Polaris Offroad Vehicle 800 Pro X User Manual

2004

PRO X

Snowmobiles

Owner's Manual

for Vehicle Maintenance

and Safety

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What’s the hottest thing on snow?

A Polaris owner’s Web site, designed just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

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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

discrepancies may result between the actual vehicle and the information presented in this

publication. 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.

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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.

Polaris Recreational Vehicles

S Snowmobiles

S All-terrain vehicles (ATVs)

S Watercraft

S RANGER utility vehicles

S Victory motorcycles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs)

S Personal Task Vehiclest (PTVs)

S All-Surface Loaders (ASLs)

We believe Polaris sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience 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

service needs during, and after, the warranty period.

We also take great pride in our Parts Apparel and Accessories (PAA)

products, available through our online store at www.purepolaris.com.

Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of

Polaris Industries Inc.

WORKMOBILES, UTILITY TASK VEHICLE and PERSONAL

TASK VEHICLE are trademarks of Polaris Industries Inc.

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

This section describes safe vehicle operation and identifies warning

decals and their locations.

Features and Controls . . . . . . . . . . . . . . . . . . . . . 28

This section illustrates the locations of your snowmobile’s controls and

features.

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

This section explains how to tailor the suspension and other features

for an optimum riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . . . 48

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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

operating procedures.

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

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

snowmobile’s regular maintenance.

Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . 112

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 113

This section is a quick reference guide to solving problems.

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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INTRODUCTION

Important Notes for Owners and Drivers

n After reading this manual, store it in the snowmobile for

convenient reference. It should remain with the snowmobile when

sold.

n The illustrations and photos used in this manual are general

representations. Your model may differ.

n 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.

n 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.

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

riding clubs.

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INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education

campaign. We encourage state and provincial governments across the

snowbelt 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

protect our environment. Please support their efforts and operate your

snowmobile with consideration for the protection and preservation of

our environment.

Respect your snowmobile;

respect your environment;

and you will earn

the respect of everyone.

Noise Level

One of the most publicized issues about snowmobiles is noise. The

Society of Automotive Engineers (SAE), the standard-setting body for

snowmobile development, recommends that snowmobiles conform to

prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE

standards. Our muffler systems are designed to reduce noise levels and

must not be altered or removed. The sound of your snowmobile may

not be welcome to non-snowmobilers, so you have a responsibility to

operate your snowmobile with concern for others. We do our part by

manufacturing quieter machines; we ask your help to further reduce the

impact of noise by operating your snowmobile safely and responsibly.

Air Pollution

Polaris engineers continuously investigate ways to reduce emission

levels of two-stroke engines. We expect our efforts to lead to the

reduction of potential air pollution.

In addition to our technological research, we encourage government

agencies, manufacturers, distributors, dealers, ecologists, and other

interested parties to work together to develop data on environmental

topics.

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INTRODUCTION

Vehicle Identification Numbers

The tunnel vehicle identification number (VIN) and engine serial

number are important for model identification when registering your

snowmobile, when obtaining insurance, and when ordering

replacement parts. In the event your snowmobile is stolen, these

numbers are essential to its recovery and identification.

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

duplicated only by mating a Polaris key blank with one of your

existing keys. If both keys are lost, the ignition switch must be

replaced. See your Polaris dealer.

NOTE: Record your snowmobile’s ID numbers and key number in the

spaces provided.

Tunnel VIN (lower right side of the tunnel) :

Vehicle Model Number:

Engine Serial Number (right front side of engine crankcase):

Key Number:

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SAFETY

Operator Safety

The following signal words and symbols appear throughout this

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

and symbols 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 personal 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 personal 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.

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SAFETY

Operator Safety

WARNING

Driving a snowmobile requires your full attention. DO NOT

drink alcohol or use drugs or medications before or while

driving. They will reduce your alertness and slow your reaction

time. In most states and provinces, it’s prohibited by law to

drive while intoxicated or under the influence of drugs.

Polaris produces high performance snowmobiles capable of

traveling at high speeds. Extra caution must be observed to

ensure operator safety. Make sure your snowmobile is in

excellent operating condition at all times. We strongly

recommend that the operator 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.

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SAFETY

Operator Safety

Stay Away From Moving Parts

WARNING

Never hold the snowmobile up or stand

behind it while warming up the track. A

loose track or flying debris could cause

serious personal injury or death.

We recommend having your dealer perform

track service and alignment procedures.

Be alert when riding, and remain properly seated to stay clear of the

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

partially exposed for proper operation. Serious injuries may result if

hands, feet, or clothing become entangled in the track.

WARNING

If fingers or clothing contact the moving parts of an engine,

serious injury can result. Always stop the engine before

attempting adjustments.

Never attempt adjustments with the engine running. Turn off the

ignition, raise the hood, make the adjustment, secure shields and

guards, secure the hood, and then restart the engine to check its

operation.

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

conditions you may encounter. Such equipment may include, but is

not limited 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 cellular telephone.

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SAFETY

Operator Safety

Riding Position

WARNING

Improper riding position may seriously reduce your ability to

control the machine and may result in serious injury or death.

Always be properly seated and in position to control your vehicle.

Operating a snowmobile requires skill and balance for proper control.

Rider positions may vary from person to person as each becomes more

skilled; but under most conditions, the proper position is to be seated

with feet on the running boards, and comfortably positioned for proper

throttle, brake, and steering control.

Riding Apparel

Be aware of the weather forecast and

especially the wind chill. A wind chill

table is provided on page 22 for your

reference. To better enjoy your ride, be

prepared, be warm and be comfortable.

WARNING

Loose clothing or long scarves may easily become entangled in

moving parts and cause serious personal injury.

Always wear an approved helmet and eye protection.

Disabled Operators

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

physical skills. Operators with cognitive or physical disabilities have

an increased risk of loss of control, which could result in serious injury

or death.

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SAFETY

Operator Safety

Excessive Speed

WARNING

High speed driving, especially at night, could result in serious

personal injury or death. Always reduce speed when driving at

night or in inclement weather.

Observe all state and local laws governing snowmobile operation.

They’ve been established for your protection.

Always be alert and pay attention to the trail ahead. Multiplying speed

(MPH) by 1.5 will equal the approximate number of feet per second

your machine travels. If your speed is 40 MPH, your machine is

traveling about 60 feet per second. If you look back for only two

seconds, your machine will travel about 120 feet. If your speed is 60

MPH, your machine will travel about 180 feet in two seconds.

Traveling at night requires extra caution. Check headlight and taillight

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

Always be able to bring your machine to a stop in the distance

illuminated by the headlight.

Ice and Snow Build-up

WARNING

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

machine, resulting in serious injury or death. Keep the underhood

area free of snow and ice.

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

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

difficulty is encountered, check for ice and snow build-up that may be

obstructing the steering linkage. Snow screens and bib kits are

available through your dealer to help reduce snow and ice build-up.

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SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles,

posts, or other obstacles. Be especially

alert if you’re snowmobiling after dark.

Always be on the alert for wire fences.

Single strands are especially dangerous,

since there may be a great distance

between posts. Guy wires on utility poles

are also difficult to distinguish.

Make sure the way is clear before crossing

railroads and other roads and highways.

The noise of your machine will drown out

the sound of approaching vehicles. Look

ahead, behind, and to both sides before

turning or crossing railroad tracks or

highways. Steep embankments may also

hide your view. Always leave yourself a

way out.

Variances in snow depth and/or water

currents may result in uneven ice

thickness. Always check with local

residents or authorities for general information on conditions when

traveling on lakes and streams that are strange to you. Before riding

your machine on a frozen body of water, be sure the ice is thick enough

to support the machine and its operator, as well as the force created by

a moving vehicle. You may drown if you and the snowmobile break

through the ice.

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.

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SAFETY

Operator Safety

Driving in Hilly Terrain

WARNING

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

of balance and machine roll-over, causing serious injury or death.

Use caution and good judgement when driving in hilly terrain.

Operating in hilly terrain requires extreme caution to maintain balance

and avoid roll-over. If climbing a hill is unavoidable, keep all your

weight low and forward.

If you must cross the face of a slope, keep your weight on the uphill

side of the machine to maintain proper balance and avoid possible

roll-over.

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

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

other side of the hill.

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

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

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

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

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

and point the front end and skis downhill. Remount the machine,

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

carefully.

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SAFETY

Operator Safety

Driving Downhill

When riding downhill, shift your weight to the rear of the machine and

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

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

machine and keep it from rolling freely downhill.

WARNING

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

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

result in brake failure.

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

also cause an overheated brake system. This condition may lead

to a sudden loss of brakes and/or fire and may result in serious

injury or death.

Clutch Guard

Do not operate the engine with the clutch guard removed.

The clutch guard is designed to protect the operator from metal parts if

the clutch should fail. Although the chance of failure is extremely

remote, don’t defeat the purpose of the guard by removing it. It’s

provided for your 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 personal injury or damage to the engine.

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SAFETY

Operator Safety

Powder Snow Operation

Moveable hood closures are included on some Polaris snowmobiles.

They are normally left open and are located on the front upper and

lower hood openings. If operating in deep snow or in extreme cold

conditions (below -20_F), Polaris recommends closing the upper hood

closure.

WARNING

Do not drive for prolonged periods on blacktop, gravel, or ice.

Doing so could cause irreversible track damage and lead to serious

personal injury.

Since snow provides the only lubrication for the power slide

suspension and, on liquid cooled models, cooling for the engine,

adequate snow cover is a requirement for operation of your machine.

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

the slide rail, track and/or engine.

If the machine becomes stuck in snow, clear the running board area of

snow, then step down the snow in front of the machine so that when

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

over. You may then mount the machine and continue riding.

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.

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SAFETY

Operator Safety

Driving on Slippery Surfaces

WARNING

Driving on ice or hard-packed snow reduces steering and braking

control, which may result in serious injury or death. Slow down

and use caution.

Excessive shifting of operator body weight when turning on

hard-packed snow or ice may lead to loss of vehicle control and result

in serious injury or death. Slow down to maintain control under these

conditions.

It’s dangerous to drive on ice or other slippery surfaces. If it’s

unavoidable, use extreme caution and operate at speeds no faster than a

walk. Never attempt an abrupt change of direction. The chance of

“spin-out” increases under these conditions.

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

dynamically balanced before installation. Any tampering may disrupt

this precision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time,

especially overnight, always make sure the skis and track are loosened

from ice and snow before attempting to drive. Apply the throttle with

enough authority to put the machine into motion, but always operate

within safety limits and, on 2-Up machines, with respect for a

passenger. See Starting a Cold Engine on page 53.

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SAFETY

Operator Safety

Maneuverability

Control and maneuverability comes not only through the steering and

skis, maximum control is achieved by shifting of body weight.

Maneuverability will change for lighter operators or machines designed

to carry a load or a passenger.

Maintenance

Your Polaris snowmobile is a well-engineered and well-constructed

recreational vehicle. Follow the recommended maintenance program

outlined beginning on page 69 of this manual to ensure that all critical

components on the snowmobile are thoroughly inspected by your

dealer at specific mileage intervals.

Rider Capacities

Polaris PRO X snowmobiles are designed for a single rider only. A

decal on the console of these models indicates single rider operation.

See page 24 for decal location.

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SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile

conditions 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 drivers should spend some time getting the feel for a machine

before attempting ambitious maneuvers.

S 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.

S Before allowing someone else use your snowmobile, know the ex-

tent of their operating skills. Check to see if they’ve taken a snow-

mobile safety course and have an operator’s certificate. For their

protection, as well as yours, make sure they take a snowmobile safe-

ty course. Everyone can benefit from the course.

S Don’t “jump” your snowmobile. Jumping may injure your back be-

cause of spinal compression. The seat and suspension of your snow-

mobile have been designed to provide protection under normal

riding conditions. Your snowmobile is not intended for this kind of

use.

S Be courteous to oncoming traffic by dimming your headlights and

reducing your speed. Your snowmobile is equipped with a high out-

put headlamp system that may cause discomfort to operators of on-

coming vehicles when on high beam.

S When traveling in a group of snowmobiles, don’t tailgate (follow too

closely). Allow ample stopping distances, and keep track of those

following you. Drive defensively to avoid accidents.

S Remove the key from the ignition.

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SAFETY

Operator Safety

Windchill/Temperature Charts

The following information is provided to help you determine when

temperatures become dangerous for riding.

