed from surfaces
before beginning preservation with waxes and rust inhibitors (grease, oil
or paint).
The machine should be stored in a dry garage or shed, out of direct sun-
light, and covered with a fabric snowmobile cover. Plastic tarp may
cause condensation to form and damage snowmobile components.
Controls and Linkage
Lubricate all bushings and cables as outlined in the Periodic Mainte-
nance Table beginning on page 80.
115
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MAINTENANCE
Extended Storage
Bearings
Grease the jackshaft and drive shaft clutch side bearings with Polaris
Premium All-Season Grease or a similar high quality grease to prevent
corrosion.
Clutch and Drive System
Remove the drive belt and store in a cool dry location. Do not lubricate
clutch components, except the driven clutch shaft bushing as outlined in
the Master Repair Manual. See your dealer.
Engine Protection
Proper preparation of the engine and fuel system is vital to the preven-
tion of rust and corrosion on precision engine parts during storage.
Whenever the machine is stored for a period of more than 60 days, the
engine must be fogged with fogging oil. Follow the engine fogging
instructions provided on the container.
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to
the fuel tank. Follow the instructions on the container, running the
engine for five minutes to get additives through the entire fuel system.
Top off with fresh fuel. Do not allow the snowmobile to run out of fuel.
116
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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.
Transporting the Snowmobile
Whenever the snowmobile is transported:
1. Be sure the fuel cap and oil cap are installed correctly.
2. Tie the snowmobile to the transporting unit securely using suitable
straps.
3. Remove the ignition key to prevent loss.
Track and Suspension
Moderate track tension should be main-
tained during summer storage. The
machine should be supported off the
ground to allow the track to hang freely.
117
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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
118
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TROUBLESHOOTING
Engine Troubleshooting
Unless you have experience and training in two-cycle engine repair,
see your dealer if technical problems arise.
Problem
Probable Cause Solution
Erratic engine oper- Drive clutch binding • 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.
119
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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 87-91 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.
120
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TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause Solution
Engine turns but fails Faulty ignition
to start
• Install new spark plug(s). If engine
still fails to start, check for spark. If
there's no spark, SEE YOUR
DEALER.
No fuel to engine
• Make sure the fuel valve is on.
• Make sure the fuel tank contains
fuel.
• Ice may be in the fuel line, filter or
pump. Add isopropyl alcohol to the
fuel system.
Poor engine com-
pression
• Mixture is too lean. A main jet that
is too small will cause seizure result-
ing in loss of power. This indicates a
major engine problem that must be
repaired before operating. SEE
YOUR DEALER.
Engine lacks power
Fouled or defective
spark plug(s)
• Replace the plug(s).
Fuel filter (loss of
high RPM power)
• 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
121
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TROUBLESHOOTING
Suspension Troubleshooting
Problem
Solution
Rear suspension bot-
toms too easily
• Adjust torsion spring preload to achieve proper static sag
(see page 46).
• Change torsion spring to stiffer optional spring (see your
dealer).
• Revalve rear track shock (see your dealer).
Rides too stiff in rear • Check for binding suspension shafts and grease all pivot
points.
• Adjust torsion spring preload to achieve proper static sag
(see page 46).
• Change torsion spring to softer optional spring (see your
dealer).
• Check track tension (see page 108).
Too much weight
transfer when climb-
ing
• Set static sag (see page 46). Adjust torsion spring blocks or
install optional torsion springs to achieve correct sag.
• Adjust limiter straps (see page 49).
Too little weight
transfer when climb-
ing
• Set static sag (see page 46). Adjust torsion spring blocks or
install optional torsion springs to achieve correct sag.
• Adjust limiter straps (see page 49).
Machine darts from
side to side
• Check ski alignment (see page 112).
• Make sure spindles and all steering components turn freely.
• Check for excessive play in steering assembly (see your
dealer).
• Ensure skags are straight on skis.
• Set static sag (see page 46).
• Check rail slide/replace if worn (see page 114).
• Install Accu-Trak dual skags (see your dealer).
Front end pushes
• Check for worn skags.
• Set static sag (see page 46).
• Check for binding front suspension shafts and steering
components, grease all pivot points (elevate front of
machine).
• Increase IFS preload (if equipped) (see page 42).
• Install single skag (see your dealer).
• Rotate RRSS to high position (see page 53).
Steering is heavy
• Make sure spindles and all steering components turn freely.
• Check ski alignment (see page 112).
• Check skags and skis for damage.
• Set static sag (see page 46).
122
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TROUBLESHOOTING
Drive Belt Troubleshooting
Belt Wear/Burn Diagnosis
Causes
Solutions
Driving at low RPM
• Drive at higher RPMs. Gear the machine down. Check
belt deflection.
