Polaris Offroad Vehicle Widetrak LX User Manual

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WARNING

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

this manual and on all product labels.

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

WARNING

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

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

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WELCOME

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

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

utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

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

ational vehicles manufactured in the world today. Many years of experi-

ence have gone into the engineering, design, and development of your

Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your manual

contains instructions for minor maintenance, but information about

major repairs is outlined in the Polaris Service Manual and should be

performed only by a Factory Certified Master Service Dealer (MSD)

Technician.

Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your ser-

vice needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and acces-

sories, available through our online store at www.purepolaris.com. Have

your accessories and clothing delivered right to your door!

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-

tries Inc.

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

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

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

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

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

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

expressly prohibited.

Printed in U.S.A.

2009 Widetrak LX Owner’s Manual

P/N 9921649

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

This section contains helpful information for owners and drivers and

illustrates the location of important identification numbers that should

be recorded in the owner’s manual.

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

This section describes safe vehicle operation and identifies warning

decals and their locations.

Features and Controls . . . . . . . . . . . . . . . . . . . 26

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

features.

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 30

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

an optimum riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 38

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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

general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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

bile’s regular maintenance.

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 105

Suspension Troubleshooting . . . . . . . . . . . . 106

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 107

This section is a quick reference guide to solving general problems.

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 120

Record maintenance and service in the log for your reference and for

future owners of the vehicle.

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

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INTRODUCTION

Important Notes for Owners and Drivers

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

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

sold.

When teaching inexperienced operators to ride, set up a predetermined

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

snowmobile before allowing them to make longer trips. Teach them

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

safety courses sponsored by local or state organizations.

Follow the maintenance program outlined in this manual. Preventive

maintenance ensures that critical components of the snowmobile are

inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with

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

to ensure warranty coverage.

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

clubs.

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

resentations. Your model may differ.

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INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education cam-

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

belt to adopt rigorous safety training programs that encourage protection

of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to pro-

tect our environment. Please support their efforts and operate your

snowmobile with consideration for the protection and preservation of

our environment.

Noise Level

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

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

snowmobile development, recommends that snowmobiles conform to

prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE standards.

Our muffler systems are designed to reduce noise levels and must not be

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

to non-snowmobilers, so you have a responsibility to operate your

snowmobile with concern for others. We do our part by manufacturing

quieter machines; we ask your help to further reduce the impact of noise

by operating your snowmobile safely and responsibly.

Air Pollution

Polaris engineers continuously investigate ways to reduce emission lev-

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

of potential air pollution.

In addition to our technological research, we encourage government

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

interested parties to work together to develop data on environmental

topics.

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INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile’s identification numbers and key number in

the spaces provided. Remove the spare key and store it in a safe place.

Your key can be duplicated only by mating a Polaris key blank with one

of your existing keys, so if both keys are lost, the ignition switch must

be replaced.

Vehicle Model Number: ___________________________________________________

Tunnel VIN: ____________________________________________________________

(lower right side of the tunnel)

Engine Serial Number: ___________________________________________________

(right front side of engine crankcase)

Key Number: ___________________________________________________________

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SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual

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

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

manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

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

death or serious injury.

CAUTION

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

minor or moderate injury.

NOTICE

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

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SAFETY

Operator Safety

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

reational vehicle. Follow the recommended maintenance program out-

lined beginning on page 61 of this manual to ensure that all critical

components on the snowmobile are thoroughly inspected by your dealer

at specific mileage intervals.

WARNING

Driving a snowmobile requires your full attention. DO NOT drink alcohol or

use drugs or medications before or while driving. They will reduce your alert-

ness and slow your reaction time. In most states and provinces, it’s prohib-

ited 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 compo-

nents 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 Clear of Track

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

exposed for proper operation.

WARNING

Serious injuries may result if hands, feet, or

clothing become entangled in the track. Be

alert when riding, and remain properly

seated to stay clear of the track.

Never hold the snowmobile up or stand

behind it while warming up the track. A loose

track or flying debris could cause serious

injury or death. We recommend having your

dealer perform all track service and align-

ment procedures.

Stay Clear of Engine

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

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

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

WARNING

Serious injury can occur if fingers or clothing contact the moving parts of an

engine. Always stop the engine before attempting adjustments.

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SAFETY

Operator Safety

Survival Preparation

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

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

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

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

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

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

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

lular telephone.

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

all times:

• Spare Drive Belt

• Extra Set of Spark Plugs

• Tow Rope

• Winter Survival Kit

• Trail Map

• Owner's Manual

• First Aid Kit

• Tool Kit

• Extra Oil

• Fuel Deicer

Riding Position

Operating a snowmobile requires skill and balance for proper control.

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

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

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

steering control.

WARNING

Improper riding position may reduce control and could result in serious injury

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

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SAFETY

Operator Safety

Riding Apparel

Be prepared, be warm and be com-

fortable when riding. Be aware of the

weather forecast, especially the

windchill, and dress accordingly. See

the chart on page 22.

WARNING

Avoid wearing loose clothing or

long scarves, which can become

entangled in moving parts and

cause serious injury.

Helmet

Wearing a helmet can prevent a

severe head injury. Whenever riding a Polaris vehicle, always wear a

helmet that meets or exceeds established safety standards.

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

Transportation (DOT) label.

Approved helmets in Europe, Asia and

Oceania bear the ECE 22.05 label. The

ECE mark consists of a circle surrounding

the letter E, followed by the distinguishing

051039

number of the country which has granted

0006.31

approval. The approval number and serial

number will also be displayed on the label.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When-

ever riding a Polaris vehicle, always wear shatterproof goggles or use a

shatterproof helmet face shield. Polaris recommends wearing approved

Personal Protective Equipment (PPE) bearing markings such as VESC

8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

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SAFETY

Operator Safety

Cargo Overload

Too much weight on the rear of the machine may reduce your ability to

steer. Do not exceed carrier and rack weight limits, and do not allow a

passenger to sit on the seat back or the cargo carrier.

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.

Rider Capacity

Driving 1-Up - Some Polaris snowmobiles are designed for a single

rider only. A decal on the console of these models indicates single rider

operation.

Driving 2-Up - Some Polaris snowmobiles are designed for up to two

riders. A decal on the hood of these models indicates that the vehicle is

designed for one operator and one passenger only. See page 23 for decal

location.

Machines designed for two riders should never be operated with more

than two people on board. When traveling with a passenger, it's the

driver's responsibility to operate the machine safely.

Slow down! Control becomes more difficult with two people on board.

More space is required to make turns, and longer distances are necessary

for stopping.

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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 travel-

ing 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 illumi-

nated by the headlight.

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SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles,

posts, or other obstacles. Be especially

alert if you’re snowmobiling after dark.

Always be on the alert for wire fences.

Single strands are especially dangerous,

since there may be a great distance

between posts. Guy wires on utility poles

are also difficult to distinguish.

Make sure the way is clear before crossing

railroads and other roads and highways.

The noise of your machine will drown out

the sound of approaching vehicles. Look

ahead, behind, and to both sides before

turning or crossing railroad tracks or high-

ways. Steep embankments may also hide

your view. Always leave yourself a way

out.

R R

Variances in snow depth and/or water currents may result in uneven ice

thickness. 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

Avalanches

Snowmobilers should always be properly

trained and equipped before traveling in

mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped

with a shovel, probe and avalanche

beacon.

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

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

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

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

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

tainous terrain.

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

lanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche condi-

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

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

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SAFETY

Operator Safety

Ice and Snow Build-up

WARNING

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

ing in serious injury or death. Keep the underhood area free of snow and ice.

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

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

is encountered, 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.

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 seri-

ous injury or death. Slow down to maintain control under these condi-

tions.

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

able, 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.

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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 pro-

vided 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

Intake Silencer

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

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

removed.

Clutches

Do not attempt to service the clutches.

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

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

cally balanced before installation. Any tampering may disrupt this preci-

sion balancing and create an unstable condition.

Cold Weather Drive-Away

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

cially overnight, always make sure the skis and track are loosened from

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

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

safety limits. See Starting the Engine on page 45.

Maneuverability

Control and maneuverability comes not only through the steering and

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

verability will change for lighter operators or machines designed to

carry a load.

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SAFETY

Operator Safety

Inadequate Snow Conditions

WARNING

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

cause irreversible track damage and lead to serious injury.

Since snow provides the only lubrication for the power slide suspension

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

cover is a requirement for operation of your machine. Driving in too lit-

tle snow will result in excessive wear and damage to the slide rail, track

and/or engine.

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

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

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

snow.

NOTICE: 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 Responsibly

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

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

new to snowmobiling, acquaint yourself with the machine and with

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

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

attempting ambitious maneuvers.

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

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

smooth, level area to begin building your operating experience.

• Before allowing someone else to use your snowmobile, know the

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

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

tection, as well as yours, make sure they take a snowmobile safety

course. Everyone can benefit from the course.

• Don't "jump" your snowmobile over large drifts or similar terrain.

Jumping may injure your back because of spinal compression that

could occur when the snowmobile impacts the ground. The seat and

suspension of your snowmobile have been designed to provide pro-

tection under normal riding conditions. Your snowmobile is not

intended for this kind of use.

• Be courteous to oncoming traffic by dimming your headlights and

reducing your speed.

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

closely). Leave enough distance between snowmobiles to provide

ample stopping room and to provide protection from flying snow and

debris. Allow even more distance when driving on slippery surfaces

or when driving in darkness or other low visibility conditions. Be

aware of any snowmobile traffic around your vehicle. Drive defen-

sively to avoid accidents.

• Remove the key from the ignition when you leave the snowmobile

unattended.

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SAFETY

Operator Safety

Windchill/Temperature Charts

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

peratures become dangerous for riding.

WIND CHILL CHART (°F)

Wind

Speed

Actual Thermometer Reading (_F)

40 35 30 25 20 15 10 -5 -10 -15 -20 -25 -30 -35 -40 -45

Equivalent Temperature (_F)

-5 -10 -15 -20 -25 -30 -35 -40 -45

-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63

MPH

Calm 40 35 30 25 20 15 10

36 31 25 19 13

34 27 21 15

32 25 19 13

30 24 17 11

-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72

-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77

-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81

-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84

-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87

-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89

29 23 16

28 22 15

28 21 14

27 20 13

26 19 12

25 18 11

25 17 10

-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91

-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93

-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95

-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97

-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

Frostbite in >> 30 min. 10 min. 5 min.

