Polaris Offroad Vehicle 700 Dragon RMK User Manual

Pantone 280 CVC  
RMK Shift  
600 RMK  
700 RMK  
700 Dragon RMK  
800 Dragon RMK  
Snowmobile Owner's Manual  
for Maintenance and Safety  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARNING  
Read, understand, and follow all of the instructions and safety precautions in  
this manual and on all product labels.  
Failure to follow the safety precautions could result in serious injury or death.  
WARNING  
The engine exhaust from this product contains chemicals known to the State of  
California to cause cancer, birth defects or other reproductive harm.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WELCOME  
Thank you for purchasing a Polaris vehicle, and welcome to our world-  
wide family of Polaris owners. We proudly produce an exciting line of  
utility and recreational products.  
• Snowmobiles  
• All-terrain vehicles (ATVs)  
RANGER utility vehicles  
• Victory motorcycles  
We believe Polaris sets a standard of excellence for all utility and recre-  
ational vehicles manufactured in the world today. Many years of experi-  
ence have gone into the engineering, design, and development of your  
Polaris vehicle, making it the finest machine we’ve ever produced.  
For safe and enjoyable operation of your vehicle, be sure to follow the  
instructions and recommendations in this owner’s manual. Your manual  
contains instructions for minor maintenance, but information about  
major repairs is outlined in the Polaris Service Manual and should be  
performed only by a Factory Certified Master Service Dealer (MSD)  
Technician.  
Your Polaris dealer knows your vehicle best and is interested in your  
total satisfaction. Be sure to return to your dealership for all of your ser-  
vice needs during, and after, the warranty period.  
We also take great pride in our complete line of apparel, parts and acces-  
sories, available through our online store at www.purepolaris.com. Have  
your accessories and clothing delivered right to your door!  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-  
tries Inc.  
Copyright 2007 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.  
2008 Owner’s Manual P/N 9921554  
RMK SHIFT/600 RMK/700 RMK/700 DRAGON RMK/800 DRAGON RMK  
2
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
This section contains helpful information for owners and drivers and  
illustrates the location of important identification numbers that should  
be recorded in the owner’s manual.  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
This section describes safe vehicle operation and identifies warning  
decals and their locations.  
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
This section identifies the locations of your snowmobile’s controls and  
features.  
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 39  
This section explains how to tailor the suspension and other features for  
an optimum riding experience.  
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 49  
This section explains procedures that must be performed before riding.  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56  
This section explains proper engine break-in, operation of features and  
general operating procedures.  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 69  
This section defines your role, and your dealer’s role, in your snowmo-  
bile’s regular maintenance.  
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 112  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 113  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118  
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 127  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Important Notes for Owners and Drivers  
After reading this manual, store it in the snowmobile for convenient ref-  
erence. It should remain with the snowmobile when the snowmobile is  
sold.  
Some of the illustrations and photos used in this manual are general rep-  
resentations. Your model may differ.  
Follow the maintenance program outlined in this manual. Preventive  
maintenance ensures that critical components of the snowmobile are  
inspected by your dealer at specific mileage intervals.  
You and your dealer must complete the registration form included with  
your snowmobile and forward it to us. This completed form is necessary  
to ensure warranty coverage.  
Protect and preserve your right to ride by joining your local trail riding  
clubs.  
When teaching inexperienced operators to ride, set up a predetermined  
course for practice. Make sure they know how to drive and control the  
snowmobile before allowing them to make longer trips. Teach them  
proper snowmobile courtesy, and enroll them in driver’s training and  
safety courses sponsored by local or state organizations.  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Preservation of the Environment  
Polaris is committed to supporting an environmental education cam-  
paign. We encourage state and provincial governments across the snow-  
belt to adopt rigorous safety training programs that encourage protection  
of our environment, including wildlife and vegetation.  
Snowmobile clubs and other organizations are working together to pro-  
tect our environment. Please support their efforts and operate your  
snowmobile with consideration for the protection and preservation of  
our environment.  
Noise Level  
One of the most publicized issues about snowmobiles is noise. The  
Society of Automotive Engineers (SAE), the standard-setting body for  
snowmobile development, recommends that snowmobiles conform to  
prescribed sound levels.  
Polaris snowmobiles are engineered to conform to these SAE standards.  
Our muffler systems are designed to reduce noise levels and must not be  
altered or removed. The sound of your snowmobile may not be welcome  
to non-snowmobilers, so you have a responsibility to operate your  
snowmobile with concern for others. We do our part by manufacturing  
quieter machines; we ask your help to further reduce the impact of noise  
by operating your snowmobile safely and responsibly.  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Vehicle Identification Numbers  
Record your snowmobile’s identification numbers and key number in  
the spaces provided below. The key number is stamped on the spare key.  
The number on the rubber-coated key is in the form of raised dots.  
Remove the spare key and store it in a safe place. An ignition key can be  
duplicated only by ordering a Polaris key blank (using your key num-  
ber) and mating it with one of your existing keys. The ignition switch  
must be replaced if all keys are lost.  
VIN  
Vehicle Model Number: ___________________________________________________  
Tunnel VIN: _____________________________________________________________  
(lower right side of the tunnel)  
Engine Serial Number (on valve cover): _______________________________________  
Key Number: ___________________________________________________________  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
The following signal words and symbols appear throughout this manual  
and on your vehicle. Your safety is involved when these words and sym-  
bols are used. Become familiar with their meanings before reading the  
manual.  
The safety alert symbol, on your vehicle or in this manual, alerts you to the  
potential for injury.  
WARNING  
The safety alert warning indicates a potential hazard that may result in serious  
injury or death.  
CAUTION  
The safety alert caution indicates a potential hazard that may result in minor  
injury or damage to the vehicle.  
CAUTION  
A caution indicates a situation that may result in damage to the vehicle.  
NOTE  
A note will alert you to important information or instructions.  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Follow the recommended maintenance program outlined beginning on  
page 71 of this manual to ensure that all critical components on the  
snowmobile are thoroughly inspected by your dealer at specific mileage  
intervals.  
WARNING  
Driving a snowmobile requires your full attention. DO NOT drink alcohol or  
use drugs or medications before or while driving or riding as a passenger.  
They will reduce your alertness and slow your reaction time.  
Snowmobiles are capable of traveling at high speeds. Use extra caution to  
ensure operator safety. Make sure your snowmobile is in excellent operating  
condition at all times. Always check major and vital safety components  
before every ride.  
All Polaris snowmobiles are designed and tested to provide safe operation  
when used as directed. Failure of critical machine components may result  
from operation with any modifications, especially those that increase speed  
or power. DO NOT MODIFY YOUR MACHINE. The snowmobile may  
become aerodynamically unstable at speeds higher than those for which it is  
designed. Loss of control may occur at higher speeds. Modifications may  
also create a safety hazard and lead to bodily injury.  
The warranty on your entire machine is terminated if any equipment has  
been added, or any modifications have been made, to increase the speed or  
power of the snowmobile.  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Stay Clear of Track  
Your snowmobile is propelled by a revolving track that must be partially  
exposed for proper operation.  
WARNING  
Serious injuries may result if hands, feet, or  
clothing become entangled in the track. Be  
alert when riding, and remain properly seated  
to stay clear of the track.  
Never hold the snowmobile up or stand  
behind it while warming up the track. A loose  
track or flying debris could cause serious  
injury or death. We recommend having your  
dealer perform all track service and alignment  
procedures.  
Stay Clear of Engine  
Never attempt adjustments with the engine running. Turn off the igni-  
tion, raise the hood, make the adjustment, secure shields and guards,  
secure the hood, and then restart the engine to check its operation.  
WARNING  
Serious injury can occur if fingers or clothing contact the moving parts of an  
engine. Always stop the engine before attempting adjustments.  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Riding Position  
Operating a snowmobile requires skill and balance for proper control.  
Rider positions may vary with experience; but under many conditions,  
the proper position is to be seated with both feet on the running boards  
and both hands on the handlebar grips for proper throttle, brake and  
steering control.  
WARNING  
Improper riding position may reduce control and could result in serious injury  
or death. Always ride in a position that allows for control of your vehicle.  
Survival Preparation  
For your safety, always ride in a group of other snowmobilers. Always  
tell someone where you’re going and how long you expect to be gone. If  
it isn’t possible to ride with others, and you must travel into remote  
areas, always carry survival equipment that’s appropriate to the condi-  
tions you may encounter. Such equipment may include, but is not lim-  
ited to: extra clothing, a sleeping bag, a flashlight, food and water, a  
signaling mirror, a means of building a fire, and a two-way radio or cel-  
lular telephone.  
Always carry the owner’s manual on your snowmobile. For added pro-  
tection, purchase and carry the following items on your snowmobile as  
well:  
• Spare Drive Belt  
• Extra Set of Spark Plugs  
• Tow Rope  
• Winter Survival Kit  
• Trail Map  
• First Aid Kit  
• Tool Kit  
• Extra Oil  
• Fuel Deicer  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Riding Apparel  
Helmet  
Wearing a helmet can prevent a severe head injury. Whenever riding a  
Polaris vehicle, always wear a helmet that meets or exceeds established  
safety standards.  
Approved helmets in the USA and Canada bear a U.S. Department of  
Transportation (DOT) label.  
Approved helmets in Europe, Asia and Oceania  
bear the ECE 22.05 label. The ECE mark consists  
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.  
Clothing  
Be prepared, be warm and be com-  
fortable when riding. Be aware of  
the weather forecast, especially the  
windchill, and dress accordingly.  
See the chart on page 21.  
WARNING  
Avoid wearing loose clothing or  
long scarves, which can become  
entangled in moving parts and  
cause serious injury. Always wear  
an approved helmet and eye pro-  
tection.  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Disabled Operators  
Safe operation of this rider-active vehicle requires good judgement and  
physical skills.  
WARNING  
Operators with cognitive or physical disabilities have an increased risk of loss  
of control, which could result in serious injury or death. Do not allow disabled  
persons to operate this vehicle.  
Rider Capacity  
Your Polaris snowmobile is designed for a single rider only. Do not  
carry a passenger.  
Excessive Speed  
WARNING  
High speed driving, especially at night, could result in serious injury or death.  
Always reduce speed when driving at night or in inclement weather.  
Always observe all state and local laws governing snowmobile opera-  
tion and speed limits. Always be alert and pay attention to the trail  
ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling  
about 60 feet (18 m) per second. If you look back for only two seconds,  
your snowmobile will travel about 120 feet (36 m). If your speed is 60  
MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in  
two seconds.  
Traveling at night requires extra caution. Check headlight and taillight  
to ensure proper operation, and don’t over-drive your headlight beam.  
Always be able to bring your snowmobile to a stop in the distance illu-  
minated by the headlight.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driver Awareness  
Slow down when traveling near poles,  
posts, or other obstacles. Be especially  
alert if you’re snowmobiling after dark.  
Always be on the alert for wire fences.  
Single strands are especially dangerous,  
since there may be a great distance  
between posts. Guy wires on utility poles  
are also difficult to distinguish.  
Make sure the way is clear before crossing  
railroads and other roads and highways.  
The noise of your snowmobile will drown  
out the sound of approaching vehicles.  
Look ahead, behind, and to both sides  
before turning or crossing railroad tracks  
or highways. Steep embankments may  
also hide your view. Always leave yourself  
a way out.  
R R  
Variances in snow depth and/or water currents may result in uneven ice  
thickness. You may drown if you break through the ice. Avoid travelling  
on frozen bodies of water.  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Avalanches  
Snowmobilers should always be properly  
trained and equipped before traveling in  
mountainous terrain:  
• Take an avalanche class  
• Travel with experienced people  
• Travel on designated trails  
• Make sure each person is equipped  
with a shovel, probe and avalanche  
beacon.  
You don’t have to be snowmobiling on a slope for an avalanche to occur.  
Be aware that all of the snow is connected. You may be riding on a flat  
slope or snow covered road, but if the snowpack above is unstable  
enough you can trigger an avalanche on a steeper slope above you.  
Always be aware of snow conditions above you as you travel in moun-  
tainous terrain.  
Before riding in mountainous terrain, call or log on to your local ava-  
lanche advisory to get current weather and snow stability information.  
For more information about avalanche training and avalanche condi-  
tions, contact local law enforcement in your area, or visit the American  
and Canadian online avalanche centers at www.avalanche.org.  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Ice and Snow Build-up  
WARNING  
Ice and snow build-up may interfere with the steering of your snowmobile,  
resulting in serious injury or death. Keep the underhood area free of snow  
and ice.  
Before driving, manually turn the skis to the left and right to be sure ice  
and snow are not interfering with full left and right steering. If difficulty  
is encountered, remove ice and snow build-up that may be obstructing  
the steering linkage.  
Driving Downhill  
When riding downhill, shift your weight to the rear of the snowmobile  
and reduce your speed to a minimum. Apply just enough throttle to keep  
the clutch engaged, allowing the engine’s compression to help slow the  
snowmobile and keep it from rolling freely downhill.  
WARNING  
When driving on long downhill stretches, pump the brakes. Riding the brakes  
may cause the brake system to overheat, which may result in brake failure.  
Excessive or repetitive use of the brakes for high speed stops will also cause  
an overheated brake system. This condition may lead to a sudden loss of  
brakes and/or fire and may result in serious injury or death.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driving on Slippery Surfaces  
WARNING  
Never attempt an abrupt change of direction when operating on slippery sur-  
faces. Proceed slowly and use extra caution.  
Driving on ice or hard-packed snow reduces steering and braking control,  
which may result in loss of control and serious injury or death. Slow down  
and use extra caution when operating on slippery surfaces.  
Driving in Hilly Terrain  
WARNING  
Climbing a hill or crossing the face of a slope may result in loss of balance  
and snowmobile rollover, causing serious injury or death. Use caution and  
good judgement when driving in hilly terrain.  
Use extra caution when operating in hilly terrain. If climbing a hill is  
unavoidable, keep your weight low and forward. If you must cross the  
face of a slope, keep your weight on the uphill side of the snowmobile to  
maintain proper balance and avoid possible rollover.  
Slow down when reaching the crest of a hill. Be prepared to react to  
obstacles, sharp drops or other people or vehicles that may be on the  
other side of the hill.  
If you’re unable to continue up a hill, turn the snowmobile downhill  
before it loses momentum. If this isn’t possible, spin the track just  
enough to dig in to prevent it from rolling back down the hill. Stop the  
engine and set the parking brake (if equipped). Keeping away from the  
downhill side of the snowmobile, pull the rear of the snowmobile  
around and point the front end and skis downhill. Remount the snowmo-  
bile, restart the engine, release the parking brake, and descend the hill  
carefully.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Drive Belt  
Do not operate the engine with the drive belt removed.  
Any servicing that requires operation without a belt must be performed  
by your dealer. Operation of the engine with the belt removed may result  
in injury or damage to the engine.  
Intake Silencer  
Do not operate the engine with the intake silencer or filter removed.  
Damage to the engine may occur if the intake silencer or filter are  
removed.  
Clutches  
Do not attempt to service the clutches.  
All clutch service must be performed by your dealer. The clutch is a  
complex mechanism that rotates at high speeds. Each clutch is dynami-  
cally balanced before installation. Any tampering may disrupt this preci-  
sion balancing and create an unstable condition.  
Cold Weather Drive-Away  
Whenever your snowmobile has been parked for a length of time, espe-  
cially overnight, always make sure the skis and track are loosened from  
ice and snow before attempting to drive. Apply the throttle with enough  
authority to put the snowmobile into motion, but always operate within  
safety limits and, on 2-up machines, with respect for a passenger.  
Maneuverability  
While much control and maneuverability is achieved through the steer-  
ing system and skis, maximum control is achieved by the shifting of  
your body weight. Maneuverability will change for lighter operators or  
snowmobiles designed to carry a load or a passenger.  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Inadequate Snow Conditions  
WARNING  
Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could  
cause irreversible track damage and lead to serious injury.  
Since snow provides the only lubrication for the power slide suspension  
and, on liquid cooled models, cooling for the engine, adequate snow  
cover is a requirement for operation of your snowmobile. Driving in too  
little snow will result in excessive wear and damage to the slide rail,  
track and/or engine.  
CAUTION  
When operating on icy surfaces or hard-packed snow, avoid overheating the  
slide rail and track. Lack of lubrication and cooling will cause overheating of  
the slide rail and track, resulting in premature wear and failure. If frequently  
operating in low cooling conditions, see your dealer for an optional wheel kit  
that will reduce the wear from overheating.  