WIND CHILL CHART (°F)

Actual Thermometer Reading (°F)

Estimated Wind

Speed in MPH

-10 -20

-30

-40

-50

-60

Equivalent Temperature (°F)

Calm

-10 -20

-15 -26

-30

-36

-58

-72

-82

-40

-47

-70

-85

-96

-50

-57

-83

-60

-68

-95

-5

-9

-21 -33 -46

-5

-18 -36 -45 -58

-99 -112

-110 -124

-10 -25 -39 -53 -67

-15 -29 -44 -59 -74

-18 -33 -48 -63 -79

-20 -35 -49 -67 -82

-88 -104 -118 -133

-94 -109 -125 -140

-2

-4

-6

-98

-113 -129 -145

-21 -37 -53 -69 -85 -100 -116 -132 -148

Wind Speeds Great-

er Than 40 MPH

Have Little Added

Effect

Little Danger

(For Properly

Clothed Person)

Increasing

Danger

Great

Danger

Danger From Freezing of Exposed Flesh

WIND CHILL CHART (°C)

Actual Thermometer Reading (°C)

Estimated Wind Speed

in KPH

-5

-10

-15

-20

-25

-30

-35

-40

Equivalent Temperature (°C)

-5

-10

-16

-23

-28

-32

-34

-35

-36

-15

-22

-29

-35

-39

-41

-43

-44

-20

-27

-36

-42

-47

-49

-51

-52

-25

-33

-42

-48

-53

-57

-59

-60

-30

-38

-48

-55

-61

-64

-66

-68

-35

-45

-54

-63

-69

-73

-75

-76

-40

-50

-61

-69

-76

-80

-82

-84

-4

-11

-17

-21

-24

-26

-27

-28

-4

-9

-7

-13

-16

-18

-19

-20

-9

-11

-12

-13

Wind Speeds Greater

Than 70 KPH Have Little

Added Effect

Little Danger

(For Properly

Clothed Person)

Increasing

Danger

Great

Danger

Danger From Freezing of Exposed Flesh

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SAFETY

Safety Decals and Locations

Warning decals have been placed on the snowmobile for your

protection. Read and follow the instructions of the decals on the

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

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

instructions of the decals on the snowmobile.

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

to purchase a replacement. Replacement safety decals are provided by

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

Clutch Cover Warning

This warning decal is found under the hood on the clutch cover:

WARNING

AVERTISSEMENT

Air Box Warning

This warning decal is

found under the hood on

the air box:

CAUTION

Do not operate above 40 mph with

hood to air box foam removed or

engine failure will result.

7075351

Pressure Cap Warning

This warning decal is found on the

coolant bottle cover of liquid cooled

models:

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SAFETY

Safety Decals and Locations

Track Warning

The track warning decal is located on the rear of the tunnel:

Passenger Warning

Polaris PRO X snowmobiles are designed for one operator only. A “No

Passenger” warning decal is located on the console:

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SAFETY

Safety Decals and Locations

Reverse Warning

Some Polaris snowmobiles are

equipped with reverse. These

models will have a reverse

warning decal on the lower dash.

WARNING

AVERTISSEMENT

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SAFETY

Safety Decals and Locations

Operation Warning

Operation warning decals are present on the console of all Polaris

snowmobiles, in both French and English.

WARNING

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SAFETY

Safety Decals and Locations

Operation Warning

AVERTISSEMENT

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FEATURES AND CONTROLS

Some Polaris snowmobiles are equipped with special features.

Controls for these features are illustrated on the following pages. Not

all models come with these features. Refer to your Owner’s Manual

Supplement for a list of specific features on your machine. Accessories

are available from your Polaris dealer.

1. Brake Lever

2. Speedometer

10. Fuel Filler Cap

11. Park Brake Lock

3 Reverse Indicator Light

4. Tachometer

5 Temperature Light

6. Engine Stop Switch

7. Throttle Control

8. Choke Control

12. Headlight Dimmer Switch

13. Electronic Reverse Button

14. Handlebar Grip Warmer/

Thumbwarmer Switch

15. Ignition Switch

16. Tether Switch (accessory)

9. Recoil Starter Handle

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FEATURES AND CONTROLS

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FEATURES AND CONTROLS

1. Hood

2. Headlight

9. Snow Flap

10. Track

3. Windshield

4. Handlebar

5. Seat

6. Storage Compartment/Trunk

7. Taillights

8. Rear Bumper

11. Suspension

12. Trailing Arm

13. Nosepan

14. Front Bumper

15. Skis

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FEATURES AND CONTROLS

Detonation Elimination Technology (D.E.T.)

Some Polaris snowmobiles are equipped with a

detonation sensor that monitors the engine and

responds to detonation by automatically reducing

the engine timing. When activated, the

“DETONATION FLASH” indicator (A) will flash

in the lower right-hand area of the

tachometer. The activated sensor reduces

engine detonation by retarding the

ignition timing. This results in decreased

engine RPM and performance.

D.E.T. Troubleshooting

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.

Possible Cause

Solution

Poor quality fuel

Replace with higher quality fuel

Verify and adjust per jetting chart

Do not modify the engine

Improper jetting

Improper engine modifications

D.E.T. Flash Signals

Use this chart to determine the meaning and course of action for each

D.E.T. flash signal.

Type of Flash

Cause

Action

3 flashes of 1 second Detonation

each

See DET Troubleshooting Chart

Solid 3-second flash, off Faulty sensor

1 second, repeats until

engine is shut down

See your Polaris dealer

Solid non-blinking light

High water tem- See your Polaris dealer. NOTE: If tempo-

perature

rary operation is unavoidable, drive slowly

and stop the engine frequently to allow the

engine to cool.

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Front Suspension Adjustments

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

re-grease all suspension parts before making any fine-tuning

adjustments.

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

vehicle speed, riding style, and trail conditions. We recommend

starting with factory settings and then customizing each adjustment

individually to suit rider preference. The machine should be

methodically tested, one change at a time, under the same conditions

(trail and snow conditions, vehicle speed, riding position, etc.) after

each adjustment until the best ride is achieved.

Independent Front Suspension (IFS)

The IFS is made up of the skis (1),

front shocks and springs (2), and the

components that connect these parts

to both the steering, such as the tie

rods (3), and to the machine itself,

such as the trailing arms (4).

Front suspension adjustments

include shocks, springs, toe,

and camber.

NOTE: Although the front

suspension on your machine

may not look exactly like the

illustration, it will have the

same parts and functions as

those illustrated.

IFS Adjustment Options

S Front shock spring preload

S Compression adjust clicker (if equipped)

S Optional springs

S Optional shock valving (if equipped with RydeFX or Walker/Evans

shocks)

S Toe (ski alignment) (see page 105)

S Camber (see your dealer)

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Front Suspension Adjustments

WARNING

Always verify ski alignment before making adjustments to the IFS.

See page105 to check alignment. If the skis are misaligned, see

your dealer, as the camber adjustment may also be affected.

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

preload. For the best ride, the spring preload should be set as low as

possible to use the full travel of the ski shock, with occasional light

bottoming. To determine if your machine is using full travel of the ski

shock, push the jounce bumper down as far as it will go on the shock

rod and test ride the machine. The bumper will move up on the rod in

direct relation to the amount of travel. If the shock travel is full, the

bumper will be seated at the top of the shock.

Shock Absorber Components

1. Retainer

2. Shock Rod

3. Jounce Bumper (RydeFX only)

4. Body

5. Threaded Spring Preload Adjuster Nut

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Front Suspension Adjustments

Adjusting Front Shock Spring Preload

Increasing spring preload will increase

ski-to-ground pressure. Decreasing

spring preload will decrease

ski-to-ground pressure. When

adjusting, be sure springs on both the

left and right sides of the machine are

at the same adjustment.

To increase front shock spring preload,

grasp the spring and turn it to the

right. Turn it to the left to decrease

preload. In the illustrations at right, B

indicates high preload and C indicates

low preload.

Increasing the spring preload too much may adversely affect the

handling of the snowmobile and the performance of the rear

suspension. Decreasing the spring preload too much may allow the

upper spring retainer to fall off. Always leave at least one thread

showing above the nut (A).

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Front Suspension Adjustments

Shock Valving

RydeFX and Walker/Evans shocks can be revalved if spring preload

alone isn’t sufficient and further adjustment is desired to control

suspension stiffness.

WARNING

Changing shock valving on RydeFX or Walker/Evans shocks

requires special tools and a sound knowledge of mechanical

theory, tool use, and shop procedures to perform the work safely

and correctly. Shocks contain high-pressure nitrogen gas. Use

extreme caution when handling high-pressure service equipment.

We recommend that this work be performed by a Polaris dealer.

Front Springs

For models without externally adjustable or revalvable shocks, 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.

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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 suspension 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 bottom out harshly on a snow-cross course.

A decal outlining rear suspension set-up options is located either under

the hood or on the clutch cover. It provides a guideline for initial

suspension set-up. Additional adjustments can be made from this

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

change. For further assistance, see your dealer.

Suspension Performance Tips

S 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.

S A new Hi-fax will offer improved performance over a worn Hi-fax.

It can also improve top speed.

S When riding on ice or hard-packed snow, adding a set of bogie

wheels to the rail may enhance the machine’s performance. Bogie

wheel kits are available from your dealer.

S Polaris offers track kits for improved flotation in deep snow. See

your dealer for assistance.

NOTE: Keep the suspension pivot points lubricated. This will reduce

moisture and rust build-up and ensure proper function of the

suspension components. Grease rear suspension pivots before

adjusting the rear suspension. Refer to Suspension Maintenance

beginning on page 107.

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PRO X Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the PRO X rear suspension

torsion spring preload, measure the

distance between the ground and rear

bumper. This is measurement X.

Take the first measurement with no

rider and with the rear suspension at

full extension. NOTE: The rear

bumper may need to be lifted upward

slightly to fully extend the rear

suspension.

Next, have the rider drop down hard

on the seat and bounce up and down

several times, collapsing the rear

suspension. With the rider seated,

measure the distance between the

ground and the rear bumper at the

exact location used for measurement

X. This is measurement Y.

To determine sag, commonly referred

to as ride-in, subtract measurement Y

from X (Sag=X-Y). Adjust sag by

rotating the torsion spring preload cams located on the rear torque arm.

Use the illustration or the decal found under the hood for reference.

The ideal amount of Sag for the PRO X rear suspension is five inches

(X-Y=5).

If the rear suspension rides in less than three inches or more than five

inches with the torsion spring preload cams at their maximum range of

adjustment, optional torsion springs (softer or stiffer, respectively) may

be required. This is only an initial set-up, and final spring preload may

vary based on rider preference and riding conditions.

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PRO X Rear Suspension Adjustments

Rear Torsion Spring Tension

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

using the engine spark plug tool. Different rate torsion springs are

available if a firmer ride is desired. 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.

1a - Turn the knob to the left for a softer ride

1b - Turn the knob to the right for a stiffer ride

2a - Soft Tension - long end of cam to front

2b - Medium tension - short end of cam up

2c - Firm tension - long end of cam up

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PRO X Rear Suspension Adjustments

Clicker Shock

The position sensitive clicker

shock is available as an option on

some models. Adjustments to the

compression damping are made by

turning the clicker knob (A) on the

shock reservoir.

Position #1 is the softest, or least

compression damping. As the

knob is turned to higher numbers,

compression damping increases,

or becomes stiffer.

When adjusting, we recommend

that you turn the clicker only one

click at a time, then test ride.

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PRO X Rear Suspension Adjustments

Optional Coil Springs

Different rate coil springs are available for some shocks if a firmer ride

is desired. Contact your dealer for more information.

Suspension Coupling

On all Polaris snowmobile rear suspensions, there are two torque arms

that control the movement of the rail beam. Prior to the advent of

suspension coupling, these torque arms could move independently of

each other. Rear suspension coupling links the movement of the front

and rear torque arms to each other. There are two types of rear

suspension coupling.

Front Rear Scissor Stop (FRSS)

The front rear scissor stop (FRSS) couples the movement of the front

torque arm with the rear torque arm and limits the amount of

independence between the movement of the front torque arm and the

rear torque arm.

When hitting a bump, the front torque arm starts to compress. The

FRSS links that movement to the rear torque arm, causing it to

compress and raise the rear suspension up as one, allowing the

suspension to hit the bump only once and eliminating kickback. Your

FRSS is preset at the factory.

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PRO X Rear Suspension Adjustments

Rear Rear Scissor Stop (RRSS)

The rear rear scissor stop (RRSS) couples the movement of the rear

torque arm with the front torque arm and limits the amount of

independent movement between the rear torque and the front torque

arm.

Adjusting the RRSS either allows more weight to transfer to the rear

for more traction, or allows less weight to transfer to the rear, resulting

in improved cornering performance. An adjustment dot is located on

the RRSS. This dot is on the longest end of the scissor stop.

Rear Rear Scissor Stop - Attributes

Moving the RRSS to a higher position, or forward hole, will have the

following effects on the suspension:

S Reduced weight transfer.

S Improved chatter bump ride.

S Improved cornering performance.

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PRO X Rear Suspension Adjustments

Weight Transfer During Acceleration

PRO X Rear Rear Scissor Stop (RRSS)

The preferred method for controlling weight

transfer during acceleration of the PRO X rear

suspension is by adjusting the RRSS. Use the

scissor stop tool (1) located in your tool kit to

make the adjustments.

To decrease weight transfer under acceleration

(for improved cornering), rotate the RRSS to

a higher position.

To increase weight transfer or ski lift during acceleration, move the

RRSS to the rearward upper position. The RRSS may also be rotated to

a lower position for even more weight transfer if desired.

A - Low Position - This setting will increase weight transfer.

B - Medium Position - This setting is the production setting and will

provide the best overall trail riding.

C - High Position - This setting will decrease weight transfer.

D - Rearward Upper Position (optional hole location) - This setting

will increase weight transfer.

NOTE: Your dealer can help you with initial set-up and additional

set-up instructions to help you achieve an optimum ride.

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Handlebar Adjustments

Handlebar with Riser Block

1. Remove the handlebar cover to expose

the handlebar mounting hardware.