WIND CHILL CHART (°C)

Wind

Speed

Actual Thermometer Reading (_C)

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

Equivalent Temperature (_C)

KPH

Calm

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

-4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57

-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62

-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65

-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67

-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69

-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70

-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72

-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73

-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74

-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75

-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76

-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

Frostbite in >> 30 min. 10 min. 5 min.

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SAFETY

Safety Decals and Locations

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

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

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

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

instructions of the decals on the snowmobile.

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

to purchase a replacement. Replacement safety decals are provided by

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

Clutch Cover Warning

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

WARNING

Do not operate engine with hood open.

Do not attempt adjustment with engine running.

Do not operate engine with this guard open.

Never run engine with drive belt removed.

Never service clutches yourself - see your dealer.

Air Box Warning

This warning decal is found under the hood on applicable models:

CAUTION

Do not operate above 40 mph with hood-to-air box foam removed

or engine failure will result.

Passenger Warning

Your Polaris Widetrak snowmobile is

designed for the operator and one pas-

senger. For more information on oper-

ating with a passenger, see Page 12.

WARNING

This vehicle is designed for opera-

tor and ONE passenger

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SAFETY

Safety Decals and Locations

Track/Seat Warning

The track/seat warning decal is on the

rear of the tunnel:

WARNING

Stay clear of track. Do not sit on seat

back. Entanglement with the track or

a fall from seat back may result in

severe injury or death.

Reverse Warning

Polaris Widetrak snowmobile is

equipped with standard reverse.

The reverse warning decal is

located above the instrument hous-

ing.

WARNING

Reverse operation, even at low

speeds, can cause loss of con-

trol resulting in serious injury

or death. To avoid loss of con-

trol, always:

• Look behind before and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

• Apply throttle slowly.

NOTE: For more information, see Owner's Manual.

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SAFETY

Safety Decals and Locations

Operation Warning

An operation warning decal is present on the console of all Polaris

snowmobiles:

WARNING

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

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

tact a Polaris dealer for a replacement.

• This vehicle is capable of high speeds. Buried objects or uneven

terrain can cause loss of control. Reduce speed and use extreme

caution when operating in unfamiliar terrain.

• Excessive speed, especially at night or with limited visibility, can

result in insufficient time for you to react to terrain changes, to

avoid unexpected obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehi-

cle.

• In an emergency, push down the Auxiliary Shut-Off Switch, located

on the top of the throttle control assembly, to stop the engine. Then

pull the brake lever to stop.

• Always wear an approved helmet, eye protection, and adequate

clothing while operating this vehicle.

• This vehicle is designed for adult use only. Check local laws for age

requirements.

• When operating with a passenger (on approved models only),

reduce speed and allow extra space for steering and stopping. A

passenger reduces your ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads,

steering and braking ability are greatly reduced. Reduce speed and

allow extra space to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you

should have a proper balance of ski carbides to track studs. See

Owner’s Manual for proper use of traction products.

• Repeated stops from high speed may cause fading or sudden loss

of braking ability.

• Parking brake may relax when used for long periods. Do not leave

brake engaged for more than five minutes.

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

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

tion to control the vehicle.

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

refueling.

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FEATURES AND CONTROLS

GeneralRepresentation

1. Fuel Filler Cap (may include a fuel gauge)

2. Ignition Switch

3. Brake Lever

4. Speedometer (may include indicator/warning lights)

5. Reverse Indicator

6. Mountain Bar

7. Engine Stop Switch (see page 54)

8. Throttle Control

9. Choke

10. Recoil Starter Handle

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FEATURES AND CONTROLS

Some Polaris snowmobiles are equipped with special features. Controls

for these features are illustrated on this page. Not all models come with

these features. Refer to your Owner’s Manual Supplement.

NOTE: Accessories are available from your Polaris dealer.

1. Headlight Dimmer

Switch

2. Parking Brake

Lock

3. Handlebar Grip

Warmer Switch

4. Thumbwarmer

Switch

5. Electronic Reverse

Button

Fuel Valve

The fuel valve is located under the

hood. Turn the fuel valve off when-

ever the snowmobile is stored or

parked.

1. Turn the valve clockwise to

turn off the fuel supply.

2. Turn the valve counter-clock-

wise to turn on the fuel supply.

OFF

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FEATURES AND CONTROLS

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Operator Seat

6. Passenger Hand Hold Strap

7. Cargo Rack

8. Taillights

9. Snow Flap

10. Track

11. Suspension

12. Trailing Arm

13. Nosepan

14. Front Bumper (do not use for pulling or dragging the snowmobile)

15. Skis

Cargo Rack

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

limit specified on the cargo rack decal. Do not allow a passenger to sit

on the seat back or the cargo rack.

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FEATURES AND CONTROLS

Backrest

The backrest is adjust-

able for either operator

or passenger use.

Raise/Lower

1. Loosen the upper

adjustment knobs to

raise or lower the

backrest.

2. Loosen the lower

adjustment knobs

to move the back-

rest forward for

operator use or

rearward for pas-

senger use.

Operator/Passenger

3. Always tighten the

knobs

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THE PERFECT FIT

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 under

the same conditions after each adjustment (trail and snow conditions,

vehicle speed, riding position, etc.) until the best ride is achieved.

Adjustments should be made to one area at a time in order to properly

evaluate the change.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. Trailing arms

IFS Adjustment Options

• Front shock spring preload

NOTE: Optional springs

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THE PERFECT FIT

Front Suspension Adjustments

WARNING

Always verify ski alignment before making adjustments to the IFS. See page

94 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 Components

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Threaded Spring Preload

Adjuster Nut

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THE PERFECT FIT

Front Suspension Adjustments

Shock Spring Preload

Increasing spring preload

will increase ski-to-ground

pressure. Decreasing spring

preload will decrease ski-to-

ground pressure.

Front Springs

For models without exter-

nally adjustable or revalv-

able shocks, the front springs

can be changed if spring pre-

load alone isn’t sufficient

and further adjustment is

desired to control suspen-

sion stiffness. Special tools

are required to adjust front

springs. If you feel that your

front suspension needs

adjustment see your Polaris

dealer for more information.

Front

Shock

Washers

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THE PERFECT FIT

Rear Suspension Adjustments

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

suspension action. Each rear suspension can be adjusted to suit rider

preference and deliver excellent performance for a given set of condi-

tions. However, all suspension designs and adjustments involve a com-

promise, 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.

See your Polaris dealer for initial suspension setup information. Addi-

tional adjustments can be made after initial setup. Make adjustments to

one area at a time so you can evaluate the change. For further assistance,

see your dealer.

Suspension Performance Tips

• Rider weight usually determines the position at which the spring pre-

load should be set. However, this may vary with riding style. With a

little experimentation, each rider can find a preferred set-up. These

adjustments are easy to make, involve very little time or effort, and

greatly affect the ride.

• In deep snow, a new rail slide will offer improved performance over a

worn rail slide. It can also improve top speed.

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

to the rail may enhance the machine’s performance. Bogie wheel kits

are available from your dealer.

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

dealer for assistance.

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

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

suspension components. Grease rear suspension pivots before

adjusting the rear suspension. See page 67.

Track Tension

Track adjustment is critical for proper handling. Always maintain cor-

rect tension and alignment. Refer to the track tension maintenance sec-

tion beginning on page 90.

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THE PERFECT FIT

WideTrak Rear Suspension Adjustments

Rear Spring Settings

Rear spring adjustment is primarily a control for riding comfort. To

check for the recommended settings:

1. Lift the rear of the machine to relieve the rear springs.

2. Slowly lower the machine and measure the distance between the

ground and the running board.

3. Without letting the suspension settle, the rider should carefully

mount the snowmobile.

4. Measure the distance between the ground and the same spot on the

running board.

The difference between the two measurements should be approximately

1 1/2" (3.8 cm). If the difference is greater than 1 1/2", the rear spring

should be adjusted equally on both sides until the desired 1 1/2" drop is

obtained.

Compensating adjustments for heavy or light drivers or cargo loads can

be made by adjusting the rear spring eye bolt length. Adjust spring ten-

sion so there is equal tension on the long leg of each spring.

Eye Bolt

NOTE: Rear spring settings will affect ski-to-ground pressure. If ski

pressure is too light it may be desirable to tighten the rear

springs for an increase in ski-to-ground pressure.

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THE PERFECT FIT

Handlebar Adjustments

Standard Handlebar

Follow these steps to adjust handlebar angle at the handlebar block.

1. Remove the mountain bar by

Bar

Bolts

removing nuts.

2. Using a 7/16-inch wrench,

loosen the four nuts on the

bottom of the adjuster block

(turn the handlebar either left

or right for access to the rear

nuts).

Nuts

NOTE: If necessary, pry the

blocks apart with a

screwdriver.

3. Adjust the handlebar to the

desired angle. Be sure the

handlebar, brake lever and

throttle lever operate

Nuts

smoothly and do not hit the

gas tank, windshield or any

other part of the machine

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

4. Torque the front bolts first, then torque the rear bolts. Torque the

bolts to 11-13 ft. lbs. (15-18 Nm).

5. Reinstall the mountain bar.

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THE PERFECT FIT

Traction Products

nCarbide Skags

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

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

with roads and other bare terrain.

Inspect skags frequently. Worn skags may reduce steering and braking

control on hard-packed snow and ice. Replace worn skags to maintain

proper balance and vehicle control.

WARNING

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

of traction products on the skis and track must be maintained to obtain proper

vehicle control on hard-packed snow or ice. See your dealer for assistance.

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THE PERFECT FIT

Accessories

Polaris offers a wide range of accessories for your snowmobile. From

map light to electric start, Polaris has the accessories that will help make

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

Use only Polaris parts and accessories on your Polaris snowmobile. Use

of unapproved parts and accessories may result in:

• Non-compliance with government/industry requirements

• Voiding of warranty

• Personal injury to self or others

This applies to, but is not limited to the following areas: brakes,

clutches, fuel systems, and exhaust systems.

NOTE: Exhaust systems are critical safety areas that must use

approved Polaris parts. Please see your Polaris dealer for ser-

vice.