Operating in Deep Snow  
If the snowmobile becomes stuck in snow, clear the running board area  
of snow, then step down the snow in front of the snowmobile so that  
when the throttle is opened, the snowmobile will be able to climb up and  
over the snow.  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driving Responsibly  
Every snowmobile handles differently, and even the most docile condi-  
tions may become dangerous if operators drive improperly. If you’re  
new to snowmobiling, acquaint yourself with the machine and with  
what it will and won’t do under various conditions. Even seasoned driv-  
ers should spend some time getting the feel for a machine before  
attempting ambitious maneuvers.  
• A snowmobile depends on the rider’s body position for proper bal-  
ance in executing turns, traversing hills, etc. Always start on a  
smooth, level area to begin building your operating experience.  
• Before allowing someone else to use your snowmobile, know the  
extent of their operating skills. Check to see if they’ve taken a snow-  
mobile safety course and have an operator’s certificate. For their pro-  
tection, as well as yours, make sure they take a snowmobile safety  
course. Everyone can benefit from the course.  
• Don't "jump" your snowmobile over large drifts or similar terrain.  
Jumping may injure your back because of spinal compression that  
could occur when the snowmobile impacts the ground. The seat and  
suspension of your snowmobile have been designed to provide pro-  
tection under normal riding conditions. Your snowmobile is not  
intended for this kind of use.  
• Be courteous to oncoming traffic by dimming your headlights and  
reducing your speed.  
• When traveling in a group of snowmobiles, don’t tailgate (follow too  
closely). Leave enough distance between snowmobiles to provide  
ample stopping room and to provide protection from flying snow and  
debris. Allow even more distance when driving on slippery surfaces  
or when driving in darkness or other low visibility conditions. Be  
aware of any snowmobile traffic around your vehicle. Drive defen-  
sively to avoid accidents.  
• Remove the key from the ignition when you leave the snowmobile  
unattended.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Windchill/Temperature Charts  
The following information is provided to help you determine when tem-  
peratures become dangerous for riding.  
WIND CHILL CHART (°F)  
Wind  
Speed  
in  
Actual Thermometer Reading (_F)  
-5 -10 -15 -20 -25 -30 -35 -40 -45  
Equivalent Temperature (_F)  
-5 -10 -15 -20 -25 -30 -35 -40 -45  
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63  
40 35 30 25 20 15 10  
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.  
WIND CHILL 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  
-
-7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57  
16  
24  
32  
40  
48  
56  
64  
72  
80  
88  
96  
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62  
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65  
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67  
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69  
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70  
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72  
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73  
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74  
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75  
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76  
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77  
Frostbite in >> 30 min. 10 min. 5 min.  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Warning decals have been placed on the snowmobile for your protec-  
tion. Read and follow the instructions of the decals and other warnings  
on the snowmobile carefully. If any of the decals depicted in this manual  
differ from the decals on your snowmobile, always read and follow the  
instructions of the decals on the snowmobile.  
If any decal becomes illegible or comes off, contact your Polaris dealer  
to purchase a replacement. Replacement safety decals are provided by  
Polaris at no charge. The part number is printed on the decal.  
Clutch Cover Warning  
The clutch cover warning decal is under the hood on the clutch cover.  
WARNING  
Do not operate engine with hood open.  
Do not attempt adjustment with engine running.  
Do not operate engine with plenum/belt guard removed.  
Never run engine with drive belt removed.  
Never service clutches yourself. See your dealer.  
Pressure Cap Warning  
The pressure cap warning decal is found under the hood on the pressure  
cap of applicable liquid cooled models.  
WARNING  
Do not open hot. Test or replace when changing coolant. Press  
down and turn to release cap. 13 PSI  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
“No Passenger” Warning  
Snowmobiles designed for only a  
single rider have a warning decal  
on the console below the steering  
post.  
WARNING  
This vehicle is designed for  
operator only.  
“No Passenger”  
“NO PASSENGER”  
Warning  
Track Warning  
The track warning decal is on the  
rear of the tunnel.  
Track  
Warning  
Hot Surface  
Warning  
WARNING  
Stay clear of track. Do not sit on  
seat back. Entanglement with the  
track or a fall from seat back may  
result in severe injury or death.  
Hot Surface Warning  
The hot surface warning is on the  
rear center of the tunnel.  
WARNING  
Hot Surface  
Do Not Touch  
Burns may result. Entire top of  
tunnel may be hot. Install only  
accessories specifically  
approved for this model by  
Polaris. Do not place clothing,  
bags or cargo on tunnel. Do not  
cover this label.  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Reverse Warning  
Polaris snowmobiles equipped with  
electric reverse have a reverse warning  
decal on the console.  
Reverse Warning  
WARNING  
Reverse operation, even at low  
speeds, can cause loss of control  
resulting in serious injury or death.  
To avoid loss of control, always:  
• Look behind before and while  
backing up.  
• Avoid sharp turns.  
• Shift to or from reverse only when  
stopped.  
• Apply throttle slowly.  
Operation Warning  
NOTE: For more information, see  
Owner's Manual.  
If electric reverse:  
• Machine stopped and engine at idle, push yellow button on LH con-  
trol to reverse. Flashing light on dash indicates reverse operation.  
• Push button again to return to forward.  
Operation Warning  
The operation warning decal is located on the console of all Polaris  
snowmobiles.  
WARNING  
To avoid serious injury or death, read and understand all warnings  
and the Owner’s Manual before operation. If manual is missing, con-  
tact a Polaris dealer for a replacement.  
• This vehicle is capable of high speeds. Buried objects or uneven  
terrain can cause loss of control. Reduce speed and use extreme  
caution when operating in unfamiliar terrain.  
(continued on next page)  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Operation Warning  
(continued from previous page)  
• Excessive speed, especially at night or with limited visibility, can  
result in insufficient time for you to react to terrain changes, to  
avoid unexpected obstacles, or to stop safely.  
• Never consume alcohol or drugs before or while operating this vehi-  
cle.  
• In an emergency, push down the Auxiliary Shut-Off Switch, located  
on the top of the throttle control assembly, to stop the engine. Then  
pull the brake lever to stop.  
• Always wear an approved helmet, eye protection, and adequate  
clothing while operating this vehicle.  
• This vehicle is designed for adult use only. Check local laws for age  
requirements.  
• When operating with a passenger (on approved models only),  
reduce speed and allow extra space for steering and stopping. A  
passenger reduces your ability to control the vehicle.  
• When operating on hard-packed snow, ice, or when crossing roads,  
steering and braking ability are greatly reduced. Reduce speed and  
allow extra space to turn or stop.  
To maintain vehicle control on ice or hard-packed surfaces, you  
should have a proper balance of ski carbides to track studs. See  
Owner’s Manual for proper use of traction products.  
• Repeated stops from high speed may cause fading or sudden loss  
of braking ability.  
• Parking brake may relax when used for long periods. Do not leave  
brake engaged for more than five minutes.  
• Before starting the engine, check throttle, brake, and steering for  
proper operation. Make sure hood is latched. Be seated and in posi-  
tion to control the vehicle.  
Oil injection system: Use unmixed fuel only. Check oil level when  
refueling.  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
5
6
4
7
8
9
3
10  
2
1
11  
12  
13  
16  
14  
15  
1. Front Bumper (do not use for  
pulling or dragging the snow-  
mobile)  
9. Rear Bumper  
10. Snow Flap  
11. Track  
12. Suspension  
13. Tunnel  
14. Side Panel  
15. Ski  
16. Nosepan  
2. Hood  
3. Headlight  
4. Windshield  
5. Mountain Bar (if equipped)  
6. Handlebar  
7. Seat  
8. Taillights  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
3
2
4
5
6
7
10  
11  
1
8
9
12  
14  
13  
1. Fuel Filler Cap  
2. Ignition Switch  
3. MFD (Multi-Function Display)  
4. Engine Stop Switch  
5. Throttle Control  
6. Recoil Starter Handle  
7. Hood Hold-Down Straps  
8. Brake Lever  
9. Parking Brake  
10. Handlebar Grip Warmer  
Switch  
11. Thumbwarmer Switch  
12. Electronic Reverse Button  
13. MFD Control  
14. Headlight Dimmer Switch  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Adjustable Headlights  
Move the adjuster to the left to  
lower the headlight beam.  
Move the adjuster to the right to  
raise the headlight beam.  
Adjustable Steering  
Adjuster  
The adjustable steering system  
allows you to adjust the handlebar  
position to fit your style of riding.  
See page 47.  
Accessory Cargo System  
The maximum weight capacity for the rear cargo area is 15 lbs. (7 kg).  
Always secure cargo before operating. Do not exceed the cargo weight  
limit. Do not allow a passenger to sit on the seat back or the cargo area.  
Fuel Valve (Carbureted Models)  
The fuel valve is located under the  
hood. Turn the fuel valve off when-  
ever the snowmobile is stored or  
parked.  
1. Turn the valve clockwise to  
turn off the fuel supply.  
ON  
OFF  
2. Turn the valve counter-clock-  
wise to turn on the fuel supply.  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Detonation Elimination Technology (DET)  
A detonation sensor monitors the engine and responds to detonation by  
automatically reducing the engine timing and adding fuel. This results in  
decreased engine RPM and performance.  
Effect of DET  
The DET system prevents damage to the engine from detonation while  
developing the maximum power of the engine safely. If the system  
senses detonation beyond a preset limit, it retards ignition timing and  
adds fuel to reduce the detonation and prevent engine damage.  
When the detonation returns to a permissible level, the system will  
return spark and fuel to normal, allowing the engine to run at rated  
power levels.  
Sensor Fail-Safe  
The DET includes a sensor fail-safe system to prevent the engine from  
damage if the sensor fails, becomes disconnected or is unable to detect  
detonation. The rider will experience a loss in power. The sensor must  
be reconnected or repaired to regain full power.  
NOTE: The check engine light will flash six times if the sensor fails or  
becomes disconnected.  
DET Troubleshooting (Carbureted Models)  
Use this chart to determine causes and solutions for detonation. If none  
of these conditions exists and the sensor remains activated, see your  
Polaris dealer for diagnosis.  
Possible Cause  
Solution  
Poor quality fuel  
Replace with higher quality fuel  
Do not modify the engine  
Improper engine modifications  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
MFD Component Identification  
Item  
2
1
1
Analog Gauge (if  
equipped)  
2
3
4
5
6
7
8
Digital Gauge  
Check Engine Indicator  
Low Oil Indicator  
High Temp Indicator  
Brake Indicator  
3
8
7
4
5
6
Reverse Indicator  
High Beam Indicator  
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
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  
5
5
6
Miles  
6
4
Kilometers  
3
Hours  
Trip 1/Trip 2/Trip F  
Service Label  
Altitude Label  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
MFD Settings  
The MFD Control Switch  
allows you to set the MFD  
display to your preferences.  
The rocker switch has a  
MODE button (top) and a  
SET button (bottom). Specific  
instructions are outlined on  
the following pages.  
MODE  
SET  
MFD Control Switch  
Standard vs. Metric  
The MFD will display either standard or metric units of measurement.  
While viewing a screen that displays measurements (MPH, km/h or  
temperatures), press and hold the MODE switch until the unit of mea-  
surement changes (about 10 seconds).  
Speedometer/Tachometer  
To change viewing preferences, press and hold the MODE button for  
three seconds. When the button is released, the new setting becomes  
active and screen colors change.  
Option  
Digital Display  
Screen Backlight  
1
2
RPM  
Blue  
Red  
Speed  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
MFD Digital Display Programs  
Press and release the MODE button to cycle through the three MFD pro-  
grams: Performance, Engine and History. Each program remains active  
until you cycle to the next program. While any program is active, press  
and release the SET button to cycle through the program’s screens.  
Performance Program  
Press and release the MODE button until the performance program  
screen is active. The default display for this screen includes electrical  
system voltage, fuel level (if equipped) and either speed or tachometer,  
whichever is selected (see page 32).  
Press and release the SET button to cycle through the following screens:  
odometer, trip 1 odometer, trip 2 odometer, fuel trip odometer (if fuel is  
low) and clock (if equipped). Use the following procedures to make  
changes to these screens.  
Odometer Setting  
The odometer records the vehicle's total  
distance traveled since manufacture. The  
odometer cannot be reset.  
Trip Settings  
Trip 1 and Trip 2 are odometers used to  
check fuel mileage or to keep track of  
distance traveled. Both odometers can be  
reset to zero.  
1. Enter the Performance Program.  
2. Press and release the SET button  
until the desired trip screen is active.  
3. Press and hold the SET button for two seconds to reset the trip  
odometer to zero.  
4. Press and release the SET button to view another trip screen if  
desired.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
MFD Digital Display Programs  
Performance Program  
Trip Settings  
Trip F automatically displays when the  
fuel level is low if the snowmobile is  
equipped with an electronic fuel gauge.  
The fuel symbol and the last fuel bar on  
the MFD gauge (if equipped) will blink  
when the fuel level reaches 1/8 of a tank.  
The Trip F odometer records distance  
traveled, and the fuel symbol continues  
to blink, until enough fuel is added to  
raise the level above 1/4 of a tank. The  
Trip F odometer will automatically reset  
to zero after refueling.  
Engine Program  
Press and release the MODE button until the engine program screen is  
active. The default display for this screen includes engine hours, electri-  
cal system voltage level, fuel level (if equipped) and either engine cool-  
ant temperature, air temperature (accessory) or altimeter (accessory).  
Press and release the SET button to cycle through the following screens:  
hour meter, engine temperature, air temperature (available as an acces-  
sory) and altimeter (available as an accessory).  
Hour Meter  
The hour meter records the total hours of  
engine operation since manufacture. This  
meter cannot be reset.  
Engine Temperature  
A thermometer measures water temperature,  
giving an indication of engine temperature.  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
MFD Digital Display Programs  
Engine Program  
Air Temperature (accessory)  
The MFD displays actual air temperature.  
Press and hold the MODE switch for ten sec-  
onds to switch between standard and metric  
units of measurement.  
Altimeter (accessory)  
The rider can calibrate the altimeter for cur-  
rent atmospheric conditions. Altimeter accu-  
racy will be +/-300 ft. (91 m) after adjustment.  
NOTE: When ALt-FT” displays, the program is in  
the standard mode. If only "ALt" displays,  
the program is in the metric mode.  
1. Enter the Engine Program.  
2. Press and release the SET button until the  
altimeter screen is active.  
3. Press and hold the SET button for five seconds.  
4. When the digits begin to flash, release the SET button.  
5. Press and release the SET button to advance the reading in 50-foot  
(15 m) increments, or press and hold the button to advance quickly.  
Adjust the altitude display to within 50 ft. (15 m) of the current alti-  
tude.  
NOTE: The gauge reads barometric pressure and allows the rider to compen-  
sate for daily fluctuations in air pressure. The gauge can adjust the  
displayed altitude to +/- 1300 ft. (396 m) from the preset value. It will  
adjust up to +1300 ft. (396 m) above the calibrated altitude. Once the  
+1300 ft. (396 m) offset has been reached, the next adjustment is -  
1300 ft. (396 m) from the calibrated altitude, and 50 ft. (15 m) will be  
added to the altitude each time the SET button is pressed.  
6. Press the MODE button to hold the reading at the adjusted value. If  
the MODE button is not pressed within five seconds, the gauge will  
automatically save the new setting.  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
MFD Digital Display Programs  
History Program  
Press and release the MODE button until the history program screen is  
active. This screen will always display electrical system voltage level  
and fuel level (if equipped).  
Press and release the SET button to cycle through the following screens:  
maximum vehicle speed, maximum engine RPM and service interval  
reminder.  
Maximum Speed/Maximum RPM  
The gauge automatically logs the maximum  
speed and engine RPM even if the history  
program is not active in the display.  
1. Enter the History Program.  
2. Press and release the SET button until  
one of the two screens is active.  
NOTE: The MPH and RPM values are both  
reset at the same time. Reset the val-  
ues before each run to obtain accurate  
readings.  
3. Press and hold the SET button for three  
seconds to reset the recorded maximum  
values for both MPH and RPM.  
NOTE: Due to electrical noise, the MFD may occasionally display MAX MPH/  
RPM values that are not representative of actual values.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
MFD Digital Display Programs  
History Program  
Service Interval Reminder  
The gauge logs the number of engine hours  
accumulated between service reminders.  
When the logged hours reaches the desig-  
nated service interval (set by the user), the  
gauge provides a reminder that service is  
due. "SErVCE" will flash in the odometer  
area and "ENG" will flash in the icon area  
for five seconds each time the engine is started (until the service  
reminder is reset.) Use the following procedures to reset the reminder.  
To reset the reminder at the existing interval:  
1. Enter the History Program.  
2. Press and release the SET button until the service interval screen is  
active.  
3. Press and hold the SET button for ten seconds, continuing to hold  
even after the display begins to flash.  