2. Using a 1/2” wrench, loosen the two

bolts on the bottom of the riser or the

two bolts on the top of the riser,

depending on the type of adjustment

required.

3. Adjust the handlebar to the desired

angle. Be sure the handlebar, brake

lever and throttle lever operate

smoothly and do not hit the gas tank,

windshield or any other part of the

machine when the handlebar is turned fully to the left or right.

4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-17.6

Nm).

5. Replace the handlebar cover.

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Accessories

Polaris offers a wide range of accessories for your snowmobile to help

make each ride more enjoyable. See your dealer for a complete list of

accessories.

NOTE: The accessory tether switch is available for all models. Order

PN 2870668.

Use only Polaris parts and accessories on your Polaris snowmobile.

Use of unapproved parts and accessories may result in:

S Non-compliance with government/industry requirements

S Voiding of warranty

S Personal injury to self or others

This applies to, but is not limited to brakes, clutches, fuel systems, and

exhaust systems.

NOTE: Exhaust systems are critical safety areas that must use ap-

proved Polaris parts. Please see your Polaris dealer for service.

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Accessories

Traction Products

Another way to tailor your machine is to install traction products. See

your dealer about installing studs and/or carbides. Many tracks with

deep lug designs cannot be studded, but your dealer will be able to

offer advice and assistance.

NOTE: Before equipping your machine with traction products, be

aware of the laws in your area pertaining to the use of traction

products.

Track studding will enhance braking control on hard-packed snow or

ice, but extreme caution is still required on such surfaces. Steering

ability may be reduced on hard-packed snow or ice.

A skag is a replaceable bar attached to the underside of the ski to assist

in turning the snowmobile and to prevent ski wear caused by contact

with roads and other bare terrain. The addition of carbide skags is

recommended with studded tracks to help maintain proper vehicle

steering and control. Similarly, if your machine is equipped with

carbide skags or you’re adding them, it may be necessary to add track

studs to maintain proper vehicle control. Proper balance must be

maintained between the number of studs and the length of carbide on

skags. The more studs used, the longer the carbide on the skags should

be. See your dealer’s track studding chart for recommended studding

and skags.

Inspect skags and studs frequently. Worn studs or skags may reduce

steering and braking control on hard-packed snow and ice. Replace

worn studs and skags to maintain proper balance and vehicle control.

When studded tracks are used, increased wear to the brake pads will

result from increased braking. Extended-wear brake pad kits are

available. See your dealer for more information.

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Accessories

CAUTION

Aggressive studding patterns may require grinding protruding stud

bolts flush to prevent idler wheel damage. Maintain track tension

on studded tracks on the tight side of the spec to prevent heat

exchanger damage. Center of stud must be at least 1 1/8″ (2.86

cm) from outside edge of the track.

CAUTION

If traction products are added to the track, wear strips must be

installed in the tunnel to avoid excessive wear.

Never add shims to the wear strip. Track damage will result

because of lack of clearance between upper carrier wheels and

track.

Use of studs longer than the recommended length on machines

equipped with center coolers will result in center cooler damage

or damage to the tunnel.

Use only Polaris traction products on your snowmobile. Track

warranties are void if track damage or failure results from improper or

excessive stud installation or the use of non-Polaris traction products.

WARNING

Loss of control can result in serious personal injury or death.

Proper balance of traction products on the skis and track must be

maintained to obtain proper vehicle control on hard-packed snow

or ice. See your dealer for assistance.

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Accessories

Wear Strips

Polaris PRO X models are manufactured with tunnel wear strips or

wear strip coolers installed. To avoid excessive tunnel wear, tunnel

wear strips must be installed whenever track studding is used.

Wear strips are designed for a specific stud length. See your dealer’s

studding chart for recommended traction accessories.

Components as viewed from the rear of the track:

1. Top of tunnel

2. Wear strip

3. Track

4. Wearstrip mounting holes

CAUTION

Whenever wear strips are relocated, be sure there’s adequate

stud clearance to the heat exchangers. Lack of clearance may

result in damage to heat exchangers.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

WARNING

Worn, damaged, or malfunctioning components may cause

serious injury or death. Before starting the engine, check all

components to be sure of proper operation.

Read and Understand Your Owner’s Manual

Read the Owner’s Manual completely and refer to it often. We’ve

attempted to provide as much information as possible to alert you to

the safety requirements of snowmobiling.

Check Throttle and Brake for Proper Operation

The throttle and brake are the primary controls of your snowmobile. If

either should malfunction, loss of control could result.

Make sure the throttle lever compresses evenly and smoothly. The

lever should immediately return to the idle position without binding or

hesitation. If the throttle does not function smoothly, DO NOT start

the engine. Have the throttle serviced immediately.

The need for a properly functioning brake is critical. Your snowmobile

is equipped with the highest quality brake system available. Check the

brakes for correct operation before starting the engine.

Throttle Safety Switch

Test the throttle safety switch system daily, before the machine is

operated.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Hydraulic Brakes

Properly functioning brakes

are critical to your safety.

Always check the following

items to assure proper

operation before starting the

engine.

Brake Lever Travel

When the brake lever is

squeezed, it should move no

closer to the handgrip than

1/2″ (1.3 cm) (A). A

distance less than this indicates low brake fluid level or air in the

hydraulic system. Refer to the brake bleeding information on page 93.

Lever Feel

A hydraulic system multiplies the force of your hand squeezing the

brake lever. Proper operation depends on an adequate supply of air and

moisture-free hydraulic brake fluid in the system. If the brake lever

feels “spongy” when squeezed, check the level and condition of the

fluid. Also check for the presence of air in the fluid system. Refer to

page 93 for more information, or see your dealer for service.

Replace brake fluid at least every two years with Polaris DOT 3 high

temperature brake fluid. All DOT 3 brake fluid is not alike. Use only

Polaris brake fluid. See page 112 for the part numbers of Polaris

products.

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.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Park Brake Lever Lock

Your snowmobile may have a park brake lever lock located over the

brake lever. Use the brake lever lock only when you want the machine

to remain stationary; for example, when parked on an incline for a

period of five minutes or less. To apply the lock, squeeze the brake

handle and push forward on the brake lever lock. Hold the lock

forward and release the brake handle.

If the brake handle is squeezed tightly enough, the lock will move

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

lock, squeeze the brake handle until the lever returns to the unlock

position. The park brake light on the console will light up when the

park brake lever lock is set and the engine is running. It will also be lit

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

on when the park brake or service brake is in use, have it serviced by

your dealer.

1. Brake Lever

2. Park Brake Lever Lock

3. Master Cylinder

Reservoir / Cover

WARNING

If the park brake lever lock is partially or entirely engaged while

riding, overheating of the brakes could occur, resulting in brake

damage. In extreme cases it could cause a fire, which could

result in serious injury or death.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Check for Proper Operation of Steering System

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

difficulty is encountered, check for ice and snow build-up that may be

obstructing the steering linkage. Make sure all greasable components

are properly lubricated.

Track Inspection

WARNING

Always inspect the track for damage before using the vehicle.

Operating the snowmobile with a damaged track increases

the possibility of track failure, which could cause loss of

control resulting in serious injury or death.

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

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

time in marginal lubrication could severely damage track rods, break

track edges, and cause other track damage. Examples of marginal

lubrication would include frozen bodies of water without snow cover,

icy trails, and no-snow conditions.

NOTE: Track damage or failure caused by operation on ice or poor

lubrication conditions voids the track warranty.

Check for Securely Latched Hood

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.

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PRE-RIDE INSPECTIONS

Start the Engine and Check

n Engine Stop Switch: Check the auxiliary shut-off switch for

proper operation. Push down to stop the engine. Pull up to release

and allow starting of the engine.

n Tether Switch: If your machine has a tether switch, make sure the

engine shuts off when the tether is removed from the switch.

n Lighting Check: Check the headlight (high and low beam),

taillight, and brake light for normal operation.

n Mirror Adjustment: If equipped, adjust your mirrors so they can

be used to their full advantage.

n Check Surroundings to Verify Clear Operating Area

Make sure you have a clear area all around your snowmobile, including

an area clear of bystanders. There’s always the possibility of some

sideways vehicle movement, of applying a little more throttle than

intended, or of debris being thrown by the track. If the surrounding

area is clear you before you start, you can devote your full attention to

operating the snowmobile.

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OPERATION

CAUTION

Inadequate cooling and lubrication will lead to overheating of the

slide rail and track, resulting in premature wear and failure.

Reduce speeds and frequently drive into fresh snow to allow

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

Avoid operating on ice, hard-packed surfaces or roads.

Starting the Engine

WARNING

Before starting the engine, always refer to all safety warnings

pertaining to snowmobile operation. Never start your snowmobile

without checking all components to be sure of proper operation.

See Check Before Starting the Engine beginning on page 48.

Starting a Cold Engine

Do not depress the throttle until the engine starts.

1. Turn key to ON.

2. Pull kill switch (shut-off switch) up to RUN.

3. Flip choke toggle to FULL ON.

4. Grasp starter handle and pull slowly until recoil engages; then pull

abruptly to start the engine.

CAUTION

Don’t pull the starter rope to full extended position or allow it to snap

back into the housing. Damage may result.

To avoid personal injury and/or engine damage, do not operate

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

5. After the engine starts, flip the choke toggle to the OFF position. If

the engine slows or wants to stop, use intermittent choking to the

HALF ON position.

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OPERATION

Starting the Engine

Starting a Warm Engine

1. Turn key to ON.

2. Pull kill switch (shut-off switch) up to RUN.

3. Grasp starter handle and pull slowly until recoil engages; then pull

to start.

If the engine does not start on the first pull, slightly depress the throttle

with your left hand (no more than 1/4″ open), and pull the rope with

your right hand. When the engine starts, immediately release the

throttle.

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

injection system, will assure proper engine break-in.

CAUTION

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

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

high speeds for extended periods during the first three hours of

use. Vary the throttle openings and machine speeds to reduce

friction on all close-fitting machined parts, allowing them to break in

slowly without damage.

Use of any lubricants other than those recommended by Polaris

may cause serious engine damage. We recommend the use of

Polaris lubricants for your vehicle.

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

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

machine.

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OPERATION

Engine Break-In

Oil Injection System

CAUTION

Serious engine damage can occur without the proper lubrication.

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

oil level doesn’t go down, contact your dealer immediately.

Always fill the oil reservoir when refueling. Fuel-to-oil mix ratios are

controlled by the oil pump and correspond to the engine’s RPM and

throttle valve opening.

Variable Exhaust System

We recommend the use of Polaris VES two-cycle oil in all snowmobile

engines equipped with variable exhaust valves (see chart below).

Oil Recommendations

The only source of engine lubrication for your engine comes from

lubrication added to the fuel and oil injection systems. We highly

recommend the use of only Polaris products. We’re continuously

testing lubricants and provide the highest performance products

available for your snowmobile’s engine. Refer to the table below to

determine the recommended oils for use in your Polaris snowmobile.

Never mix brands of oil. Serious chemical reactions can cause

injection system blockage, resulting in serious engine damage. They

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.

Engine

Style

Premium

2-Cycle

Premium Gold

2-Cycle

VES

2-Cycle

Fan Cooled

Good

Better

N/A

Best

Liquid Cooled

w/VES

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OPERATION

WARNING

A loose track or flying debris could cause serious personal injury

or death. Stand clear of the front of the machine and the moving

track. Never hold the snowmobile up or stand behind it while

warming up the track. Do not use excessive throttle during

warm-up or when the track is free-hanging. Be sure the rear

support is stable.

WARNING

Use of traction products such as studs, ice growsers, etc. will

increase the possibility of track damage and/or failure. This could

cause loss of control, resulting in serious injury or death. Always

inspect for track damage before operating the snowmobile.

Track Warm-Up

Follow these steps to ensure proper warm-up

of the engine, drive train and track.

1. Use an appropriate stand to securely

support therearofthesnowmobile 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 outdoor temperatures.

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

the machine to the ground.

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

This will loosen frozen snow from the ski bottoms, allowing the

machine to move forward more easily.

6. The engine, drive system and track are now properly warmed up and

the machine may be driven following normal safety practices.

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OPERATION

Fuel

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

S Always exercise extreme caution whenever handling gasoline.

S Always refuel with the engine stopped, and outdoors or in a

well ventilated area.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

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

S If gasoline spills on your skin or clothing, immediately wash it

off with soap and water and change clothing.

S Never start the engine or let it run in an enclosed area. Engine

exhaust fumes are poisonous and can cause loss of con-

sciousness or death in a short time.

S Turn the fuel valve off whenever the snowmobile is stored or

parked.

WARNING

The engine exhaust from this product contains chemicals known

to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

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OPERATION

Fuel

The fuel used in your Polaris engine is as important to engine life and

performance as the lubricant used. Most Polaris snowmobile engines

are designed to run on 87 octane non-oxygenated or 89 octane

oxygenated pump gasoline, but a higher octane fuel (premium 91

octane) is preferred for the PRO X models. Always use the premium

fuel switch when using premium fuel in your machine.

Premium Fuel Switch

Your Polaris snowmobile is equipped

with a key function to adjust the

timing on the machine as you change

fuels. It’s very important to the life of

your engine that you use this feature.

When using fuels with a pump-posted

octane rating of 91 or higher, turn the

key switch to the ON/PREM position.