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PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition

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

enced pages. Look for a checkmark (n) on the referenced pages to

locate the pre-ride inspection items

Item

See Page

Drive Belt Condition

Steering System

Recoil Rope

83, 86

Parking Brake Lock/Brake Lever/

Brake System

40, 41, 77

Auxiliary Shut-Off Switch (Engine Stop

Switch)

Ignition Switch

Taillight/Brakelight/Headlight

Suspension Mounting Bolts

Skags (Wear Bars)

Ski Saddle and Spindle Bolts

Hood Straps/Latches

Throttle Lever/Safety Switch

Rear Wheel Idler Bolts

Track Alignment/Condition

Rail Slide Condition

39, 54, 55

91, 96

42, 92

Chaincase Oil Level

Injection Oil Level

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PRE-RIDE INSPECTIONS

Before Starting the Engine

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

to snowmobile operation. Never start the engine without checking all

vehicle components to be sure of proper operation.

WARNING

Operating the vehicle with worn, damaged, or malfunctioning components

could result in serious injury or death. Never start the engine without check-

ing all vehicle components to be sure of proper operation.

Read and Understand Your Owner’s Manual

Read the Owner’s Manual completely and refer to it often. The manual

is your guide to safe and enjoyable snowmobiling experience.

n Throttle Lever

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

Always make sure both are functioning properly.

Squeeze the throttle lever to make sure it compresses evenly and

smoothly. When released, the lever should immediately return to the

idle position without binding or hesitation. If the throttle does not func-

tion smoothly, or if you discover excessive lever freeplay, DO NOT start

the engine. Have the throttle serviced immediately. See page 55.

n Throttle Safety Switch

Test the throttle safety switch system before the machine is operated.

See page 54.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

n 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

Squeeze the brake lever. It should

move no closer to the handgrip

than 1/2 inch (1.3 cm). A smaller

distance indicates low brake fluid

level or air in the hydraulic sys-

tem. See pages 78-79 or see your

dealer for service.

1/2 inch (1.3 cm)

Lever Feel

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

level and condition. Also check for the presence of air in the fluid sys-

tem. See pages 78-79 or see your dealer for service.

Replace brake fluid at least every two years. We recommend the use of

Polaris DOT 4 high temperature brake fluid. See page 105 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

n Parking Brake Lever Lock

Your snowmobile may have a

parking brake lever lock located

over the brake lever. Use the

brake lever lock only when you

want the machine to remain sta-

tionary; for example, when

parked on an incline for a period

of five minutes or less.

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/

Cover

4. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze the brake lever tightly and push forward on

the lock. Hold the lock forward while releasing the brake lever.

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

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

The brake light will illuminate if the parking brake lever lock is set

while the engine is running. It will also illuminate when the service

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

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

Lock Release

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

to the unlocked position.

WARNING

If the parking brake lever lock is partially or entirely engaged while riding, the

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

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

the lever lock is completely disengaged before operating the snowmobile.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

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

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

obstructing the steering linkage. Make sure all greasable components

are properly lubricated.

n Track

WARNING

Always inspect the track for damage before using the vehicle. Operating the

snowmobile with a damaged track increases the possibility of track failure,

which could cause loss of control resulting in serious injury or death.

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

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

time with inadequate lubrication could severely damage track rods,

break track edges, and cause other track damage. Examples of inade-

quate lubrication would include frozen bodies of water without snow

cover, icy trails, and no-snow conditions.

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

poor lubrication conditions voids the track warranty.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

n Hood Latches

The hood of the snowmobile protects the operator from moving parts as

well as aiding in sound emission control and other functions. Under no

circumstances should your snowmobile be operated with the hood open

or removed. Always ensure that the hood straps are in good condition

and that the latches are securely in place before operating the snowmo-

bile.

n Seat Latches

If your snowmobile is equipped with a removable seat, ensure that the

seat latches are securely in place before every use of the snowmobile.

n Recoil Rope

Inspect the recoil rope and handle for excessive wear, and make sure the

knot securing the rope inside the handle is secure. If excessive wear is

found, see your Polaris dealer for replacement.

n Transmission

Make sure the transmission is not in reverse before starting the engine

(if equipped with reverse).

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PRE-RIDE INSPECTIONS

Start the Engine and Check

n Engine Stop Switch

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

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

n Lighting

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

Replace burned out lamps before operating.

n Mirrors (if equipped)

Adjust the mirrors so they can be used to their full advantage.

n Operating Area

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

make sure bystanders are a safe distance from the machine.

n Ignition Switch

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

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OPERATION

Starting the Engine

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

in serious engine damage, especially if the transmission is in

reverse. Never engage the starter when the engine is running.

1. Turn the fuel valve on. See

CHOKE POSITIONS

page 27.

2. Turn the key to the ON

OFF

position.

3. Pull the engine stop switch

up to the RUN position.

HALF ON

FULL ON

4. If starting a cold engine,

flip the choke toggle to

FULL CHOKE. Do not

use the choke if starting a

warm engine.

NOTE: Do not depress the throttle until the engine starts.

5. If equipped with electric start, turn the key to START to crank the

engine. Release the key to the ON position when the engine starts.

NOTICE: Don’t pull the starter rope to the fully extended position and

don’t allow it to snap back into the housing. Damage may

result. To avoid engine damage, do not operate the electric

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

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

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

engine.

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

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

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

HALF CHOKE position.

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OPERATION

Engine Break-In

No single action on your part is as important to long, trouble-free

machine life as proper break-in of a new or rebuilt engine. Premix the

first tank of gasoline with one pint of Polaris injection oil for each five

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

tion system, will assure proper engine break-in.

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

operation will damage close-fitted engine parts. Do not

operate at full throttle or high speeds for extended periods

during the first three hours of use. Vary the throttle openings

and machine speeds to reduce friction on all close-fitting

machined parts, allowing them to break in slowly without

damage.

Use of any lubricants other than those recommended by

Polaris may cause serious engine damage. We recommend

the use of Polaris lubricants for your vehicle.

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

regular checks on fluid levels, lines, and all other important

areas of the machine.

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OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 50.

NOTICE: Serious engine damage can occur without the proper

lubrication. Check the oil tank level often during the first tank

of fuel. If the oil level doesn't go down, contact your dealer

immediately.

Oil Recommendations

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

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

systems. Polaris recommends the use of VES II 2 Cycle Oil for this

engine. See page 105 for the part numbers of Polaris products.

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

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

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

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

with each other.

Slide Rail and Track Cooling

NOTICE: Inadequate cooling and lubrication will lead to overheating of

the slide rail and track, resulting in premature wear and

failure. Reduce speeds and frequently drive into fresh snow to

allow adequate cooling and polishing of the slide rail and track

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

roads.

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OPERATION

Track Warm-Up

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.

Follow these steps to ensure proper warm-up of the engine, drive train

and track.

1. Use an appropriate stand to securely sup-

port the rear of the snowmobile at the rear

bumper. The track should be approxi-

mately 4 inches (10 cm) off the ground.

2. Start the engine and allow it to warm up

two to three minutes.

3. Depress the throttle abruptly and allow

the track to rotate several revolutions.

NOTE: It will take longer to warm up the

track sufficiently during colder out-

door temperatures.

4. Release the throttle, apply the brakes,

shut off the engine and lower the 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.

• Always exercise extreme caution whenever handling gasoline.

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

ventilated area.

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

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

refueling is performed or where gasoline is stored.

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

and water and change clothing.

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

fumes are poisonous and can cause loss of consciousness or death in a

short time.

• Turn the fuel valve off whenever the snowmobile is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known to cause

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

outdoors or in well-ventilated areas.

Your Polaris engine is designed to run on 87 octane non-oxygenated or

89 octane oxygenated pump gasoline. There’s a great deal of variability

in the quality of the 87 octane gasoline available, so we encourage the

use of premium fuel when possible. Do not use lower than 87 octane

fuel. Do not use fuel containing more than 10% ethanol (including E85).

NOTICE: 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 Reserve Capacity (Mechanical Gauge)

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

mechanical fuel gauge reads RES.

Fuel System Deicers

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

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

(8-16 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 105 for the part numbers of

Polaris products.

If you use oxygenated fuel containing ethanol, additional alcohol deic-

ers or water absorbing additives are not required and should not be used.

NOTICE: Prolonged exposure to petroleum based products may

damage paint. Always protect painted surfaces when

handling fuel.

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OPERATION

n Oil

Low Oil Indicator Light

The low oil indicator light will indicate when to add oil. See page 47 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 ter-

rain. Maintaining the proper oil level will prevent system aeration and

possible loss of pumping action, which could result in engine damage.

NOTICE: Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris 2-

cycle oils for your snowmobile. Never mix brands.

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

n 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 47 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.

Carburetion

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

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

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

plugs and cause generally poor engine performance.

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

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

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

Either condition may be caused by improper carburetor adjustment.

WARNING

Improper carburetor adjustments may result in operator safety hazards as

well as serious engine damage. Always have your Polaris dealer perform any

carburetor adjustments.

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OPERATION

Carburetion

Jetting Guidelines

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

amount of oxygen available for combustion. In low elevations and cold

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

temperatures, the air is less dense.

RMK carburetors are preset to operate at altitudes of 6000-8000 feet

(1800-2400 m) above sea level (see page 74 for more information). Car-

buretors must be re-calibrated if the snowmobile is operated outside this

production temperature and/or altitude range. The main jet installed in

production is not correct for all altitudes and/or temperatures.

NOTICE: 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. Refer to your Owner’s Manual

Supplement.

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

n Engine Stop Switch

Push down on the engine

stop switch 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.

Stop Switch

n Throttle Safety Switch

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

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

valves do not return to the normal closed position. Test the throttle

safety switch system daily before operation.

WARNING

Operating the snowmobile with a faulty throttle safety switch can result in

serious injury or death in the event of an accident. If the throttle safety switch

does not shut off the engine during a carburetor/throttle system malfunction,

immediately push down the engine stop switch. Do not start the engine again

until the malfunction has been corrected by your dealer.

Test the throttle safety switch

system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it

to idle.

3. Hold the throttle lever pin

stationary by exerting pres-

sure on the pivot pin in the direction shown in the illustration.

4. Apply a slight amount of throttle. A properly functioning switch

must shut down the engine.

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OPERATION

n Throttle Lever

WARNING

An improperly functioning throttle lever may cause erratic machine behavior

and loss of control, which could result in serious injury or death. If the throttle

lever does not work properly, DO NOT start the engine.

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor(s) to determine

what caused the safety switch to activate.

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

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

completely.

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

go through normal starting procedures.

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

Polaris dealer for service.

Excessive 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 54 for more information about the

engine stop switch and throttle safety switch.