4. When the display stops flashing, release the button. The service  
interval has been reset.  
To reset the reminder at a new interval:  
1. Enter the History Program.  
2. Press and release the SET button until the service interval screen is  
active.  
3. Press and hold the SET button for five seconds, until the hours begin  
to flash. Immediately release the button.  
4. Press the button again, up to five times, to advance the reminder in  
20-hour increments.  
NOTE: The maximum interval is 200 hours.  
To disable the service interval reminder, press the SET button once after  
reaching 200 hours on the display. The gauge will display "OFF".  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES  
Instrumentation  
Gauge Cleaning  
1. Wipe the gauge face as needed using a clean cloth and a mild soap  
and water solution. Wipe dry with clean, soft cloth.  
2. Clean the back side of the gauge using a clean cloth and a mild soap  
and water solution. Do not remove the electrical connectors or 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.  
CAUTION  
To prevent damage to the lens, do not use alcohol for cleaning. Do not allow  
chemicals or sprays to contact the lens. Immediately clean off any gasoline  
that splashes on the gauge during refueling.  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Front Suspension Adjustments  
Independent Front Suspension (IFS)  
Break in the suspension for approximately 150 miles (240 km) before  
making any fine-tuning adjustments.  
Settings will vary from rider to rider, depending on rider weight, vehicle  
speed, riding style, and trail conditions. We recommend starting with  
factory settings and then customizing each adjustment individually to  
suit rider preference. The snowmobile should be methodically tested,  
one change at a time, under the same conditions (trail and snow condi-  
tions, vehicle speed, riding position, etc.) after each adjustment until the  
best ride is achieved.  
IFS Components  
1. Ski  
2
2. Front shock and spring  
3. Rod ends  
4. Upper control arms  
5. Lower control arms  
IFS Adjustment Options  
• Shock spring preload  
• Shock valving  
5
3
4
• Optional springs  
• Toe (ski alignment) (see  
page 106)  
1
• Camber (see your dealer)  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Front Suspension Adjustments  
Walker Evans Air Shocks  
Walker Evans Air shocks are oil filled shocks that use nitrogen pressure  
for spring force.These shocks are tuned for high performance riding in a  
wide range of winter riding conditions.You will notice slight differ-  
ences in ride height and spring rate at high and low temperature  
extremes. Sled will sit higher at room temperature on showroom  
floor. This will not affect the overall shock tuning or ride quality.  
Always have your Walker Evans Air Shocks serviced annually to  
replenish the Nitrogen charge and refresh the oil.  
Troubleshooting  
• See your dealer for any damaged parts or service items.  
• Always install foam sleeve on IFS for service and trailering.  
Your dealer must always recharge both IFS shocks if charge pressure is in question.  
Checking pressure without recharging is not possible without loosing pressure.  
If One IFS Shock Feels Soft  
• Check front suspension components for bent parts (look closely at rear  
leg of lower A-arm) before continuing with shock troubleshooting.  
• Look for oil leakage around shaft seal. If leaking, rebuild with new seal  
and check for any nicks or dings in shaft.  
• Always remove and recharge both IFS shocks together.  
If Both IFS Shocks Feel Soft  
• Remember that at extreme temperature (lower than -15 degrees F) the  
IFS may have more free sag and feel slightly softer.  
• Always remove and recharge both IFS shocks together.  
If Front Track Shock Feels Soft  
• Remember that at extreme temperature (lower than -15 degrees F) the  
IFS may have more free sag and feel slightly softer.  
• Check for oil leakage around the shock boot or shaft seal if boot is  
removed. If leaking rebuild with new seal and check for any nicks or dings  
in shaft.  
• Recharge Front Track Shock to specification.  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Front Suspension Adjustments  
Standard Shocks  
The tension at which the shock coil spring is set is called spring preload.  
For the best ride, the suspension should be adjusted to use the full travel  
of the shocks with occasional light bottoming. To determine if your  
machine is using full travel, push the jounce bumper down on the shock  
rod until it contacts the body and test ride the machine. The bumper will  
move up on the rod in relation to the amount of travel that was used dur-  
ing the ride. If the travel is full, the bumper will be seated at the top of  
the rod.  
Shock Absorber Components  
1. Retainer  
2. Jounce Bumper  
4
5
3. Shock Rod  
4. Body  
6
3
5. Threaded Spring Preload Adjuster Nut  
6. Spring  
2
1
Front Shock Spring Preload  
(RMK Standard Only)  
Increasing spring preload will increase ski-to-ground  
pressure. Decreasing spring preload will decrease ski-  
to-ground pressure. When adjusting, be sure the  
springs on both the left and right sides of the machine  
are at the same adjustment.  
To increase front shock spring preload, grasp the  
spring and turn it to the left. Turn it to the right to  
decrease preload.  
High  
Preload  
Low  
Preload  
Increasing the spring preload too much may adversely  
affect the handling of the snowmobile and the perfor-  
mance of the suspension. Never exceed one inch of preload 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 holding  
the spring between the retainer on top of the shock and the threaded  
spring preload adjuster nut on the shock body.  
Front Shock Springs  
(Standard only)  
The front springs can be changed if spring preload alone isn't sufficient  
and further adjustment is desired to control suspension stiffness. See  
your Polaris dealer for more information.  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Rear Suspension Adjustments  
Rider weight, riding style, trail conditions, and vehicle speed all affect  
suspension action.  
Each rear suspension can be adjusted to suit rider preference and deliver  
excellent performance for a given set of conditions. However, all sus-  
pension designs and adjustments involve a compromise, or trade-off.  
For example, a suspension set up for snow-cross racing would provide a  
very stiff ride on the trail. A suspension set up for trail riding would bot-  
tom out harshly on a snow-cross course.  
Make adjustments to one area at a time so you can evaluate the change.  
For further assistance, see your dealer.  
Suspension Performance Tips  
• Rider weight usually determines the position at which the spring pre-  
load should be set. However, this may vary with riding style. With a  
little experimentation, each rider can find a preferred set-up. These  
adjustments are easy to make, involve very little time or effort, and  
greatly affect the ride.  
• In deep snow, a new rail slide will offer improved performance over a  
worn slide. It can also improve top speed.  
NOTE: Keep the suspension pivot points lubricated. This will reduce moisture  
and rust build-up and ensure proper function of the suspension com-  
ponents. Grease rear suspension pivots before adjusting the rear sus-  
pension. Refer to the suspension lubrication information beginning on  
page 76.  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Rear Suspension Adjustments  
Initial Spring Preload Setting (Sag Method)  
To set up the rear suspension torsion  
spring preload, measure the distance  
between the ground and rear bumper.  
This is measurement X.  
X
Take this measurement with no rider  
and with the rear suspension at full  
extension.  
NOTE: The rear bumper may need to  
be lifted upward slightly to fully  
extend the suspension.  
Next, have the rider drop down hard  
on the seat and bounce up and down  
several times, collapsing the rear  
suspension. With the rider seated,  
measure the distance between the  
ground and the rear bumper at the  
exact location used for measure-  
ment X. This is measurement Y.  
Y
To determine sag, commonly referred to as ride-in, subtract measure-  
ment Y from X (Sag=X-Y). Adjust sag by rotating the torsion spring  
preload cams located on the rear torque arm. See illustration. The ideal  
amount of sag for this rear suspension is five inches (12.7 cm) (X-Y=5  
in./12.7 cm).  
If the rear suspension rides in less than four inches or more than six  
inches with the torsion spring preload cams at their maximum range of  
adjustment, optional torsion springs (softer or stiffer, respectively) may  
be required. This is only an initial setup, and final spring preload may  
vary based on rider preference and riding conditions.  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Rear Suspension Adjustments  
Torsion Spring Preload  
To adjust rear torsion spring preload, rotate the three-position cam using  
the engine spark plug tool. Different rate torsion springs are available if  
a firmer ride is desired. Contact your dealer for more information.  
The following information is provided only as a guideline to be used for  
initial suspension set-up. Your set-up may vary based on your desired  
riding style.  
Soft (long end of cam to front)  
Medium (short end of cam up)  
Firm (long end of cam up)  
Soft  
Medium  
Firm  
Limiter Strap Position  
The following information is pro-  
vided only as a guideline to be used  
for initial suspension set-up. Your  
set-up may vary based on your  
High  
Low  
desired riding style.  
High: Limiter strap in high position  
increases ski pressure  
Low: Limiter strap in low position  
decreases ski pressure  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Rear Suspension Adjustments  
Shock Compression Valving  
RMK Standard Rear Track Shock  
The standard RMK rear track shock is an Arvin MPV Select shock that  
allows for adjustments to the compression valving. Adjustments are  
made by turning the adjustment screw located near the base of the  
shock.  
In half-turn increments, turn the screw clockwise to increase compres-  
sion valving and stiffen the ride. Turn the screw counterclockwise to  
reduce compression and soften the ride. There are approximately three  
full turns of adjustment available.  
If bottoming continues after the screw has been turned fully clockwise,  
the torsion spring should be adjusted (see page 44). Return the screw to  
its original starting position after the torsion spring has been adjusted.  
Adjustment Screw  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Handlebar Adjustments  
WARNING  
Some aftermarket accessories (including windshields and cargo bags) may  
interfere with the handlebar. Such accessories could limit your ability to steer  
the vehicle and/or may contact the brake lever. This could lead to loss of con-  
trol resulting in serious injury or death. Always be sure that accessories do  
not contact the handlebar or brake lever at any handlebar position.  
Handlebar position and handlebar angle can be adjusted to rider prefer-  
ence. The optimum position for the proper vehicle balance is with the  
riser block aligned with the steering post.  
After making handlebar adjustments, check to make sure wires are not  
pinched or kinked. Make sure the handlebars, brake lever and throttle  
lever operate smoothly and do not hit the gas tank, windshield or any  
other part of the vehicle when the handlebars are turned fully to the left  
or right.  
When adjustments are complete, torque the front adjuster block bolts  
first, then torque the rear bolts. Torque the bolts to 11-13 ft. lbs. (15-18  
Nm).  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Handlebar Adjustments  
Handlebar Position  
1. Loosen the four bolts on the  
bottom of the adjuster block.  
Loosen top bolts to adjust  
handlebar angle  
NOTE: If necessary, pry the blocks  
apart with a screwdriver.  
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.  
NOTE: 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.  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Accessories  
Polaris offers a wide range of accessories for your snowmobile to help  
make each ride more enjoyable.  
Use only Polaris parts and accessories on your Polaris snowmobile. Use  
of unapproved parts and accessories may result in:  
• Non-compliance with government/industry requirements  
Voiding of warranty  
• Injury to self or others  
This applies, but is not limited to the following areas: brakes, clutches,  
fuel systems, and exhaust systems.  
NOTE: Exhaust systems are critical safety areas that must use approved  
Polaris parts. Please see your Polaris dealer for service.  
Tether Switch  
The accessory tether switch is available for all models. Order part num-  
ber 2870668.  
48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Pre-Ride Checklist  
Inspect all items on the checklist for proper operation or condition  
before each use of the snowmobile. Procedures are outlined on the refer-  
enced pages. Look for a checkmark (n) on the referenced pages to  
locate the pre-ride inspection items.  
Item  
See Page  
Drive Belt Condition  
Steering System  
Recoil Rope  
97  
53  
51  
Parking Brake Lock/Brake Lever/Brake System  
Throttle Lever  
51, 52, 91  
50  
Throttle Safety Switch  
Auxiliary Shut-Off Switch (Engine Stop Switch)  
Ignition Switch  
50  
55, 65  
55, 65  
55  
Taillight/Brakelight/Headlight  
Coolant Level  
86  
Gearcase Oil Level  
N/A  
77  
Engine Oil Level  
Suspension Mounting Bolts  
Skags (Wear Bars)  
54  
107  
54  
Ski Saddle and Spindle Bolts  
Hood Straps/Latches  
Seat Latches (if equipped)  
Rear Wheel Idler Bolts  
Tether Switch/Strap  
50  
N/A  
54, 103  
55  
Track Alignment/Condition  
Rail Slide Condition  
53, 104  
108  
77  
Chaincase Oil Level  
Oil Level  
62  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
Before starting the engine, always refer to all safety warnings pertaining  
to snowmobile operation. Never start the engine without checking all  
vehicle components to be sure of proper operation.  
WARNING  
Operating the vehicle with worn, damaged, or malfunctioning components  
could result in serious injury or death. Never start the engine without check-  
ing all vehicle components to be sure of proper operation.  
Read and Understand Your Owner's Manual  
Read the Owner's Manual completely and refer to it often. The manual  
is your guide to safe and enjoyable snowmobiling experience.  
n Throttle Lever  
The throttle and brake are the primary controls of your snowmobile.  
Always make sure both are functioning properly.  
Squeeze the throttle lever to make sure it compresses evenly and  
smoothly. When released, the lever should immediately return to the  
idle position without binding or hesitation. If the throttle does not func-  
tion smoothly, or if you discover excessive lever freeplay, DO NOT start  
the engine. Have the throttle serviced immediately.  
n Throttle Safety Switch  
Test the throttle safety switch system before the snowmobile is operated.  
See page 63 for procedure.  
n Hood Latches  
The hood of the snowmobile protects the operator from moving parts as  
well as aiding in sound emission control and other functions. Under no  
circumstances should your snowmobile be operated with the hood open  
or removed. Always ensure that the hood straps are in good condition  
and that the latches are securely in place before operating the snowmo-  
bile.  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Recoil Rope  
Inspect the recoil rope and handle for excessive wear, and make sure the  
knot securing the rope inside the handle is secure. If excessive wear is  
found, see your Polaris dealer for replacement.  
n Brakes  
Always check the following items for proper operation before starting  
the engine.  
Brake Lever Travel  
Squeeze the brake lever. It  
should move no closer to the  
handgrip than 1/2" (1.3 cm).  
1/2" (1.3 cm)  
A smaller distance indicates  
low brake fluid level or air in  
the hydraulic system. Refer  
to the brake bleeding infor-  
mation on page 94.  
Brake Lever Feel  
If the brake lever feels “spongy” when squeezed, check the brake fluid  
level and condition. Add fluid as needed. See page 93.  
Check for the presence of air in the fluid system. See page 94 for more  
information, or see your dealer for service.  
WARNING  
Continued use of “spongy” brakes may cause a complete loss of brakes,  
which could result in serious injury or death. Always have the brakes serviced  
at the first sign of sponginess.  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Parking Brake Lever Lock  
Use the parking brake lever lock  
only when you want the snowmobile  
to remain stationary; for example,  
when parked on an incline for a  
period of five minutes or less.  
3
4
2
1
1. Brake Lever  
2. Parking Brake Lever Lock  
3. Master Cylinder Reservoir/  
Cover  
4. Fluid Level Indicator  
Lock Engagement  
To engage the lock, squeeze the brake lever tightly and push forward on  
the lock. Hold the lock forward while releasing the brake lever.  
NOTE: If the brake lever is squeezed tightly enough, the lock will move freely  
into place. Do not force the lock or it may break.  
The parking brake light on the gauge will light up if the parking brake  
lever lock is set while the engine is running. It will also be lit when the  
service brake is in use. If the parking brake light does not come on when  
the parking brake or service brake is in use, have it serviced by your  
dealer.  
Lock Release  
To release the lock, squeeze the brake lever tightly. The lock will return  
to the unlocked position.  
WARNING  
If the parking brake lever lock is partially or entirely engaged while riding, the  
brakes may overheat, resulting in brake damage. In extreme cases it could  
cause a fire, which could result in serious injury or death. Always ensure that  
the lever lock is completely disengaged before operating the snowmobile.  
52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Steering System  
Manually turn the skis completely to the right and to the left. If any dif-  
ficulty is encountered, remove any ice and snow build-up that may be  
obstructing the steering linkage.  
n Track Inspection  
WARNING  
Operating the snowmobile with a damaged track increases the possibility of  
track failure, which could cause loss of control resulting in serious injury or  
death. Always inspect the track for damage before using the vehicle.  
Use of traction products such as studs increases the possibility of track  
damage and/or failure. Driving at high speeds for extended periods of  
time in marginal lubrication could severely damage track rods, break  
track edges and cause other track damage. Examples of marginal lubri-  
cation would include frozen bodies of water without snow cover, icy  
trails, and no-snow conditions.  
NOTE: Track damage or failure caused by operation on ice or poor lubrication  
conditions voids the track warranty.  
Deep Lug Tracks (if equipped)  
The 2.4" powder track is designed specifically for deep snow applica-  
tions. Operation in low snow conditions at high speeds may cause track  
lug separation. Track lug separation is not covered under the Polaris  
limited warranty policy. Polaris does not recommend operation above  
70 mph with this track.  