Insufficient warm-up
Towing at low RPM
• Warm the engine at least five minutes. Take the drive
belt off the machine in extremely cold weather and
warm it up. Break machine loose from the snow.
• Do not tow in deep snow. Use fast, aggressive throttle
to engage clutch.
Riding with high RPM
and slow speed (8000
RPM/10 MPH)
• Lower the gear ratio. Reduce RPM. Avoid riding in
high ambient temperatures. Check for snow ingestion.
Ice and snow build-up
between track and tunnel
• Warm the engine at least five minutes. Take the drive
belt off the machine in extremely cold weather and
warm it up. Break machine loose from the snow.
Poor engine performance • Check for carburetor and choke synchronization, fouled
plugs, debris in the carburetor(s) and water, ice or dirt
in the fuel tank or fuel line.
Loading machines onto
trailers
• Skis may gouge into trailers and prevent the drivetrain
from spinning properly. Use enough speed to drive the
machine completely onto the trailer. Push and pull it to
finish loading if necessary.
Clutch malfunction
• Inspect clutch components. See your dealer.
Slow, easy clutch engage- • Use fast, aggressive throttle to engage clutch.
ment
123
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WARRANTY
Service and Warranty Information
Obtaining Service and Warranty Assistance
Read and understand the service data and the Polaris warranty information con-
tained in this manual. Contact your Polaris dealer for replacement parts, service
or warranty. Your dealer receives frequent updates on changes, modifications
and tips on snowmobile maintenance, which may supersede information con-
tained in this manual. Your dealer is also familiar with Polaris policies and pro-
cedures and will be happy to assist you.
When contacting us about parts, service, or warranty, always provide the fol-
lowing information:
1. Serial number
2. Model number
3. Dealer name
4. Date of purchase
5. Details of trouble experienced
6. Length of time and conditions of operation
7. Previous correspondence
Use the page provided near the front of your Owner's Manual to record the
identification numbers of your snowmobile and its engine.
Polaris Customer Service
United States: 1-888-704-5290
Canada: 1-204-925-7100
124
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WARRANTY
Service and Warranty Information
Polaris Anti-Theft System
The Polaris anti-theft system (PATS) monitoring program is designed to aid
owners of registered snowmobiles in recovery of stolen machines.
Administration
1. Polaris snowmobile owner reports theft.
A. In addition to notifying the proper law enforcement officials,
the owner must call Polaris Customer Service.
B. Owners must provide their name, address, telephone num-
ber and the model and serial number of stolen machines.
2. Polaris warranty will provide all dealerships with a monthly updated list of
all stolen units to further monitor thefts.
3. Polaris warranty will aid in notifying the proper owner when a unit is
recovered.
125
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WARRANTY
Limited Warranty
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-
ITED WARRANTY on all components of the Polaris snowmobile against defects in
material or workmanship. This warranty covers the parts and labor charges for repair or
replacement of defective parts that are covered by this warranty. The warranty begins on
the date of purchase. This warranty is transferable to another consumer, during the war-
ranty period, through a Polaris dealer.
Registration
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-
ment. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.
Initial dealer preparation and setup of your snowmobile is very important in ensuring
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer
setup will void your warranty coverage.
Warranty Coverage and Exclusions
Limitations of warranties and remedies
This warranty excludes any failures not caused by a defect in material or workmanship.
The warranty does not cover accidental damage, normal wear and tear, abuse or
improper handling. The warranty also does not cover any snowmobile that has been
structurally altered, neglected, improperly maintained, used for racing or used for pur-
poses other than for which it was manufactured. The warranty does not cover any dam-
ages that occur during trailer transit or as a result of unauthorized service or parts. In
addition, this warranty does not cover physical damage to paint or finish, stress cracks,
tearing or puncturing of upholstery material, corrosion or defects in parts, components
or the snowmobile due to fire, explosions or any other cause beyond Polaris' control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the snowmobile.
The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option,
repair or replacement of any defective materials, or components or products. THE REM-
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-
ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-
GENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-
sion or limitation of incidental or consequential damages or implied warranties, so the
above limitations or exclusions may not apply to you if inconsistent with controlling
state law.
126
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WARRANTY
Limitations of warranties and remedies
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-
RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations
on how long an implied warranty lasts, so the above limitation may not apply to you if
inconsistent with controlling state law.
How to Obtain Warranty Service
If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-
rized to repair Polaris snowmobiles. When requesting warranty service you must present
your copy of the Warranty Registration form to the dealer. (The cost of transportation to
and from the dealer is YOUR responsibility). Polaris recommends that you use your
original selling dealer; however, you may use any Polaris Servicing Dealer to perform
warranty service.