When the engine is started, a yellow

Premium Fuel light illuminates on the

instrument panel. When the key is in

this position, the fuel must be a minimum of 91 octane. Return the key

switch to the ON/REG position when not using premium fuel.

If you’re uncertain about the quality or octane rating of the fuel you

use, turn your key switch to ON/REG. The Premium Fuel light will go

out. This setting will adjust the timing of your engine to run on fuels

with 87 octane or higher. Polaris does not recommend using fuel with

lower than 87 octane. Running your machine on ON/REG will help

protect your engine from damage caused by low octane fuels.

CAUTION

Using fuels with a lower than recommended octane or operating

with obstructed fuel systems will result in serious and costly

engine damage. Always use the recommended fuels for your

machine.

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OPERATION

Fuel

Fuel Reserve Capacity

There are approximately two gallons of fuel left in the tank when the

fuel gauge indicates reserve (RES).

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of

isopropyl-based fuel system deicer. Add one to two ounces per gallon

(8-16 milliliters per liter) of gasoline to prevent engine damage

resulting from fuel system icing and lean fuel mixtures. Never use

deicers or additives containing methanol. See page 112 for the part

numbers of Polaris products.

If you use oxygenated fuel containing ethanol, additional alcohol

deicers or water absorbing additives are not required and should not be

used.

CAUTION

Prolonged exposure to petroleum based products may damage

paint. Always protect painted surfaces when handling fuel.

Oil

Low Oil Level

Always do a visual check of the oil level

when refueling. When the oil reaches the

low level mark, add one U.S. quart of

recommended oil to the tank. See page 55

for oil recommendations.

The Polaris oil cap on the oil tank may be

vented to allow proper oil flow. See your

Polaris dealer for recommended

replacement parts.

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OPERATION

Oil

Low Oil Indicator Light

The low oil indicator light will indicate when to add oil. See page 55

for oil recommendations.

When the low oil indicator light is on, oil should be added before

further operation of the snowmobile. Visually check the oil level in the

bottle. The engine may be operated as long as oil is visible in the oil

tank. If oil is not visible, continued operation may cause serious

engine damage.

Never mix brands of oil. Serious chemical reactions can cause

injection system blockage, resulting in serious engine damage. They

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.

Always maintain the oil level above the tank’s low level line. This is

especially important when the machine is operated in mountainous

terrain. Maintaining the proper oil level will prevent system aeration

and possible loss of pumping action, which could result in engine

damage.

CAUTION

Mixing brands or using a non-recommended oil may cause serious

engine damage. We recommend the use of Polaris VES oil in all

snowmobile engines equipped with variable exhaust valves. Never

mix brands.

CAUTION

Operating the snowmobile without proper engine lubrication can

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

refueling.

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OPERATION

Carburetion

Proper carburetor adjustment is critical. A lean mixture (too much air,

too little fuel) may result in piston burning, bearing failure, or

complete engine failure. A rich mixture (too much fuel, too little air)

may foul plugs and cause generally poor engine performance.

A lean mixture may be caused by things like fuel line restrictions,

foreign matter in the carburetor or clogged fuel filters. A rich mixture

may be caused by snow build-up on the pre-filter in the air intake

system. Either condition may be caused by improper carburetor

adjustment.

WARNING

Improper carburetor adjustments may result in operator safety

hazards as well as serious engine damage. Always have your

Polaris dealer perform any carburetor adjustments.

Jetting Guidelines

Changes in altitude and temperature affect air density, which is the

amount of oxygen available for combustion. In low elevations and

cold temperatures, the air has more oxygen. In higher elevations and

higher temperatures, the air is less dense.

Carburetors on most Polaris models are calibrated for an altitude of

0-2000 ft (0-600 meters) and ambient temperatures between -10 to +10

F (-23 to -12 C). All carburetors must be re-calibrated if operated

outside this production temperature and/or altitude range. The main jet

installed in production is not correct for all altitudes and/or

temperatures.

CAUTION

A main jet that’s too small will cause a lean operating condition and

may cause serious engine damage. Jet the carburetors carefully for

elevation and temperature according to the jetting charts in your

Owner’s Manual Supplement.

NOTE: It’s the owner’s responsibility to ensure that the correct jets are

installed in the machine for a geographical area. Be very careful when

jetting down in warm weather. As the weather turns colder it will be

necessary to re-jet upward to prevent engine damage. When selecting

the proper main jet always use the lowest elevation and temperature

that is likely to be encountered.

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OPERATION

Engine Stop Switch

Push down on the engine stop

switch (A) to stop the engine in an

emergency. This will ground out

the ignition and bring the engine to

a quick stop. To restart the engine,

the switch must be pulled up to the

ON position.

Throttle Safety Switch

Test the throttle safety switch system daily before operation.

While seated in a normal riding

position, and with the engine

idling, hold the throttle lever pin

stationary by exerting pressure on

the pivot pin in the direction shown

in the illustration (B). Apply a

slight amount of throttle. A

properly functioning switch must

shut down the engine.

The throttle safety switch is designed to stop the engine whenever all

pressure is removed from the throttle lever and the throttle cable or

valves do not return to the normal closed position.

WARNING

Operating the snowmobile with a faulty throttle safety switch

can result in serious injury or death in the event of an accident.

If the throttle safety switch does not shut off the engine during a

carburetor/throttle system malfunction, immediately push down

the engine stop switch. Do not start the engine again until the

malfunction has been corrected by your dealer.

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OPERATION

Throttle Lever

WARNING

An improperly functioning throttle lever may cause erratic machine

behavior and loss of control, which could result in serious injury or

death. If the throttle lever does not work properly, DO NOT start

the engine.

If the engine stops abruptly when the throttle lever is released:

1. Turn the ignition switch to OFF.

2. Visually inspect thethrottle cableand carburetor(s)to determinewhat

caused the safety switch to activate.

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

The lever and cable must return to the idle position quickly and

completely.

4. If the throttle lever operates properly, turn the ignition switch on and

go through normal starting procedures.

5. If the engine doesn’t start, take the snowmobile to an authorized

Polaris dealer for service.

Excessive free play in the throttle cable may cause the safety switch to

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

machine to an authorized Polaris dealer for service.

If an emergency exists and it’s necessary to start the engine, the throttle

safety switch and engine stop switch may be disconnected from the

wire harness. When these switches are disconnected, the ignition key

switch must be used to shut off the engine. DO NOT continue to

operate the machine with the throttle safety switch disconnected.

Return the machine to an authorized Polaris dealer for service as soon

as possible.

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OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the

event of an emergency. Refer to page 62 for more information about

the engine stop switch and throttle safety switch.

SYSTEM

WHAT IT DOES

THROTTLE

CONDITION

Ignition Switch

Brake

Interrupts ignition circuit

Slows jackshaft

All

Choke

Floods engine

Half throttle or less

Engine Stop Switch

Interrupts ignition circuit

All

Throttle Safety Switch Interrupts ignition circuit

Tether Switch (Option) Interrupts ignition circuit

WARNING

Excessive or repetitive use of brakes for high speed stops will

cause an overheated brake system. This overheated condition

could cause sudden loss of brakes and/or fire, resulting in

serious injury or death.

When traveling on long downhill stretches, pump the brakes.

Riding the brakes may cause the brake system to overheat and

result in brake failure.

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OPERATION

Emergency Starting

Your machine is equipped with a tool kit containing essential tools for

emergency use. If the recoil starter system fails, an emergency start

strap is provided in the kit.

WARNING

Serious injury can result from wrapping the start strap around your

hand while using the emergency starting procedure. DO NOT

wrap the start strap around your hand. Keep all bystanders away

from the snowmobile when using the emergency starting

procedure.

To use the emergency start strap:

1. Open the clutch guard.

2. Push on the inner

sheave of the clutch

and rotate clockwise

slightly to relieve belt

tension.

3. Starting at one of the

tower struts, wind the

strap counterclockwise

around the clutch as

shown.

4. Pull the strap abruptly so the strap comes free of the clutch while

starting the engine.

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OPERATION

Reverse Operation

WARNING

Improper reverse operation, even at low speeds, may cause loss

of control, resulting in serious injury or death.

S Always look behind the vehicle before and while backing.

S Always avoid sharp turns.

S Shift to or from reverse only when stopped.

S Always apply throttle slowly.

Electronic Reverse (PERCt)

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

If your machine is running at an altitude of over 6000 feet, adjust the

ignition setting as described under the heading Altitude Settings.

Always make sure the vehicle is stopped and the engine is running at

idle before shifting to reverse.

1. Make sure the area behind your vehicle is clear.

2. Push the yellow reverse button on the handlebar for one second, then

release. Theenginewill automatically reduceRPM and start areverse

rotation. Aflashing reverselight on theinstrument panel will indicate

that the machine is in reverse.

3. Slowly apply the throttle until movement starts and you’re sure the

machine is in reverse.

NOTE: The maximum engine RPM will be 6000 when in reverse.

NOTE: If the engine stops running, the snowmobile will be in for-

ward gear when it’s restarted.

CAUTION

Operating the electric starter or the recoil while the engine is

running can result in personal injury and/or engine damage. Do

not operate the electric or pull-rope starter while the engine is

running.

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OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Disengaging Reverse

Push the yellow reverse button on the handlebar for one second and

release. The engine will slow and and begin to rotate forward. The

light on the instrument panel will shut off. Make sure the area around

your vehicle is clear and apply throttle slowly until you’re sure the

machine is in forward gear.

Altitude Setting

At higher altitudes (above 6000 feet), the engine will require a different

ignition setting to improve the success of the reverse system. To set

for a higher altitude, start the engine and hold the button down until the

light on the instrument panel flashes rapidly, then release the button.

To set the reverse for lower elevations, continue holding the button

down until the reverse indicator light blinks slowly. Once set, it’s

stored in memory until changed, whether the machine is running or

not.

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OPERATION

Towing

For your safety, do not attempt to using the tow hitch until you’ve read

the following warnings and understand the proper hitch functions.

WARNING

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

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

in serious injury or death. DO NOT tow toboggans, sleds,

saucers, or any type of vehicle with a rope. Only a stiff metal

pole connecting the towed object and the tow hitch on the

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

toboggan or sled, make sure the pole is at least four feet (1.2

meters) long to prevent any possibility of contact between the

snowmobile’s track and a person riding in the towed object.

Braking distances increase when towing loads. Slow down to

maintain control of the snowmobile.

If the snowmobile becomes inoperable and must be towed, and if it

isn’t possible to use a rigid tow bar, attach the tow rope to the ski

spindles (not to the ski loops) to prevent damage to the steering

components. Remove the drive belt before towing, and have a rider 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 serious damage to the engine and drive system. Always

remove the drive belt from a disabled snowmobile before towing.

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MAINTENANCE

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 machine.

NOTE: Polaris has accessory covers

and track stands available to fit all mod-

els. See your dealer for more information.

Polaris Recommended Maintenance Program

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

recommended regular maintenance and service checks outlined in this

manual.

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

performed by a qualified service technician. For continued optimum

performance 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

registered 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 adjust your

snowmobile. If you’re not familiar with safe service or adjustment

procedures and the use of tools, or if you don’t feel comfortable

performing these tasks yourself, contact an authorized Polaris dealer

for service.

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MAINTENANCE

Maintenance Chart

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

Weekly or

before

long trip

150

500

1000

See

Page

miles

(240 km

(800 km) (1600 km)

Check brake operation and

adjustment

Daily

48, 90

Test engine stop switch

Test tether strap

Daily

Test throttle safety switch

Throttle lever operation

48, 62

Check operation of headlights,

taillight, brakelight

Check park brake function

Secure hood

Daily

Check track alignment

Steering arm and tie rod ends

Throttle cable condition

Coolant level

102

104

Check track tension

101

Check chaincase oil level

Check gearcase oil level

Check drive chain tension

Check drive belt condition

97, 98

Check and tighten loose

suspension mounting bolts

Tighten ski saddle and spindle

bolts

Check front limiter strap

condition, tighten bolts

Check ski skags- replace when

worn to half original diameter

107

Check Hi-fax thickness, replace

when worn (Dealer)

Tighten rear idler wheel bolts

Flush Chaincase

102

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MAINTENANCE

Maintenance Chart

Item

Weekly or

before

long trip

150

500

miles

1000

miles

(1600 km)

See

Page

miles

(240 km

(800 km)

Tighten idler adjusting bolt jam

nuts

101

Check spark plug condition

Inspect coolant filter, replace if

necessary

Grease ski pivots

Grease ski spindles

Grease center steering arm(s)

Lubricate steering post support

bracket and pivot (aerosol)

Check cylinder base stud torque

on all Polaris engines. (Specifica-

tion: 32 ft. lbs ± 2 ft. lbs.) (Dealer)

Grease lower steering post pivot

Grease driveshaft bearing

(always perform before storage)

Check and drain water trap

Grease rear suspension pivot

shafts

Grease jackshaft bearing

(always perform before storage)

Lubricate throttle cable

Lubricate choke slide and cable

Check clutch alignment and offset

Check cooling system level,

specific gravity

Inspect oil line condition

Inspect fuel filter and replace

Check brake fluid level

Inspect fuel lines and replace

Inspect exhaust system for weak

or missing retaining springs

Inspect exhaust pipe for cracks or

damage

Inspect clutch sheaves for

damage, wear, belt residue

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MAINTENANCE

Maintenance Log

Present this section of your manual to your dealer each time your

snowmobile is serviced. This will provide you and future owners with

an accurate log of maintenance and services performed on the

snowmobile.