CAUTION  
High speed use on hard-packed surfaces is not recommended for models  
equipped with a deep lug track. Track lug damage may occur. Keep high  
speed use to a minimum, including frequent slow-speed intervals for track  
cooling.  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Suspension Inspection  
Loose nuts and bolts can reduce your snowmobile's reliability and cause  
needless repairs and down time. Before beginning any snowmobile trip,  
a visual inspection will uncover potential problems. Check the follow-  
ing items on a weekly basis or before any long trip.  
Item  
Check  
Page  
Suspension mounting bolts  
Rear idler wheel bolts  
Rear idler adjusting bolt locknuts  
Torque arm bolts  
Tightness  
Tightness  
Tightness  
Tightness  
Tightness  
Condition  
Condition  
Tension  
--  
103  
--  
--  
Carrier and bogie wheel bolts  
Front torque arm limiter strap  
Rail slide  
--  
--  
108  
102  
75  
--  
Track  
All rear suspension components  
Ski runner/skag  
Lubrication  
Condition  
Tightness  
Tightness  
Ski spindle bolts  
--  
Tie rod end nuts  
--  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Start the Engine and Check  
Before starting the engine, always refer to all safety warnings pertaining  
to snowmobile operation. Never engage the starter when the engine is  
running. Never start the engine without checking all vehicle components  
to be sure of proper operation. See Before Starting the Engine beginning  
on page 50.  
n Engine Stop Switch  
Check the auxiliary shut-off switch for proper operation. Push the  
switch down to stop the engine. Pull it up to allow restarting.  
n Ignition Switch  
Make sure the engine stops when the ignition switch is turned to OFF.  
n Tether Switch  
If your machine has a tether switch, remove the tether from the switch to  
make sure the engine stops immediately.  
n Lighting  
Check the headlight (high and low beam), taillight, and brake light.  
Replace burned out lamps before operating.  
n Mirror Adjustment  
If equipped, adjust your mirrors so they can be used to their full advan-  
tage.  
n Operating Area  
Before driving away, check your surroundings. Be aware of obstacles  
and make sure bystanders are a safe distance from the snowmobile.  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Starting the Engine  
CAUTION  
Engaging the starter when the engine is running WILL result in serious  
engine damage, especially if the transmission is in reverse. Never engage  
the starter when the engine is running.  
1. Turn the key to the ON position. Pull the engine stop switch up to  
the RUN position.  
2. Carbureted models: Turn  
the fuel valve on. If starting  
a cold engine, flip the  
CHOKE POSITIONS  
choke toggle to FULL  
CHOKE. Do not use the  
choke if starting a warm  
engine. After the engine  
starts, flip the choke toggle  
to the OFF position. If the  
engine slows or wants to  
stop, use intermittent chok-  
ing to the HALF CHOKE  
position.  
OFF  
1/2 CHOKE  
FULL CHOKE  
NOTE: Do not depress the throttle until the engine starts.  
CAUTION  
Don't pull the starter rope to the fully extended position and don't allow it to  
snap back into the housing. Damage may result. To avoid injury and/or  
engine damage, do not operate the electric starter or pull-rope starter while  
the engine is running.  
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.  
NOTE: It may require as many as eight to ten pulls to prime the fuel system  
and start the engine if the fuel tank has been completely emptied.  
5. Repeat the cranking procedure as needed until the engine starts.  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Engine Break-In  
No single action on your part is as important to long, trouble-free  
machine life as proper break-in of a new or rebuilt engine. Premix the  
first tank of gasoline with one pint of Polaris injection oil for each five  
gallons of fuel. This, in addition to the lubrication supplied by the injec-  
tion system, will assure proper engine break-in.  
CAUTION  
Excessive heat build-up during the first three hours of operation will damage  
close-fitted engine parts. Do not operate at full throttle or high speeds for  
extended periods during the first three hours of use. Vary the throttle open-  
ings and machine speeds to reduce friction on all close-fitting machined  
parts, allowing them to break in slowly without damage.  
Use of any lubricants other than those recommended by Polaris may cause  
serious engine damage. We recommend the use of Polaris lubricants for your  
vehicle.  
Drive with extra caution during the break-in period. Perform regular checks  
on fluid levels, lines, and all other important areas of the machine.  
57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Engine Break-In  
Oil Injection System  
Always fill the oil reservoir when refueling.  
CAUTION  
Serious engine damage can occur without the proper lubrication. Check the  
oil tank level often during the first tank of fuel. If the oil level doesn't go down,  
contact your dealer immediately.  
Oil Recommendations  
This snowmobile is equipped with a variable exhaust system (VES).  
Engine lubrication comes from oil added to the fuel and oil injection  
systems. Polaris recommends the use of VES II 2 Cycle Oil for this  
engine. See page 112 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  
CAUTION  
Inadequate cooling and lubrication will lead to overheating of the slide rail  
and track, resulting in premature wear and failure. Reduce speeds and fre-  
quently drive into fresh snow to allow adequate cooling and polishing of the  
slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or  
roads.  
58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Track Warm-Up  
WARNING  
A loose track or flying debris could cause serious injury or death. Stand clear  
of the front of the machine and the moving track. Never hold the snowmobile  
up or stand behind it while warming up the track. Do not use excessive throt-  
tle during warm-up or when the track is free-hanging. Be sure the rear sup-  
port is stable.  
WARNING  
Use of traction products such as studs, ice growsers, etc. will increase the  
possibility of track damage and/or failure. This could cause loss of control,  
resulting in serious injury or death. Always inspect for track damage before  
operating the snowmobile.  
Follow these steps to ensure proper warm-up  
of the engine, drive train and track.  
1. Use an appropriate stand to securely  
support the rear of the snowmobile at the  
rear bumper. The track should be  
approximately 4" (10 cm) off the  
ground.  
2. Start the engine and allow it to warm up  
two to three minutes.  
3. Depress the throttle abruptly and allow  
the track to rotate several revolutions.  
NOTE: It will take longer to warm up the track sufficiently during colder out-  
door temperatures.  
4. Release the throttle, apply the brakes, shut off the engine and lower  
the snowmobile to the ground.  
5. Grasp the skis by their front loops and move them from side to side  
to loosen snow and ice.  
59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Fuel Safety  
WARNING  
Gasoline is highly flammable and explosive under certain conditions.  
• Always exercise extreme caution whenever handling gasoline.  
• Always refuel outdoors or in a well-ventilated area.  
• Always turn off the engine before refueling.  
• Do not overfill the tank. Do not fill the tank neck.  
• Do not smoke or allow open flames or sparks in or near the area where  
refueling is performed or where gasoline is stored.  
• If gasoline spills on your skin or clothing, immediately wash it off with soap  
and water and change clothing.  
• Never start the engine or let it run in an enclosed area. Engine exhaust  
fumes are poisonous and can cause loss of consciousness or death in a  
short time.  
WARNING  
The engine exhaust from this product contains chemicals known to cause  
cancer, birth defects or other reproductive harm. Operate this vehicle only  
outdoors or in well-ventilated areas.  
60  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Fuel  
For peak performance, Polaris recommends the use of 91 octane or  
higher fuel. Although 87 octane fuel is usable, some engine perfor-  
mance will be lost and fuel economy will decrease. Do not use lower  
than 87 octane fuel. Do not use fuel containing more than 10% ethanol  
(including E85).  
CAUTION  
Operating with obstructed fuel systems will result in serious engine damage.  
Perform maintenance as recommended.  
Damage to the fuel pump will occur if the snowmobile is operated with an  
empty fuel tank. Do not allow the snowmobile to run out of fuel. Always refuel  
when the level is low.  
Prolonged exposure to petroleum based products may damage paint. Always  
protect painted surfaces when handling fuel.  
Fuel 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 112 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.  
61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Oil  
n Low Oil Indicator Light  
The low oil indicator light will alert the operator if the oil level is low.  
Visually check for oil in the bottle. Add oil before further operation of  
the snowmobile. See page 58 for oil recommendations.  
CAUTION  
Operating the snowmobile without adequate engine lubrication can result in  
serious engine damage. Always check the oil level when refueling. Add oil  
as needed.  
n Low Oil Level  
Maintaining the proper oil level will prevent system aeration and possi-  
ble loss of pumping action, which could result in engine damage. This is  
especially important when the machine is operated in mountainous ter-  
rain.  
Maintain the oil level at the bottom of the filler neck. Always check and  
fill the oil tank when refueling. Never operate the engine if oil is not vis-  
ible in the tank.  
NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil flow.  
See your Polaris dealer for recommended replacement parts.  
62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
n Engine Stop Switch  
Push down on the engine stop  
switch to ground out the ignition  
and stop the engine quickly. Pull  
the switch up to the RUN position  
Stop  
Switch  
to allow restarting.  
n Throttle Safety Switch  
The throttle safety switch is designed to stop the engine whenever all  
pressure is removed from the throttle lever and the throttle cable or  
valves do not return to the normal closed position.  
WARNING  
Operating the snowmobile with a faulty throttle safety switch can result in  
serious injury or death in the event of an accident. If the throttle safety switch  
does not shut off the engine during a throttle system malfunction, immedi-  
ately push down the engine stop switch. Do not start the engine again until  
the malfunction has been corrected by your dealer.  
Test the throttle safety switch system daily before operation.  
1. Sit on the seat.  
2. Lock the parking brake.  
3. Start the engine and allow it to idle.  
4. Hold the throttle lever pin stationary by  
exerting pressure on the pivot pin in  
the direction shown in the illustration.  
5. Apply a slight amount of throttle. A  
properly functioning switch must shut  
down the engine.  
63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
n Throttle Lever  
WARNING  
An improperly functioning throttle lever may cause erratic machine behavior  
and loss of control, which could result in serious injury or death. If the throttle  
lever does not work properly, DO NOT start the engine.  
If the engine stops abruptly when the throttle lever is released:  
1. Turn the ignition switch to OFF.  
2. Visually inspect the throttle cable and throttle body to determine  
what caused the safety switch to activate.  
3. Test the throttle lever by compressing and releasing it several times.  
The lever and cable must return to the idle position quickly and  
completely.  
4. If the throttle lever operates properly, turn the ignition switch on and  
go through normal starting procedures.  
5. If the engine doesn't start, take the snowmobile to an authorized  
Polaris dealer for service.  
NOTE: Excessive freeplay in the throttle cable may cause the safety switch to  
activate, preventing the engine from starting. If this occurs, return the  
snowmobile to an authorized Polaris dealer for service.  
If an emergency exists and it's necessary to start the engine, the throttle  
safety switch and engine stop switch may be disconnected from the wire  
harness. When these switches are disconnected, the ignition key switch  
must be used to shut off the engine. DO NOT continue to operate the  
snowmobile with the throttle safety switch disconnected. Return the  
snowmobile to an authorized Polaris dealer for service as soon as possi-  
ble.  
64  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
n Emergency Stopping  
The following chart lists methods for stopping the snowmobile in the  
event of an emergency. See page 63 for more information about the  
engine stop switch.  
THROTTLE  
CONDITION  
SYSTEM  
Ignition Switch  
WHAT IT DOES  
Interrupts ignition circuit  
Slows jackshaft  
All  
Brake  
All  
Engine Stop Switch  
Choke (if equipped)  
Throttle Safety Switch  
Interrupts ignition circuit  
Floods engine  
All  
Half throttle or less  
Interrupts ignition circuit  
All  
All  
Tether Switch (if equipped) Interrupts ignition circuit  
65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Electronic Reverse (PERCt)  
Electronic reverse will activate only if the engine RPM is below 4000.  
The maximum engine RPM will be 6000 when in reverse.  
WARNING  
Improper reverse operation, even at low speeds, may cause loss of control,  
resulting in serious injury or death. Damage will occur to the chaincase or  
transmission if shifting is attempted when the engine is operating above idle  
speed.  
• Shift to or from reverse only when the snowmobile is stopped and when  
engine speed is at idle.  
• Look behind the snowmobile before and while backing.  
• Avoid sharp turns.  
• Apply throttle slowly.  
CAUTION  
Engaging the starter when the engine is running WILL result in serious  
engine damage, especially if the transmission is in reverse. Never engage  
the starter when the engine is running.  
66  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Electronic Reverse (PERCt)  
Engaging Reverse  
1. Stop the snowmobile and leave the  
engine idling.  
2. Make sure the area behind your snow-  
mobile is clear.  
3. Push the yellow reverse button on the  
left-hand control for one second, then  
release. The engine will automatically  
reduce RPM and start a reverse rota-  
tion.  
Reverse Button  
NOTE: A reverse light on the instrument panel will indicate that the transmis-  
sion is in reverse.  
4. Apply the throttle slowly to make sure the transmission is in  
reverse.  
NOTE: 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.  
CAUTION  
Engaging the starter when the engine is running WILL result in serious  
engine damage, especially if the transmission is in reverse. Never engage  
the starter when the engine is running.  
2. Push the yellow reverse button for one second and release. The  
engine will slow and begin to rotate forward. The light on the  
instrument panel will shut off.  
3. Apply the throttle slowly to make sure the transmission is in for-  
ward.  
67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Daily Storage  
At the end of each ride, park the snowmobile  
on a level surface and support it at the rear  
with an appropriate track stand. The track  
should be suspended approximately 4" (10 cm)  
off the ground.  
Remove the key and cover the snowmobile.  
Towing  
Do not use the front bumper to pull or drag the snowmobile. The front  
bumper is not designed for this type of use and may detach from the  
vehicle if force is applied.  
For your safety, do not attempt to use a tow hitch until you've read the  
following warnings and understand the proper hitch functions.  
WARNING  
Objects towed with a rope have no braking power and can easily collide with  
the rear of the snowmobile or other objects, resulting in serious injury or  
death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a  
rope. Only a stiff metal pole connecting the towed object and the tow hitch on  
the snowmobile should be used. If passengers are to be towed on a tobog-  
gan or sled, make sure the pole is at least four feet (1.2 meters) long to pre-  
vent any possibility of contact between the snowmobile's track and a person  
riding in the towed object.  
Braking distances increase when towing loads. Slow down to maintain con-  
trol of the snowmobile.  
If the snowmobile becomes inoperable and must be towed, and if it isn't  
possible to use a rigid tow bar, attach the tow rope to the ski spindles  
(not to the ski loops) to prevent damage to the steering components.  
Remove the drive belt before towing, and have someone ride on the  
towed snowmobile to operate the brake and steering when necessary.  
CAUTION  
Towing a disabled snowmobile with the drive belt in place can result in seri-  
ous damage to the engine and drive system. Always remove the drive belt  
from a disabled snowmobile before towing.  
68  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Emission Control Information  
Any qualified repair shop or qualified person may maintain, replace, or  
repair the emission control devices or systems on your snowmobile.  
Emission Control Label  
Your snowmobile is equipped at the time of sale with an emission con-  
trol information (ECI) label and a factory-installed emissions informa-  
tion hangtag. These items are required by U.S. Environmental  
Protection Agency regulations. The ECI label is permanently affixed to  
either the right side of the tunnel or the engine recoil cover. The ECI  
label should not be removed, even after you purchase the snowmobile.  
You may remove the factory-installed emissions information hangtag,  
which is intended solely for your use in making a purchasing decision.  
Emission Control Maintenance Requirements  
Your snowmobile is certified to operate on gasoline with a minimum  
octane level of 87 (R+M)/2. The emission control system designation  
per SAE J1930 is EM. If your snowmobile is equipped with a check  
engine light and it comes on, you must take your snowmobile to a quali-  
fied dealer for diagnostic service. Specifications and adjustments for  
engine tune-ups are located in the Service Manual, which is available to  
your qualified service technician. Reverse (if equipped) must not be  
engaged during engine tune-ups.  
69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Emission Control Information  
Owner's Responsibilities  
Please read the Snowmobile Engine Emissions Limited Warranty on  
page 125, and read the maintenance section of your owner's manual.  
You are responsible for ensuring that the specified maintenance is per-  
formed, including the emission-related maintenance outlined in these  
sections of the manual.  
You must inspect the air intake system on your snowmobile prior to  
each use (including the airbox foam filter and hood foam filters) and  
clean these components as necessary. Polaris considers the specified  
maintenance for the spark plugs, oil changes, air intake system and  
exhaust valves to be critical emission-related maintenance. The speci-  
fied maintenance for the fuel filter is recommended additional emission-  
related maintenance. Polaris recommends that you contact an authorized  
Polaris dealer to perform any service that may be necessary.  
70  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Polaris Recommended Maintenance Program  
To ensure many trouble-free miles of snowmobiling enjoyment, follow  
recommended regular maintenance and perform service checks as out-  
lined in this manual. Record maintenance and service in the Mainte-  
nance Log beginning on page 127.  