THROTTLE

CONDITION

SYSTEM

WHAT IT DOES

Ignition Switch

Brake

Interrupts ignition circuit

Slows jackshaft

All

Choke

Floods engine

Half throttle or less

Engine Stop Switch

Throttle Safety Switch

Interrupts ignition circuit

All

WARNING

Excessive or repetitive use of brakes for high speed stops will cause an over-

heated 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. Snowmobiles equipped with electric start have a recoil

for emergency starting. If the recoil starter system fails, an emergency

start strap is provided in the kit.

Reverse Operation

WARNING

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

resulting in serious injury or death. Damage will occur to the chaincase or

transmission if shifting is attempted when the engine is operating above idle

speed.

• Shift to or from reverse only when the snowmobile is stopped and when

engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

Mechanical Reverse

Make sure the shift lever is shifted completely into forward or reverse

position. Some models are equipped with a reverse indicator light that

will help you make that determination.

Do not force the shift lever into reverse if resistance is felt. The gears

may not always be aligned for shifting into reverse, and forcing the lever

may cause damage. If resistance is felt, gently apply the throttle to move

the gears to a different position and try to shift again.

The transmission may not always be in the gear indicated by the shift

lever. Apply the throttle slowly until you're sure which gear is engaged.

Sometimes the drive belt will drag in the drive clutch, causing slight

tension in the transmission and making it hard to shift. Shutting the

engine off will remove this tension and ease shifting. This should only

happen during the break-in of a new belt or when the drive/driven clutch

center distance is too long. If this is the case, belt tension adjustments

should be made by your dealer.

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OPERATION

Towing

Do not use the front bumper to pull or drag the snowmobile. The front

bumper is not designed for this type of use and may detach from the

vehicle if force is applied.

For your safety, do not attempt to 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 tobog-

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

vent any possibility of contact between the snowmobile’s track and a person

riding in the towed object.

Braking distances increase when towing loads. Slow down to maintain con-

trol of the snowmobile.

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

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

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

Remove the drive belt before towing, and have a rider on the towed

snowmobile to operate the brake and steering when necessary.

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

result in serious damage to the engine and drive system.

Always remove the drive belt from a disabled snowmobile

before towing.

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MAINTENANCE

Emission Control Information

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

repair the emission control devices or systems on your snowmobile.

Emission Control Label

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

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

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

Protection Agency regulations. The ECI label is permanently affixed to

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

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

You may remove the factory-installed emissions information hangtag,

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

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum

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

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

qualified dealer for diagnostic service. Specifications and adjustments

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

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

be engaged during engine tune-ups.

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MAINTENANCE

Emission Control Information

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty, and

read the maintenance section of your owner's manual. You are responsi-

ble for ensuring that the specified maintenance is performed. Polaris

recommends that you contact an authorized Polaris dealer to perform

any service that may be necessary.

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MAINTENANCE

Polaris Recommended Maintenance Program

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

recommended regular maintenance and perform service checks as out-

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

nance Log beginning on page 120.

The recommended maintenance schedule on your snowmobile calls for

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

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

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

mance and component life, continue maintenance checks at 1000 mile

(1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception

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

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

occur as a result of owner neglect in performing recommended regular

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

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

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

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

able performing these tasks yourself, contact an authorized Polaris

dealer for service.

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

sure the exhaust system and engine have cooled before

tipping the snowmobile on its side for service or inspection.

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MAINTENANCE

Periodic Maintenance Interval Table

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

may need to increase frequency based on riding conditions. When

inspection reveals the need for replacement parts, always use genuine

Polaris parts, available from your Polaris dealer.

Item

See

Page

Frequency

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

Season

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

CLUTCH

Clutch Offset Alignment

(without belt)

Drive Belt Condition

Clutches (disassemble)

Belt Tension

Clutch Sheaves

ENGINE

Engine Mounts

Recoil Rope

Engine Mounting Plate

Engine Torque Stop

Cylinder Head Bolts

Cylinder Base Nuts

Ignition Timing BTDC

Spark Plug Condition

Exhaust Pipe

Exhaust Retaining

Springs

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

C - Clean

R - Replace

L - Lubricate

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Page

Frequency

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

Season

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

BRAKES

Hose Routing

Hose Condition

Fluid Leaks

Brake Pads

Brake Disc

Parking Brakes

Brake System

Brake fluid

40,77

FUEL MANAGEMENT

Pilot Air Screws

Carburetor (synchronize)

Idle RPM

Throttle Lever

39,55

Oil Pump Lever

(synchronize)

Throttle Cable

Choke Cable

Vent Lines

Throttle Position Sensor

Choke

N/A

Fuel Filter

Fuel Lines

Oil Filter

Oil Lines

Oil Change

Air Box

Drain and Water Traps

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

C - Clean R - Replace L - Lubricate

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Page

Frequency

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

Season

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

ELECTRICAL

Auxiliary Shut-Off Switch

Throttle Safety Switch

Ignition Switch

Taillight

39,54

Brakelight

Headlight

CHASSIS

Ski Toe Alignment

Suspension Mounting

Bolts

Steering Fasteners

Rear Suspension

Fasteners

Suspension Shock Oil

Cooling Fins and Shroud

Drive Shaft Bearings

Jackshaft Bearings

Skags (Wear Bars)

Ski Saddle/Spindle Bolts

Ski Pivots

Ski Spindle

Steering Arm(s)

Upper/ Lower Steering

Post Support Bracket

Hood Straps

Battery Fluid Level

Rear Wheel Idler Bolts

and Nuts

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

C - Clean

R - Replace

L - Lubricate

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Page

Frequency

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

Season

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

CHASSIS

Rear Suspension Pivot

Shafts

Camber Alignment

Radius Rod Bushings

Handlebar Centering

Track Alignment

Track Tension

Front Limiter Strap

Rail Slide Condition

Chaincase Oil

N/A

Gearcase Oil

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

C - Clean R - Replace L - Lubricate

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MAINTENANCE

Lubrication

Suspension and Steering

Lubricate the suspension and steering components with Polaris Pre-

mium All-Season Grease at 500 miles (800 km) and annually or every

1000 miles (1600 km) thereafter. A grease gun kit, complete with grease

and adaptors, is available to lubricate all fittings on Polaris snowmo-

biles. See page 105 for the part numbers of Polaris products.

The illustration shows the lubrication points of suspension and steering

components. Grease the left and right spindles. Raise the front end of

the machine to permit better grease entry into the spindle area.

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

• Grease the jackshaft and driveshaft clutch side bearings.

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

• Grease the steering post lower pivot.

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

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MAINTENANCE

Lubrication

Rear Suspension

WideTrak Rear Suspension

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MAINTENANCE

Lubrication

Jackshaft Bearing

The jackshaft bearing on your model may be equipped with a grease fit-

ting, but this component is greased for life at the factory. Additional

lubrication is not required.

Driveshaft Bearing

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 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 and cables

lightly with oil or grease. Before

turning the engine off, operate the

choke intermittently to draw mois-

ture out of the choke plunger area

and reduce the possibility of the

choke becoming frozen.

Coupler Greasing

(WideTrak)

Grease the couplers on the drive-

shaft and jackshaft.

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MAINTENANCE

Lubrication

n Gearcase Oil Level (WideTrak)

Check the gearcase oil level at

the intervals outlined in the

maintenance charts beginning

on page 65. Change the gear-

case oil after the first 500 miles

(800 km), then every 1000 miles

(1600 km) or seasonally.

To check the oil level, place the

machine on a level surface. The

oil level should be between the

“safe” marks on the dipstick (1).

See your Polaris dealer for the

recommended oil for your

machine. Do not overfill.

Clean the magnetic plug (2)

every 500 miles (800 km) and

whenever checking or changing

lubricant.

NOTICE: Mixing brands or using non-recommended lubricants could

result in excessive wear to chain, sprockets and bearings.

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 con-

ditions 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.

NOTICE: 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. Refer to your

Owner’s Manual Supplement.

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

vative added during the assembly process. Avoid prolonged idle speeds,

which cause plug fouling and carbonization.

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

Owner’s Manual Supplement.

• Spark plug torque is 18-22 ft. lbs. (24.4-29.8 Nm).

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

NOTICE: 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 carbure-

tor(s). Refer to your Owner’s Manual Supplement.

Normal Plug

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

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

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

NOTE: The tip should not be white. A white insulator tip indicates over-

heating, caused by use of an improper spark plug or incorrect

carburetion adjustments.

Wet Fouled Plug

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

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

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

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

rect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to 18-22

ft. lbs. (24.4-29.8 Nm).

4. Reinstall the spark plug cap.

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MAINTENANCE

Intake Filter

The intake foam filter and screen limits snow ingestion into the intake

system. When operating in loose powder snow, check the top of the

foam filter and screen periodically to remove any accumulation of snow.

NOTICE: Operating the snowmobile with the intake filters removed may

cause carburetor icing. The result will be poor fuel economy

or carburetor malfunction. Always reinstall the intake filters

before operating the snowmobile.

Foam Filter

Intake

Foam Filter and Screen

Air Intake Box

NOTE: These illustrations are general representations. Your model

may differ.

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MAINTENANCE

Carburetor

Water/Sediment Trap Service

Most Polaris snowmobiles contain patented carburetor bowl water/sedi-

ment traps located at the bottom of each carburetor. The trap, consisting

of a hose with a plug, should be drained about every 1000 miles (1600

km) and inspected for contamination.

WARNING

When draining the traps, fuel spillage will occur. Always work in a well venti-

lated area away from anything that may cause the fuel to ignite, such as open

flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline

warnings found on page 49.

Plug Cleaning Procedure

1. Turn the fuel valve off.

Clamp

2. Position a container or shop towels to

catch the contaminated gasoline.

3. Slide the clamp away from the drain

plug and remove the drain plug from the

sediment tube.

4. Wipe residue from the plug and reinstall

it. Reposition and tighten the clamps.

Continue until all the traps have been

emptied.

Drain

Plug

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MAINTENANCE

Carburetor

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

jet installed at the time of manufacture is not necessarily correct for your

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

jet is installed.

NOTICE: Operating the snowmobile with incorrect jetting can result in

serious engine damage. Have your Polaris dealer perform all

carburetor adjustments to ensure all adjustments are done

correctly.

Carburetor Adjustments

The frequency at which the carburetors are synchronized or balanced is

important. Properly adjusted carburetors can greatly improve engine

performance, fuel economy, engine life, and reliability.

If you notice any of the following conditions, the carburetor may need

adjustment:

• Hard starting

• Poor idle

• Overheated pistons and cylinder walls

• Plug fouling

• Poor engine response to various throttle valve openings

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MAINTENANCE

Fuel Filter/Fuel Lines

The fuel filter is located inside the fuel tank. This component requires

no maintenance.