150 Mile (240 km) Initial Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

500 Mile (800 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

1000 Mile (1600 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

2000 Mile (3200 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

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MAINTENANCE

Maintenance Log

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

Type of Service

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

Type of Service

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MAINTENANCE

Lubrication

Lubricate the suspension and steering components with Polaris

Premium grease at 500 miles (800 km) and annually or about

every 1000 miles (1600 km) thereafter. See page 112 for the part

numbers of Polaris products.

The illustration shows the location of suspension and steering

components. A + indicates a grease point or fitting.

S Grease the left and right spindles. Raise the front end of the ma-

chine to permit better grease entry into the spindle area.

S Lubricate both of the front ski pivots at the fittings as shown.

S Grease the jackshaft and driveshaft clutch side bearings.

S Use an aerosol lubricant on the steering post support bracket.

S Grease the center steering arms.

S Grease the steering post lower pivot.

S Grease the rear suspension pivot shafts (raise the rear of unit).

A grease gun kit, complete with grease and adaptors, is available to

lubricate all fittings on Polaris snowmobiles. See page 112.

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MAINTENANCE

Lubrication

The suspension pivot shafts should be lubricated with Polaris Premium

All Season Grease at 500 miles (800 km) initially, every 1000 miles

(1600 km) after that, and before off-season storage each year. Lack of

lubrication will adversely affect your ride and the life of the

suspension. For detailed information about suspension lubrication and

adjustments, see your Polaris dealer.

NOTE: The following illustrations are general representations. Your

model may differ in appearance. Lubrication points are indicated by a

L, and forward is to the left.

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MAINTENANCE

Lubrication

Jackshaft Bearing Greasing

Loosen the driven clutch retaining bolt and pull

the clutch outward to expose the bearing and

grease fitting. Inject grease into the grease fitting

in the flangette until grease purges from inside or

outside the bearing seal (may take only two

pumps). Push the clutch back onto the shaft and

replace the clutch retaining bolt. Torque to 18 ft.

lbs. (24.4 Nm).

Driveshaft Bearing Greasing

Inject grease into the fitting on the speedometer

drive adaptor until grease purges from inside or

outside the bearing seal (approximately two

pumps).

Throttle Cable

Lubricate the throttle cable (1) lightly

with grease or oil. With the engine off,

turn the handlebars to the left and

lubricate liberally as shown.

Choke and Cable

Lubricate the choke slide (2) 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

possibility of the choke becoming

frozen.

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MAINTENANCE

Lubrication

Chaincase Oil Level

It’s the operator’s responsibility to check and maintain the proper

chaincase oil level.

To check the oil level, place the machine on a level surface. The oil

level should be between the “safe” marks on the dipstick (A). Add

Polaris synthetic chaincase oil through the dipstick opening. Do not

overfill. See page 112 for the part numbers of Polaris products.

Flush the chaincase after the first 500 miles, then every 1000 miles or

seasonally. Clean the magnetic plug (B) whenever checking or

changing lubricant.

CAUTION

Mixing brands or using non-recommended lubricants could result

in excessive wear to internal components. Always use

Polaris-recommended products for your vehicle.

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MAINTENANCE

Spark Plugs

It’s very important to use the correct spark plug for your machine. A

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

spark plug with a heat range too low will cause excessive fouling and

engine malfunctioning.

In selecting a spark plug heat range for production, a manufacturer

assumes that the engine will be operated under extreme heavy duty

conditions and selects a spark plug that will protect the engine from

internal damage if the purchaser actually does operate the engine in this

manner. This selection could cause the customer who normally

operates the engine under medium or light duty to have spark plug

failure. Refer to your Owner’s Manual Supplement for the specific

spark plug to be used in your machine.

CAUTION

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.

A new engine can cause temporary spark plug fouling due to the

preservative added during the assembly process. Avoid prolonged idle

speeds, which cause plug fouling and carbonization.

S Use recommended spark plugs with the proper gap. Refer to your

Owner’s Manual Supplement for specific information.

S Spark plug torque is 18-22 ft. lbs. (24-30 Nm).

S Always carry spare spark plugs in case of an emergency.

CAUTION

Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs.

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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: Incorrect fuel mixture can often cause a spark plug to appear

too dark or too light in color. Before changing spark plug heat ranges,

be sure the correct main jet is installed in the carburetor(s). Refer to

the Owner’s Manual Supplement or see your dealer.

1. Normal

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

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

indicates 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

carburetion adjustments.

2. Wet Fouled

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

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

electrodes are not worn. General causes of fouling are excessive oil,

use of non-recommended injection oil, improper use of the choke, or

incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the

tool pouch, rotate the spark plug

counterclockwise to remove.

3. Reverse the procedure for spark plug

installation.

4. Torque to 18-22 ft. lbs. (24-30 Nm).

5. Install spark plug cap.

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MAINTENANCE

Intake Filter

The intake foam filter limits snow

ingestion into the intake system.

When operating in loose powder

snow, check the top of the foam

filter periodically to remove any

accumulation of snow.

NOTE: These illustrations are

general representations. Your

model may differ.

1. Intake Foam Filter

2. Air Intake box

CAUTION

Operating the snowmobile with the intake filters removed may

cause carburetor icing. The result will be poor fuel economy

or carburetor malfunction. Always reinstall the intake filters

before operating the snowmobile.

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MAINTENANCE

Variable Exhaust System (VES)

Maintenance of the VES is limited to a periodic inspection and

cleaning of system components. Every 1000 to 2000 miles (800-1600

km), bring the machine to an authorized Polaris dealer to have the VES

disassembled, inspected, and cleaned.

NOTE: To ensure maximum performance and minimize required

maintenance, follow the oil recommendation chart on page 55. The

use of other lubricants may cause improper function of the valve mech-

anism and increase the frequency of required cleaning due to excessive

build-up of carbon deposits.

Water Pump Belt Inspection

Polaris Libery large block

liquid-cooled engines

require inspection of the

water pump belt at 1500

miles (2400 km). Inspect

belt width (A) and

condition, and replace if

cracked or worn past the

width service limit (.250″ /

6.35mm). New belt width

is approximately .345″

(8.75 mm). See your

Polaris dealer if the belt

needs to be replaced.

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MAINTENANCE

Water/Sediment Trap Service

Most Polaris snowmobiles contain patented carburetor bowl

water/sediment traps located at the bottom of each carburetor. The

trap, consisting of a hose with a plug, should be drained at least every

1000 miles (1600 km) and inspected for contamination.

WARNING

When draining the traps, fuel spillage will occur. Always work in

a well ventilated area away from anything that may cause the fuel

to ignite, such as open flames, sparks, heaters, trouble lights,

cigarettes, etc. Review the gasoline warnings found on page 57.

Plug Cleaning Procedure

1. Turn the fuel tank supply valve off.

2. Position a container or shop towels to

catch the contaminated gasoline.

3. Slide the clamp (1) away from the

drain plug (2) and remove the drain

plug from the sediment tube.

4. Wipe residue from the plug and

reinstall it. Reposition and tighten

the clamps. Continue until all the

traps have been emptied.

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MAINTENANCE

Fuel Filter/Fuel Lines

Inspect the in-tank fuel filter (1) and fuel

lines regularly. Give special attention to the

system’s fuel line condition after periods of

storage. Normal deterioration from weather

and fuel compounds may occur.

CAUTION

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

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

damaged or kinked, replace it promptly.

Oil Filter

Edge models have an oil filter that’s built into the oil sending unit

located in the bottom of the oil tank. Any time the sending unit is

replaced, bleed the oil injection system of all trapped air. See your

dealer for instructions, or have your dealer perform the replacement

and bleeding operation.

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Carburetor

The number stamped in the end of the main jet indicates the jet size.

The jet installed at the time of manufacture is not necessarily correct

for your elevation. It’s your dealer’s responsibility to make sure the

correct main jet is installed.

CAUTION

Operating the snowmobile with incorrect jetting can result in serious

engine damage. Have your Polaris dealer perform all carburetor

adjustments to ensure all adjustments are done correctly.

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:

S Hard starting

S Poor idle

S Overheated pistons and cylinder walls

S Plug fouling

S Poor engine response to various throttle valve openings

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MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 1000

miles (1600 km). To inspect, allow the engine and exhaust system to

cool completely. Open the hood and inspect the muffler and pipes for

cracks or damage. Check for weak or missing retaining springs or

damper/support grommets.

WARNING

Hot exhaust system parts can cause serious burns. Allow

adequate time for the exhaust system to cool. Never perform

this procedure with the engine running.

Engine Cooling - Liquid Cooled Models

The cooling system on liquid cooled models consists of the following

major components:

S Coolant bottle

S Water pump

S Cylinders

S Heads

S Inlet and outlet manifolds

S Pressure cap

S Heat exchangers

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MAINTENANCE

Engine Cooling - Liquid Cooled Models

Coolant Mixture

The coolant supplied in the system is a 50/50 mixture of

ethylene-glycol and distilled water. This mixture provides protection

against freezing at temperatures to -34° F (-37° C). If greater

protection is required, the percentage of antifreeze to water may be

increased. 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. Contact you dealer if greater

protection is required.

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.

Coolant High Temperature Indicator Light

The high temperature indicator light is controlled by a switch in the

engine cooling system on liquid cooled models. If the engine coolant

reaches a certain temperature, the switch completes a circuit that turns

the light on. If you must drive your machine after the high temperature

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

the engine to cool down. See your dealer.

Coolant Level

Maintain the coolant level at the “full cold” line on the coolant bottle

when the engine is cold.

CAUTION

Operating the snowmobile with insufficient coolant will result in

overheating and serious engine damage. Always maintain the

coolant level as recommended.

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

recovery system components are:

S Coolant bottle or overflow tank

S Engine filler neck

S Pressure cap (on some models)

S Connecting hoses

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MAINTENANCE

Engine Cooling - Liquid Cooled Models

Flushing the Cooling System

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

the system should be completely drained every two years and a fresh

50/50 or 60/40 mixture of antifreeze and distilled water should be

added. This service must be done when the engine is cold. Ask your

Polaris dealer to check the coolant when he performs the fall tune-up

on your snowmobile.

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.

If the pressure cap (A) needs replacement,

contact your dealer for the correct part. Use of a

non-standard pressure cap will not allow the

recovery system to function properly.

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MAINTENANCE

Engine Cooling - Liquid Cooled Models

Bleeding the Cooling System

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.

If coolant becomes low in the tank, bleed the system of trapped air

using the following procedure:

1. Allow the system to cool completely, then loosen the bleed screw

and fill the reservoir to the FULL COLD mark. Tighten the screw.

2. Apply the parking brake and run the engine at idle RPM until the

thermostat opens (5 to 8 minutes) and stays open. NOTE: As the

thermostat draws in cold coolant from the heat exchangers, the

cold coolant may close the thermostat. Make sure it opens and

stays open.

3. Tip the snowmobile slightly onto its right side. Cycle the RPM

from idle to enough RPM (4000) to get coolant to flow, but not

enough to engage the clutch. This allows air to bleed from the rear

crossover tube. NOTE: There must be enough coolant flow to

purge the air from the crossover hose or rear cooler so you can

observe this air reaching the bottle.

4. Tilt the machine slightly onto its left side so that the coolant bottle

is the highest point in the cooling system. Cycle the RPM as

outlined in step 3. NOTE: There must be enough coolant flow to

purge the air from the front close-off cooler so you can observe the

air reaching the bottle.

5. Return the snowmobile to its upright position and loosen the bleed

screw at the top of the water outlet manifold. When all trapped air

has been purged, tighten the screw.

6. Turn off the engine and release the parking brake. Allow the

system to cool completely. NOTE: After cooldown, three (3) or

more ounces of coolant may have to be added.

7. Remove the pressure cap and check the coolant level. Add coolant

to the fill line if necessary.

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MAINTENANCE

Drive Chain Tension

To obtain correct chain tension:

1. Rotate the driven clutch

counterclockwise to move all chain

slack to the tensioner side. Lock

the brake lever lock, or have an

assistant hold the brake lever

firmly.

2. Loosen the adjuster bolt jam

nut (A).

3. Finger tighten the adjuster

bolt (B) 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.

5. The chain is now tensioned. Release the brake lever lock.

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MAINTENANCE

Hydraulic Brake Inspection

Frequently inspect the brake

lever reserve. Firmly depress

the brake lever and measure

the clearance between the lever

and handlebar grip (A). This

distance, called brake lever

reserve, should be no less than

1/2″ (1.3 cm).

Brake pads must be replaced

when the brake pad material

becomes thinner than the backing plate (approximately 1/16″). A kit is

available for replacing brake pads. See your dealer.

WARNING

Brake failure during operation can result in serious injury or death.

Properly functioning brakes are vital to your safety. Be sure the

brake pads do not drag on the disc and that brake lever travel is

not excessive.

Always replace brake pads when the brake pad material becomes

thinner than the backing plate (approximately 1/16″).