The recommended maintenance schedule on your snowmobile calls for  
service and maintenance inspections at 150 miles (240 km), 500 miles  
(800 km) and 1000 miles (1600 km). These inspections should be per-  
formed by a qualified service technician. For continued optimum perfor-  
mance and component life, continue maintenance checks at 1000 mile  
(1600 km) intervals.  
All necessary replacement parts and labor incurred, with the exception  
of authorized warranty repairs, become the responsibility of the regis-  
tered owner. If, during the course of the warranty period, part failures  
occur as a result of owner neglect in performing recommended regular  
maintenance, the cost of repairs are the responsibility of the owner.  
Personal safety is critical when attempting to service or make adjust-  
ments to your snowmobile. If you're not familiar with safe service or  
adjustment procedures and the use of tools, or if you don't feel comfort-  
able performing these tasks yourself, contact an authorized Polaris  
dealer for service.  
CAUTION  
Hot components can cause damage to plastic. Always make sure the  
exhaust system and engine have cooled before tipping the snowmobile on its  
side for service or inspection.  
71  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Interval Table  
The following chart is a guide based on average riding conditions. You  
may need to increase frequency based on riding conditions. When  
inspection reveals the need for replacement parts, always use genuine  
Polaris parts, available from your Polaris dealer.  
Item  
See  
Page  
Frequency  
1000 mi.  
150 mi.  
500 mi.  
2000 mi.  
Pre-  
Season  
(240 km) (800 km) (1600 km) (3200 km)  
CLUTCH  
Clutch Alignment Offset  
(without belt)  
96  
I
I
I
Drive Belt Condition  
Clutches (disassemble)  
Belt Tension  
97  
96  
--  
I
I
C
I
I
C
I
I
I
I
I
I
Clutch Sheaves  
96  
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  
99  
--  
I
I
I
I
--  
I
I
I
I
I
I
I
I
I
I
I
I
--  
I
I
--  
C
I
C
R
I
I
I
I
I
Coolant Level  
86  
--  
I
I
Coolant Hose  
I
Heat Exchangers  
Coolant Circulation  
Coolant Leaks  
89  
--  
I
I
I
I
--  
I
I
I
I
I
I
Spark Plug Condition  
Exhaust Pipe  
79  
85  
85  
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  
72  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Interval Table  
Item  
See  
Page  
Frequency  
1000 mi.  
150 mi.  
500 mi.  
2000 mi.  
Pre-  
Season  
(240 km) (800 km) (1600 km) (3200 km)  
BRAKES  
Hose Routing  
Hose Condition  
Fluid Leaks  
--  
--  
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  
91  
Brake Disc  
--  
Parking Brake  
Brake System  
Brake Fluid  
52  
51, 91  
93  
R
FUEL MANAGEMENT  
I
Pilot Air Screws  
--  
I
I
I
I
(carbureted models)  
Carburetor (carbureted  
models) (synchronize)  
83  
I
Idle RPM  
--  
50, 64  
--  
I
I
I
I
I
I
I
I
I
I
Throttle Lever  
I
Oil Pump Lever  
(synchronize)  
Throttle Cable  
76  
76  
L
L
L
L
L
L
Choke Cable  
(carbureted models)  
Choke (carbureted  
models)  
76  
I
I
I
Vent Lines  
--  
--  
I
I
I
I
I
I
I
I
I
Throttle Position Sensor  
Fuel Lines  
82  
82  
82  
82  
--  
I
I
I
I
Fuel Filter  
R
R
I
R
R
I
Oil Filter  
Oil Lines  
I
I
Air Box/Plenum  
I
I
I
I
Fuel Injectors  
(fuel injected models)  
--  
I
I
Drain/Water Traps  
(carbureted models)  
84  
I
I
I
73  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Interval Table  
Item  
See  
Page  
Frequency  
1000 mi.  
150 mi.  
500 mi.  
2000 mi.  
Pre-  
Season  
(240 km) (800 km) (1600 km) (3200 km)  
ELECTRICAL  
Engine Stop Switch  
Throttle Safety Switch  
Ignition Switch  
Taillight  
63  
63  
--  
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
I
I
55  
55  
55  
I
Brakelight  
I
Headlight  
I
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  
Walker Evans Air  
Shocks  
--  
See your dealer for service  
at 1500 mi. (2000 km)  
Suspension Shock Oil  
Cooling Fins/Shroud  
Drive Shaft Bearings  
Jackshaft Bearings  
Skags (Wear Bars)  
--  
--  
I
I
I
I
I
I
I
I
I
I
I
I
76  
109  
107  
--  
L
L
I
L
L
I
L
L
I
I
I
Ski Saddle/Spindle  
Bolts  
I
I
I
Drive Chain Tension  
Hood Latches  
90  
50  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Rear Wheel Idler Bolts  
Idler Bolt Jam Nut  
103  
103  
75  
I
I
I
I
I
I
Rear Suspension Pivot  
Shafts  
L
L
L
Camber Alignment  
Handlebar Centering  
Tether Switch and Strap  
Track Alignment  
--  
--  
I
I
I
I
I
I
I
I
I
I
55  
104  
103  
--  
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  
108  
77  
I
I
I
R
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean  
R - Replace  
L - Lubricate  
74  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
Front Suspension  
The front suspension does not require lubrication.  
Rear Suspension  
Lubricate the suspension pivot shafts with Polaris Premium All Season  
Grease at the intervals outlined in the Periodic Maintenance Table  
beginning on page 72 and before seasonal storage. When operating in  
heavy, wet snow conditions, lubricate every 500 miles (800 km).  
Lack of lubrication will adversely affect your ride and the life of the sus-  
pension. For more information about suspension lubrication and adjust-  
ments, see your Polaris dealer.  
+
+
+
+
75  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
Driveshaft Bearing  
Fitting  
Inject grease into the fitting on the speed-  
ometer sensor housing until grease purges  
from the seal on the inside of the tunnel.  
This should take approximately two  
pumps. Do not use more than four pumps.  
Throttle Cable  
Lubricate the throttle cable lightly  
with grease or oil. With the  
engine off, turn the handlebars to  
the left and lubricate liberally as  
shown.  
Choke and Choke Cable  
Lubricate the choke slide and  
cables lightly with oil or grease.  
Before turning the engine off,  
operate the choke intermittently to  
draw moisture out of the choke  
plunger area and reduce the possi-  
bility of the choke becoming fro-  
zen.  
76  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
n Chaincase Oil  
Check the chaincase oil level at the  
intervals outlined in the maintenance  
charts beginning on page 71. The sight  
glass is located on the lower rear of the  
chaincase. Maintain the oil level at or  
slightly below the center of the sight  
glass. Change the chaincase oil after the  
first 500 miles (800 km), then every  
1000 miles (1600 km) or seasonally.  
Fill  
Plug  
Polaris recommends the use of Polaris  
Synthetic Chaincase Lube. See page 112  
for the part numbers of Polaris products.  
Oil Check  
1. Position the vehicle on a level sur-  
face.  
Sight Glass  
2. View the oil level at the sight glass.  
3. Remove the fill plug and add the  
recommended oil as needed. Do not  
overfill.  
4. Reinstall the fill plug, making sure it  
is seated properly.  
Maintain Level Here  
77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
Chaincase Oil  
Oil Change  
1. Position the vehicle on a level surface.  
2. Remove the drain plug and drain the  
oil into a drain pan. Allow the oil to  
drain completely.  
3. Clean off all metal shavings from the  
plug.  
4. Install a new sealing washer on the  
drain plug.  
Drain Plug  
NOTE: 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.  
78  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
Spark plug condition is indicative of engine operation. The spark plug  
firing end condition should be read after the engine has been warmed up  
and the vehicle has been driven at higher speeds. Immediately check the  
spark plug for correct color.  
WARNING  
A hot exhaust system and engine can cause serious burns. Wear protective  
gloves when removing a spark plug for inspection.  
NOTE: On carbureted models, incorrect fuel mixture can often cause a spark  
plug to appear too dark or too light in color. Before changing spark  
plug heat ranges, be sure the correct main jet is installed in the carbu-  
retor(s). Refer to the Owner's Manual Supplement or see your dealer.  
Normal Spark Plug  
The normal insulator tip is gray, tan or light brown. There will be few  
combustion deposits. The electrodes are not burned or eroded. This indi-  
cates the proper type and heat range for the engine and the service.  
NOTE: The tip should not be white. A white insulator tip indicates overheating,  
caused by use of an improper spark plug or incorrect carburetor/throt-  
tle body adjustments.  
Wet Fouled Spark Plug  
The wet fouled insulator tip is black. A damp oil film covers the firing  
end. There may be a carbon layer over the entire nose. Generally, the  
electrodes are not worn. General causes of fouling are excessive oil, use  
of non-recommended injection oil, improper use of the choke, or incor-  
rect carburetion adjustments.  
79  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
A new engine can cause temporary spark plug fouling due to the preser-  
vative added during the assembly process. Avoid prolonged idle speeds,  
which cause plug fouling and carbonization. Change the spark plugs  
every 2000-2500 miles (3200-4000 km).  
CAUTION  
Using non-recommended spark plugs can result in serious engine damage. A  
spark plug with a heat range too high will always cause engine damage if the  
engine is operated in conditions more severe than intended for that plug.  
Always use the spark plugs recommended for your snowmobile. See your  
Owner’s Manual Supplement.  
• Use recommended spark plugs with the proper gap.  
• Use only resistor-type spark plugs.  
• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).  
• Always carry spare spark plugs.  
Spark Plug Removal and Replacement  
1. Remove the spark plug cap.  
2. Using the special wrench provided in the tool pouch, rotate the  
spark plug counterclockwise to remove it.  
3. Reverse the procedure for spark plug installation.  
4. Torque to specification.  
5. Reinstall the spark plug cap.  
80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Intake Filters  
The intake foam filter limits  
snow ingestion into the intake  
system. When operating in loose  
powder snow, check the top of  
the foam filter periodically to  
remove any accumulation of  
Intake Foam Filters/Pre-filter  
snow.  
CAUTION  
Operating the snowmobile with the intake filters removed may cause intake  
icing. The result will be poor fuel economy or intake malfunction. Always rein-  
stall the intake filters before operating the snowmobile.  
81  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Fuel Injectors (Fuel Injected Models)  
All fuel injector service must be performed by an authorized Polaris  
dealer. Do not attempt to clean or service the fuel injectors.  
Fuel Pump  
All fuel pump service must be performed by an authorized Polaris  
dealer. Do not attempt to service the fuel pump.  
Fuel Filter  
See your Polaris dealer for replacement of the fuel filter at the intervals  
outlined in the Periodic Maintenance Table beginning on page 72.  
Fuel Lines  
Inspect the fuel lines regularly for signs of deterioration or damage.  
Always check fuel line condition after periods of storage. Normal dete-  
rioration from weather and fuel compounds may occur. Replace worn or  
damaged fuel lines promptly.  
CAUTION  
Kinking the fuel lines or using a pliers or similar tools to remove fuel lines  
may cause damage to the lines. If a fuel line has been damaged or kinked,  
replace it promptly.  
Oil Lines  
Inspect oil line condition at the intervals outlined in the Periodic Main-  
tenance Table beginning on page 72.  
Oil Filter  
Have your dealer change the oil filter  
and bleed the system at the intervals  
outlined in the Periodic Maintenance  
Table beginning on page 72.  
NOTE: The direction of the arrows indi-  
cates the direction of flow  
through the filter.  
82  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Carburetor (Carbureted Models)  
The number stamped in the end of the main jet indicates the jet size. The  
jet installed at the time of manufacture is not necessarily correct for your  
elevation. It's your dealer's responsibility to make sure the correct main  
jet is installed.  
CAUTION  
Operating the snowmobile with incorrect jetting can result in serious engine  
damage. Have your Polaris dealer perform all carburetor adjustments to  
ensure all adjustments are done correctly.  
Carburetor Adjustments  
The frequency at which the carburetors are synchronized or balanced is  
important. Properly adjusted carburetors can greatly improve engine  
performance, fuel economy, engine life, and reliability.  
If you notice any of the following conditions, the carburetor may need  
adjustment:  
• Hard starting  
• Poor idle  
• Overheated pistons and cylinder walls  
• Plug fouling  
• Poor engine response to various throttle valve openings  
83  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Carburetor (Carbureted Models)  
Carburetor Water/Sediment Trap  
Most Polaris snowmobiles contain patented carburetor bowl water/sedi-  
ment traps located at the bottom of each carburetor. The trap, consisting  
of a hose with a plug, should be drained about every 1000 miles (1600  
km) and inspected for contamination.  
WARNING  
When draining the traps, fuel spillage will occur. Always work in a well venti-  
lated area away from anything that may cause the fuel to ignite, such as open  
flames, sparks, heaters, trouble lights, cigarettes, etc. Review the fuel warn-  
ings on page 60.  
Cleaning Procedure  
1. Turn the fuel valve off.  
2. Place a container or shop  
towels below the plug to  
catch drained fuel.  
3. Slide the clamp away from  
the drain plug and remove  
the drain plug from the sedi-  
ment tube.  
4. Wipe residue from the plug  
Clamp  
and reinstall it. Reposition  
and tighten the clamp.  
5. Repeat the draining proce-  
dure for any remaining traps.  
Drain  
Plug  
84  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Exhaust System  
Check the exhaust system for wear or damage at the intervals outlined in  
the Periodic Maintenance Table beginning on page 71.  
WARNING  
Hot exhaust system parts can cause serious burns. Allow adequate time for  
the exhaust system to cool. Never perform this procedure with the engine  
running.  
Always allow the engine and exhaust system to cool completely before  
inspecting.  
1. Open the hood and inspect the muffler and pipes for cracks or dam-  
age.  
2. Check for weak or missing retaining springs or damper/support  
grommets.  
3. Check for loose clamps on the pipe covers.  
85  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cooling System  
Coolant  
The coolant supplied in the system is a 60/40 mixture of ethylene-glycol  
and distilled water. This mixture provides protection against freezing.  
Contact your dealer if greater protection is required.  
Use Premium 60/40 anti-freeze coolant, which is already premixed and  
ready to use. Do not dilute with water. Never exceed a 60% antifreeze/  
40% water mixture. See page 112 for the part numbers of Polaris prod-  
ucts.  
NOTE: Never add tap water to the cooling system. Minerals cause deposits  
and may react adversely with the metals in the engine and cooling  
system.  
n Coolant Level  
The engine coolant level is controlled by the recovery system. The  
recovery system components are:  
• Coolant bottle or overflow tank  
• Filler neck  
• Pressure cap  
• Connecting hoses  
Always maintain the coolant level between the minimum and maximum  
marks on the coolant bottle (when engine is cold) to prevent overheating  
and serious engine damage.  
CAUTION  
Operating the snowmobile with insufficient coolant will result in overheating  
and serious engine damage. Always maintain the coolant level as recom-  
mended.  
86  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cooling System  
Coolant High Temperature Indicator Light  
The high temperature indicator light will illuminate when engine cool-  
ant temperature becomes too hot for safe continued operation of the  
engine. If you must drive your snowmobile after the high temperature  
indicator light has come on, drive slowly and stop frequently to allow  
the engine to cool down. Driving in deep snow will also help cool the  
engine. See your dealer for service. Add coolant if the level is low.  
NOTE: 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.  
87  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cooling System  
Bleeding the Cooling System  
WARNING  
Steam and hot liquids will cause serious 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.  
CAUTION  
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.  
88  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Cooling System  
Bleeding the Cooling System  
Bleed the cooling system at the intervals outlined in the Periodic Main-  
tenance Table beginning on page 72. Perform the bleeding procedure  
when the engine is cold.  
1. Remove the pressure cap and fill the coolant bottle with properly  
mixed coolant to the maximum mark.  
2. Elevate the front end of the machine slightly to aid in bleeding of  
the heat exchangers.  
3. Remove the bleed screw from the water outlet manifold and/or the  
thermostat housing. Allow the coolant to bleed through the system  
until it runs out the bleed holes. Reinstall the bleed screw into the  
manifold.  
4. Add coolant to the coolant bottle to the maximum mark.  
5. Start the engine and run at a fast idle for two to three minutes.  
Loosen the bleed screw occasionally to purge any trapped air.  
6. Stop the engine and check the coolant bottle level. Fill as required.  
7. Feel the heat exchangers under the running boards. If the system is  
bled properly, they'll be warm to the touch. If they're not, repeat step  
5. Lift the front of the machine slightly to assist in the bleeding.  
8. Replace the pressure cap and carefully lower the front end of the  
machine.  