Please work with your dealer to resolve any warranty issues. Your dealer will contact the
appropriate personnel at Polaris if additional assistance is needed.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-
ommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
127
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WARRANTY
Conditions and Exclusions
In order to qualify for warranty, the product must have been properly set up and tested
by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle
Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer
sign the PDI form prior to delivery may void the warranty. Failure to provide proof of
required periodic maintenance upon request may result in denial of warranty coverage.
Use of the recommended Polaris products for lubrication and maintenance as directed by
the Owner's manual is highly recommended. Should a failure occur during the warranty
period resulting from the use of non-recommended products, warranty coverage may be
denied.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination. The following items are excluded from warranty con-
sideration if the failure was due to wear or not the direct result of a defect:
Skis
Ski wear rods
Tracks
Slide rails
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
Light bulbs/Sealed beam lamps
Idler wheels
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered "consumable," meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
Spark Plugs
Filters
Fuel
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Sealants
Hotel fees
Meals
Towing charges
Mileage
Rentals/Loss of product use
Shipping/ handling fees
Product pick-up/delivery
Loss of vacation/personal time
This warranty also excludes failures resulting from improper lubrication; improper
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold
or contamination; operator error or abuse; improper component alignment, tension,
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
128
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WARRANTY
Polaris Second Year Engine Service Contract
Second Year Engine Service Contract is standard on all eligible new and unused snow-
mobiles that were Snow Checked through an authorized Polaris dealer during the
March/April Snow Check promotion. The free Second Year Engine Service Contract is
honored by all authorized Polaris snowmobile dealers in North America and is transfer-
able 120 days after the original purchase date, free of charge, through any Polaris snow-
mobile dealer. Coverage on Snow Check units is automatic. Although you do not
receive a warranty card, your dealership should have printed a copy of the warranty reg-
istration form. This form is your proof of warranty.
Consumer Exclusions
• Each repair visit after the first twelve months of standard warranty coverage is 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.
129
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WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle's warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer's authorized location.
This policy does not apply to Safety Recalls.
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 124).
130
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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.
131
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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.
132
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MAINTENANCE LOG
Present this section of your manual to your dealer each time your snow-
mobile is serviced. This will provide you and future owners with an
accurate log of maintenance and services performed on the snowmobile.
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
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MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
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MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
135
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INDEX
A
D
Accessories . . . . . . . . . . . . . . . . . . . 55
Adjustable Headlights . . . . . . . . . . . 29
Air Pollution . . . . . . . . . . . . . . . . . . . 6
Avalanches. . . . . . . . . . . . . . . . . . . . 15
DET. . . . . . . . . . . . . . . . . . . . . . . . . . 29
Detonation Elimination Technology. 29
Digital Display . . . . . . . . . . . . . . . . . 30
Disabled Operators . . . . . . . . . . . . . . 12
Drive Belt . . . . . . . . . . . . . . . . . . . . . 19