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MAINTENANCE

Brakes

Brake Components

1. Brake Caliper

2. Chaincase

3. Brake Disc

4. Backing Plate

5. Brake Pad Material (Replace when thickness is less than 1/16″).

Excessive Brake Lever Travel

Hydraulic brakes are self-adjusting, but if excessive brake pad

clearance develops, as described on page 90, the machine should be

returned to an authorized Polaris dealer for inspection and adjustment.

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MAINTENANCE

Brakes

Brake Fluid

WARNING

After opening a bottle of brake fluid, always discard any

unused portion. Never store or use a partial bottle. Brake

fluid is hygroscopic, meaning it rapidly absorbs moisture from

the air. The moisture causes the boiling temperature of the

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

possibility of accident or severe 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.

Maintain the brake fluid level between the MIN and MAX marks on

the master cylinder reservoir. Use only Polaris DOT 3 high temperature

brake fluid. See page 112 for the part numbers of Polaris products.

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MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

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

Bleed the system before operating the snowmobile.

WARNING

Operating the vehicle with a spongy brake lever can result in

loss of brakes, which could cause an accident and lead to

serious injury or death. Never operate the vehicle with a

spongy-feeling brake lever.

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

possible. 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. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleedervalve and direct theflow

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 92.

8. Reinstall the gasket and cover.

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MAINTENANCE

Headlights

Headlight Adjustment

25’ (7.6 m)

The headlight may be adjusted for

vertical aim using the following

procedure:

1. Place the snowmobile on a level

surface with the headlight

approximately 25 feet (7.6m)

from a wall.

Lamp Center

Height

2″ (5.1 cm)

2. Measure the distance from the

floor to the center of the

headlight and make a mark on

the wall.

3. Start the engine and turn the

headlight switch to high beam.

4. Observe the headlight aim. The

most intense part of the

headlight beam should be aimed

2″ (5.1 cm) below the mark

placed on the wall in step 2.

NOTE: Rider weight must be

included on the seat.

5. Turn the adjustment nut (A),

located inside the hood, just

below the headlamp opening.

Turn the knob in or out as

needed for proper aim.

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MAINTENANCE

Headlights

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.

Removing Halogen Bulbs - High/Low Beam

1. Pinch the ends of the spring (1)

together and lift until it releases

from the spring retainer.

2. Lift spring carefully around

wire harness (2) and flip to

outside of housing.

3. With the wire harness attached

to the bulb (3), withdraw bulb

from housing.

4. Grasp bulb by metal base and carefully separate bulb from

harness.

Installing the Bulb

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

2. Insert bulb into housing.

3. Carefully flip spring back into housing placing it around wire

harness.

4. Squeeze spring together until it is over the spring retainer and

release.

5. Verify headlight aim.

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MAINTENANCE

Clutch System

WARNING

If you become aware of higher than normal clutch engagement or

an unusual vibration or shift pattern, see your dealer immediately.

Do not operate the machine until repairs have been made.

All clutch maintenance and repairs must be performed by an

authorized Polaris dealer. Any unauthorized modifications to

clutches, such as adding or removing weights, will void the

warranty.

CAUTION

The bushings in the weights and rollers of Polaris clutches are

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

lubricate clutch bushings.

Periodically inspect the clutch sheaves for damage, wear, or belt

residue. To maintain optimum performance, clean with non-oil based

cleaners such as isopropyl alcohol.

Clutch Alignment and Offset

Clutch center distance and alignment (A) are

crucial to maintaining optimum performance.

See your Owner’s Manual Supplement for the

recommended offset between the drive and

driven clutches with the belt removed.

The drive belt is a very important part of the drive

system. 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 performance. See your dealer for service and

adjustments.

NOTE: A worn belt will continue to function,

but will not deliver maximum performance. Always

carry a spare belt in case of an emergency.

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MAINTENANCE

Clutch System

Periodically check the condition and tension of the drive belt, and

always carry a spare belt. For improved drive-away during extremely

cold temperatures, remove the belt and warm it to room temperature.

Reinstall it before starting the snowmobile. The following procedures

apply to standard, electronic reverse and TEAM driven clutches.

Drive Belt Removal

1. Be sure the key switch is off and the engine has come to a

complete stop. Apply the brake (or lock the parking brake if

equipped).

2. Open the hood, remove the clutch guard retaining pin and open the

clutch guard.

3. Locate the L-wrench in the tool kit and install it into the open

threaded hole in the outer sheave of the clutch. Rotate the wrench

until the sheaves open far enough to remove the belt.

Drive Belt Installation

1. Drop the drive belt over the

drive clutch and pull back the

slack (A). 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 to tighten

the sheaves. Remove the

wrench and store in the tool kit.

3. Close the clutch guard and

reinstall the retaining pin.

4. Close and secure the hood and

release the parking brake.

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MAINTENANCE

Clutch System

Drive Belt Deflection

Measure belt deflection with both

clutches at rest and in their full

neutral position.

Place a straight edge on the belt (A)

and apply downward pressure while

measuring at point B. This

measurement should be 1 1/4”.

Drive Belt Adjustment

1. Loosen the 7/6” jam nut on the belt width adjuster.

2. Using a 1/8” Allen wrench, adjust the threaded set screw (C) as

needed. NOTE: Turn the set screw in (clockwise) to increase the

distance between the sheaves and out (counterclockwise) to

decrease the distance.

3. Tighten the jam nut.

Clutch Center Distance

See your Owner’s Manual Supplement for recommended center

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

Due to tolerances in belt length, it may be necessary for your dealer to

make minor adjustments in the driven clutch to achieve correct belt

tension.

Torque Stop

If your snowmobile is equipped

with an engine torque stop (1),

periodically check torque stop

clearance. With clutches in

proper alignment, the torque stop

clearance should be a minimum

of .010″ to a maximum of .030″

from the engine case (2). Adjust

if necessary, and lock the jam

nut.

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MAINTENANCE

Chain Tension

Maintain the proper chain tension as outlined on page 89.

Oil Level

Maintain the oil level between the safe marks as indicated on the oil

bottle (see page 59).

Tool Kit

A tool kit is included with each

machine for emergency and

routine maintenance. Your tool kit

will contain only the tools

applicable to your model.

1. Emergency Start Strap

2. Phillips Screwdriver

3. Tubular Socket

4. Tubular Socket Handle

5. Wrench

6. Screwdriver (550 PRO X)

7. Scissor Stop Wrench

8. Box End Wrench

Always keep the tool kit with the snowmobile.

If necessary, a replacement tool kit may be purchased from your Polaris

dealer.

NOTE: The tools and maintenance items mentioned in this book, as

well as a long line of other Polaris accessories, are available at your

Polaris dealer.

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MAINTENANCE

For Your Protection

For added protection, carry the following items on your snowmobile at

all times:

SSpare Drive Belt

STow Rope

SFuel Deicer

STrail Map

SFirst Aid Kit

SExtra Set of Spark Plugs

SExtra Oil

SWinter Survival Kit

SOwner’s Manual

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your

Polaris dealer. His experienced and trained service technician will keep

your machine in peak operating condition.

100

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MAINTENANCE

WARNING

Track Maintenance

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

checks and adjustments recommended on the following pages,

stay clear of all moving parts. Never perform track measurement

or adjustments with the engine running.

Track Tension

Track adjustment is critical for proper handling. Always maintain

correct tension and alignment.

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

and limber.

1. Turn the machine off.

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

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

at the specified distance (see Track Tension Data below) ahead of

the center of the rear idler wheel. NOTE: Measure at the point

where the weight is hanging.

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

and the plastic Hi-fax (C).

If the track needs adjustment:

Hi-fax

5. Loosen rear idler shaft bolt (D).

6. Loosen locknuts (A).

7. Tighten or loosen the

track adjusting screws (B)

as necessary to provide

equal adjustment on both

sides of the track.

weight

Track

Track Tension Data

Model

Weight

Measurement

Location

Measurement

PRO X

10 lbs. (4.54 kg)

16″ ahead of rear

1 1/4 - 1 1/2”

(3.2 - 3.8 cm)

idler shaft

101

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MAINTENANCE

Track Maintenance

If the track needs adjustment (continued):

8. Repeat measurement on the other side of the track. NOTE: Check

more frequently when machine is new.

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

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

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

11. Tighten locknuts (A).

12. Tighten idler shaft bolts (D) and torque to 35 ft. lbs. (47.5 Nm).

Track Alignment

Periodically check that the track is

centered and running evenly on the

slide rails. Misalignment will cause

excessive wear to the track and slide

rail.

1. Safely support the rear of the

machine with the track off the

ground.

2. Start the engine and apply a small

amount of throttle until the track

turns slowly at least five complete

revolutions. Stop the engine and

let the track come to a stop (do not

apply brakes).

3. Inspect track alignment by looking

through the track window to make

sure the rails (A) are evenly

spaced on each side. If the track runs to the left, loosen left

locknut and tighten the left adjusting bolt. If the track runs to the

right, loosen right locknut and tighten the right adjusting bolt.

4. After adjustments are complete, tighten locknuts and torque idler

shaft bolts to 35 ft. lbs. (47.5 Nm).

5. Repeat steps 2 and 3 to verify proper alignment.

102

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MAINTENANCE

Track Maintenance

Track Inspection

WARNING

Broken track rods are a serious safety hazard. They 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.

Using a hoist, safely lift and support the

rear of the snowmobile off the ground.

Rotate the track by hand to check for

possible damage.

Carefully examine the track along the

entire length of each rod, bending the

track and inspecting for breakage. The

three most common damage areas are

shown in the illustration.

Replace the track if any rod damage is

found.

Track Lubrication

WARNING

Operating with insufficient lubrication between the Hi-fax and track

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

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

Avoid operating for extended periods on ice and other surfaces that

have little or no snow for lubrication.

The slide rail requires adequate snow cover for sufficient lubrication.

Excessive wear indicates insufficient lubrication. A new Hi-fax can

cause faster heat build-up in limited lubrication, resulting in excessive

wear. NOTE: If excessive Hi-fax wear occurs due to poor snow

conditions, additional wheel kits are available. See your dealer for

more information.

NOTE: Track damage or failure caused by operation on ice or under

other poor lubrication conditions will void the track warranty.

103

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MAINTENANCE

Steering System

Steering Inspection and Adjustment

Each week, or before a long ride, check all fasteners and tighten if

necessary. Specifically check fasteners marked with a +.

104

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MAINTENANCE

Steering System

Ski Alignment

WARNING

Improper ski alignment or adjustment may cause loss of steering

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

change the ski alignment or camber adjustment. See your

Polaris dealer.

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

weight compressing the suspension, measure from the straight edge of

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

between the skis at point X should be 1/8″ to 1/4″ greater than at point

NOTE: If the skis are misaligned, we recommend that your dealer

correct the alignment, since camber adjustment may also be affected.

10″

105

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MAINTENANCE

Steering System

Ski Skags

WARNING

Worn skis and/or skags will adversely affect handling. Loss of

vehicle control may result, causing serious injury or death.

See your dealer’s studding chart for recommended skags. If you

install longer or more aggressive carbide skags than the original

equipment, it may also be necessary to add track studs to maintain

proper vehicle control while turning on hard-packed snow or ice.

Check skags weekly to maintain positive steering characteristics. Skags

must be replaced when worn to half their original diameter.

NOTE: Carbide skags must be replaced if any abnormal wear or

chipping is found.

Skag Replacement

1. Raise and support the front of the machine so the skis are

approximately 6″ (15.2 cm) from the ground.

2. Remove the attaching hardware and pry the skag (A) downward.

3. Remove the forward portion of the skag.

Reverse this procedure for new skag installation.

106

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MAINTENANCE

Suspension Maintenance

Hi-Fax Wear

Check Hi-fax wear by

measuring the thickness at

several points along the rail

(A). Replace Hi-fax when a

thickness of 7/16″ (1.1 cm)

is reached. Take the machine

to your dealer for Hi-fax

replacement.

7/16″ (1.1 cm)

107

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MAINTENANCE

Suspension Maintenance

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 following items on a weekly basis or before any long trip:

n Check rear idler wheel bolts for tightness.

n Check rear idler adjusting bolt locknuts for tightness.

n Check front torque arm limiter strap condition.

n Check slide rail Hi-fax condition greatly affects performance - have

your dealer replace when worn to minimum thickness.

n Check track tension (beginning on page 101).

n Lubricate/grease all suspension components (see page 74).

n Check ski runner/skag condition.

Extended Storage

Off-season or extended storage of your snowmobile requires preventive

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

many components.

Cleaning and Preservation

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

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

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

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

surfaces before beginning preservation with waxes and rust inhibitors

(grease, oil or paint).

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

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

cause condensation to form and damage snowmobile components.

Controls and Linkage

All bushings, spindle shafts, tie rod ends, and cables should receive a

light coat of oil or grease.

108

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MAINTENANCE

Extended Storage

Bearings

Grease the jackshaft and drive shaft clutch side bearings with Polaris

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

corrosion. See page 112 for part numbers.

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Lubricate the

sheave faces of the drive and driven clutches with a light coat of oil or

Polaris Cable Lubricant. See page 112 for part numbers. Do not

lubricate clutch components, except the driven clutch shaft bushing as

outlined in the Master Repair Manual. See your dealer.

Engine and Carburetor Protection

Proper preparation of the engine and fuel system is vital to the

prevention 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 can. See page 112.