89  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain Tension  
Check drive chain tension weekly  
and before each long trip. To  
obtain correct chain tension:  
1. Rotate the driven clutch  
counterclockwise to move all  
chain slack to the tensioner  
side. Lock the brake lever  
lock, or have an assistant  
hold the brake lever firmly.  
Adjuster  
Bolt  
2. Loosen the adjuster bolt jam  
nut.  
Jam  
Nut  
3. Finger tighten the adjuster  
bolt until it can no longer be  
adjusted by hand, then back  
off 1/4 turn.  
4. Tighten the jam nut while  
holding the adjuster bolt.  
Torque to 21 ft. lbs. (28 Nm).  
5. Release the brake lever lock.  
90  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
n Hydraulic Brake Inspection  
Inspect the brake lever travel before each use of the snowmobile. See  
page 51.  
Brake pads must be replaced when the brake pad material becomes thin-  
ner than the backing plate, approximately 1/16" (1.5mm). A kit is avail-  
able for replacing brake pads. See your dealer.  
WARNING  
Brake failure during operation can result in serious injury or death. Properly  
functioning brakes are vital to your safety. Be sure the brake pads do not  
drag on the disc and that brake lever travel is not excessive.  
Always replace brake pads when the brake pad material becomes thinner  
than the backing plate, approximately 1/16" (1.5mm).  
91  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
Brake Components  
• Brake Disc  
Bleed Screw  
Brake Disc  
• Bleed Screw  
Brake Line  
• Brake Line  
Brake  
• Brake Caliper  
Caliper  
• Brake Pad Material -  
Replace when thickness is  
less than 1/16" (1.5mm).  
Brake Pad  
Material  
Excessive Lever Travel  
Hydraulic brakes are self-  
adjusting, but if excessive  
brake pad clearance develops  
(see page 91) bring the snow-  
mobile to an authorized  
Polaris dealer for inspection  
and adjustment.  
92  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
n 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 rap-  
idly absorbs moisture from the air. The moisture causes the boiling tempera-  
ture of the brake fluid to drop, which can lead to early brake fade and the  
possibility of accident or serious injury.  
WARNING  
Keep the master cylinder cover free of dirt and debris. The vent slits allow for  
diaphragm movement, and if they become plugged, movement of brake fluid  
below the diaphragm may be restricted, altering brake function.  
CAUTION  
Brake fluid will damage decals, paint and some plastics. Always wipe up  
spills immediately.  
Replace brake fluid at least every two  
years with Polaris DOT 4 high tem-  
perature brake fluid. See page 112 for  
the part numbers of Polaris products.  
Sight Glass  
The brake fluid level can be seen  
through a plastic sight glass in the  
brake reservoir. If the fluid is suffi-  
cient, the sight glass will be black. If  
the sight glass is any color other than  
black, add brake fluid.  
93  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
Bleeding the Hydraulic Brake System  
Air in the hydraulic brake system will cause spongy brake lever action.  
Bleed the system before operating the snowmobile.  
WARNING  
Operating the vehicle with a spongy brake lever can result in loss of brakes,  
which could cause an accident and lead to serious injury or death. Never  
operate the vehicle with a spongy-feeling brake lever.  
During the bleeding procedure, keep the brake handle as level as possi-  
ble. The reservoir must be in this position to minimize the possibility of  
air entering the system through the reservoir vent.  
1. Remove brake master cylinder reservoir cover and gasket.  
2. Fill the master cylinder reservoir to between the MIN and MAX  
marks or 1/4"-5/16" (.6-.8 cm) below the lip of the reservoir 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 93.  
8. Reinstall the gasket and cover.  
94  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lights  
Removing Halogen Bulbs  
NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a  
residue, causing a hot spot that will shorten the life of the lamp. If fin-  
gers do touch the bulb, clean it with an alcohol-moistened towel.  
1. Remove the plenum cov-  
ering from the headlight  
assembly.  
Bulb  
Spring  
2. Lift the rubber boot to  
expose the bulb.  
Harness  
3. Push down on the spring  
to release it from the  
housing.  
4. With the wire harness  
attached to the bulb, with-  
draw the bulb from the housing.  
5. Grasp the bulb by its metal base and carefully separate the bulb  
from the harness.  
Installing Halogen Bulbs  
1. Hold the bulb by its metal base and install it into the wire harness.  
2. Insert the bulb into the housing.  
3. Connect the spring to the housing.  
4. Carefully flip the spring back into the housing, placing it around the  
wire harness.  
5. Reinstall the plenum covering on the headlight assembly.  
6. Adjust headlight aim. See page 28.  
Replacing Taillight Bulbs  
1. Remove the screws securing  
the taillight lens.  
Screws  
2. Remove the bulb and install a  
new bulb.  
3. Reinstall the lens.  
95  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
Periodically inspect clutch sheaves for damage, wear or belt residue. To  
maintain optimum performance, clean with non-oil based cleaners such  
as isopropyl alcohol.  
WARNING  
If you become aware of higher than normal clutch engagement or an unusual  
vibration or shift pattern, see your dealer immediately. Do not operate the  
snowmobile until repairs have been made.  
All clutch maintenance and repairs must be performed by an authorized  
Polaris dealer. Any unauthorized modifications to clutches, such as adding or  
removing weights, will void the warranty.  
CAUTION  
The bushings in the weights and rollers of Polaris clutches are made of a  
material that may be damaged if lubricated. Do not lubricate clutch bushings.  
Clutch Alignment Offset  
Clutch alignment offset is important for maintaining optimum perfor-  
mance. Please see your Polaris dealer if you experience a decrease in  
performance.  
Clutch Center Distance  
See your Owner's Manual Supplement for recommended center distance  
for your machine. If adjustment is necessary, see your dealer.  
96  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
n Drive Belt Condition  
Belt width and length must match the center distance of the clutches and  
sheave width of the drive clutch. For this reason, Polaris recommends  
that only O.E.M. belts be used. Other belts may match the dimensions,  
but can drastically change the shift pattern, resulting in poor perfor-  
mance. See Drive Belt Troubleshooting on page 117.  
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.  
NOTE: A worn belt will continue to function, but will not deliver maximum per-  
formance. Always carry a spare belt in case of an emergency.  
For improved drive-away during extremely cold temperatures, remove  
the belt and warm it to room temperature. Reinstall it before starting the  
snowmobile.  
Drive Belt Installation  
1. Drop the drive belt over the drive  
clutch and pull back the slack.  
NOTE: To ensure satisfactory belt life,  
install belts so they operate in  
the same direction of rotation by  
positioning the identification  
numbers so that you can read  
them. If required, separate the  
sheaves as outlined in the belt  
removal procedures.  
2. Rotate the L-wrench counter-clockwise to tighten the sheaves while  
working the belt to the outer edge of the sheaves.  
3. Remove the wrench and store it in the tool kit.  
4. Reinstall the side panel.  
5. Close and secure the hood.  
97  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
Drive Belt Removal  
CAUTION  
Do not attempt to remove the drive belt after operating in reverse. The snow-  
mobile must be stopped after forward motion to prevent damage to compo-  
nents during belt removal.  
1. Stop the engine after operating in a forward motion.  
NOTE: For easier accessibility, make sure the clutch tool access hole is visible  
between the 11:00 and 2:00 positions of the clutch sheave.  
2. Turn the ignition key off.  
Access Hole  
Wait for the engine to come  
to a complete stop.  
3. Lock the parking brake.  
4. Open the hood.  
11:00  
2:00  
5. Remove the left side panel.  
6. Locate the L-wrench in the  
tool kit. Install the wrench  
into the open threaded access  
hole in the outer sheave of  
the clutch.  
7. Turn the wrench clockwise  
until the sheaves open far  
enough to remove the belt.  
98  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
nDrive Belt Deflection  
Straight  
Edge  
Measure  
A
Measure belt deflection with both  
clutches at rest and in their full  
neutral position.  
Place a straight edge on the belt  
and apply downward pressure  
while measuring at point A. This  
measurement should be 1 1/4"  
(3.2 cm).  
Drive Belt Adjustment  
1. Install the L-wrench into the open threaded hole in the outer sheave  
of the clutch (see page 98). Turn the wrench clockwise slightly to  
remove pressure from the sheaves.  
2. Loosen the 7/16" jam nut.  
3. Using a 1/8" Allen wrench, turn the set screw inward (clockwise) to  
increase the distance between the sheaves or outward (counter-  
clockwise) to decrease the distance.  
4. Tighten the jam nut. Store the L-wrench in the tool kit.  
Torque Stop  
.010"-.030"  
(.25-.75 mm)  
Periodically check torque stop clear-  
ance. With clutches in proper align-  
ment, measure rear torque stop  
clearance from the engine case. Rear  
torque stop clearance should be .010"-  
.030" (.25-.75mm). Adjust if neces-  
sary. Secure the nut.  
99  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Replacement  
When replacing the track, always install a track having the lug size rec-  
ommended for your model. See your Polaris dealer.  
CAUTION  
Installing tracks with larger lugs on machines equipped with coolers will result  
in damage to the cooler or tunnel. Always install a track having the lug size  
recommended for your model.  
Track Inspection  
WARNING  
Broken track rods can cause a rotating track to come off the machine, which  
could cause serious injury or death. Never operate with a damaged track.  
Never rotate a damaged track under power.  
1. Using a hoist, safely lift and sup-  
port the rear of the snowmobile  
off the ground.  
2. Rotate the track by hand to check  
for damage.  
3. Carefully examine the track along  
the entire length of each rod.  
Bend the track to check for  
breakage.  
4. Replace the track if any rod dam-  
age is found.  
Rods  
100  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Lubrication  
WARNING  
Operating with insufficient lubrication between the rail slide and track guide  
clips can cause track failure, loss of vehicle control and loss of braking ability,  
which can result in serious injury or death.  
Avoid operating for extended periods on ice and other surfaces that have lit-  
tle or no snow for lubrication.  
The slide rail requires adequate snow cover for sufficient lubrication.  
Excessive wear indicates insufficient lubrication. A new rail slide can  
cause faster heat build-up in limited lubrication, resulting in excessive  
wear.  
NOTE: Track damage or failure caused by operation on ice or under other  
poor lubrication conditions will void the track warranty.  
CAUTION  
High speed use on hard-packed surfaces is not recommended for models  
equipped with a deep lug track. Track lug damage may occur. Keep high  
speed use to a minimum, including frequent slow-speed intervals for track  
cooling.  
101  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Tension  
WARNING  
Moving parts can cut and crush body parts. When performing the checks and  
adjustments recommended on the following pages, stay clear of all moving  
parts. Never perform track measurement or adjustments with the engine run-  
ning.  
Track tension is critical for maximum efficiency and performance.  
Track tension controls the approach angle of the track to the rail beam in  
powder snow conditions. Deep snow performance will be optimized at  
the specified tension. Looser tensions will cause the track to “bunch” in  
front of the rail tips, causing improper approach angle and poor perfor-  
mance. New tracks will need to be retightened and aligned after the first  
ride.  
TRACK TENSION DATA CHART  
Measurement  
Location  
Slack  
Measurement  
Suspension  
Weight  
IQ RMK  
10 lbs. (4.54 kg)  
16" (40 cm)  
ahead of rear  
idler shaft  
3/8"-1/2"  
(1-1.3 cm)  
NOTE: Tension adjustments should be made only after the track is warmed up  
and limber.  
1. Turn the engine off.  
2. Lift the rear of the snowmobile and safely support it off the ground.  
3. Place the recommended weight or downward pressure on the track  
at the specified distance (see chart) ahead of the center of the rear  
idler wheel.  
NOTE: Measure at the point where the weight is placed.  
4. Check for specified slack between the wear surface of the track clip  
and the plastic rail slide.  
102  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Tension  
Adjusting  
Screw  
Idler Shaft Bolt  
Lock  
Nut  
10 lbs.  
(4.54 kg)  
16" (40 cm)  
If the track needs adjustment:  
5. Loosen the rear idler shaft bolt.  
6. Loosen the lock nuts.  
7. Tighten or loosen the track adjusting screws as necessary to provide  
equal adjustment on both sides of the track.  
8. Repeat the measurement on the other side of the track.  
NOTE: Check more frequently when the snowmobile is new.  
9. Start the engine and slowly rotate the track at least five revolutions.  
Let the track come to a stop (do not apply brakes).  
10. Check track alignment (see page 104) and adjust as necessary.  
11. Tighten the lock nuts.  
12. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).  
103  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
nTrack Alignment  
Periodically check that the track is  
centered and running evenly on the  
slide rails. Misalignment will cause  
excessive wear to the track and slide  
rail.  
1. Safely support the rear of the  
snowmobile with the track off the  
ground.  
2. Start the engine and apply a small  
amount of throttle until the track  
turns slowly at least five com-  
plete revolutions. Stop the engine  
and let the track come to a stop  
(do not apply brakes).  
Window  
Rail  
3. Inspect track alignment by looking through the track window to  
make sure the rails are evenly spaced on each side. If the track runs  
to the left, loosen the left locknut and tighten the left adjusting bolt.  
If the track runs to the right, loosen the right locknut and tighten the  
right adjusting bolt.  
4. After adjustments are complete, tighten the locknuts and torque  
idler shaft bolts to 35 ft. lbs. (47.5 Nm).  
5. Repeat steps 2 and 3 to verify proper alignment.  
104  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
Steering Inspection and Adjustment  
Check all steering system fasteners weekly and before a long ride.  
Tighten any loose fasteners.  
+
+
+
+
+
105  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
Ski Alignment  
WARNING  
Improper ski alignment or adjustment may cause loss of steering control,  
resulting in serious injury or death. Do not attempt to change the ski align-  
ment or camber adjustment. See your Polaris dealer.  
With the handlebars in a straight ahead position, and with vehicle  
weight compressing the suspension, measure from the straight edge of  
the skis at the center of the ski mounting bolt. The measurement  
between the skis at point X should be 1/8" to 1/4" (3-6 mm) greater than  
the measurement at point Y.  
NOTE: If the skis are misaligned, we recommend that your dealer correct the  
alignment, since camber adjustment may also be affected.  
X
10 in.  
(25.4 cm)  
10 in.  
(25.4 cm)  
Y
106  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
nSki Skags  
WARNING  
Worn skis and/or skags will adversely affect handling. Loss of vehicle control  
may result, causing serious injury or death.  
See your dealer's studding chart for recommended skags. If you install longer  
or more aggressive carbide skags than the original equipment, it may also be  
necessary to add track studs to maintain proper vehicle control while turning  
on hard-packed snow or ice.  
Check skags before each use of the snowmobile to ensure positive steer-  
ing characteristics. Skags must be replaced when worn to half their orig-  
inal diameter.  
NOTE: Carbide skags must be replaced if any abnormal wear or chipping is  
found.  
Skag Replacement  
NOTE: Some models are equipped with single skags. Other models are  
equipped with dual skags.  
1. Raise and support the front of  
the snowmobile so the skis  
are approximately 6" (15 cm)  
from the ground.  
2. Remove the attaching nuts  
and pry the skag downward.  
3. Remove the front end of the  
skag.  
4. Remove the rear end of the  
skag.  
5. Reverse the steps to install a  
skag.  
Skag  
107  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
nRail Slide Wear  
For ease of inspection, all  
Polaris rail slides have a  
wear limit indicator groove  
to indicate the minimum  
permissible slide thick-  
ness. Replace the rail  
Minimum  
Thickness  
slides if they are worn to  
the top of the groove at any  
point along their length.  
Failure to do so may result  
in permanent damage to  
the track or rails.  
Replace when  
worn to top of  
groove  
108  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 112 for the part numbers of Polaris prod-  
ucts.  
Cleaning and Preservation  
Proper storage starts with cleaning, washing, and waxing the hood,  
chassis, and plastic parts. Wipe down remaining surfaces with a damp  
cloth. Clean and touch up with paint any rusted or previously painted  
surfaces. Be sure that corrosive salt and acids are removed from surfaces  
before beginning preservation with waxes and rust inhibitors (grease, oil  
or paint).  
The snowmobile should be stored in a dry garage or shed, out of direct  
sunlight, and covered with a fabric snowmobile cover. Plastic tarp may  
cause condensation to form and damage snowmobile components.  
Controls and Linkage  
Lubricate all bushings, spindle shafts, tie rod ends and cables as outlined  
in the Periodic Maintenance Table beginning on page 72.  
Bearings  
Grease the jackshaft and drive shaft clutch side bearings with Polaris  
Premium All-Season Grease or a similar high quality grease to prevent  
corrosion.  
Clutch and Drive System  
Remove the drive belt and store in a cool dry location. Do not lubricate  
clutch components, except the driven clutch shaft bushing as outlined in  
the Master Repair Manual. See your dealer.  