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

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

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

damaged fuel lines promptly.

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

remove fuel lines may cause damage to the lines. If a fuel line

has been damaged or kinked, replace it promptly.

Oil Filter

The oil filter on your model is assembled into the oil sending unit

located in the bottom of the oil tank. This component requires no main-

tenance.

If service is performed to the oil injection system, trapped air must be

bled from the system. See your dealer for instructions, or have your

dealer perform this service.

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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.

Drive Chain Tension

Your WideTrak is equipped with an automatic chain tensioner. No main-

tenance or inspection should be necessary.

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MAINTENANCE

Brakes

n Hydraulic Brake Inspection

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

page 40.

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

ner than the backing plate (approximately 1/16 inch/1.5 mm). 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 inch/1.5 mm).

Brake Components

1. Brake Caliper

2. Chaincase

3. Brake Disc

4. Backing Plate

5. Brake Pad Material

(Replace when thick-

ness is less than 1/16

inch/1.5 mm)

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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 rap-

idly absorbs moisture from the air. The moisture causes the boiling tempera-

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

possibility of accident or 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.

NOTICE: Brake fluid will damage decals, paint and some plastics.

Always wipe up spills immediately.

The brake fluid level can be seen through a plastic sight glass in the

brake reservoir. If the fluid is sufficient, the sight glass will be black. If

the sight glass is any color other than black, add brake fluid.

We recommend the use of Polaris DOT 4 high temperature brake fluid.

See page 105 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 possi-

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

air entering the system through the reservoir vent.

1. Remove brake master cylinder reservoir cover and gasket.

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

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

opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a

solid stream free of air bubbles.

WARNING

Overfilling the master cylinder leaves no room for fluid expansion and may

cause the brakes to lock, resulting in serious injury or death. Always add

brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level.

8. Reinstall the gasket and cover.

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MAINTENANCE

Lights

Headlight Adjustment

The headlight may be adjusted for vertical aim using the following pro-

cedure:

1. Place the snowmobile on a level surface with the headlight approxi-

mately 25 feet (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight

and make a mark on the wall.

3. Start the engine and turn the headlight switch to high beam.

4. Observe the headlight aim. The most intense part of the headlight

beam should be aimed two (2) inches (5.1 cm) below the mark

placed on the wall in step 4.

NOTE: Rider weight must be included on the seat.

5. Turn the adjustment nut, located inside the hood, just below the

headlamp opening. Turn the knob in or out as needed for proper

aim.

25 ft. (7.6 m)

Lamp Center Height

2 in. (5.1 cm)

Adjustment

Nut

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MAINTENANCE

Lights

NOTE: Avoid touching a halogen bulb with bare fingers. Oil from skin

leaves a residue, causing a hot spot that will shorten the life of

the lamp. If fingers do touch the bulb, clean it with an alcohol-

moistened towel.

Headlight Bulb Replacement

1. Pinch the ends of the spring (1)

together and lift until it releases

from the spring retainer.

2. Lift the spring carefully around

the wire harness (2) and flip it to

the outside of the housing.

3. With the wire harness attached

to the bulb (3), withdraw the

bulb from the housing.

4. Grasp the bulb by its metal base

and carefully separate the bulb from the harness.

5. Hold the new bulb by its metal base and install it into the wire har-

ness.

6. Insert the bulb into the housing. Carefully flip the spring back into

the housing, placing it around the wire harness.

7. Squeeze the spring together until it's over the spring retainer and

release.

8. Verify headlight aim. See page 80.

Taillight/Brakelight Replacement

1. Remove the screws (1) securing the

taillight housing (2).

2. Remove and replace the bulb (3).

3. Reassemble all components.

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MAINTENANCE

Clutch System

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

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

ers such as isopropyl alcohol.

WARNING

If you become aware of higher than normal clutch engagement or an unusual

vibration or shift pattern, see your dealer immediately. Do not operate the

machine until repairs have been made.

All clutch maintenance and repairs must be performed by an authorized

Polaris dealer. Any unauthorized modifications to clutches, such as adding or

removing weights, will void the warranty.

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

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

lubricate clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor-

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

performance.

Clutch Center Distance

Refer to your Owner’s Manual Supplement for recommended center

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

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MAINTENANCE

Clutch System

n Drive Belt Condition

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

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

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

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

mance. See Belt Troubleshooting on page 107.

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

always carry a spare. Inspect the belt for signs of excessive wear: frayed

edges, missing cogs, cracks and excessive looseness. Replace the belt if

any of these conditions exist.

NOTE: A worn belt will continue to function, but will not deliver maxi-

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

emergency.

For improved drive-away during extremely cold temperatures, remove

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

snowmobile.

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MAINTENANCE

Clutch System

Drive Belt Removal

1. Stop the engine after operating in

a forward motion.

2. Turn the ignition key off. Wait for

the engine to stop completely.

3. Lock the parking brake (if

equipped).

4. Open the hood.

5. Remove the clutch guard retain-

ing pin and open the clutch

guard.

6. Firmly grasp the belt midway

between the clutches and pull

upward and rearward to remove. See illustration.

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MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the

drive clutch and pull back

the slack.

NOTE: To ensure satisfactory

belt life, install belts so

they operate in the

same direction of rota-

tion by positioning the

identification numbers

so that you can read

them. If required, sepa-

rate the sheaves as

outlined in the belt removal procedures.

2. Turn the driven clutch moveable sheave clockwise while pushing

inward and forcing the belt down between the sheaves.

3. Hold the belt down between

the sheaves and roll the bot-

tom portion over the outer

clutch sheave. Work the belt

to the outer edge of the

sheave.

4. Close the clutch guard and

reinstall the retaining pin.

5. Close and secure the hood

and release the parking

brake.

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MAINTENANCE

Clutch System

n Drive Belt Deflection

Measure belt deflection with

both clutches at rest and in

their full neutral position.

Place a straight edge on the

belt (1) and apply downward

pressure while measuring at

point 2. This measurement

should be 1 1/4 inches (32

mm).

Drive Belt Adjustment

Belt deflection should be adjusted without removing the clutch from the

jackshaft.

1. Loosen the 7/16-inch jam nut on the belt width adjuster.

2. Using a 1/8-inch Allen wrench, adjust the threaded set screw as

needed.

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

between the sheaves and out (counterclockwise) to decrease

the distance.

3. Tighten the jam nut.

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MAINTENANCE

Clutch System

Torque Stop

Periodically check torque stop

clearance. With clutches in

proper alignment, the torque stop

clearance should be .010-.030

inch (.25-.75 mm) from the

engine case.

.010-.030 in.

(.25-.75 mm)

Adjust if necessary, and lock the

jam nut.

Tool Kit

A tool kit is included with each machine for emergency and routine

maintenance. Always keep the tool kit with the snowmobile.

Chain Tension

Maintain the proper chain tension as outlined on page 76.

Fall Tune-Up

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

Polaris dealer.

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MAINTENANCE

Track

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.

1. Using a hoist, safely lift

and support the rear of the

snowmobile off the ground.

2. Rotate the track by hand to

check for possible damage.

3. Carefully examine the track

along the entire length of

each rod (+). Bend the

track to check for break-

age.

4. Replace the track if any rod

damage is found.

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MAINTENANCE

Track

Track Lubrication

WARNING

Operating with insufficient lubrication between the rail slide and track guide

clips can cause track failure, loss of vehicle control and loss of braking ability,

which can result in serious injury or death.

Avoid operating for extended periods on ice and other surfaces that have lit-

tle or no snow for lubrication.

The slide rail requires adequate snow cover for sufficient lubrication.

Excessive wear indicates insufficient lubrication. A new rail slide can

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

wear.

NOTE: If excessive rail slide wear occurs due to poor snow conditions,

additional wheel kits are available. See your dealer for more

information.

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

other poor lubrication conditions will void the track warranty.

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MAINTENANCE

Track

WARNING

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

adjustments recommended on the following pages, stay clear of all moving

parts. Never perform track measurement or adjustments with the engine run-

ning.

Track Tension

Track adjustment is critical for proper handling. Always maintain cor-

rect tension and alignment. Tension adjustments should be made only

after the track is warmed up and limber.

WARNING

Improper track tension can cause serious damage to the snowmobile, which

can result in loss of vehicle control and serious injury or death. Always main-

tain the track tension as specified.

1. Turn the engine off.

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

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

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

idler wheel.

NOTE: Measure at the point where the weight is hanging.

Weight

Measurement

Location

Measurement

10 lbs. (4.54 kg)

16 inches (40 cm) ahead of

rear idler shaft

3/4-1 inch (2-2.5 cm)

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

and the plastic rail slide.

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MAINTENANCE

Track

Track Tension

If the track needs adjustment:

5. Loosen the rear idler

shaft bolt.

Slack

Measurement

Locknut

6. Loosen the locknuts.

Idler Shaft

Adjusting

Screw

7. Tighten or loosen the

track adjusting screws

as necessary to pro-

vide equal adjustment

on both sides of the

track.

Bolt

8. Repeat the measure-

ment on the other side

of the track.

Track

16 in. (40 cm)

10 lbs. (4.54 kg)

NOTE: Check more fre-

quently when

machine is new.

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

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

10. Check track alignment (see page 92) and adjust as necessary.

11. Tighten the locknuts.

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

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MAINTENANCE

Track

n Track Alignment

Periodically check that the track is

centered and running evenly on the

slide rails. Misalignment will cause

excessive wear to the track and slide

rail.

1. Safely support the rear of the

machine with the track off the

ground.

2. Start the engine and apply a

small amount of throttle until

the track turns slowly at least

five complete revolutions. Stop

the engine and let the track

come to a stop (do not apply

brakes).

Rails

3. Inspect track alignment by looking through the track window to

make sure the rails are evenly spaced on each side. If the track runs

to the left, loosen the left locknut and tighten the left adjusting bolt.

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

right adjusting bolt.

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

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

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

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MAINTENANCE

Steering System

Steering Inspection

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

sary. Specific fasteners that should be checked are marked with a + in

the illustration.

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MAINTENANCE

Steering System

Ski Alignment

WARNING

Improper ski alignment or adjustment may cause loss of steering control,

resulting in serious injury or death. Do not attempt to change the ski align-

ment or camber adjustment. See your Polaris dealer.

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

weight compressing the suspension, measure from the straight edge of

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

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

at point Y.

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

rect the alignment, since camber adjustment may also be

affected.