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

the fuel tank. See page 112 for the part numbers of Polaris products.

Follow the instructions on the can, running the engine for five minutes

to get additives through the entire fuel system. Top off with fresh fuel.

HINT: For easier starting after extended storage, add lubricant to the

fuel in the tank at a 40:1 ratio and run the engine for three to five

minutes before storage. This will lubricate the fuel pump diaphragm to

keep it flexible and help prevent loss of prime.

If stabilizer is not used, drain the carburetors by removing the water

trap drain plugs (see page 82). Catch fuel in a container or shop cloth.

Reinstall plugs securely. Observe all fire safety rules when draining

carburetors. See gasoline warnings on page 57.

Jet restriction caused by improper storage can cause lean conditions

and very poor slow speed driving quality.

109

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MAINTENANCE

Extended Storage

Engine and Carburetor Protection

Using a fuel stabilizer and topping off the fuel tank eliminates the need

to drain the fuel system. If you prefer to drain the fuel tank, use the

following procedure:

1. Transfer unused fuel from the fuel tank to an approved fuel container

using a siphon pump. Do not re-use fuel after storage.

2. Securely support the front of the snowmobile with a jack stand so the

machine is elevated and the engine is tilted rearward.

3. Remove the spark plug(s).

4. Rotate the engine slowly, watching the piston until it’s at bottom dead

center (BDC), the lowest position in the cylinder. On twin cylinder

models, the opposite piston will be up.

5. Pour approximately two ounces of Polaris injector oil into the spark

plug hole.

6. Wait one to two minutes and perform steps 3 to 5 on remaining

cylinders.

7. Replace the spark plugs and lower the machine to the floor.

Electrical Connections

Separate electrical connector blocks and clean corrosive build-up from

connectors. Lubricate or pack connector blocks with dielectric grease

and re-connect. See page 112 for the part numbers of Polaris products.

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.

110

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MAINTENANCE

Extended Storage

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. See illustration.

Transporting the Snowmobile

Whenever the snowmobile is transported:

1. Turn the fuel valve clockwise to OFF to shut off the fuel supply

(1). Turn the valve counter-clockwise to ON to turn the fuel supply

on (2). NOTE: The fuel valve is located under the hood of your

machine.

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.

111

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricants

2870791

2874438

2874439

Fogging Oil (12 oz. Aerosol)

VES II Synthetic 2-Cycle Oil (qt.)

VES II Synthetic 2-Cycle Oil (gal.)

Chaincase Lubricants

2873105

2872951

Synthetic Chaincase Lubricant (qt.)

Synthetic Chaincase Lubricant (12 oz.)

Grease / Specialized Lubricants

2871312

2871322

2871423

2871329

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)

Coolant

2871323

2871534

Anitfreeze, 60/40 Premix (gal.)

Anitfreeze, 60/40 Premix (qt.)

Additives / Miscellaneous

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT3 Brake Fluid (12 oz.)

Engine Degreaser (12 oz.)

Isopropyl

2871326

2870652

2870990

2872893

2870505

2872889

2872890

Brake and Clutch Cleaner

Carb and Throttle Body Cleaner

112

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TROUBLESHOOTING

Engine Troubleshooting

CAUTION: Unless you have experience and training in two-cycle

engine repair, see your dealer if technical problems arise.

Problem

Probable Cause

Solution

Erratic engine

operating RPM

during accelera-

tion or load

Drive clutch binding -Disassemble drive clutch to inspect shift

weights for wear and free operation.

SEE YOUR DEALER.

-Clean and polish stationary shaft hub.

Driven clutch

variations

malfunction

-Replace ramp buttons and rollers.

SEE YOUR DEALER.

-Inspect movable sheaves for excessive

bushing clearance and replace if necessary.

SEE YOUR DEALER.

-Replace drive belt.

Harsh drive

clutch

Drive belt worn or

too narrow

engagement

Excessive belt/sheave -SEE YOUR DEALER.

clearance

Drive belt turns Wrong belt for

application

-Replace drive belt.

over

Clutch alignment out -Adjust alignment offset.

of spec

Engine mount broken -Inspect and adjust or replace.

or loose

SEE YOUR DEALER.

Machine fails to Clutch jammed

move

-Belt twisted, spring broken, weights stuck,

lubricated. SEE YOUR DEALER.

Track jammed

-Foreign object caught or Hi-fax melted to

track clips due to lack of lubrication.

-Machine may be frozen to ground. Track

may be iced up.

Chaincase sprocket or -Chain is loose or broken, chain tightener is

chain jammed or bro- loose. SEE YOUR DEALER.

ken

113

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause

Solution

Noise in drive

system

Broken drive clutch

components

-SEE YOUR DEALER.

Bearing failure/

-SEE YOUR DEALER.

chaincase, jackshaft,

or front drive shaft

Drive belt surface flat

spots

-Inspect and replace if necessary.

-Inspect and adjust or replace.

-Inspect and replace if necessary.

Drive chain loose or

worn, sprocket teeth

broken

Poor low RPM Worn drive belt

performance

Excessive belt/sheave -SEE YOUR DEALER.

clearance

Loose torque stop

Sticky clutch

Seized engine

-Inspect and adjust.

-SEE YOUR DEALER.

Engine doesn’t

turn

-SEE YOUR DEALER. Seizure is a result

of poor lubrication, inadequate fuel supply,

broken parts, or improper cooling.

Hydrostatic lock

-Fuel may have entered crankcase while

vehicle was standing or being transported.

SEE YOUR DEALER to correct cause.

Drain plug(s) are located on lower crank-

case for emergency draining.

Engine requires Poor gasoline or not

more than enough fuel getting to

-Replace with fresh winter fuel.

normal pulls to engine

start

114

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause

Solution

Engine turns

but fails to start

Faulty ignition

-Remove spark plug(s) and replace with

new plug(s). If engine still fails to start,

check for spark; if no spark SEE YOUR

DEALER.

No fuel to engine

-Make sure the fuel valve is “ON”. Check

tank level and fill up with correct fuel.

-Ice in fuel line, filter, or pump. On the

standard Polaris carburetor, the choke will

not function with the throttle depressed.

See second item under “Probable Cause” of

“Engine continually backfires”.

Flooded engine (nor-

mal situation caused

by too much chok-

ing)

-Hold throttle open, crank engine several

times (may be necessary to change plug(s),

however, the plug(s) may operate satisfac-

torily when dried).

Poor engine compres-

sion

-Running too lean a mixture (too small a

main jet will cause seizure resulting in loss

of power). SEE YOUR DEALER. This

indicates a major engine problem that must

be repaired before engine is run.

Engine lacks

power

Fouled or defective

spark plug

-Change and test operation.

Fuel filter (loss of

high RPM power)

-Check fuel filter flow. Disconnect hose

and drain about 1/2 cup. Fuel flow should

be steady and encompass the entire diame-

ter of fuel line. If not, replace filter.

Incorrect clutching

-SEE YOUR DEALER.

Carburetor and fuel

pump

-There’s no adjustment to change power

output. SEE YOUR DEALER.

Engine

continually

backfires

Faulty plug(s)

Carburetor

-Change plug(s)

-Dirt or ice in fuel system. (Deicer should

be added to non-ethanol fuel at all times for

assurance against fuel line icing.)

115

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TROUBLESHOOTING

Suspension Troubleshooting

Problem

Solution (perform only one change at a time)

Rear suspension

-Increase torsion spring preload

-Increase rear shock compression damping by turning screw

bottoms too easily

clockwise

-Increase torsion spring wire diameter (see your dealer)

Rides too stiff in

rear

-Check for binding suspension shafts and grease all pivot points

-Decrease torsion spring preload adjustments

-Decrease rear shock compression valving by turning screw

counterclockwise (if equipped with optional Indy Select shock)

-Change to lighter valving if (if equipped with Fox shocks)

-Check for proper track tension

Machine darts from -Make sure skis are aligned properly

side to side

-Make sure spindles and all steering components are free turning

-Make sure skags are straight on skis

-Check Hi-fax and replace if worn

-Reduce ski pressure:

SReduce IFS spring preload

SReduce rear torsion spring preload

Front end pushes

Steering is heavy

-Check for worn skags

-Check for binding suspension shafts and grease all pivot points

-Increase IFS spring preload by adjusting cam or threaded ad-

juster

-Decrease front limiter strap length

-Check ski alignment

-Check skags and skis for damage

-Reduce ski pressure:

SIncrease front track spring preload

SReduce IFS spring preload by adjusting cam

SReduce rear torsion spring preload

Setting up for deep -Change worn Hi-fax

snow operation

-Move front track shock assembly to upper position

116

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TROUBLESHOOTING

Belt Troubleshooting

Belt Wear/Burn

Belt Wear/Burn Diagnosis

Causes

Solutions

Driving at low RPM

Drive at higher RPMs. Gear the machine down. Check belt

deflection.

Insufficient warm-up

Warm the engine at least five minutes. Take the drive belt off

the machine in extremely cold weather and warm it up.

Break machine loose from the snow.

Towing at low RPM

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

engage clutch.

Riding with high RPM Lower the gear ratio. Remove windage plates from the

and slow speed (8000

clutch. Reduce RPM. Avoid riding in high ambient

RPM/10 MPH)

temperatures.

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 carb and choke synchronization, fouled plugs,

debris in the carbs, and water, ice, or dirt in gas tank or fuel

line.

Loading machines onto Skis may gouge into trailers and prevent the drivetrain from

trailers

spinning properly. Use enough speed to drive the machine

completely onto the trailer. Push and pull it to finish

loading if necessary.

Clutch malfunction

Inspect clutch components. See your dealer.

Use fast, aggressive throttle to engage clutch.

Slow, easy clutch en-

gagement

117

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WARRANTY

Service And Warranty Information

Obtaining Service and Warranty Assistance

Read and understand the service data and the Polaris warranty

information contained in this manual. Contact your Polaris dealer for

replacement parts, service or warranty. Your dealer receives frequent

updates on changes, modifications and tips on snowmobile

maintenance, which may supersede information 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 5. Details of trouble experienced

2. Model number 6. Length of time and conditions of operation

3. Dealer name

7. Previous correspondence

4. Date of purchase

Use the page provided near the front of your Owner’s Manual to record

the identification numbers of your snowmobile and its engine.

Polaris Customer Service

United States: 1-763-417-8650

Canada: 1-204-925-7100

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 offi-

cials, the owner must call Polaris Customer Service.

B. Owners must provide their name, address, telephone num-

ber and the model and serial number of stolen machines.

2. Polaris warranty will provide all dealerships with a monthly

updated list of all stolen units to further monitor thefts.

3. Polaris warranty will aid in notifying the proper owner when a unit

is recovered.

118

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WARRANTY

Limited Warranty

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-

ITED WARRANTY on all components of the Polaris snowmobile against defects in

material or workmanship. This warranty covers the parts and labor charges for repair or

replacement of defective parts that are covered by this warranty. The warranty begins on

the date of purchase. This warranty is transferrable to another consumer, during the war-

ranty period, through a Polaris dealer.

Registration

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will

record the registration for warranty. No verification of registration will be sent to the

purchaser as the copy of the Warranty Registration Form will be the warranty entitle-

ment. If you have not signed the original registration and received the customer copy,

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.

Initial dealer preparation and setup of your snowmobile is very important in ensuring

trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer

setup will void your warranty coverage.

Warranty Coverage and Exclusions

Limitations of warranties and remedies

This warranty excludes any failures not caused by a defect in material or workmanship.

The warranty does not cover accidental damage, normal wear and tear, abuse or improper

handling. The warranty also does not cover any snowmobile that has been structurally

altered, neglected, improperly maintained, used for racing or used for purposes other

than for which it was manufactured. The warranty does not cover any damages that oc-

cur 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 punc-

turing of upholstery material, corrosion or defects in parts, components or the snowmo-

bile 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, NEG-

LIGENCE, 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.

119

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WARRANTY

Warranty Coverage and Exclusions

Limitations of warranties and remedies

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-

PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-

LAR 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

recommend the use of Polaris engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered

by warranty.

120

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WARRANTY

Conditions and Exclusions

In order to qualify for warranty, the product must have been properly set up and tested by

a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-

Delivery Inspection, perform all applicable service bulletins and have the consumer sign

the PDI form prior to delivery may void the warranty. Failure to provide proof of re-

quired 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

Tires

Slide Rails

Suspension components

Drive Belts

Hydraulic components

Circuit Breakers/Fuses

Electronic components

Wheels

Clutches and components

Steering components

Batteries

Light bulbs/Sealed beam lamps

Finished and unfinished surfaces

Brake components

Seat components

Throttle body components

Engine components

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

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage / repair

Coolants

Fuel

Sealants

Hotel fees

Towing charges

Mileage

Meals

Shipping/ handling fees

Product pick-up / delivery

Rentals / Loss of product use Loss of vacation / personal time

This warranty also excludes failures resulting from improper lubrication; improper en-

gine timing; improper fuel; surface imperfections caused by external stress, heat, cold or

contamination; operator error or abuse; improper component alignment, tension, adjust-

ment or altitude compensation; failure due to snow, water, dirt or other foreign substance

ingestion/contamination; improper maintenance; modified components; use of after mar-

ket 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 dam-

aged by abuse, accident, fire or any other casualty not determined a defect of materials or

workmanship.