109  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Extended Storage  
Engine and Carburetor Protection (Carbureted Models)  
Proper preparation of the engine and fuel system is vital to the preven-  
tion of rust and corrosion on precision engine parts during storage.  
Whenever the machine is stored for a period of more than 60 days, the  
engine must be fogged with fogging oil. Follow the engine fogging  
instructions provided on the container.  
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to  
the fuel tank. Follow the instructions on the container, running the  
engine for five minutes to get additives through the entire fuel system.  
Top off with fresh fuel. Do not allow the snowmobile to run out of fuel.  
If stabilizer is not used, drain the carburetors by removing the water trap  
drain plugs. See page 84.  
Jet restriction caused by improper storage can cause lean conditions and  
very poor slow speed driving quality.  
Engine Protection (Fuel Injected Models)  
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.  
NOTE: Do not spray fogging oil into the plenum. Remove the plenum and  
spray the fogging oil into the boost box. Continue spraying until the  
engine stops.  
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to  
the fuel tank. Follow the instructions on the container, running the  
engine for five minutes to get additives through the entire fuel system.  
Top off with fresh fuel. Do not allow the snowmobile to run out of fuel.  
See page 68.  
110  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Extended Storage  
Electrical Connections  
Replace worn or frayed electrical wire and connectors. Be sure wiring  
harness is properly secured away from sharp edges, steering linkage,  
moving parts, and hot exhaust parts.  
Track and Suspension  
Moderate track tension should be maintained during summer storage.  
The machine should be supported off the ground to allow the track to  
hang freely.  
Transporting the Snowmobile  
Whenever the snowmobile is transported:  
1. Turn the fuel valve off. See page 28.  
2. Be sure the fuel cap and oil cap are installed correctly.  
3. Always tie the snowmobile to the transporting unit securely using  
suitable straps.  
4. Remove the ignition key to prevent loss.  
111  
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS PRODUCTS  
Part No.  
Description  
Engine Lubricants  
Fogging Oil (12 oz. Aerosol)  
2870791  
2871098  
2871097  
2871240  
2871721  
2871722  
2872347  
2874438  
2874439  
2874443  
Premium 2-Cycle Engine Oil (qt.)  
Premium 2-Cycle Engine Oil (gal.)  
Premium 2-Cycle Engine Oil (2.5 gal.)  
Premium Gold Synthetic 2-Cycle Engine Oil (qt.)  
Premium Gold Synthetic 2-Cycle Engine Oil (gal.)  
Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)  
VES II Synthetic 2-Cycle Engine Oil (qt.)  
VES II Synthetic 2-Cycle Engine Oil (gal.)  
VES II Synthetic 2-Cycle Engine Oil (2.5 gal.)  
Chaincase Lubricants  
2873105  
2872951  
Synthetic Chaincase Lubricant (qt.)  
Synthetic Chaincase Lubricant (12 oz.)  
Grease/Specialized Lubricants  
Grease Gun Kit, Premium All Season (3 oz.)  
Premium All Season Grease (3 oz. cartridge)  
Premium All Season Grease (14 oz. cartridge)  
Dielectric Grease (Nyogelt)  
2871312  
2871322  
2871423  
2871329  
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  
112  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
Unless you have experience and training in two-cycle engine repair,  
see your dealer if technical problems arise.  
Problem  
Probable Cause Solution  
Erratic engine oper- Drive clutch binding • SEE YOUR DEALER.  
ating RPM during  
Driven clutch mal-  
function  
• SEE YOUR DEALER.  
• Replace the drive belt.  
• SEE YOUR DEALER.  
acceleration or load  
variations  
Harsh drive clutch  
engagement  
Drive belt worn or  
too narrow  
Excessive belt/  
sheave clearance  
Drive belt turns over Wrong belt for appli- • Replace the drive belt.  
cation  
Clutch alignment out • SEE YOUR DEALER.  
of spec  
Engine mount bro-  
ken or loose  
• Inspect and replace. SEE YOUR  
DEALER.  
Machine fails to  
move  
Clutch jammed  
• Check for twisted belt or broken  
spring. SEE YOUR DEALER.  
Track jammed  
• Foreign object may be caught or the  
rail slide melted to the track clips  
due to lack of lubrication.  
• Track may be iced up or frozen to  
the ground.  
Chaincase sprocket  
or chain jammed or  
broken  
• Chain is loose or broken or chain  
tightener is loose. SEE YOUR  
DEALER.  
113  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause Solution  
Noise in drive sys-  
tem  
Broken drive clutch • SEE YOUR DEALER.  
components  
Bearing failure/  
chaincase, jackshaft,  
or front drive shaft  
• SEE YOUR DEALER.  
Drive belt surface  
flat spots  
• Inspect and replace as needed.  
Drive chain loose  
• Inspect and adjust (or replace).  
• SEE YOUR DEALER.  
Drive chain worn,  
sprocket teeth bro-  
ken  
Poor low RPM per-  
formance  
Worn drive belt  
• Inspect and replace as needed.  
• SEE YOUR DEALER.  
Excessive belt/  
sheave clearance  
Loose torque stop  
Sticky clutch  
• Inspect and adjust.  
• SEE YOUR DEALER.  
• Use 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.  
114  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause Solution  
Engine turns but fails Faulty ignition  
to start  
• Install new spark plug(s). If engine  
still fails to start, check for spark. If  
there's no spark, SEE YOUR  
DEALER.  
No fuel to engine  
• Make sure the fuel valve is on.  
• Use the choke. See page 56.  
• 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).  
• SEE YOUR DEALER.  
• SEE YOUR DEALER.  
Fuel filter (loss of  
high RPM power)  
Incorrect clutching  
Carburetor and fuel  
pump  
• There is no adjustment to change  
power output. SEE YOUR  
DEALER.  
Engine continually  
backfires  
Faulty plug(s)  
• Change plug(s).  
Carburetor / Fuel  
System  
• 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  
115  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Suspension Troubleshooting  
Problem  
Solution  
Rear suspension bot-  
toms too easily  
• Set static sag (see page 43). Adjust torsion spring blocks or  
install optional torsion springs to achieve correct sag  
dimensions.  
Rides too stiff in rear • Check for binding suspension components and grease all  
pivot points.  
• Set static sag (see page 43). Adjust torsion spring blocks or  
install optional torsion springs to achieve correct sag  
dimensions.  
Too much weight  
transfer when climb-  
ing  
• Set static sag (see page 43). Adjust torsion spring blocks or  
install optional torsion springs to achieve correct sag.  
• Move limiter strap to high position (see page 44).  
Too little weight  
transfer when climb-  
ing  
• Set static sag (see page 43). Adjust torsion spring blocks or  
install optional torsion springs to achieve correct sag.  
• Move limiter strap to low position (see page 44).  
Front end pushes  
• Check for worn skags.  
• Check for binding front suspension shafts/steering compo-  
nents, grease all pivot points (elevate front of machine).  
• Set static sag (see page 43). Adjust torsion spring blocks or  
install optional torsion springs to achieve correct sag.  
• Increase IFS preload (if equipped) (see page 41).  
• Move limiter strap to high position (see page 44).  
Steering is heavy  
• Make sure spindles and all steering components turn freely.  
• Check ski alignment (see page 106).  
• Check skags and skis for damage.  
• Set static sag (see page 43).  
Machine darts from  
side to side  
• Check ski alignment (see page 106).  
• Check for binding front suspension shafts/steering compo-  
nents, grease all pivot points (elevate front of machine).  
• Check for excessive play in steering assembly (see dealer).  
• Ensure skags are straight on skis.  
• Set static sag (see page 43).  
• Check rail slide/replace if worn (see page 108).  
• Install Accu-Trak dual skags (see your dealer).  
116  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Drive Belt Troubleshooting  
Belt Wear/Burn Diagnosis  
Solutions  
Causes  
Driving at low RPM  
• Drive at higher RPM. Gear the machine down. Check  
belt deflection.  
Insufficient warm-up  
Towing at low RPM  
• Warm the engine at least five minutes. Take the drive  
belt off the machine in extremely cold weather and  
warm it up. Break machine loose from the snow.  
• Do not tow in deep snow. Use fast, aggressive throttle  
to engage clutch.  
Riding with high RPM  
and slow speed (8000  
RPM/10 MPH)  
• Lower the gear ratio. Reduce RPM. Avoid riding in  
high ambient temperatures. Check for snow ingestion.  
Ice and snow build-up  
between track and tunnel  
• Warm the engine at least five minutes. Take the drive  
belt off the machine in extremely cold weather and  
warm it up. Break machine loose from the snow.  
Poor engine performance • Check for 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  
117  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Service And Warranty Information  
Obtaining Service and Warranty Assistance  
Read and understand the service data and the Polaris warranty informa-  
tion contained in this manual. Contact your Polaris dealer for replace-  
ment parts, service or warranty. Your dealer receives frequent updates  
on changes, modifications and tips on snowmobile maintenance, which  
may supersede information contained in this manual. Your dealer is also  
familiar with Polaris policies and procedures and will be happy to assist  
you.  
When contacting us about parts, service, or warranty, always provide the  
following information:  
1. Serial number  
2. Model number  
3. Dealer name  
4. Date of purchase  
5. Details of trouble experienced  
6. Length of time and conditions of operation  
7. Previous correspondence  
Use the page provided near the front of your Owner’s Manual to record  
the identification numbers of your snowmobile and its engine.  
Polaris Customer Service  
United States: 1-888-704-5290  
Canada: 1-204-925-7100  
118  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Service And Warranty Information  
Polaris Anti-Theft System  
The Polaris anti-theft system (PATS) monitoring program is designed to  
aid owners of registered snowmobiles in recovery of stolen machines.  
Administration  
1. Polaris snowmobile owner reports theft.  
A. In addition to notifying the proper law enforcement officials, the  
owner must call Polaris Customer Service.  
B. Owners must provide their name, address, telephone number and  
the model and serial number of stolen machines.  
2. Polaris warranty will provide all dealerships with a monthly updated  
list of all stolen units to further monitor thefts.  
3. Polaris warranty will aid in notifying the proper owner when a unit  
is recovered  
119  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Limited Warranty  
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-  
ITED WARRANTY on all components of the Polaris snowmobile against defects in  
material or workmanship. This warranty covers the parts and labor charges for repair or  
replacement of defective parts that are covered by this warranty. The warranty begins on  
the date of purchase. This warranty is transferable to another consumer, during the war-  
ranty period, through a Polaris dealer.  
Registration  
At the time of sale, the Warranty Registration Form must be completed by your dealer  
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will  
record the registration for warranty. No verification of registration will be sent to the  
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-  
ment. If you have not signed the original registration and received the customer copy,  
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE  
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.  
Initial dealer preparation and set-up of your snowmobile is very important in ensuring  
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer  
set-up will void your warranty coverage.  
Warranty Coverage and Exclusions  
Limitations of warranties and remedies  
This warranty excludes any failures not caused by a defect in material or workmanship.  
The warranty does not cover accidental damage, normal wear and tear, abuse or  
improper handling. The warranty also does not cover any snowmobile that has been  
structurally altered, neglected, improperly maintained, used for racing or used for pur-  
poses other than for which it was manufactured. The warranty does not cover any dam-  
ages that occur during trailer transit or as a result of unauthorized service or parts. In  
addition, this warranty does not cover physical damage to paint or finish, stress cracks,  
tearing or puncturing of upholstery material, corrosion or defects in parts, components  
or the snowmobile due to fire, explosions or any other cause beyond Polaris’ control.  
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that  
are not compatible with the snowmobile.  
The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option,  
repair or replacement of any defective materials, or components or products. THE REM-  
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-  
ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL  
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL  
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF  
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-  
GENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-  
sion or limitation of incidental or consequential damages or implied warranties, so the  
above limitations or exclusions may not apply to you if inconsistent with controlling  
state law.  
120  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Limitations of warranties and remedies  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE  
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-  
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR  
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-  
RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations  
on how long an implied warranty lasts, so the above limitation may not apply to you if  
inconsistent with controlling state law.  
How to Obtain Warranty Service  
If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-  
rized to repair Polaris snowmobiles. When requesting warranty service you must present  
your copy of the Warranty Registration form to the dealer. (The cost of transportation to  
and from the dealer is YOUR responsibility). Polaris recommends that you use your  
original selling dealer; however, you may use any Polaris Servicing Dealer to perform  
warranty service.  
Please work with your dealer to resolve any warranty issues. Your dealer will contact the  
appropriate personnel at Polaris if additional assistance is needed.  
This warranty gives you specific legal rights, and you may also have other rights which  
vary from state to state.  
If any of the above terms are void because of state or federal law, all other warranty  
terms will remain in effect.  
Engine Oil  
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-  
ommend the use of Polaris engine oil.  
2. Damage resulting from the use of non-recommended lubricants may not be covered  
by warranty.  
121  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Conditions and Exclusions  
In order to qualify for warranty, the product must have been properly set up and tested  
by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle  
Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer  
sign the PDI form prior to delivery may void the warranty. Failure to provide proof of  
required periodic maintenance upon request may result in denial of warranty coverage.  
Use of the recommended Polaris products for lubrication and maintenance as directed by  
the Owner’s manual is highly recommended. Should a failure occur during the warranty  
period resulting from the use of non-recommended products, warranty coverage may be  
denied.  
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental  
conditions and/or contamination. The following items are excluded from warranty con-  
sideration if the failure was due to wear or not the direct result of a defect:  
Skis  
Ski wear rods  
Tracks  
Slide rails  
Suspension components  
Brake components  
Seat components  
Clutches and components  
Steering components  
Batteries  
Finished and unfinished surfaces  
Carburetor/Throttle body components  
Engine components  
Drive belts  
Hydraulic components  
Circuit breakers/Fuses  
Electronic components  
Light bulbs/Sealed beam lamps  
Idler wheels  
Warranty applies to the product only and does not allow for coverage of personal loss.  
Some items are considered “consumable,” meaning they are considered part of normal  
maintenance or part of completing an effective repair. The following items are excluded  
from warranty coverage in the event of a warranty claim:  
Spark Plugs  
Filters  
Fuel  
Lubricants such as oil, grease, etc.  
Batteries (unless defective)  
Cosmetic damage/repair  
Coolants  
Sealants  
Hotel fees  
Meals  
Towing charges  
Mileage  
Rentals/Loss of product use  
Shipping/ handling fees  
Product pick-up/delivery  
Loss of vacation/personal time  
This warranty also excludes failures resulting from improper lubrication; improper  
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold  
or contamination; operator error or abuse; improper component alignment, tension,  
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign  
substance ingestion/contamination; improper maintenance; modified components; use  
of aftermarket components resulting in failure; unauthorized repairs; repairs made after  
the warranty period expires or by an unauthorized repair center; use of the product in  
competition or for commercial purposes. Warranty will not apply to any product which  
has been damaged by abuse, accident, fire or any other casualty not determined a defect  
of materials or workmanship.  
122  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Polaris Second Year Engine Service Contract  
Second Year Engine Service Contract is standard on all eligible new and unused snow-  
mobiles that were Snow Checked through an authorized Polaris dealer during the  
March/April Snow Check promotion. The free Second Year Engine Service Contract is  
honored by all authorized Polaris snowmobile dealers in North America and is transfer-  
able 120 days after the original purchase date, free of charge, through any Polaris snow-  
mobile dealer. Coverage on Snow Check units is automatic. Although you do not  
receive a warranty card, your dealership should have printed a copy of the warranty reg-  
istration form. This form is your proof of warranty.  
Consumer Exclusions  
• Each repair visit after the first twelve months of standard warranty coverage is subject  
to a $50 deductible.  
• The free Second Year Engine Service Contract applies to the first 5,000 miles or two  
(2) calendar years from date of purchase, whichever comes first. Tampering with the  
odometer shall void all warranties/service contracts. No extensions to coverage under  
this engine service contract can be given. Used snowmobiles are not eligible under this  
program.  
• Snowmobiles used for commercial purposes or for racing are excluded from coverage.  
Coverage  
Coverage for second year engine failures due to defects in materials and workmanship  
will be determined by Polaris in its sole discretion. Coverage is automatic with no addi-  
tional paperwork required. The free Second Year Engine Service Contract is subject to a  
$50 deductible per visit. Regular, documented service maintenance visits are required to  
validate this warranty.  
A partial list of items excluded from coverage includes:  
• Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.  
• Damage caused by the failure of other components of the snowmobile.  
• Failures caused by improper fuel or oil.  
• Piston seizures, unless caused by a defective engine component.  
• Failures caused due to improper adjustments.  