10 in. (25.4 cm)

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MAINTENANCE

Steering System

n Ski Skags

WARNING

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

may result, causing serious injury or death.

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

longer or more aggressive carbide skags than the original equipment, it may

also be necessary to add track studs to maintain proper vehicle control while

turning on hard-packed snow or ice.

Check skags 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 chip-

ping is found.

Skag Replacement

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

mately 6I (15.2 cm) from the ground.

2. Remove the attaching hardware and pry the skag downward.

3. Remove the rear end of the skag.

4. Remove the front end of the skag.

5. Reverse the steps to install a skag.

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MAINTENANCE

Suspension Maintenance

n Rail Slide Wear

Minimum

Thickness

For ease of inspection, all

Polaris rail slides have a

wear limit indicator groove

to indicate the minimum per-

missible slide thickness.

Replace the rail slides if they

are worn to the top of the

groove at any point along

their length. Failure to do so

may result in permanent

damage to the track or rails.

Replace when

worn to top of

groove

Suspension Inspections

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

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

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

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

n Check suspension mounting bolts for tightness.

n Check rear idler wheel bolts for tightness. See page 91.

n Check rear idler adjusting bolt locknuts for tightness.

n Check front torque arm limiter strap condition.

n Check rail slide condition.

n Check track tension. See page 90.

n Lubricate/grease all suspension components. See page 66.

n Check ski runner/skag condition. See page 95.

n Check ski spindle bolts for tightness.

n Check tie rod end nuts for tightness.

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MAINTENANCE

Battery

WARNING

Battery electrolyte is poisonous. It contains acid! Serious burns can result

from contact with the skin, eyes, or clothing. If contact occurs, seek immedi-

ate medical attention.

KEEP OUT OF REACH OF CHILDREN.

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Call physician immedi-

ately.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, open flames, cigarettes,

etc. away. Ventilate when charging or using in closed space. Always shield

eyes when working near batteries.

Battery Fluid

A poorly maintained battery will

Upper Mark

deteriorate rapidly. Check the battery

fluid level often. The fluid level

should be kept between the upper and

lower level marks.

Add only distilled water. Tap water

Lower

contains minerals that are harmful to Mark

a battery.

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MAINTENANCE

Battery

Battery Connections

Always keep battery terminals and connections free of corrosion. If

cleaning is necessary, remove the corrosion with a stiff wire brush.

Wash with a solution of one tablespoon baking soda and one cup water.

Rinse well with tap water and dry off with clean shop towels. Coat the

terminals with dielectric grease or petroleum jelly. Be careful not to

allow cleaning solution or tap water into a conventional battery.

Battery Removal

WARNING

Improperly connecting or disconnecting battery cables can result in an explo-

sion and cause serious injury or death. When removing the battery, always

disconnect the negative (black) cable first. When reinstalling the battery,

always connect the negative (black) cable last.

1. Disconnect the battery hold-down straps.

2. Remove the battery vent tube from battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable last.

5. Carefully lift the battery out of the snowmobile. Do not tip it side-

ways or spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of

one tablespoon baking soda and one cup water to prevent

damage to the vehicle.

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MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the bat-

tery and result in a shorter life. It can also hinder vehicle performance.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder. Attach the hold down strap.

3. Install the battery vent tube.

NOTE: The vent tube must be free of obstructions and securely

installed. Route the vent tube properly to prevent kinks and to

allow for proper drainage.

WARNING

Battery gases could accumulate in an improperly installed vent tube and

cause an explosion, resulting in serious injury or death. Always ensure that

the vent tube is free of obstructions and is securely installed as

recommended.

4. Coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Verify that cables and vent tube are properly routed.

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MAINTENANCE

Battery

Battery Storage

When your snowmobile is placed in storage for one month or more (in

summer or in winter):

• Remove the battery.

• Charge it to the proper level.

• Store it in a cool dry place.

• Check and/or charge monthly.

• Have the battery tested and recharged before reinstalling it in the

vehicle.

If a battery with a low charge freezes, the cells could be damaged.

Always maintain a full charge on a stored battery. See the table below.

Charge condition

Will freeze at:

100%

75%

50%

25%

-75_ F(-59_ C)

-24_ F(-31_ C)

0_ F(-18_ C)

+13_ F(-11_ C)

+18_ F(-8_ C)

100

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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 inches

(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 infor-

mation.

101

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MAINTENANCE

Extended Storage

Off-season or extended storage of your snowmobile requires preventive

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

many components.

Cleaning and Preservation

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

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

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

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

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

or paint).

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

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

cause condensation to form and damage snowmobile components.

Engine and Carburetor Protection

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

tion of rust and corrosion on precision engine parts during storage.

Whenever the machine is stored for a period of more than 60 days, the

engine must be fogged with fogging oil. Follow the engine fogging

instructions provided on the can. See page 103.

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

the fuel tank. 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 min-

utes 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 73). Catch fuel in a container or shop cloth. Rein-

stall plugs securely. Observe all fire safety rules when draining carbure-

tors. See gasoline warnings on page 49.

Jet restriction caused by improper storage can cause lean conditions and

very poor slow speed driving quality.

102

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MAINTENANCE

Extended Storage

Engine and Carburetor Protection

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

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

lowing procedure:

1. Transfer unused fuel from the fuel tank to an approved fuel con-

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

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

the machine is elevated and the engine is tilted rearward.

3. Remove the spark plug(s).

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

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

inder models, the opposite piston will be up.

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

plug hole.

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

inders.

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

Controls and Linkage

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

light coat of oil or grease.

Bearings

Grease the drive shaft clutch side bearing with Polaris Premium All-

Season Grease or a similar high quality grease to prevent corrosion. See

page 105 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 105 for the part numbers of Polaris

products. Do not lubricate clutch components, except the driven clutch

shaft bushing as outlined in the Master Repair Manual. See your dealer.

103

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MAINTENANCE

Extended Storage

Electrical Connections

Separate electrical connector blocks and clean corrosive build-up from

connectors. Lubricate or pack connector blocks with dielectric grease

and re-connect. See page 105 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.

Battery

Always prepare and maintain the battery as outlined on page 97.

Track and Suspension

Moderate track tension should be maintained during summer storage.

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

hang freely.

Transporting the Snowmobile

Whenever the snowmobile is transported:

1. Turn the fuel valve off.

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

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

suitable straps.

4. Remove the ignition key to prevent loss.

104

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POLARIS PRODUCTS

Description

Part No.

Engine Lubricants

2870791

2871098

2871097

2871240

2871721

2871722

2872347

2874438

2874439

2874443

Fogging Oil (12 oz. Aerosol)

Premium 2-Cycle Engine Oil (qt.)

Premium 2-Cycle Engine Oil (gal.)

Premium 2-Cycle Engine Oil (2.5 gal.)

Premium Gold Synthetic 2-Cycle Engine Oil (qt.)

Premium Gold Synthetic 2-Cycle Engine Oil (gal.)

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

VES II Synthetic 2-Cycle Engine Oil (qt.)

VES II Synthetic 2-Cycle Engine Oil (gal.)

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

Chaincase Lubricants

2873105

2872951

Synthetic Chaincase Lubricant (qt.)

Synthetic Chaincase Lubricant (12 oz.)

Grease / Specialized Lubricants

Grease Gun Kit, Premium All Season (3 oz.)

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Dielectric Grease (Nyogel™)

2871312

2871322

2871423

2871329

Additives / Miscellaneous

2871326

2870652

2872189

2872893

2870505

2872889

2872890

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT4 Brake Fluid (12 oz.)

Engine Degreaser (12 oz.)

Isopropyl

Brake and Clutch Cleaner

Carb and Throttle Body Cleaner

105

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SUSPENSION TROUBLESHOOTING

Problem

Solution (perform only one change at a time)

Rear suspension bot- • Verify sag dimension (see page 91). Adjust torsion spring

toms too easily

blocks or install optional torsion springs to achieve correct

sag dimensions.

Rear suspension

rides too stiff

• Check for binding suspension components and grease all

pivot points.

• Verify sag dimension (see page 91). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Decrease shock compression damping (see page 34).

Too much weight

transfer when climb-

ing

• Verify sag dimension (see page 91). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

Too little weight

transfer when climb-

ing

• Verify sag dimension (see page 91). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

Front end pushes

• Check for worn skags

• Check for binding front suspension shafts and steering com-

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

• Verify sag dimension (see page 91). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Increase IFS preload (see page 32).

Steering is heavy

• Check skags and skis for damage.

• Check for binding front suspension shafts and steering com-

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

• Verify sag dimension (see page 91). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Decrease IFS preload (see page 32).

Machine darts from • Ensure skis are properly aligned (see page 94).

side to side

• Check for binding front suspension shafts and steering com-

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

• Ensure skags are straight on skis.

106

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TROUBLESHOOTING

Belt Wear/Burn Troubleshooting

Belt Wear/Burn Diagnosis

Causes

Solutions

Driving at low RPM

Drive at higher RPMs. Gear the machine down. Check

belt deflection.

Insufficient warm-up

Towing at low RPM

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

off the machine in extremely cold weather and warm it up.

Break machine loose from the snow.

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

engage clutch.

Riding with high RPM

and slow speed (8000

RPM/10 MPH)

Lower the gear ratio. Remove windage plates from the

clutch. Reduce RPM. Avoid riding in high ambient

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 the gas tank or

fuel line.

Loading machines

onto trailers

Skis may gouge into trailers and prevent the drive train

from spinning properly. Use enough speed to drive the

machine completely onto the trailer. Push and pull it to

finish loading if necessary.

Clutch malfunction

Inspect clutch components. See your dealer.

Use fast, aggressive throttle to engage clutch.

Slow, easy clutch

engagement

107

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TROUBLESHOOTING

Engine Troubleshooting

NOTE: 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 acceler-

ation or load

variations

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

malfunction

• Replace ramp buttons and rollers. SEE

YOUR DEALER.

• Inspect movable sheaves for excessive

bushing clearance and replace if neces-

sary. SEE YOUR DEALER.

Harsh drive

Drive belt worn or too • Replace drive belt.

clutch engage- narrow

ment

Excessive belt/sheave

• SEE YOUR DEALER.

clearance

Drive belt turns Wrong belt for applica- • Replace drive belt.

over

tion

Clutch alignment out

of spec

• Adjust alignment offset.

Engine mount broken

or loose

• Inspect and adjust or replace. SEE

YOUR DEALER.