121

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WARRANTY

Polaris Second Year Engine Service Contract

Second Year Engine Service Contract is standard on all eligible new and unused

snowmobiles 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

transferable 120 days after the original purchase date, free of charge, through any Polaris

snowmobile 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

registration 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 cover-

age.

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

additional 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.

S 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 ex-

cluded from coverage.

Electrical components are excluded from coverage.

The gearcase and transmission are excluded from coverage.

122

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

Polaris Industries. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you

have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you

move or are traveling within the country where your vehicle was purchased, Warranty or

Service Bulletin repairs may be requested from any authorized Polaris dealer who sells

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized Polaris dealer. You must show the dealer

photo identification from the country of the selling dealer’s authorized location as proof

of residence. Upon residence verification, the servicing dealer will be authorized to per-

form the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the

customs department of the destination country before you move. Vehicles importation

rules vary considerably from country to country. You may be required to present docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen outside of the country in which

the vehicle was originally purchased, all warranty coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-

cials or military personnel on assignment outside of the country where the vehicle was

purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Service (see page 118).

123

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . 44-47

Air Box . . . . . . . . . . . . . . . . . . . . . . . . 23

Driver Awareness . . . . . . . . . . . . . . . . . 15

Driveshaft Bearing Greasing . . . . . . . . 76

Driving Downhill . . . . . . . . . . . . . . . . . 17

Driving in Hilly Terrain . . . . . . . . . . . . 16

Driving on Slippery Surfaces . . . . . . . . 19

Driving Responsibly . . . . . . . . . . . . . . . 21

Bearings . . . . . . . . . . . . . . . . . . . . . . . 109

Before Starting the Engine . . . . . . . 48-51

Belt Troubleshooting . . . . . . . . . . . . . 117

Bleeding the Cooling System . . . . . 67-88

Bleeding the Hydraulic Brake System . 93

Brake Components . . . . . . . . . . . . . . . . 91

Brake Fluid . . . . . . . . . . . . . . . . . . . . . . 92

Brake Lever Travel . . . . . . . . . . . . . 49, 91

Brake, Park . . . . . . . . . . . . . . . . . . . . . . 50

Brakes . . . . . . . . . . . . . . . . . . . . . . . 91-93

Brakes, Hydraulic . . . . . . . . . . . . . . . . . 49

Electrical Connections . . . . . . . . . . . . 110

Electronic Reverse . . . . . . . . . . . . . 66-67

Emergency Starting . . . . . . . . . . . . . . . 65

Emergency Stopping . . . . . . . . . . . . . . 64

Engine and Carburetor Protection . . . 110

Engine and Carburetor Protection . . . 109

Engine Break-In . . . . . . . . . . . . . . . . . . 54

Engine Stop Switch . . . . . . . . . . . . 52, 62

Engine Troubleshooting . . . . . . . 113-115

Excessive Speed . . . . . . . . . . . . . . . . . . 14

Exhaust System . . . . . . . . . . . . . . . . . . 85

Carburetion . . . . . . . . . . . . . . . . . . . . . . 61

Carburetor . . . . . . . . . . . . . . . . . . . . . . 84

Chain Tension . . . . . . . . . . . . . . . . . . . . 99

Chaincase Oil Level . . . . . . . . . . . . . . . 77

Choke and Cable . . . . . . . . . . . . . . . . . 76

Cleaning and Preservation . . . . . . . . . 108

Clutch Alignment . . . . . . . . . . . . . . . . . 96

Clutch and Drive System . . . . . . . . . . 109

Clutch Center Distance . . . . . . . . . . . . . 98

Clutch Cover . . . . . . . . . . . . . . . . . . . . 23

Clutch Guard . . . . . . . . . . . . . . . . . . . . 17

Clutch System . . . . . . . . . . . . . . . . 96-98

Clutches . . . . . . . . . . . . . . . . . . . . . . . . 19

Coil Springs . . . . . . . . . . . . . . . . . . . . . 40

Cold Weather Drive-Away . . . . . . . . . . 19

CONTROLS . . . . . . . . . . . . . . . . . . 28-31

Controls and Linkage . . . . . . . . . . . . . 108

Coolant Level . . . . . . . . . . . . . . . . . . . . 86

Coolant Mixture . . . . . . . . . . . . . . . . . . 86

Cooling . . . . . . . . . . . . . . . . . . . . . . 85-88

Fall Tune-Up . . . . . . . . . . . . . . . . . . . 100

FEATURES AND CONTROLS . . . 28-31

Flushing the Cooling System . . . . . . . . 87

For Your Protection . . . . . . . . . . . . . . 100

Front Rear Scissor Stop . . . . . . . . . . . . 40

Front Springs . . . . . . . . . . . . . . . . . . . . 35

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 57-59

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . 83

Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . 83

Fuel Reserve Capacity . . . . . . . . . . . . . 59

Fuel System Deicers . . . . . . . . . . . . . . . 59

Halogen Bulbs . . . . . . . . . . . . . . . . . . . 95

Handlebar Adjustments . . . . . . . . . . . . 43

Handlebar with Riser Block . . . . . . . . . 43

Headlight Adjustment . . . . . . . . . . . . . 94

Headlights . . . . . . . . . . . . . . . . . . . 94-95

Hi-Fax Wear . . . . . . . . . . . . . . . . . . . . 107

High Temperature Indicator . . . . . . . . . 86

Hydraulic Brake Inspection . . . . . . . . . 90

D.E.T. Flash Signals . . . . . . . . . . . . . . . 31

D.E.T. Troubleshooting . . . . . . . . . . . . 31

Daily Storage . . . . . . . . . . . . . . . . . . . . 69

Detonation Elimination Technology . . 31

Disabled Operators . . . . . . . . . . . . . . . . 13

Drive Belt . . . . . . . . . . . . . . . . . . . . . . . 17

Drive Belt Adjustment . . . . . . . . . . . . . 98

Drive Belt Deflection . . . . . . . . . . . . . . 98

Drive Belt Installation . . . . . . . . . . . . . 97

Drive Belt Removal . . . . . . . . . . . . . . . 97

Drive Chain Tension . . . . . . . . . . . . . . . 89

Ice and Snow Build-up . . . . . . . . . . . . . 14

IFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Intake Filter . . . . . . . . . . . . . . . . . . . . . 80

Intake Silencer . . . . . . . . . . . . . . . . . . . 19

INTRODUCTION . . . . . . . . . . . . . . . 7-9

124

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INDEX

Jackshaft Bearing Greasing . . . . . . . . . 76

Jetting Guidelines . . . . . . . . . . . . . . . . . 61

SAFETY . . . . . . . . . . . . . . . . . . . . . 10-27

Safety Decals and Locations . . . . . 23-27

Sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Scissor Stop . . . . . . . . . . . . . . . . . . 40-41

Service Contract . . . . . . . . . . . . . . . . . 122

Shock Absorber Components . . . . . . . . 33

Shock Spring Preload, Front . . . . . . . . 34

Shock Valving . . . . . . . . . . . . . . . . . . . 35

Shock, Clicker . . . . . . . . . . . . . . . . . . . 39

Signal words . . . . . . . . . . . . . . . . . . . . . 10

Skag Replacement . . . . . . . . . . . . . . . 106

Ski Alignment . . . . . . . . . . . . . . . . . . 105

Ski Skags . . . . . . . . . . . . . . . . . . . . . . 106

Spark Plugs . . . . . . . . . . . . . . . . . . . 78-79

Spring Preload . . . . . . . . . . . . . . . . . . . 37

Start the Engine and Check . . . . . . . . . 52

Starting . . . . . . . . . . . . . . . . . . . . . . . . . 65

Starting a Cold Engine . . . . . . . . . . . . . 53

Starting a Warm Engine . . . . . . . . . . . . 54

Starting the Engine . . . . . . . . . . . . . . . . 53

Steering Adjustment . . . . . . . . . . . . . . 104

Steering Inspection . . . . . . . . . . . . . . . 104

Steering System . . . . . . . . . . 51, 104-106

Stopping . . . . . . . . . . . . . . . . . . . . . . . . 64

Storage . . . . . . . . . . . . . . . . . 69, 108-110

Survival Preparation . . . . . . . . . . . . . . . 12

Suspension . . . . . . . . . . . . . . . . . . . . . 111

Suspension Coupling . . . . . . . . . . . . . . 40

Suspension Maintenance . . . . . . 107-108

Suspension Performance Tips . . . . . . . 36

Suspension Troubleshooting . . . . . . . 116

Suspension, Front . . . . . . . . . . . . . . 32-35

Suspension, Rear . . . . . . . . . . . . . . 36-42

Symbols . . . . . . . . . . . . . . . . . . . . . . . . 10

Lighting Check . . . . . . . . . . . . . . . . . . . 52

Low Oil Indicator . . . . . . . . . . . . . . . . . 60

Low Oil Level . . . . . . . . . . . . . . . . . . . 59

Lubrication . . . . . . . . . . . . . . . . . . . 74-77

MAINTENANCE . . . . . . . . . . . . . 69-111

Maintenance . . . . . . . . . . . . . . . . . . . . . 20

Maintenance Chart . . . . . . . . . . . . . 70-71

Maintenance Log . . . . . . . . . . . . . . 72-73

Maintenance Program . . . . . . . . . . . . . 69

Maneuverability . . . . . . . . . . . . . . . . . . 20

Mirror Adjustment . . . . . . . . . . . . . . . . 52

Moving Parts . . . . . . . . . . . . . . . . . . . . 12

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 59-60

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 83

Oil Injection System . . . . . . . . . . . . . . . 55

Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 99

Oil Recommendations . . . . . . . . . . . . . 55

Operating Area . . . . . . . . . . . . . . . . . . . 52

OPERATION . . . . . . . . . . . . . . . . . 53-68

Operation Warning . . . . . . . . . . . . . 26-27

Operator Safety . . . . . . . . . . . . . . . 10-22

Passenger . . . . . . . . . . . . . . . . . . . . . . . 24

PERC . . . . . . . . . . . . . . . . . . . . . . . 66-67

Plug Cleaning . . . . . . . . . . . . . . . . . . . . 82

POLARIS PRODUCTS . . . . . . . . . . . . 112

Powder Snow Operation . . . . . . . . . . . . 18

PRE-RIDE INSPECTIONS . . . . . . . 48-52

Premium Fuel Switch . . . . . . . . . . . . . . 58

Pressure Cap . . . . . . . . . . . . . . . . . . . . . 23

TABLE OF CONTENTS . . . . . . . . . . . . .

Tether Switch . . . . . . . . . . . . . . . . . . . . 52

THE PERFECT FIT . . . . . . . . . . . . 32-47

Throttle Cable . . . . . . . . . . . . . . . . . . . . 76

Throttle Lever . . . . . . . . . . . . . . . . . . . . 63

Throttle Safety Switch . . . . . . . . . . . . . 62

Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 99

Torque Stop . . . . . . . . . . . . . . . . . . . . . 98

Torsion Spring Tension . . . . . . . . . . . . 38

Towing . . . . . . . . . . . . . . . . . . . . . . . . . 68

Track . . . . . . . . . . . . . . . . . . . . . . . 24,111

Track Alignment . . . . . . . . . . . . . . . . . 102

Track Inspection . . . . . . . . . . . . . . 51, 103

Track Lubrication . . . . . . . . . . . . . . . . 103

Rear Rear Scissor Stop . . . . . . . . . . . . . 41

Recommended Maintenance Program . 69

Reverse . . . . . . . . . . . . . . . . . . . . . . . . . 25

Reverse Operation . . . . . . . . . . . . . . . . 66

Reverse, Electronic . . . . . . . . . . . . 66-67

Rider Capacities . . . . . . . . . . . . . . . . . . 20

Riding Apparel . . . . . . . . . . . . . . . . . . . 13

Riding Position . . . . . . . . . . . . . . . . . . . 13

125

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INDEX

Track Maintenance . . . . . . . . . . . 101-103

Track Tension . . . . . . . . . . . . . . . . . . . 101

Track Tension Data . . . . . . . . . . . . . . 101

Track Warm-Up . . . . . . . . . . . . . . . . . . 56

Traction Products . . . . . . . . . . . . . . . . . 45

Transporting the Snowmobile . . . . . . 111

TROUBLESHOOTING . . . . . . . 113-117

Warning Labels . . . . . . . . . . . . . . . 23-27

WARRANTY . . . . . . . . . . . . . . . 118-123

Water Pump Belt Inspection . . . . . . . . . 81

Water/Sediment Trap Service . . . . . . . . 82

Wear Strips . . . . . . . . . . . . . . . . . . . . . . 47

Weight Transfer During Acceleration . 42

WELCOME . . . . . . . . . . . . . . . . . . . . . .

Windchill/Temperature Charts . . . . . . . 22

Variable Exhaust System . . . . . . . . 55, 81

Vehicle Identification Numbers . . . . . . .

126

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For your nearest Polaris dealer,

call 1-800-POLARIS

or visit www.polarisindustries.com

Polaris Sales Inc.,

2100 Hwy. 55, Medina, MN 55340

Phone (763) 417-8650 Fax (763) 542-0599

Part No. 9918227

Printed in USA

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