• Failure due to unauthorized service.  
• Failures due to lack of service as required in the owner’s manual or Polaris updates.  
This includes off-season storage as listed in the owner’s manual.  
• Failure due to use of unauthorized parts or modifications.  
• Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,  
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and  
exhaust manifolds excluding paint coverage.  
• Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring  
and other electrical components are excluded from coverage.  
• Cooling system coverage is limited to the water pump assembly and components, fan,  
fan bearings, temperature sensor, gasket and seals.  
• Non wear related throttle body parts are covered. The fuel pump is covered.  
• Clutches and related clutch parts, including but not limited to, the drive belt, are  
excluded from coverage.  
• Electrical components are excluded from coverage.  
• Gearcases and transmissions are excluded from coverage.  
123  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Exported Vehicles  
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-  
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD  
OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-  
TION.  
This policy does not apply to vehicles that have received authorization for export from  
Polaris Industries. Dealers may not give authorization for export. You should consult an  
authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you  
have any questions.  
This policy does not apply to vehicles registered to government officials or military per-  
sonnel on assignment outside the country of the selling dealer’s authorized location.  
This policy does not apply to Safety Recalls.  
How to Get Service  
In the Country where your vehicle was purchased:  
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you  
move or are traveling within the country where your vehicle was purchased, Warranty or  
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells  
the same line as your vehicle.  
Outside the Country where your vehicle was purchased:  
If you are traveling temporarily outside the country where your vehicle was purchased,  
you should take your vehicle to an authorized Polaris dealer. You must show the dealer  
photo identification from the country of the selling dealer’s authorized location as proof  
of residence. Upon residence verification, the servicing dealer will be authorized to per-  
form the warranty repair.  
If You Move:  
If you move to another country, be sure to contact Polaris Customer Assistance and the  
customs department of the destination country before you move. Vehicles importation  
rules vary considerably from country to country. You may be required to present docu-  
mentation of your move to Polaris Industries in order to continue your warranty cover-  
age. You may also be required to obtain documentation from Polaris Industries in order  
to register your vehicle in your new country.  
If Purchased From A Private Party:  
If you purchase a Polaris product from a private citizen outside of the country in which  
the vehicle was originally purchased, all warranty coverage will be denied.  
Notice  
If your vehicle is registered outside of the country where it was purchased, and you have  
not followed the procedure set out above, your vehicle will no longer be eligible for war-  
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-  
cials or military personnel on assignment outside of the country where the vehicle was  
purchased will continue to be covered by the basic warranty.)  
For questions call Polaris Customer Assistance (see page 118).  
124  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Snowmobile Engine Emissions Limited Warranty  
This snowmobile engine emissions limited warranty is in addition to the Polaris stan-  
dard limited warranty for snowmobiles.  
Polaris Industries Inc. warrants that the new engine, including all parts of its emission-  
control system, is designed, built and equipped so it conforms to current U.S. Environ-  
mental Protection Agency regulations applicable to snowmobile emissions under 40  
CFR1051, 1065 and 1068 at the time of sale to the ultimate purchaser. Polaris warrants  
that the engine is free from defects in materials and workmanship that may keep it from  
meeting these regulations.  
The warranty period for this emissions certified snowmobile engine starts on the date  
when the engine is first purchased and continues for 4000 kilometers (2485 miles) of  
vehicle travel, 200 hours of operation, or 30 calendar months, whichever comes first.  
This engine emissions limited warranty covers the parts and labor charges for repair or  
replacement of defective parts that are covered by this warranty. This includes compo-  
nents whose failure increases the snowmobile engine's emissions. To the extent they are  
present on your snowmobile engine, this includes electronic controls, fuel injection  
components, exhaust gas recirculation system components, and aftertreatment system  
components. Replacing or repairing other components not covered by this warranty is  
the responsibility of the snowmobile owner.  
The exclusive remedy for breach of this limited warranty shall be, at the exclusive  
option of Polaris, repair or replacement of any defective materials, components or 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 PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY  
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-  
TIES NOT STATED IN THIS WARRANTY.  
125  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Snowmobile Engine Emissions Limited Warranty  
Some states do not allow limitations on how long an implied warranty lasts, so the above  
limitation may not apply if it is inconsistent with the controlling state law. This limited  
warranty excludes failures not caused by a defect in material or workmanship. This lim-  
ited 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 any engine that has been used in racing competition. This limited  
warranty also does not cover physical damage, corrosion or defects caused by fire,  
explosions or other similar causes beyond the control of Polaris.  
Owners are responsible for performing the scheduled maintenance identified in the  
owner's manual. Polaris can deny an emissions warranty claim if any specified critical  
emissions-related maintenance is not performed. Performance of other scheduled main-  
tenance is strongly recommended, but is not necessary to keep the emissions-related  
warranty valid. Any qualified repair shop or qualified person may maintain, replace, or  
repair the emission control devices or systems on your snowmobile. Polaris recom-  
mends that you contact an authorized Polaris dealer to perform any service that may be  
necessary.  
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 and may result in civil penalties.  
126  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
Present this section of your manual to your dealer each time your snow-  
mobile is serviced. This will provide you and future owners with an  
accurate log of maintenance and services performed on the snowmobile.  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
150 mi.  
(240 km)  
500 mi.  
(800 km)  
1000 mi.  
(1600 km)  
2000 mi.  
(3200 km)  
127  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
128  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
129  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
A
D
Accessories . . . . . . . . . . . . . . . . . . . 48  
Apparel for Riding. . . . . . . . . . . . . . 12  
Avalanches. . . . . . . . . . . . . . . . . . . . 15  
Drive Belt . . . . . . . . . . . . . . . . . . . . . 18  
Drive Belt Adjustment. . . . . . . . . . . . 99  
Drive Belt Condition . . . . . . . . . . . . . 97  
Drive Belt Deflection. . . . . . . . . . . . . 99  
Drive Belt Installation . . . . . . . . . . . . 97  
Drive Belt Removal. . . . . . . . . . . . . . 98  
Drive Belt Troubleshooting. . . . . . . 117  
Drive Chain Tension . . . . . . . . . . . . . 90  
Driver Awareness . . . . . . . . . . . . . . . 14  
Driving Downhill. . . . . . . . . . . . . . . . 16  
Driving in Hilly Terrain. . . . . . . . . . . 17  
Driving on Slippery Surfaces . . . . . . 17  
Driving Responsibly . . . . . . . . . . . . . 20  
B
Brake Components. . . . . . . . . . . . . . 92  
Brake Fluid . . . . . . . . . . . . . . . . . . . 93  
Brake Inspection . . . . . . . . . . . . . . . 91  
Brake Lever Feel . . . . . . . . . . . . . . . 51  
Brake Lever Travel . . . . . . . . . . 51, 92  
Brake System, Bleeding. . . . . . . . . . 94  
Brakes . . . . . . . . . . . . . . . . . . 51, 91-94  
Break-In, Engine . . . . . . . . . . . . . 57-58  
Bulbs, Replacing . . . . . . . . . . . . . . . 95  
E
C
Electrical Connections. . . . . . . . . . . 111  
Emission Control Information. . . 69-70  
Emission Control Label. . . . . . . . . . . 69  
Emission Control Maintenance . . . . . 69  
Engine Break-In. . . . . . . . . . . . . . 57-58  
Engine Protection (600 RMK). . . . . 110  
Engine Protection (DRAGON) . . . . 110  
Engine Stop Switch . . . . . . . . . . . . . . 63  
Engine, Starting . . . . . . . . . . . . . . . . . 56  
Environment Preservation . . . . . . . . . . 6  
Exhaust System . . . . . . . . . . . . . . . . . 85  
Eye Protection . . . . . . . . . . . . . . . . . . 12  
Carburetor . . . . . . . . . . . . . . . . . . 83-84  
Carburetor Adjustments. . . . . . . . . . 83  
Carburetor Protection (600 RMK). 110  
Carburetor Water/Sediment Trap . . 84  
Cargo System. . . . . . . . . . . . . . . . . . 28  
Chaincase Oil. . . . . . . . . . . . . . . . 77-78  
Choke Cable. . . . . . . . . . . . . . . . . . . 76  
Clutch Alignment Offset . . . . . . . . . 96  
Clutch Center Distance . . . . . . . . . . 96  
Clutch Cover Warning. . . . . . . . . . . 22  
Clutch System . . . . . . . . . . . . . . . 96-99  
Clutches . . . . . . . . . . . . . . . . . . . . . . 18  
Coolant. . . . . . . . . . . . . . . . . . . . . . . 86  
Coolant High Temperature Light. . . 87  
Coolant Level. . . . . . . . . . . . . . . . . . 86  
Cooling System . . . . . . . . . . . . . . 86-89  
Cooling System Bleeding . . . . . . 88-89  
Cooling System Flushing. . . . . . . . . 87  
F
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 82  
Fuel Injectors. . . . . . . . . . . . . . . . . . . 82  
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 82  
Fuel Pump . . . . . . . . . . . . . . . . . . . . . 82  
Fuel Recommendations . . . . . . . . . . . 61  
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 60  
Fuel System Deicers . . . . . . . . . . . . . 61  
Fuel Valve . . . . . . . . . . . . . . . . . . . . . 28  
D
DET . . . . . . . . . . . . . . . . . . . . . . . . . 29  
Detonation Elimination Technology 29  
Digital Display. . . . . . . . . . . . . . . . . 31  
Digital Display Programs . . . . . . 33-37  
Disabled Operators . . . . . . . . . . . . . 13  
G
Gauge Cleaning . . . . . . . . . . . . . . . . . 38  
130  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
H
O
Handlebar Adjustments. . . . . . . . 46-47  
Handlebar Angle. . . . . . . . . . . . . . . . 47  
Handlebar Position . . . . . . . . . . . . . . 47  
Headlight Adjustments . . . . . . . . . . . 28  
Helmet Recommendations . . . . . . . . 12  
Hood Latches . . . . . . . . . . . . . . . . . . 50  
Hot Surface Warning . . . . . . . . . . . . 23  
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 82  
Oil Injection System . . . . . . . . . . . . . 58  
Oil Level . . . . . . . . . . . . . . . . . . . . . . 62  
Oil Lines . . . . . . . . . . . . . . . . . . . . . . 82  
Oil Recommendations . . . . . . . . . . . 58  
Oil, Chaincase. . . . . . . . . . . . . . . . . . 77  
Oil, Engine . . . . . . . . . . . . . . . . . . . . 62  
Operating in Deep Snow. . . . . . . . . . 19  
Operation Warning . . . . . . . . . . . 24-25  
I
Ice and Snow Build-up . . . . . . . . . . . 16  
IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 39  
Instrumentation . . . . . . . . . . . . . . 30-38  
Intake Filters . . . . . . . . . . . . . . . . . . . 81  
Intake Silencer . . . . . . . . . . . . . . . . . 18  
P
Parking Brake Lever Lock . . . . . . . . 52  
Passenger Warning . . . . . . . . . . . . . . 23  
Polaris Products . . . . . . . . . . . . . . . 112  
Pre-Ride Checklist . . . . . . . . . . . 49-55  
Pressure Cap Warning . . . . . . . . . . . 22  
L
Lights . . . . . . . . . . . . . . . . . . . . . . . . 95  
Limiter Strap Position. . . . . . . . . . . . 44  
Low Oil Indicator Light . . . . . . . . . . 62  
Lubrication . . . . . . . . . . . . . . . . 75-78  
Choke . . . . . . . . . . . . . . . . . . . . 76  
Choke Cable . . . . . . . . . . . . . . . 76  
Driveshaft Bearing . . . . . . . . . . 76  
Front Suspension. . . . . . . . . . . . 75  
Rear Suspension . . . . . . . . . . . . 75  
Throttle Cable . . . . . . . . . . . . . . 76  
R
Rail Slide Wear. . . . . . . . . . . . . . . . 108  
Recoil Rope . . . . . . . . . . . . . . . . . . . 51  
Reverse Operation . . . . . . . . . . . 66-67  
Reverse Warning . . . . . . . . . . . . . . . 24  
Rider Capacity . . . . . . . . . . . . . . . . . 13  
S
Safety . . . . . . . . . . . . . . . . . . . . . . 8-21  
Safety Decals . . . . . . . . . . . . . . . 22-25  
Sag Settings . . . . . . . . . . . . . . . . . . . 43  
Sediment Trap. . . . . . . . . . . . . . . . . . 84  
Shock Components . . . . . . . . . . . . . . 40  
Shock Compression Valving . . . . . . 45  
Shock Spring Preload, Front. . . . . . . 41  
Shock Springs, Front . . . . . . . . . . . . 41  
Shocks, Air . . . . . . . . . . . . . . . . . . . . 40  
Shocks, Standard. . . . . . . . . . . . . . . . 40  
Skags. . . . . . . . . . . . . . . . . . . . . . . . 107  
Ski Alignment. . . . . . . . . . . . . . . . . 106  
Slide Rail and Track Cooling . . . . . . 58  
M
Maintenance Interval Table . . . . 72-74  
Maintenance Program. . . . . . . . . . . . 71  
Maneuverability . . . . . . . . . . . . . . . . 18  
MFD Components. . . . . . . . . . . . . . . 30  
MFD Digital Display . . . . . . . . . . . . 33  
MFD Digital Display Programs . 34-37  
MFD Settings . . . . . . . . . . . . . . . . . . 32  
N
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
131  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
S
T
Snow Build-up. . . . . . . . . . . . . . . . . 16  
Snow Conditions . . . . . . . . . . . . . . . 19  
Spark Plugs . . . . . . . . . . . . . . . . . 79-80  
Speed . . . . . . . . . . . . . . . . . . . . . . . . 13  
Spring Preload . . . . . . . . . . . . . . . . . 43  
Starting the Engine . . . . . . . . . . . . . 56  
Steering Adjustments. . . . . . . . . . . . 28  
Steering Inspection . . . . . . . . . 53, 105  
Steering System . . . . . . . . . . . . 105-108  
Stop Switch . . . . . . . . . . . . . . . . . . . 63  
Stopping. . . . . . . . . . . . . . . . . . . . . . 65  
Storage, Daily . . . . . . . . . . . . . . . . . 68  
Storage, Extended . . . . . . . . . . 109-111  
Survival Preparation . . . . . . . . . . . . 11  
Suspension Adjustments, Front . . 39-41  
Suspension Adjustments, Rear . . 42-45  
Suspension Inspection . . . . . . . . . . . 54  
Suspension Lubrication, Front. . . . . 75  
Suspension Lubrication, Rear . . . . . 75  
Suspension Performance Tips . . . . . 42  
Suspension, Front . . . . . . . . . . . . . . 39  
Switch, Stop. . . . . . . . . . . . . . . . . . . 63  
Switch, Throttle Safety . . . . . . . . . . 63  
Tether Switch. . . . . . . . . . . . . . . . . . . 48  
Throttle Lever . . . . . . . . . . . . . . . 50, 64  
Throttle Safety Switch. . . . . . . . . 50, 63  
Torque Stop . . . . . . . . . . . . . . . . . . . . 99  
Torsion Spring Preload . . . . . . . . . . . 44  
Towing. . . . . . . . . . . . . . . . . . . . . . . . 68  
Track Alignment . . . . . . . . . . . . . . . 104  
Track Care for Storage . . . . . . . . . . 111  
Track Inspection . . . . . . . . . . . . 53, 100  
Track Lubrication . . . . . . . . . . . . . . 101  
Track Replacement . . . . . . . . . . . . . 100  
Track Tension . . . . . . . . . . . . . 102-103  
Track Warm-Up. . . . . . . . . . . . . . . . . 59  
Track Warning. . . . . . . . . . . . . . . . . . 23  
Track, Deep Lug . . . . . . . . . . . . . . . . 53  
Transporting the Snowmobile . . . . . 111  
Troubleshooting, Drive Belt . . . . . . 117  
Troubleshooting, Engine . . . . . 113-115  
Troubleshooting, Rear Suspension . 116  
V
Vehicle Identification Numbers. . . . . . 7  
W
Warning Labels/Decals . . . . . . . . 22-25  
Warranty, Engine Emissions . . . . . . 125  
Windchill/Temperature Charts . . . . . 21  
132  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Philips CRT Television RX47 User Manual
Philips Iron GC148 User Manual
Philips MP3 Player ACT211 05 User Manual
Philips TV Antenna 42PFL6805 User Manual
Polaris Offroad Vehicle Trail RMK User Manual
Polycom IP Phone 5000 User Manual
Powermate Portable Generator PMC605000 User Manual
Prince Castle Outdoor Timer 755 HS10 User Manual
Printek Printer 4000se User Manual
PYLE Audio Speaker PAHT4 User Manual