Drive Belt Adjustment . . . . . . . . . . 103
Drive Belt Condition. . . . . . . . . . . . 102
Drive Belt Deflection . . . . . . . . . . . 103
Drive Belt Installation. . . . . . . . . . . 105
Drive Belt Removal. . . . . . . . . . . . . 104
Drive Chain Tension . . . . . . . . . . . . . 95
Driver Awareness . . . . . . . . . . . . . . . 14
Driveshaft Bearing . . . . . . . . . . . . . . 84
Driving Downhill . . . . . . . . . . . . . . . 17
Driving in Hilly Terrain . . . . . . . . . . 18
Driving on Slippery Surfaces . . . . . . 16
Driving Responsibly . . . . . . . . . . . . . 21
B
Bearings. . . . . . . . . . . . . . . . . . . . . 116
Brake Components. . . . . . . . . . . . . . 96
Brake Fluid . . . . . . . . . . . . . . . . . . . 97
Brake Inspection . . . . . . . . . . . . . . . 96
Brake Lever Travel . . . . . . . . . . 60, 96
Brake System Bleeding . . . . . . . . . . 98
Brakelight Replacement. . . . . . . . . 100
Brakes . . . . . . . . . . . . . . . . . . 60, 96-98
C
Carbide Skags . . . . . . . . . . . . . . . . . 57
Cargo Area. . . . . . . . . . . . . . . . . . . . 29
Chaincase Oil. . . . . . . . . . . . . . . . 85-86
Choke. . . . . . . . . . . . . . . . . . . . . . . . 85
Cleaning and Preservation. . . . . . . 115
Clutch Alignment Offset . . . . . . . . 101
Clutch and Drive System. . . . . . . . 116
Clutch Center Distance . . . . . . . . . 101
Clutch Cover Warning. . . . . . . . . . . 23
Clutch Safety . . . . . . . . . . . . . . . . . . 19
Clutch System . . . . . . . . . . . . . 101-105
Cold Weather Drive-Away . . . . . . . 19
Compression Damping,
E
Electrical Connections . . . . . . . . . . 117
Engine Break-In . . . . . . . . . . . . . 66-67
Engine Protection . . . . . . . . . . . . . . 116
Engine Restarting . . . . . . . . . . . . . . . 65
Engine Safety . . . . . . . . . . . . . . . . . . 10
Engine Starting . . . . . . . . . . . . . . . . . 65
Engine Stop Switch. . . . . . . . . . . . . . 72
Environment . . . . . . . . . . . . . . . . . . . . 6
Exhaust System . . . . . . . . . . . . . . . . . 94
F
Rear Shock (Premium Shock) . 50
Controls and Linkage. . . . . . . . . . . 115
Coolant. . . . . . . . . . . . . . . . . . . . . . . 91
Coolant Level. . . . . . . . . . . . . . . . . . 91
Cooling System . . . . . . . . . . . . . . 91-93
Cooling System, Bleeding . . . . . . . . 93
Cooling System, Flushing . . . . . . . . 92
Customer Service. . . . . . . . . . . . . . 124
Front Rear Scissor Stop. . . . . . . . . . . 51
Front Suspension Adjustments . . 41-43
Front To Rear Coupling . . . . . . . . . . 51
FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fuel . . . . . . . . . . . . . . . . . . . . . . . 69-70
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 90
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 90
Fuel Pump . . . . . . . . . . . . . . . . . . . . . 90
Fuel Mode Change Wires (800) . . . . 70
Fuel Resistor (600) . . . . . . . . . . . . . . 70
Fuel System Deicers . . . . . . . . . . . . . 69
136
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INDEX
G
O
Gauge Cleaning. . . . . . . . . . . . . . . . . 40
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 89
Oil Indicator Light . . . . . . . . . . . . . . 71
Oil Injection System. . . . . . . . . . . . . 67
Oil Level. . . . . . . . . . . . . . . . . . . . . . 71
Oil Lines. . . . . . . . . . . . . . . . . . . . . . 89
Oil Recommendations . . . . . . . . . . . 67
Operating in Deep Snow . . . . . . . . . 20
Operation Warning. . . . . . . . . . . 25-26
Operator Safety. . . . . . . . . . . . . . . 8-22
H
Handlebar Adjustments. . . . . . . . . . . 54
Handlebar Angle. . . . . . . . . . . . . . . . 54
Handlebar Position . . . . . . . . . . . . . . 54
Headlight Adjustment. . . . . . . . . . . . 29
Headlight Bulb Installation. . . . . . . . 99
Headlight Bulb Removal . . . . . . . . . 99
High Temperature Light . . . . . . . . . . 92
Hood Latches . . . . . . . . . . . . . . . . . . 63
Hot Surface Warning . . . . . . . . . . . . 24
P
Parking Brake Lever Lock . . . . . . . . 61
Passenger Warnings . . . . . . . . . . . . . 24
Preload, IFS Shock Spring . . . . . . . . 42
Pre-Ride Checklist . . . . . . . . . . . . . . 58
Pre-Ride Suspension Inspection. . . 114
Pressure Cap Warning . . . . . . . . . . . 23
I
Ice and Snow Build-up . . . . . . . . . . . 16
IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
IFS Adjustment Options . . . . . . . . . . 41
IFS Components . . . . . . . . . . . . . . . . 41
Inadequate Snow Conditions . . . . . . 20