Machine fails

to move

Clutch jammed

• Belt twisted, spring broken, weights

stuck, lubricated. SEE YOUR

DEALER.

Track jammed

• Foreign object caught or rail slide

melted to track clips due to lack of

lubrication.

• Machine may be frozen to ground.

Track may be iced up.

Chaincase sprocket or

chain jammed or bro-

ken

• Chain is loose or broken, chain tight-

ener is loose. SEE YOUR DEALER.

108

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Noise in drive

system

Broken drive clutch

components

• SEE YOUR DEALER.

Bearing failure/ chain- • SEE YOUR DEALER.

case, jackshaft, or front

drive shaft

Drive belt surface flat

spots

• Inspect and replace if necessary.

Drive chain loose or

worn, sprocket teeth

broken

• Inspect and adjust or replace.

Poor low RPM Worn drive belt

performance

• Inspect and replace if necessary.

• SEE YOUR DEALER.

Excessive belt/sheave

clearance

Loose torque stop

Sticky clutch

• Inspect and adjust.

• SEE YOUR DEALER.

Engine doesn’t Wire connections

start (electric

start models)

Engine doesn’t Seized engine

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 crankcase for emer-

gency draining.

109

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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 cor-

rect 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 contin-

ually backfires”.

Flooded engine (normal • Hold throttle open, crank engine sev-

situation caused by too

much choking)

eral times (may be necessary to

change plug(s), however, the plug(s)

may operate satisfactorily when

dried).

Poor engine compression • 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 diameter 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 continu- Faulty plug(s)

• Change plug(s)

ally backfires

Carburetor

• Dirt or ice in fuel system. (Deicer

should be added to non-ethanol fuel

at all times for assurance against fuel

line icing.)

Engine requires Poor gasoline or not

more than nor- enough fuel getting to

• Replace with fresh winter fuel.

mal pulls to

start

engine

110

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WARRANTY

Service And Warranty Information

Obtaining Service and Warranty Assistance

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

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

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

on changes, modifications and tips on snowmobile maintenance, which

may supersede information contained in this manual. Your dealer is also

familiar with Polaris policies and procedures and will be happy to assist

you.

When contacting us about parts, service, or warranty, always provide the

following information:

1. Serial number

2. Model number

3. Dealer name

4. Date of purchase

5. Details of trouble experienced

6. Length of time and conditions of operation

7. Previous correspondence

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

the identification numbers of your snowmobile and its engine.

Polaris Customer Service

United States: 1-888-704-5290

Canada: 1-204-925-7100

111

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WARRANTY

Service And Warranty Information

Polaris Anti-Theft System

The Polaris anti-theft system (PATS) monitoring program is designed to

aid owners of registered snowmobiles in recovery of stolen machines.

Administration

1. Polaris snowmobile owner reports theft.

NOTE: A. In addition to notifying the proper law enforcement officials,

the owner must call Polaris Customer Service.

NOTE: 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

112

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WARRANTY

Limited Warranty

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

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

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

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

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

ranty period, through a Polaris dealer.

Registration

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

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

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

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

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

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your snowmobile is very important in ensuring

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

set-up will void your warranty coverage.

Warranty Coverage and Exclusions

Limitations of warranties and remedies

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

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

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

structurally altered, neglected, improperly maintained, used for racing or used for pur-

poses other than for which it was manufactured. The warranty does not cover any dam-

ages that occur during trailer transit or as a result of unauthorized service or parts. In

addition, this warranty does not cover physical damage to paint or finish, stress cracks,

tearing or puncturing of upholstery material, corrosion or defects in parts, components

or the snowmobile due to fire, explosions or any other cause beyond Polaris’ control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the snowmobile.

The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option,

repair or replacement of any defective materials, or components or products. THE REM-

EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-

ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL

HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL

OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF

EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-

GENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-

sion or limitation of incidental or consequential damages or implied warranties, so the

above limitations or exclusions may not apply to you if inconsistent with controlling

state law.

113

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WARRANTY

Limitations of warranties and remedies

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR

WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-

RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations

on how long an implied warranty lasts, so the above limitation may not apply to you if

inconsistent with controlling state law.

How to Obtain Warranty Service

If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-

rized to repair Polaris snowmobiles. When requesting warranty service you must present

your copy of the Warranty Registration form to the dealer. (The cost of transportation to

and from the dealer is YOUR responsibility). Polaris recommends that you use your

original selling dealer; however, you may use any Polaris Servicing Dealer to perform

warranty service.

Please work with your dealer to resolve any warranty issues. Your dealer will contact the

appropriate personnel at Polaris if additional assistance is needed.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty

terms will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-

ommend the use of Polaris engine oil.

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

by warranty.

114

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WARRANTY

Conditions and Exclusions

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

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

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

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

required periodic maintenance upon request may result in denial of warranty coverage.

Use of the recommended Polaris products for lubrication and maintenance as directed by

the Owner’s manual is highly recommended. Should a failure occur during the warranty

period resulting from the use of non-recommended products, warranty coverage may be

denied.

Warranty does not apply to parts exposed to friction surfaces, stresses, environmental

conditions and/or contamination. The following items are excluded from warranty con-

sideration if the failure was due to wear or not the direct result of a defect:

Skis

Ski wear rods

Tracks

Slide rails

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Drive belts

Hydraulic components

Circuit breakers/Fuses

Electronic components

Light bulbs/Sealed beam lamps

Idler wheels

Warranty applies to the product only and does not allow for coverage of personal loss.

Some items are considered “consumable,” meaning they are considered part of normal

maintenance or part of completing an effective repair. The following items are excluded

from warranty coverage in the event of a warranty claim:

Spark Plugs

Filters

Fuel

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage/repair

Coolants

Sealants

Hotel fees

Meals

Towing charges

Mileage

Rentals/Loss of product use

Shipping/ handling fees

Product pick-up/delivery

Loss of vacation/personal time

This warranty also excludes failures resulting from improper lubrication; improper

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

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

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

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket components resulting in failure; unauthorized repairs; repairs made after

the warranty period expires or by an unauthorized repair center; use of the product in

competition or for commercial purposes. Warranty will not apply to any product which

has been damaged by abuse, accident, fire or any other casualty not determined a defect

of materials or workmanship.

115

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WARRANTY

Polaris Second Year Engine Service Contract

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

mobiles that were Snow Checked through an authorized Polaris dealer during the

March/April Snow Check promotion. The free Second Year Engine Service Contract is

honored by all authorized Polaris snowmobile dealers in North America and is transfer-

able 120 days after the original purchase date, free of charge, through any Polaris snow-

mobile dealer. Coverage on Snow Check units is automatic. Although you do not

receive a warranty card, your dealership should have printed a copy of the warranty reg-

istration form. This form is your proof of warranty.

Consumer Exclusions

• Each repair visit after the first twelve months of standard warranty coverage is subject

to a $50 deductible.

• The free Second Year Engine Service Contract applies to the first 5,000 miles or two

(2) calendar years from date of purchase, whichever comes first. Tampering with the

odometer shall void all warranties/service contracts. No extensions to coverage under

this engine service contract can be given. Used snowmobiles are not eligible under this

program.

• Snowmobiles used for commercial purposes or for racing are excluded from coverage.

Coverage

Coverage for second year engine failures due to defects in materials and workmanship

will be determined by Polaris in its sole discretion. Coverage is automatic with no addi-

tional paperwork required. The free Second Year Engine Service Contract is subject to a

$50 deductible per visit. Regular, documented service maintenance visits are required to

validate this warranty.

A partial list of items excluded from coverage includes:

• Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.

• Damage caused by the failure of other components of the snowmobile.

• Failures caused by improper fuel or oil.

• Piston seizures, unless caused by a defective engine component.

• Failures caused due to improper adjustments.

• Failure due to unauthorized service.

• Failures due to lack of service as required in the owner’s manual or Polaris updates.

This includes off-season storage as listed in the owner’s manual.

• Failure due to use of unauthorized parts or modifications.

• Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,

and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and

exhaust manifolds excluding paint coverage.

• Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring

and other electrical components are excluded from coverage.

• Cooling system coverage is limited to the water pump assembly and components, fan,

fan bearings, temperature sensor, gasket and seals.

• Non wear related throttle body parts are covered. The fuel pump is covered.

• Clutches and related clutch parts, including but not limited to, the drive belt, are

excluded from coverage.

• Electrical components are excluded from coverage.

• Gearcases and transmissions are excluded from coverage.

116

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WARRANTY

Exported Vehicles

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

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

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

TION.

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

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

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

have any questions.

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

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

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

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

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

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

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

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

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

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

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

form the warranty repair.

If You Move:

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

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

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

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

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

to register your vehicle in your new country.

If Purchased From A Private Party:

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

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

Notice

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

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

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

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

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

For questions call Polaris Customer Assistance (see page 111).

117

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WARRANTY

Snowmobile Engine Emissions Limited Warranty

This snowmobile engine emissions limited warranty is in addition to the Polaris

standard limited warranty for snowmobiles.

Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-

certified snowmobile engine is designed, built and equipped so it conforms with U.S.

Environmental Protection Agency regulations applicable to snowmobile emissions.

Polaris warrants that the engine is free from defects in materials and workmanship that

would cause it to fail to meet these regulations. The warranty period for this emissions

certified snowmobile engine starts on the date when the engine is first purchased and

continues for a period of 200 hours of engine operation, 4000 kilometers (2485 miles) of

vehicle travel, or 30 calendar months from the date of purchase, whichever comes first.

This engine emissions limited warranty covers the parts and labor charges for repair or

replacement of defective parts that are covered by this warranty. This includes all

components whose failure increases the snowmobile engine's emissions. Replacing or

repairing other components not covered by this warranty is the responsibility of the

snowmobile owner.

The exclusive remedy for breach of this limited warranty shall be, at the exclusive

option of Polaris, repair or replacement of any defective materials, components or

products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR

INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED

WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATE IN THIS WARRANTY. Some states do not allow limitations on how

long an implied warranty lasts so the above limitation may not apply if it is inconsistent

with the controlling state law.

118

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WARRANTY

Snowmobile Engine Emissions Limited Warranty

This limited warranty excludes failures not caused by a defect in material or

workmanship. This limited warranty does not cover damage due to accidents, abuse, or

improper handling, maintenance or use. This limited warranty also does not cover any

engine that has been structurally altered, or when the snowmobile has been used in

racing competition. This limited warranty also does not cover physical damage,

corrosion or defects caused by fire, explosions or other similar causes beyond the

control of Polaris.