Instrumentation . . . . . . . . . . . . . . 30-40
Intake Filters . . . . . . . . . . . . . . . . . . . 90
Intake Silencer . . . . . . . . . . . . . . . . . 19
R
Rail Slide Wear . . . . . . . . . . . . . . . 114
Rear Rear Scissor Stop. . . . . . . . . . . 52
Rear Suspension Adjustments . . 44-45
Rear To Front Coupling . . . . . . . . . . 52
Recoil Rope . . . . . . . . . . . . . . . . . . . 63
Recommended Maintenance . . . . . . . 9
Registration, Warranty . . . . . . . . . . 126
Reverse . . . . . . . . . . . . . . . . . . . . 75-76
Reverse Warning . . . . . . . . . . . . . . . 25
Rider Capacity . . . . . . . . . . . . . . . . . 13
Riding Apparel . . . . . . . . . . . . . . . . . 11
Riding Position. . . . . . . . . . . . . . . . . 10
RRSS . . . . . . . . . . . . . . . . . . . . . . . . 52
L
Lights . . . . . . . . . . . . . . . . . . . . 99-100
Limiter Strap Position, SwitchBack . 49
Low Oil Indicator Light . . . . . . . . . . 71
Lubrication . . . . . . . . . . . . . . . . . 83,-86
M
Maintenance Interval Table . . . . 80-82
Maintenance Program. . . . . . . . . . . . 79
Maneuverability . . . . . . . . . . . . . . . . 19
Matte Finish Cleaning. . . . . . . . . . . 106
MFD Battery Replacement . . . . . 39-40
MFD Components. . . . . . . . . . . . . . . 30
MFD Digital Display Programs . 32-38
MFD Settings . . . . . . . . . . . . . . . . . . 31
S
Safety Decals . . . . . . . . . . . . . . . 23-26
Safety Symbols. . . . . . . . . . . . . . . . . . 8
Sag . . . . . . . . . . . . . . . . . . . . . . . 46-47
Shock Compression Damping
Front Suspension (IFS). . . . . . . 43
Front/Rear Track . . . . . . . . . . . 50
Shock Valving, IFS . . . . . . . . . . . . . 43
N
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Signal Words . . . . . . . . . . . . . . . . . . . 8
137
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INDEX
S
T
Ski Alignment . . . . . . . . . . . . . . . . 112
Ski Pressure . . . . . . . . . . . . . . . . . . . 49
Ski Skags . . . . . . . . . . . . . . . . . . . . 113
Slide Rail and Track Cooling . . . . . 67
Snow Conditions . . . . . . . . . . . . . . . 20
Spark Plug Condition. . . . . . . . . . . . 88
Spark Plug Removal . . . . . . . . . . . . 89
Spark Plugs . . . . . . . . . . . . . . . . . . . 87
Speed . . . . . . . . . . . . . . . . . . . . . . . . 13
Spring Preload, IFS Shock. . . . . . . . 42
Spring Preload, Rear . . . . . . . . . . 46-47
Starting the Engine . . . . . . . . . . . . . 65
Starting the Engine, Restarting . . . . 65
Steering Inspection/Adjustment. . . 111
Steering System . . . . . . . . . 62, 111-114
Stopping, Emergency. . . . . . . . . . . . 74
Storage, Daily . . . . . . . . . . . . . . . . . 77
Storage, Extended . . . . . . . . . . 115-117
Studs . . . . . . . . . . . . . . . . . . . . . . . . 56
Survival Preparation . . . . . . . . . . . . 12
Suspension Adjustments, Rear . . 46-53
Suspension Coupling, IQ. . . . . . . . . 51
Suspension Inspection, Pre-Ride . . 114
Suspension Maintenance . . . . . . . . 114
Suspension Performance Tips . . . . . 45
Suspension, Rear, Lubrication. . . . . 83
Taillight/Brakelight Replacement . . 100
Throttle Cable . . . . . . . . . . . . . . . . . . 84
Throttle Lever . . . . . . . . . . . . . . . 59, 73
Throttle Safety Switch. . . . . . . . . 59, 72
Torque Stop. . . . . . . . . . . . . . . . . . . 105
Torsion Spring Preload, IQ . . . . . . . . 48
Towing . . . . . . . . . . . . . . . . . . . . . . . 77
Track . . . . . . . . . . . . . . . . . . . . . . . . . 62
Track Alignment . . . . . . . . . . . . . . . 110
Track Care for Storage . . . . . . . . . . 117
Track Inspection . . . . . . . . . . . . . . . 107
Track Lubrication . . . . . . . . . . . . . . 107
Track Maintenance . . . . . . . . . 107-110
Track Safety . . . . . . . . . . . . . . . . . . . 10
Track Tension . . . . . . . . . . 45, 108-109
Track Warm-Up . . . . . . . . . . . . . . . . 68
Track Warning . . . . . . . . . . . . . . . . . 24
Traction Products . . . . . . . . . . . . 56-57
Transporting the Snowmobile. . . . . 117
Troubleshooting, Drive Belt . . . . . . 123
Troubleshooting, Engine. . . . . 119-121
Troubleshooting, Suspension . . . . . 122
Tune-Up . . . . . . . . . . . . . . . . . . . . . 106
V
Vehicle Identification Numbers . . . . . 5
W
Wear Strips . . . . . . . . . . . . . . . . . . . . 57
Weight Transfer . . . . . . . . . . . . . . . . 53
Windchill. . . . . . . . . . . . . . . . . . . . . . 22
138
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