Owners are responsible for performing the scheduled maintenance identified in the

owner's manual. Polaris can deny an emissions warranty claim if any specified critical

emissions-related maintenance is not performed. Performance of other scheduled

maintenance is strongly recommended, but is not necessary to keep the emissions-

related warranty valid.

Any qualified repair shop or person may maintain, replace, or repair the emission con-

trol devices or systems on your snowmobile. Polaris recommends that you contact an

authorized Polaris dealer to perform any service that may be necessary for your snow-

mobile. Polaris also recommends that you use only Pure Polaris parts. It is a potential

violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer

reduces the effectiveness of the vehicle's emission controls. Tampering with emission

controls is prohibited by federal law.

119

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MAINTENANCE LOG

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

mobile is serviced. This will provide you and future owners with an

accurate log of maintenance and services performed on the snowmobile.

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

120

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

121

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

122

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

123

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . 37

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

Air Pollution . . . . . . . . . . . . . . . . . . . 5

Apparel . . . . . . . . . . . . . . . . . . . . . . 11

Avalanches. . . . . . . . . . . . . . . . . . . . 15

Disabled Operators . . . . . . . . . . . . . . 12

Drive Belt . . . . . . . . . . . . . . . . . . . . . 18

Adjustment . . . . . . . . . . . . . . . . 86

Condition . . . . . . . . . . . . . . . . . . 83

Deflection . . . . . . . . . . . . . . . . . 86

Installation . . . . . . . . . . . . . . . . . 85

Removal. . . . . . . . . . . . . . . . . . . 84

Drive Chain Tension . . . . . . . . . . . . . 76

Driver Awareness . . . . . . . . . . . . . . . 14

Driving Downhill. . . . . . . . . . . . . . . . 18

Driving in Hilly Terrain. . . . . . . . . . . 17

Driving on Slippery Surfaces . . . . . . 16

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

Backrest . . . . . . . . . . . . . . . . . . . . . . 29

Battery . . . . . . . . . . . . . . . . . . . . 97-100

Battery Connections. . . . . . . . . . . . . 98

Battery Fluid . . . . . . . . . . . . . . . . . . 97

Battery Installation. . . . . . . . . . . . . . 99

Battery Removal . . . . . . . . . . . . . . . 98

Battery Storage . . . . . . . . . . . . . . . 100

Before Starting the Engine. . . . . . 39-43

Brake Components. . . . . . . . . . . . . . 77

Brake Fluid . . . . . . . . . . . . . . . . . . . 78

Brake Inspection . . . . . . . . . . . . . . . 77

Brake Lever Feel . . . . . . . . . . . . . . . 40

Brake Lever Travel . . . . . . . . . . . . . 40

Brake System Bleeding . . . . . . . . . . 79

Brakelight Replacement. . . . . . . . . . 81

Brakes . . . . . . . . . . . . . . . . . . 40, 77-79

Break-In Period . . . . . . . . . . . . . . . . 46

Electrical Connections. . . . . . . . . . . 104

Emission Control Information. . . 59-60

Engine Break-In. . . . . . . . . . . . . . . . . 46

Engine Care for Storage . . . . . 102-103

Environment . . . . . . . . . . . . . . . . . . . . 5

Exhaust System . . . . . . . . . . . . . . . . . 76

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 75

Fuel Lines . . . . . . . . . . . . . . . . . . . . . 75

Fuel Reserve . . . . . . . . . . . . . . . . . . . 50

Fuel System Deicers . . . . . . . . . . . . . 50

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 27

Carbide Skags . . . . . . . . . . . . . . . . . 36

Carburetion . . . . . . . . . . . . . . . . . 52-53

Carburetor . . . . . . . . . . . . . . . . . . 73-74

Carburetor Adjustments. . . . . . . . . . 74

Carburetor Jetting . . . . . . . . . . . . . 107

Carburetor Storage. . . . . . . . . . 102-103

Carburetor Trap . . . . . . . . . . . . . . . . 73

Cargo . . . . . . . . . . . . . . . . . . . . . . . . 12

Cargo Rack . . . . . . . . . . . . . . . . . . . 28

Chain Tension . . . . . . . . . . . . . . . . . 87

Choke. . . . . . . . . . . . . . . . . . . . . . . . 45

Cleaning the Vehicle . . . . . . . . . . . 102

Clutch Alignment. . . . . . . . . . . . . . . 82

Clutch Center Distance . . . . . . . . . . 82

Clutch Cover Warning. . . . . . . . . . . 23

Clutch Guard . . . . . . . . . . . . . . . . . . 18

Clutch System . . . . . . . . . . . . . . . 82-87

Clutches . . . . . . . . . . . . . . . . . . . . . . 19

Clutching Chart . . . . . . . . . . . . . . . 107

Cold Weather Drive-Away . . . . . . . 19

Gearcase Oil Level . . . . . . . . . . . . . . 69

Handlebar Adjustments . . . . . . . . . . . 35

Headlight Adjustment . . . . . . . . . . . . 80

Headlight Bulb Replacement. . . . . . . 81

Hood Latches. . . . . . . . . . . . . . . . . . . 43

Ice and Snow Build-up . . . . . . . . . . . 16

IFS Adjustment Options . . . . . . . . . . 30

IFS Components . . . . . . . . . . . . . . . . 30

Intake Filter . . . . . . . . . . . . . . . . . . . . 72

Intake Silencer. . . . . . . . . . . . . . . . . . 19

Jetting Guidelines . . . . . . . . . . . . . . . 53

124

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INDEX

Lever, Shift (Mechanical Reverse) . . 57

Lights . . . . . . . . . . . . . . . . . . . . . 80-81

Headlight Adjustment. . . . . . . . 80

Lubrication

Rail Slide Wear. . . . . . . . . . . . . . . . . 96

Recoil Rope . . . . . . . . . . . . . . . . . . . 43

Reverse Operation . . . . . . . . . . . . . . 57

Reverse Warning . . . . . . . . . . . . . . . 24

Reverse, Mechanical. . . . . . . . . . . . . 57

Rider Capacity . . . . . . . . . . . . . . . . . 12

Riding Position . . . . . . . . . . . . . . . . . 11

Choke and Cable. . . . . . . . . . . . 68

Driveshaft Bearing . . . . . . . . . . 68

Jackshaft Bearing . . . . . . . . . . . 68

Rear Suspension . . . . . . . . . . . . 67

Throttle Cable . . . . . . . . . . . . . . 68

Safety . . . . . . . . . . . . . . . . . . . . . . 7-22

Safety Decals . . . . . . . . . . . . . . . 23-25

Shock Components . . . . . . . . . . . . . . 31

Shock Spring Preload . . . . . . . . . . . . 32

Ski Alignment. . . . . . . . . . . . . . . . . . 94

Ski Skags . . . . . . . . . . . . . . . . . . . . . 95

Slide Rail and Track Cooling . . . . . . 47

Snow Conditions. . . . . . . . . . . . . . . . 20

Spark Plugs . . . . . . . . . . . . . . . . . 70-71

Speed. . . . . . . . . . . . . . . . . . . . . . . . . 13

Spring Settings, Rear . . . . . . . . . . . . 34

Springs, Front . . . . . . . . . . . . . . . . . . 32

Starting the Engine . . . . . . . . . . . . . . 45

Starting, Emergency . . . . . . . . . . . . . 57

Steering Inspection . . . . . . . . . . . . . . 93

Steering Lubrication . . . . . . . . . . . . . 66

Steering System . . . . . . . . . . 42, 93-95

Stop Switch. . . . . . . . . . . . . . . . . . . . 54

Stopping, Emergency . . . . . . . . . . . . 56

Storage, Daily . . . . . . . . . . . . . . . . . 101

Storage, Extended. . . . . . . . . . 102-104

Survival Preparation . . . . . . . . . . . . . 10

Suspension Adjustments, Front . 30-32

Suspension Adjustments, Rear . . . . . 33

Suspension Adjustments. . . . . . . . . . 34

Suspension Inspections. . . . . . . . . . . 96

Suspension Lubrication . . . . . . . 66-67

Suspension Lubrication, Rear. . . . . . 67

Suspension Performance Tips. . . . . . 33

Suspension Troubleshooting. . . . . . 106

Maintenance Interval Table . . . . . . . 62

Maintenance Program. . . . . . . . . . . . 61

Maneuverability . . . . . . . . . . . . . . . . 19

ng . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Oil . . . . . . . . . . . . . . . . . . . . . . . . 51-52

Oil Filter . . . . . . . . . . . . . . . . . . . . . . 75

Oil Indicator Light . . . . . . . . . . . . . . 51

Oil Injection System . . . . . . . . . . . . . 47

Oil Level . . . . . . . . . . . . . . . . . . . . . . 52

Oil Recommendations. . . . . . . . . . . . 47

Oil, Gearcase (WideTrak). . . . . . . . . 69

on . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operation Warning . . . . . . . . . . . . . . 25

Parking Brake Lever Lock . . . . . . . . 41

Passenger Warning . . . . . . . . . . . . . . 23

Periodic Maintenance Table . . . . 62-65

Polaris Products . . . . . . . . . . . . . . . 105

Pre-Ride Checklist . . . . . . . . . . . . . . 38

Pre-Ride Inspections. . . . . . . . . . 38-44

125

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INDEX

Throttle Lever . . . . . . . . . . . . . . 39, 55

Throttle Safety Switch. . . . . . . . 39, 54

Tool Kit . . . . . . . . . . . . . . . . . . . . . . 87

Torque Stop . . . . . . . . . . . . . . . . . . . 87

Towing. . . . . . . . . . . . . . . . . . . . . . . 58

Track

Vehicle Identification Numbers. . . . . . 6

Windchill/Temperature Charts . . . . . 22

Alignment . . . . . . . . . . . . . . . . 92

Damage . . . . . . . . . . . . . . . . . . 42

Inspection. . . . . . . . . . . . . . . . . 88

Lubrication. . . . . . . . . . . . . . . . 89

Tension . . . . . . . . . . . . . 33, 90-91

Warm-Up. . . . . . . . . . . . . . . . . 48

Track Cooling . . . . . . . . . . . . . . . . . 47

Track/Seat Warning. . . . . . . . . . . . . 24

Transporting the Snowmobile . . . . 104

Troubleshooting, Belt Wear. . . . . . 107

Troubleshooting, Engine . . . . . 108-110

Troubleshooting, Suspension. . . . . 106

Tune-Up. . . . . . . . . . . . . . . . . . . . . . 87

126

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